Yhau-Cg Direct Fired Absorption Chiller-Heater: Pre-Start Up

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YHAU-CG DIRECT FIRED

ABSORPTION CHILLER-HEATER
CHECKLIST Supersedes 155.32-CL1 (317) Form 155.32-CL1 (1120)

CHILLER-HEATER START UP AND COMMISSIONING CHECKLIST

CUSTOMER:_____________________________________ JOB NAME: _____________________________________


ADDRESS:______________________________________ LOCATION: _____________________________________
PHONE:_________________________________________ CUSTOMER ORDER NO: __________________________
JCI TEL NO: _____________________ JCI ORDER NO: __________________ JCI CONTRACT NO: ______________

UNIT MODEL NO: ____________________________ UNIT SERIAL NO: _______________________________


The work (as checked below) is in process and will be completed by: _____________ / ____________ / ___________
Month Day Year

The following work must be completed in accordance with installation instructions:

PRE-START UP
A. General

1. All major components, boxes, and crates have c. Cooling tower fan..................................................
been received and accounted for by a YORK/John-
d. Residential hot water pump..................................
son Controls Service representative.....................
3. Detachable flanges are properly installed close to the:
2. Any damage, or signs of possible damage, have
been documented to the transportation company.... a. Chilled or hot water box........................................
b. Cooling water box.................................................
3. Unit is installed in an area protected from weather
and maintained at a temperature above freezing.... c. Residential hot water box.....................................

4. Vibration-proof rubber sheets are installed be- 4. A mesh strainer is installed on the:
tween chiller base and site foundation..................... a. Chilled or hot water inlet line................................
5. Unit is located in accordance with minimum clear- b. Cooling water inlet line.........................................
ance dimensions, foundation bolts are properly in- c. Residential hot water line.....................................
stalled, and the levelness of the unit is within accept-
5. Air piping work is complete, leak tested, and
able range. (Tolerance for leveling length is: 1.0 for
flushed for the following lines:
every 1,000 mm and width: 2.0 for ever 1,000 mm.)..
a. Chilled or hot water...............................................
6. HG compound gauge pressure reading is about
the same as before shipment.................................. b. Cooling water........................................................
c. Fuel gas................................................................
7. Thermal insulation is done according to the speci-
fications detailed in this manual................................ d. Flue or Chimney...................................................
e. Residential hot water............................................
8. Valves, thermowells, plugs, and sight glasses are
not covered with insulation........................................ 6. Clean the mesh strainers on the line........................
7. Start the chilled or hot water, cooling water, and
B. Piping
residential hot water pump... .....................................
1. Piping is installed between the unit at the source 8. The water box pressure does not exceed the
of supply......................................... ........................... maximum pressure for the:
2. The following and its related equipment are ready a. Chilled or hot water...............................................
for operation: b. Cooling water........................................................
a. Chilled or hot water pump .................................... c. Residential hot water pump..................................
b. Cooling water pump .............................................

JOHNSON CONTROLS 1
FORM 155.32-CL1

ISSUE DATE: 11/18/2020

9. The flow rate is adjusted within acceptable range for: F. Evacuate Nitrogen Charge
a. Chilled or hot water...............................................
1. Remove the plug in the purge line.......................
b. Cooling water........................................................
2. Evacuate nitrogen gas until the HT-GEN
c. Residential hot water........................................... .
compound gauge indicates approximately 0.005
10. The flue damper has an open limit switch. Its MP.a.G (0.725 PSI)...................................................
signal is connected to the control panel as an
3. Reinstall plug in purge line.....................................
interlock signal..........................................................
4. Navigate to the Control Panel Setting screen...........
11. Add glycol or antifreeze to the chilled water for
EXEL AND EXWL..................................................... 5. Press the Purge Pump ON button............................
6. Check the oil level in the purge pump.......................
C. Valve and Sensor Check
7. Evacuate the nitrogen gas using the vacuum pump
1. Adjusting valves are set correctly............................. until the HT-GEN compound gauge indicates ap-
proximately -0.1 MP.a.G (-14.5 PSI).........................
2. The diaphragm valves in the purge line are closed.
8. Close all open manual valves...................................
3. Spindle valve in the purge line is open.....................
9. Press the Purge Pump OFF button...........................
4. Changeover valves are set in operation mode........
10. Turn the power switch (MCB) off...............................
5. The detection component of the thermosensor is
inserted into the thermowell according to design 11. Replace lubricant oil for the vacuum pump...........
requirements.............................................................
G. Panel Checks
D. Electrical
1. The thermal relays conform to the factory inspec-
1. The main and control power supply is available, tion sheet..................................................................
and voltage is set within acceptable range............. 2. The interlock (answerback) signal for the chilled/
2. The insulation resistance of each motor and hot water pump and cooling water pump is
MCB secondary side is within acceptable range.... available....................................................................

3. All wiring is complete from the main power sup- 3. The indicators on the control panel are correct.........
ply to the power panel, but is not cut to final 4. The temperature setting parameters for capacity
length or connected to the panel............................. control are correct.....................................................
4. The wiring between the control panel and the 5. The date and time reflect local time zone..............
residential hot water control valve are connected
properly..................................................................... 6. The rotation direction of the solution circulation
pump, solution spray pump, refrigerant pump, and
5. The external control wiring is completed from the burner fan is correct................................................ ..
control panel to the water pump motor starters,
and other related equipment..................................... 7. The water flow suspension switch works properly....

E. Vacuum Pump H. Fuel Gas Line Check

1. Confirm the vacuum pump motor rotation is 1. Gas type and calorific value of fuel gas corresponds
correct........................................................................ to specification..........................................................
2. Verify the vacuum pump is charged with the cor- 2. Gas supply pressure is within acceptable range.....
rect amount of lubricant oil....................................
3. Gas shut-off valves for the main burner and pilot
burner lines perform within acceptable range........
4. Close the measuring port valves for the pilot and
main gas line.............................................................
5. Open the valves for the pilot and main gas lines....

2 JOHNSON CONTROLS
FORM 155.32-CL1

ISSUE DATE: 11/18/2020

I. Adjust Combustion 16. Check for abnormal noise or vibration......................


1. Manually start each water pump............................... 17. Confirm that the consumption of fuel gas at low
2. Confirm the water box covers do not leak while the combustion is within acceptable range.....................
water pump operates................................................ 18. Verify that the concentration of Carbon Monoxide
3. Stop each water pump manually............................... (CO) and Oxygen (O2) is within acceptable range
when the exhaust gas is at low combustion..............
4. Set each water pump operation mode to automatic.
19. Confirm that the consumption of fuel gas at high
5. Navigate to the Control Panel Setting screen........... combustion is within the acceptable range...............
6. Press the appropriate Operation Mode button.......... 20. Verify that the concentration of Carbon Monoxide
7. Press the Manual Purge ON button.......................... (CO) and Oxygen (O2) is within the acceptable
range when the exhaust gas is at high combus-
8. Purge the non-condensable gas from the ab-
tion............................................................................
sorber. Use the procedure detailed in SECTION
7 - MAINTENANCE of the manual............................ 21. Collect the combustion data......................................

9. Open the refrigerant manual blow valve................... 22. Verify that the flame current is within the accept-
able range.................................................................
10. Navigate to the Control Panel Setting screen...........
23. Verify that the draft pressure is within the accept-
11. Press the Control Valve Mode Manual button..........
able range.................................................................
12. Make sure that the Refrigerant Pump Auto button
is pressed..................................................................
13. Verify that the steam control valve is closed.............
14. Press the OPER. button on the Control Panel..........
15. Check that the following start properly:
a. Solution circulation pump.....................................
b. Solution spray pump.............................................
c. Refrigerant pump..................................................

NOTES:
________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

JOHNSON CONTROLS 3
FORM 155.32-CL1

ISSUE DATE: 11/18/2020

START UP B. Purge Amount Check

1. Verify that the purge amount from the absorber is


A. Operation Check within acceptable range............................................

1. Press the Control Valve Mode Auto button.............. 2. Close the spindle valve to facilitate purging from
the absorber..............................................................
2. Check that the capacity control valve works
automatically according to the chilled water outlet 3. Continuously purge from the purge tank until the
temperature............................................................... exhausted gas amount reduces and becomes
stable........................................................................
3. Press the STOP button on the Control Panel...........
4. Operate the chiller for about 1 hour without operat-
4. Check that the dilution process completes...............
ing the vacuum pump................................................
5. Press the OPER. button on the Control Panel..........
5. Verify that the amount of purge from the purge
6. Operate the chiller-heater for 3 hours or longer........ tank is within the acceptable range...........................
7. Close the refrigerant manual blow valve...................
C. Purge System Check
8. Operate the chiller-heater for an additional hour or
longer........................................................................ 1. Press the Purge Mode Auto button..........................
9. Check that the cooling water temperature is con- 2. Change the lubricant oil of the vacuum pump...........
trolled within the acceptable range...........................
3. Open the valve of the ballast valve part-way............
10. Check that the specific gravity of the refrigerant is
within the acceptable range......................................
D. Remote Operation Check
11. Check that the chilled water outlet temperature is
lower than the chilled water inlet temperature.......... Confirm that the chiller-heater starts and stops prop-
erly using the remote signal...........................................
12. Record the running data on the data sheets.............

E. Operation Instruction

Review the operation and maintenance instructions


with the customer...........................................................

a. Customer Names:

1.

2.

3.

Customer Signature: ________________________________________

Title: ________________________________________

Form Completed by: ________________________________________

Date: ____________ / ____________ / ___________


Month Day Year

4 JOHNSON CONTROLS
FORM 155.32-CL1

ISSUE DATE: 11/18/2020

DIRECT FIRED ABSORPTION CHILLER-HEATER COMMISSIONING DATA SHEET (1/3)


User:
Model: MFG.No.: User's machine code:

Insulation Resistance Electric Power Supply


Standard: 5 MΩ or more (with 500 V meg- R-Gnd S-Gnd T-Gnd Specification: AC V/ Hz
ger)
Circuit breaker MΩ Standard: Within +/- 10% of spec.
R-S V
U-Gnd V-Gnd W-Gnd R-T V
Solution circulation pump MΩ S-T V
Solution spray pump MΩ R-Gnd V
Refrigerant pump MΩ S-Gnd V
Purge pump MΩ T-Gnd V

Thermal Relay Setting Refrigerant Purity Temperature Setting


Standard: 1.040 (kg/L) or less
Solution circulation pump A Low chilled water supply: check Cooling
the density table.
Solution spray pump A Specific gravity Set base temp. °C
Refrigerant pump A Turbidity Auto. stop temp °C
Purge pump A Auto restart diff. °C
Heating
Pump Discharge Pressure Purge Amount Set base temp. °C
Solution circulation pump MPa.G Standard: 4 cc/min or less Auto. stop temp. °C
Solution spray pump MPa.G Purge tank cc Auto. restart diff. °C
Refrigerant pump MPa.G Absorber cc

NOTES:
________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

JOHNSON CONTROLS 5
FORM 155.32-CL1

ISSUE DATE: 11/18/2020

DIRECT FIRED ABSORPTION CHILLER-HEATER COMMISSIONING DATA SHEET (2/3)


COMBUSTION DATA
SPECIFI- STAN-
MEASURED BY LOW MIDDLE HIGH
CATION DARD
OUTPUT VALUE % Control panel
FUEL DAMPER POSITION % Damper pointer
AIR DAMPER POSITION % Damper pointer
FUEL PRIMARY PRESSURE Pressure gauge
(P1)
FUEL SECONDARY PRES- Pressure gauge
SURE (P2)
FUEL CONSUMPTION (SEE m3/h Flow meter
NOTES)
FUEL CONSUMPTION (SEE m3N/h Calculation or flow
NOTES) meter

EXHAUST GAS O2 CON- % Exhaust gas analyzer 4.0~8.0


CENTRATION
EXHAUST GAS CO CON- ppm Exhaust gas analyzer ≤100
CENTRATION
EXHAUST GAS CO2 CON- % Exhaust gas analyzer
CENTRATION
WIND BOX PRESSURE Water manometer
DRAFT PRESSURE (P3) Water manometer 0~-49 kPa
FURNACE PRESSURE (P4) Water manometer
FLAME CURRENT μA Flame current meter ≥2.0
BURNER FAN OPERATION A Cramp meter
CURRENT
EXHAUST GAS TEMPERA- °C Control panel ≤250
TURE

NOTES:
If gas flow rate is taken as m3/h, calculate m3N/h with fuel pressure and ambient temperature. Ambient temperature: °C

Air
P1 P2

Gas
P4 P3

LD20247

6 JOHNSON CONTROLS
FORM 155.32-CL1

ISSUE DATE: 11/18/2020

DIRECT FIRED ABSORPTION CHILLER-HEATER COMMISSIONING DATA SHEET (3/3)


User:
Model: MFG.No.: User's machine code:
Running Data
Date: Measured by Specification Standard : : :
Output Valve % Control panel
Fuel Exhaust gas temperature °C Control panel ≤ 250°C
Fuel Consumption Flow meter
Inlet temperature °C Control panel
Outlet temperature °C Control panel
Chilled/Hot Inlet pressure Pressure gauge
Water Outlet pressure Pressure gauge
[3] Pressure drop DPG or calculation [4]
[1] Flow rate FM or calculation [2]
Inlet temperature °C Control panel 20.0~32.0°C
Outlet temperature °C Control panel 20.0~37.5°C
Cooling Inlet pressure Pressure gauge
Water Outlet pressure Pressure gauge
[7] Pressure drop DPG or calculation [8]
[5] Flow rate FM or calculation [6]
≤ -0.003
HG pressure (gauge) MPa.G Compound gauge
MPa
HG pressure (sensor) kPa.abs Control panel ≤ 94.7 kPa
Absorption HG temperature °C Control panel ≤165°C
Cycle HG solution concentration % Control panel
Absorber temperature °C Control panel
Refrigerant temperature °C Control panel
Refrigerant temperature kg/L Control panel
HG Level gauge
LG Level gauge
Liquid
Absorber Level gauge
Level
Evaporator (lower) Level gauge
Evaporator (upper) Level gauge

NOTES:
Same
Height
P P
Operating hours________hours

Number of purge times________times

OUT
Fill out each specification pressure drop according to the factory inspection report (actual value).
If differential pressure gauge (DPG) is not available, calculate each pressure drop.

If flow meter (FM) is not available, calculate each flow rate as below.
IN

Waterbox LD20020

[1] = [2] x √[3] / [4] [5] = [6] x √[3] / [4]

JOHNSON CONTROLS 7
FORM 155.32-CL1
ISSUE DATE: 11/18/2020

Table 1 - PURGE AMOUNT MEASUREMENT DATA SHEET (1/1)

User:
Model: YHAU - MFG.No.: User's machine code:
Measured Date: Measured by:

Purge Amount from Purge Line Flame Reaction Test


Standard: 4.0 cc/min. or smaller Reaction (Strong/Weak/None)
Amount of Gas (P) cc/min

Purge Amount from Purge Tank


Elapsed time 1 hour
Consumed time for measurement (m) min.
Total gas amount (a) cc
Actual gas amount (b) cc

(b) = (a) - (P) x (m)

Purge Amount from Absorber


Standard: 4.0 cc/min. or smaller
Elapsed time (T) min. 1 2 3 5 10 15 20 30
Total gas amount (A) cc
Increased gas amount (B) cc
Actual gas amount (C) cc/min.
(B) = (A) - previous(A)
(B) - (P) x { (T) - previous(T) }
(C) = (T) - previous(T)

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