Hyundai HDFN-80-1400, Operation Instructions Manual

Page 1: ...HYUNDAI CLIMATE CONTORL CO LTD Operation Instructions Gas Oil Direct fired Absorption Chiller heater Models HDFN 80 1400...

Page 2: ...dling and maintenance service of the absorption chiller heater however its excellent performance and durability would not come to play This manual gives information on the construction functions of th...

Page 3: ...sufficiently If the air required for combustion is in short it may cause an oxygen poor accident 8 Do NOT put heavy materials on the absorption chiller heater and the control panel It may cause injury...

Page 4: ...is completed as per the operation sequence to eliminate a possibility of tube damages etc NEVER stop the operation of the cooling water pump as well until it is completed as per the operating sequenc...

Page 5: ...ock a fire or a burn 8 Be sure to use the fuses with correct capacity Without using them it may cause a machine trouble or a fire 9 Do NOT let the absorption chiller heater and the control panel get w...

Page 6: ...ure Control 17 3 3 Solution Flow Rate Control 18 3 4 Low Load Control 19 3 5 Emergency Stop 19 3 6 Protective Devices 19 CHAPTER 2 PREPARATION AND OPERATION 4 Preparation for Operation 24 4 1 Evacuati...

Page 7: ...6 9 1 3 Recording operation data 46 9 1 4 Others 46 9 2 Periodical Inspection 46 9 3 Maintenance of Purge Pump 47 9 4 Cooling Water Control 50 9 4 1 Temperature control 50 9 4 2 Water quality control...

Page 8: ...ium Bromide Solution 64 2 1 General Properties 64 2 2 Solubility 65 2 3 Specific Gravity 65 2 4 Specific Heat 65 2 5 Vapor Pressure 65 2 6 PH 65 2 7 Corrosiveness 65 2 8 Others 65 3 Adjustment Procedu...

Page 9: ...solution dilute lithium bromide solution hereinafter referred to dilute solution being collected at the bottom of the shell The absorption heat generated here is removed outside by the cooling water f...

Page 10: ...ructure to keep high vacuum However hydrogen gas generates when the anti corrosion thin film is formed in the vessel The purge system is provided to collect the hydrogen gas and non condensable gas su...

Page 11: ...11 Fig 1 1 External View of Chiller heater...

Page 12: ...ce valve V 25 Service valve V 28 By pass valve for de crystallization V 35 By pass valve for de crystallization V 41 Valve for purging changeover V 42 Sight glass Sight glass Sight glass Valve for pur...

Page 13: ...pass valve for de crystallization V 41 Sight glass Sight glass Sight glass Valve for purging V 2 Valve for purging V 3 Valve for purging V 4 Purge pump Manometer Chilled hot water inlet Chilled hot wa...

Page 14: ...he upper shell containing the condenser and low pressure generator is kept at a high vacuum of about 60 mmHg abs the condensed refrigerant is sent to the evaporator by differential pressure between th...

Page 15: ...is sprayed on the surface of the absorber tubes to be cooled down in the low temperature heat exchanger Point i a A state where the concentrated solution absorbs the refrigerant to be diluted in the a...

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Page 17: ...Compare to the set point Valve action Fuel control Rise up Open Chilled water Balanced Stop outlet temperature Go down Close 3 2 Hot Water Temperature Control The signal sent from the temperature sen...

Page 18: ...olution level with the electrode the speed of solution pump is controlled to keep the correct level Level too high Solution pump stop Level high Speed of solution pump decrease Solution level in high...

Page 19: ...on due to external cause the main gas valve closes automatically to stop operation of the chiller heater Refer to the Table 3 1 List of Protective Devices for detail stop of operation 3 6 Protective D...

Page 20: ...20 Fig 3 5 Operation Flow Chart...

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Page 22: ...be open when air pressure falls Do Do Applied for gas fired and oil fired with proportional control type Flame detector UV Detect misfire and reduced fire Do Do Pressure switch for high pressure gener...

Page 23: ...Over current relay for refrigerant pump motor M2 49 Rating current Do Combustion shut down and sol Pump stop Refrigeration pump motor protection Over current relay for purge motor M3 49 Rating curren...

Page 24: ...on 2 Connect the solution service valve with the vessel with a vacuum vinyl hose and fill the hose with solution to purge out air 3 Insert the end of the vinyl hose into the bottom of the vessel and f...

Page 25: ...a vacuum vessel separately and connect it with the service valve for discharge And then open the service valve for discharge to discharge refrigerant after checking if the vessel is vacuumed If soluti...

Page 26: ...ary wiring between the motor and control panel phase checking test is done at the factory But for safety purpose confirm the motor rotating direction by checking its discharge pressure current operati...

Page 27: ...may not be stabilized and evaporation temperature is likely to change abruptly which may cause freezing or other troubles However in case load is stabilized at factory etc there is no need for such t...

Page 28: ...he level of 1 2 to 1 3 from the bottom of the sight glass of the absorber And then check the concentration of the concentrated solution with the solution temperature at the outlet of the generator the...

Page 29: ...29 5 3 Adjustment Procedure for Trial Operation 5 3 1 Outline of solution flow The outline of the solution flow and the position of the valves are shown as below Fig 5 2 Outline Location of Valves...

Page 30: ...e control valve manual butterfly valve Location Intermediate concentration solution line From the high temp heat exchanger outlet to the low pressure generator inlet 30 Function Flow rate control of i...

Page 31: ...nd heating Diaphragm valve Location By pass line from the dilute solution pump discharge to the refrigerant pump discharge Fully opened Be sure not to open the valve excessively Excessive opening may...

Page 32: ...procedure 1 Adjust the flow rate of GL by the valve V 31 2 Adjust the flow rate of GL 1 by the valve V 30 GL2 changes because GL GL1 GL2 Be sure that the total flow rate GL changes slightly due to pr...

Page 33: ...pressure generator 160 165 140 145 Adjustment procedure of pressure and solution temperature at the high pressure generator Pressure at the High Pressure Generator Solution Temperature at High Pressur...

Page 34: ...0 10 0 10 7 8 5 9 3 450 20 8 22 5 11 3 12 1 9 5 10 4 500 23 2 25 0 12 5 13 4 10 7 11 6 600 22 8 24 2 12 2 13 0 10 6 11 3 1 5 2 5 700 26 5 28 2 14 2 15 1 12 3 13 1 800 30 2 32 2 16 2 17 2 14 1 14 9 90...

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Page 36: ...ss button switch START When switched to START the chiller heater is operated automatically as per the following process 1 The solution pump starts 2 The forced fan starts and pre purges for about 90 s...

Page 37: ...and refrigerant pump runs continuously 3 When the solution temperature of the high pressure generator drops below 110 the refrigerant pump stops 4 After about 20 minutes of stopping operation the sol...

Page 38: ...d temp of H P gen Refrigerant pump operation Igniting system Stop Temperature control start Main stop switch ON Dilute operation Approx 20 min Damper low Combustion position Solution pump stop Below p...

Page 39: ...0 for the stoppage order of heating operation Fig 5 10 Cooling Operation Flow Diagram STOP Start switch ON Hot water thermostat ON with heating load N Hot water flow rate o H P gen Solution level r H...

Page 40: ...nerator is low at starting The service operation pump up the solution to the high pressure generator to provide the condition suitable for start up 2 In the case that crystallization of solution occur...

Page 41: ...confirm that the number of non condensable gas bubbles is less than 2 per minute The degree of vacuum must be below 2 mmHg Note The ballast valve must be kept open during vacuuming the chiller heater...

Page 42: ...hiller heater is operating 2 In heating season be sure to perform the purging while the chiller heater stops 3 In heating season be sure to close the service valves for maintenance and for manometer 4...

Page 43: ...condensable gas only is accumulated in the reservoir 3 The non condensable gas in the reservoir is purged into the atmosphere by simultaneous use of the purge pump 4 Operation frequency of purge pump...

Page 44: ...e chiller heater has corrosivity an inhibitor is added to the solution When anti corrosive thin film is formed on the inside surface of the chiller heater by the inhibitor hydrogen gas generates The a...

Page 45: ...by pass valve and damp the refrigerant to the absorber When the refrigerant level is out of sight from the evaporator sight glass close the by pass valve 3 Carry out service level is out of sight from...

Page 46: ...the discharge pipe of the vacuum pump and soak the other end of the vinyl hose into the pump oil container Be sure that the point of the hose is not soaked in the oil more than 6 mm ii Close the manua...

Page 47: ...stallation condition operating hour and so forth However it is inevitable It is essential in order to maintain the chiller heater in normal and good condition to know the state of the chiller heater c...

Page 48: ...rature 4 Combustion Condition Visual Chilled Water 5 Inlet Temperature 6 Outlet Temperature 7 Flow Rate h Hot Water 8 Inlet Temperature 9 Outlet Temperature 10 Flow Rate h Cooling Water 11 Inlet Tempe...

Page 49: ...ed Fan Check Forced Fan Overhaul Burner Nozzle Overhaul Explosion Door Check Refrigerant Check Solution Sampling Thermometer Check Pressure Gauge Check Chilled Hot Water Pump Cooling Water Pump Coolin...

Page 50: ...e efficiency due to deposit of scales on the heat exchangers and may also cause a serious accident such as submersion of the chiller heater by the corrosion damage of heat transfer tubes perform water...

Page 51: ...ut down period periodical circulation of the cooling water by the pump is recommended This is for equalization of the density of chemicals in the cooling water In case of leaving the cooling water lin...

Page 52: ...rs do not remain inside the tubes and water boxes 3 Check if the packing of the sluice plate and flange are not damaged and fitted correctly 4 Check if the sluice plate is set in correctly between the...

Page 53: ...fter preparing at a prescribed concentration in a container charge the chemical from the drain port and make it circulate by circulation pump The circulation time depends on the amount of removal of t...

Page 54: ...first Generally air volume required for combustion theoretical air volume is 1m3 1 000 kcal regardless of kind of fuel The biggest problem for the burner is combustion under insufficient air The cont...

Page 55: ...pilot and main governors for actuation and controllability Strainer Clog Pay attention to gas pressure or oil pressure during operation and clean it when it goes down Forced Fan Driving parts and bear...

Page 56: ...tor Clean the glass of the flame detector Gas pressure switch High and low applied for gas fired type Check the deviation between actuation and setting point by changing gas pressure or setting point...

Page 57: ...rate is short Check the cooling Check cooling water temperature control system Tubes for cooling water are dirty Check the cooling water pump and cooling water system Clean the cooling water tubes Not...

Page 58: ...r Temperature low switch U6 Chilled water load is too small Chilled water temperature is too low Check the setting point of chilled water thermostat and chilled water controller Check the chilled wate...

Page 59: ...ut taking no countermeasures crystallization may take place because of no dilution operation In case of power failure open the damp valve located at the lower part of the low pressure generator to dra...

Page 60: ...DIX Technical Information and Data for Reference 1 Principle of Absorption Chiller heater 2 Properties of Lithium Bromide Solution 3 Adjustment Procedure of Inhibitor for Lithium Bromide Solution 4 Sp...

Page 61: ...ressure kg ata Saturation temperature Over atmosphere Atmosphere Vacuum 20 10 8 5 1 0 21 11 9 6 2 760 mmHg 634 0 355 2 149 4 92 5 55 3 17 5 9 2 7 5 6 5 6 1 5 7 213 86 183 20 174 53 158 09 119 61 100 0...

Page 62: ...ter by vacuum pump but such a way is not good because the volume becomes so big In the absorption chiller the refrigerant vapor is absorbed into lithium bromide solution As the vapor s partial pressur...

Page 63: ...unning in the heat exchanger tubes to be condensed and liquefied The condensed water is supplied to the evaporator as refrigerant As mentioned above the absorption chiller consisting of the evaporator...

Page 64: ...Bromide Solution 2 1 General Properties As supposed from the fact that lithium and bromide belong to alkali and halogen group the general chemical property of lithium bromide is similar to salt and it...

Page 65: ...gh efficiency is expected in the absorption chiller heater using water and lithium bromide 2 5 Vapor Pressure The essential reason why lithium bromide is used as absorbent in the chiller heater is tha...

Page 66: ...66 Fig 8 Lithium Bromide Temperature Specific Gravity Concentration Curve...

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Page 68: ...on of the chiller heater for 5 days or more Besides it must be sampled after continuous operation of the chiller heater for 5 hours or more on the sampling day 2 At dilution operation discharge refrig...

Page 69: ...y metals Especially be careful not to put LiOH in the eyes 4 Spill over As the cooling load changes both the refrigerant level of the evaporator and the solution level of the absorber also change Fig...