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Hyundai HDFN-80-1400 Operation Instructions Manual

Gas/ oil direct-fired absorption chiller-heater
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HYUNDAI
CLIMATE CONTORL CO., LTD.
Operation Instructions
Gas/ Oil Direct-fired Absorption Chiller-heater
Models:
HDFN-80 ~ 1400

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Summary of Contents for Hyundai HDFN-80-1400

  • Page 1 HYUNDAI CLIMATE CONTORL CO., LTD. Operation Instructions Gas/ Oil Direct-fired Absorption Chiller-heater Models: HDFN-80 ~ 1400...
  • Page 2 Please read this manual through carefully so that you can use Hyundai Climate Control Co., Ltd. Gas/Oil Directfired Absorption Chillerheater under favorable conditions for a long period.
  • Page 3 PRECAUTIONS The following cautions shall be observed in order to ensure safe operations of the gas/oil direct- fired absorption chillerheater. 1.Cautions before Starting Operation. Read this manual through before operating the absorption chillerheater. Especially, understand the operating procedures of the important operations well prior to their actual operations. Do NOT use other fuels than designated in the nameplate of the absorption chillerheater.
  • Page 4 NEVER switch off the main power source during operation of the absorption chillerheater. Besides, do NOT switch off even the machine is not operated except for a special case. Do NOT touch the switches in the control panel with wet hands. It may cause an electric shock. NEVER touch the combustion system.
  • Page 5 4. Cautions for Changeover between Cooling and Heating, Inspection and Maintenance At the time of changeover between cooling and heating operation, be sure to understand the operating procedure for changeover well and then changeover as per the procedure correctly. When the oil in the purge pump is replaced with new oil, be sure to stop the operation of the pump to avoid injury and to splash of the oil.

  • Page 6: Table Of Contents

    CONTENTS CHAPTER 1 COMPONENT AND FUNCTION 1. Construction and Function of Major Components Evaporator  Absorber  High Pressure Generator  Low Pressure Generator  Condenser  10 Solution Heat Exchangers  10 Purging System  10 Pumps  10 Solution pump, refrigerant pump ...
  • Page 7 5.6.1 Cooling to heating  5.6.2 Heating to cooling  Service Operation  6. Purging  40 Importance of Purging  40 Purging Operation  41 Vacuum Measurement  42 Continuous Purging  42 6.4.1 Explanation on the system of continuous purging  42 6.4.2 Operation procedure ...
  • Page 8 APPENDIX --- TECHNICAL INFORMATION AND DATA FOR REFRRENCE 1. Principle of Absorption Chillerheater  61 Vacuum  61 Principle of Absorption Chillerheater  61 Reason why heating can produce chilled water  61 1.2.1 Explanation on refrigeration cycle  62 1.2.2 Double effect (twostage) absorption chiller ...

  • Page 9: Chapter 1 Component And Function

    CHAPTER 1 COMPONENT AND FUNCTION Construction and Function of Major Components Hyundai Climate Control Co., Ltd. Gas (oil) Directfired Absorption Chillerheater using pure water as refrigerant, lithium bromide solution as absorbent, and gas (oil) as energy source. The chillerheater consists of the main shell with low pressure generator, condenser, absorber and evaporator, and the separate shell with high pressure generator, and solution pump, refrigeration pump, solution heat exchangers, airpurging device, etc., and piping and control system.

  • Page 10: Condenser

    Condenser The condenser is provided to condense, liquefy and cool down the refrigerant vapor generated in the low pressure generator and the refrigerant drained in the tubes of the low pressure generator by the cooling water flowing into the condenser tubes. The liquefied and cooled refrigerant is sent to the upper part of the evaporator through the connection pipe by the gravity and differential pressure and it is sprayed on the external surface of the evaporator tubes.
  • Page 11 Fig. 1.1 External View of Chiller-heater...

  • Page 14: Cooling And Heating Cycle

    2. Cooling and Heating Cycle Both cooling and heating operation is available with a single unit of the chillerheater only by switchingover. The absorption cycle in each operation mode is explained respectively as follows : Cooling Cycle (See Fig.2.1 A) The main shell is divided into two parts, lower shell and upper shell.

  • Page 15: Heating Cycle

    generator and is mixed with the concentrated solution from the low pressure generator. Point g~h : A state where the concentrated solution going out from the low pressure generator is cooled down in the low temperature heat exchanger. Point h~I : A state where the concentrated solution is sprayed on the surface of the absorber tubes to be cooled down in the low temperature heat exchanger.

  • Page 17: Capacity Control And Protective Devices

    Capacity Control and Safety Devices Chilled Water Temperature Control The signal sent from the temperature sensor installed at the water head of the chilled water outlet controls the fuel consumption of the high pressure generator to ensure an efficient operation even to part load.

  • Page 18: Solution Flow Rate Control

    Solution Flow Rate Control The reduction of the solution flow rate by the speed control of solution pump ensures an efficient and stable operation in cooling operation at partial load. Since the pressure of the high pressure generator reduces due to the reduction of the fuel consumption in partial load, the solution level in the high pressure generator tends to rise up.

  • Page 19: Low Load Control

    Low Load Control Chilled water temperature, hot water temperature and solution flow rate are controlled by the way mentioned above and the chillerheater keeps on efficient and stable operation from full load to low load. When the load of chilled water or that of hot water goes down under the set point, the gas control valve closes to stop the operation of the chillerheater.
  • Page 20 Fig. 3.5 Operation Flow Chart...
  • Page 22 Table 3.1 List of Protective Devices Description Symbol Set Point Active Condition Protective Action Protection Purpose Pressure differential switch for 63EW Approx. 80% of Contact to be open when Combustion shut-down, sol. pump Freeze and boiling prevention chilled/hot water rating flow flow falls and refrigeration pump stop Chilled water low temp.
  • Page 23 Description Symbol Set Point Active Condition Protective Action Protection Purpose Over-current rely for solution INV5 Rating current Solution pump #2 motor pump #2 motor protection (option) Over-current relay for refrigerant M2-49 Rating current Combustion shut-down and sol. Refrigeration pump motor pump motor Pump stop protection...

  • Page 24: Chapter 2 Preparation And Operation

    CHAPTER 2 PREPARATION AND OPERATION Preparation for Operation The preparation works stated in this chapter must be done by service engineers of Hyundai Climate Control Co., Ltd. or its registered service agent. 4.1 Evacuation (Vacuum confirmation test) (1) Evacuation After the installation of the absorption chiller-heater, nitrogen gas charged and pressurized in the chiller-heater shall be discharged from the vessel and then evacuation is performed.
  • Page 25 (3) Evacuation After completing the charge of solution, refrigerant and alcohol, operate the purge pump to purge air out of the chiller-heater. (4) Discharge of solution and refrigerant in the chiller-heater When solution must be discharged from the machine for some reason, it is easily discharged by opening the service valve for discharge as the discharge pressure of the solution pump is higher than the atmospheric pressure while the chiller-heater is operating as long as the pump is operating.

  • Page 26: Checking Of Rotation Direction Of Each Motor

    4.3 Checking of Rotating Direction of each Motor As for the secondary 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, operating noise after checking the phase of the primary wiring in the field.

  • Page 27: Operation Procedure

    Operating Procedure 5.1 Cautions During Initial Period of Operation Since a new machine just after installation does not have enough fitting of each part to bear severe operation, operate the chiller-heater with a great care in the initial period according to the following suggestions.

  • Page 28: Preparation For Start-Up

    Checking of the charging amount of solution and refrigerant Check shall be performed when the load of the chiller-heater is 100%. If the refrigerant volume is too small, crystallization or cavitation of the refrigerant pump may occur to result in accidents. On the contrary, if it is too much, the chiller-heater may not display its full performance.

  • Page 29: Adjustment Procedure For Operation

    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: Adjustment Procedure For Solution Flow Rate

    5.3.2 Adjustment procedure for solution flow rate (1) Function of each butterfly valve and initial setting of valve opening (Table 5.1) ----- Same settings for both cooling and heating Table 5.1 Function and Initial Setting of each Butterfly Valve Initial Setting for Symbol Name...
  • Page 31 Table 5.2 Functions and Initial Settings of the Valve Opening for Heating Operation Initial Setting Symbol Name Location and Function for valve Remarks Opening Refrigerant Location Refrigerant vapor line Fully opened. Fine adjustment of vapor valve for from the high pressure the high pressure Adjust the valve change-over...
  • Page 32 Initial Setting Remarks Symbol Name Location and Function for valve Opening V-30 Dilute solution Function Flow rate control of dilute distribution flow solution to the low rate control pressure generator (manual butterfly valve) Fully closed V -29 Intermediate Location Intermediate solution flow rate concentration solution line control valve...
  • Page 33 (Spraying flow rate to the evaporator --- refrigerant) 5) Adjust the flow rate by the valve V-18. Set the initial setting of the valve opining refer to table 5.1. After the operating conditions get stable, adjust the valve finely to such an extent cooling capacity may not drop (the indicator should be chilled water outlet temperature).
  • Page 34 Models Dilute Solution Flow Rate Inlet Pressure of Dilute Solution of Low Temp. Heat Exchanger HDFN Kg/cm 16.7~18.0 9.0~9.6 7.7~8.4 18.5~20.0 10.0~10.7 8.5~9.3 1.0~2.0 20.8~22.5 11.3~12.1 9.5~10.4 23.2~25.0 12.5~13.4 10.7~11.6 22.8~24.2 12.2~13.0 10.6~11.3 26.5~28.2 14.2~15.1 12.3~13.1 1.5~2.5 30.2~32.2 16.2~17.2 14.1~14.9 33.9~36.1 18.2~19.3 15.8~16.8...

  • Page 36: Cooling Operation

    5.4 Cooling Operation 5.4.1 Start-Up (1) Operate the chilled water pump. (2) Operate the chilled water pump. No indication lamp is provided for cooling water flow rate. As the cooling water pump is interlocked with the chiller-heater, the machine does not start as far as the cooling water pump does not run.
  • Page 37 Stopping operation is done automatically as per the following process: 1) The fuel valve is closed after the burner transfers to the low combustion condition and the main burner puts out. The indication lamp, “COMBUSTION” goes off. 2) The chiller-heater starts dilute operation after stopping operation and the solution pump and refrigerant pump runs continuously.

  • Page 38: Heating Operation

    Chilled water flow rate . Start switch ON Chilled water thermostat ON Cooling water pump operation. (with cooling load) H.P. gen. Solution level. H.P. gen. Temperature Exchange gas temperature Gas pressure (Applied for gas fired type) Chilled water temperature Normal air pressure Forced fan motor ON Normal Solution pump Operation...

  • Page 39: Stoppage

    (2) Open the main fuel valve. (3) The process to be followed is the same as mentioned in the cooling operation and the chiller-heater is operated automatically. Note : The refrigerant pump does not operate in heating operation. Refer to the Fig. 19 for the stert-up order.

  • Page 40: Changeover Between Cooling And Heating Cycle

    5.6 Changeover between Cooling and Heating Cycle. 5.6.1 Cooling to heating Perform dilute operation to equalize the solution concentration and change the cycle. (1) Change the selection switch in the control panel to heating from cooling. (Snap switch – SW-4) (2) Operate the cooling-heating change-over valves: V7 : Open (adjustment is required.) V12 : Open (adjustment is required.)

  • Page 41: Purging Operation

    (1) Reduction of cooling capacity due to the rise of evaporating pressure and the drop of absorbing ability. (2) Increase in fuel consumption (3) Growth of corrosion inside the chiller-heater due to the consumption of the inhibitor in the lithium bromide solution, which may cause to shorten the machine life. (4) Deterioration of the operating cycle due to cut-out of the pressure switch by the rise of the pressure and temperature in the high temperature portion and actuation of the solution temperature control device, which may accelerate the deterioration of the packings and O-...

  • Page 42: Vacuum Measurement

    (10) Switch off the purge pump after closing the manual purge valve without fail. (11) In case the capacity of the purge pump drops (in case the degree of vacuum does not reach below 7 mmHg), check the manual purge valve is closed and replace the oil in the purge pump. Use vacuum pump oil for the purge pump oil.

  • Page 43: Continuous Purging

    6.4 Continuous Purging 6.4.1 Explanation on the system of continuous purging (1) Non-condensable gas is sucked by ejecting solution at the suction portion from the nozzles--- ejector actuation. The opening of the valve V-10 must be set at about one and a half turn opening from the fully closed position.

  • Page 44: Operation Procedure

    6.4.2 Operation procedure (1) Open the valve V-10 when purging continuously. (Leave it opened while the purge pump is running.) (The valve V-10 is usually set at about one and a half turn opening from the fully closed position. When non-condensable gas in the shell is less and the cavitation sound occurs, throttle the valve V-10.) All other valves are closed fully.

  • Page 45: DeCrystallization

    (Solution concentration at the high pressure generator outlet) 1) Read the high pressure generator pressure. 2) Read the intermediate concentrated solution temperature at the high pressure generator outlet. 3) Then, draw a horizontal line of the pressure value obtained above 1) and search for a point of intersection with the perpendicular stood from the solution temperature obtained above 2).

  • Page 46: Chapter 3 Maintenance And Inspection

    (2) Replace the oil in the purge pump with fresh oil and operate the pump for about one hour once a week. Maintenance and Inspection Proper maintenance will ensure the full performance of Hyundai Climate Control Co., Ltd. Direct-fired Absorption Chiller-heater. It is required for securing efficient operation, safety operation and long life of the machine.

  • Page 47: Others

    9.1.4 Others (1) Make sure that smell of gas is not detected around the chiller-heater. (2) Make sure that no abnormal sound occurs after the gas burner is fired. (3) Make sure that no abnormal conditions are found in the connection between the burner and the gas line.
  • Page 48 Table 9.1 Gas (oil) Absorption Chiller Heater Inspection List Cooling Heating Cooling/Heating Date Inspector Inspection Items Date/Time Unit ℃ Ambient Temperature mmAq or ㎠G 1.SupplyFuel Pressure ㎥/h or lit./h 2. Fuel Flow Rate Combustion ℃ 3. Exhaust Gas Temperature 4. Combustion Condition (Visual) ℃...
  • Page 49 Table 9.2 Periodical Inspection Every 6 Every Every 2 Inspection Item Monthly Other Months Year Years ○ Control Cap. System ○ Protective Device ○ Chilled Water Tube Cleaning ○ Cooling Water Tube Cleaning ( ○ Purge Pump Capacity ○ Purge Pump Overhaul ○...

  • Page 50: Cooling Water Control

    9.4 Cooling Water Control 9.4.1 Temperature control Cooling water condition effects on the operation cycle of the chiller-heater greatly. Generally, too low or too high temperature of cooling water may cause the following troubles : Too low temperature of cooling water ------- Solution crystallization Too high temperature of cooling water ---- High pressure trip and capacity drop In general, absorption chiller-heaters are designed to be operated at 32 ℃...

  • Page 51: During Prolonged ShutDown

    Make-up water is needed to supplement splash loss of the cooling water in the cooling tower and besides the blow-down of cooling water is also needed to prevent condensation due to evaporation. In order to determine the volume of blow-down, increase the volume gradually to maintain the target water quality according to the inspection result of cooling water quality during operation, and determine the blow-down volume.

  • Page 52: Mechanical Cleaning

    heater to the cooling tower during operation, thus narrowing the temperature difference between the chiller-heater inlet and outlet. (4) Absorber dilute solution temperature rises and the chiller-heater internal pressure becomes higher. If any one of the above phenomena is found, take preventive measures as early as possible for the sake of the capacity and service life of the chiller-heater.
  • Page 53 3) Mud If mud content is high, it can not be removed by mechanical cleaning. Remove the scale by mechanical cleaning mentioned above. (3) Connect piping for cleaning Drain out water from the tube side and water boxes through the drain ports, Fig. 22 shows the connection method for acid cleaning of the absorber and condenser system.

  • Page 54: Cautions For Use

    Combustion control means keeping air ratio to be proper value (approx. 1.2 ~ 14) constantly. Hyundai Climate Control Co., Ltd. Gas/oil Direct-fired Absorption chiller-heater’s burner is designed to keep the air ratio to be constant for stable combustion.
  • Page 55 Table 9.4 Checking List on Combustion (1/2) Frequency Semi- Annuall Item Contents Checking Procedure annually or more more Leakage Check by soap water, pressure drop or ○ smell Piping Corrosion, mechanical Visually check corrosion and damage ○ damages, etc. ○ Leakage Check by soap water or smell Valves...
  • Page 56 Frequency Semi- Annuall Item Contents Checking Procedure annually or more more ○ Main fuel valve Check valve action and confirm function (Shut-off valve) at misfire. Check if gas passes through the shut-off valve with gauge or bubble test in the water especially at time of initial running ○...

  • Page 57: Troubleshooting And Countermeasure

    Troubleshooting and Countermeasure It was already stated in the previous chapter that it is important to know whether or not the chiller- heater was operating normally in daily inspection and maintenance. When trouble occurs, the countermeasures itemized in the chapter should be taken quickly in order to restore the normal operation of the chiller-heater.

  • Page 58: Improper Combustion

    10.3 Improper Combustion Cause Steps to be Taken Fuel flow rate is excessively high or low  Adjust fuel control valve and air damper opening  Check and adjust fuel supply pressure  Adjust gas supply pressure Gas supply pressure fluctuates (for gas-fired unit) ...

  • Page 59: In Case Of Power Failure

    Misfire of burner ( Poor igniter transformer ( Check and replace with new ( Dirty and poor flame detector igniter transformer ( Failed actuation of the fuel shut- ( Check and replace with new off valve flame detector ( Failed protect relay ( Check and replace with new gas ( Improper air-fuel ratio shut-off valve...
  • Page 60 APPENDIX (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. Spill-over...

  • Page 61: Principle Of Absorption Chiller-Heater

    Principle of Absorption Chiller-heater 1.1 Vacuum The earth on which we are living is compressed by the weight of air layer surrounding the earth approximate 10km above. It is called the atmospheric pressure and the lower pressure than the pressure is called vacuum. To talk about vacuum in absorption chiller-heater, it is necessary to know the relation between the known that water boils at 100 ℃...

  • Page 62: Explanation On Refrigeration Cycle

    When water is heated at the atmospheric pressure, it boils and generates steam at 100 ℃. That is, the heating energy is consumed in order to raise water temperature (sensible heat) and to generate steam from water (evaporating latent heat) (Fig. 1). 1.2.2 Explanation on refrigerating cycle As mentioned above, the lower the pressure, water evaporates at the lower temperature.
  • Page 63 water, combustion gas, etc. flowing in the heat exchanger tubes and a part of water in it is evaporated to result in increasing its concentration to the original condition. The concentrated solution flows into the absorber and absorbs the refrigerant vapor again. While, the evaporated refrigerant vapor flows into the condenser and is cooled down by cooling water running in the heat exchanger tubes to be condensed and liquefied.

  • Page 64: Double Effect (Two-Stage) Absorption Chiller

    1.2.3 Double effect (two-stage) absorption chiller The absorption chiller mentioned above is the single effect type. The following is a simple explanation on the double effect absorption chiller. (Condenser) As shown in Fig. 5, the two generators are provided in two-stage in the chiller-heater. One is the high pressure generator heated by the combustion device such as gas and oil and the other is the low pressure generator heated by the refrigerant vapor which generates in the high pressure generator.

  • Page 65: Solubility

    2.2 Solubility The solubility of lithium bromide in water is very large. The concentration of saturated solution at 20 ℃ of room temperature is approx. 60 %. As shown in Fig. 6, when water evaporates from aqueous solution or the concentration reaches higher than the saturated point or the liquid temperature drops, salts of 1, 2, 3, or 5H2O precipitates to cause so-called crystallization.
  • Page 66 Fig. 8 Lithium Bromide Temperature-Specific Gravity-Concentration Curve...

  • Page 68: Adjustment Procedure Of Inhibiter For Lithium Bromide Solution

    3. Adjustment Procedure of Inhibitor for Lithium Bromide Solution 3.1 General This is to describe the procedure of analysis and adjustment of lithium bromide solution in the chiller- heater to be installed at site. 3.2 Standard of Lithium Bromide Solution Table 3 Threshold Valve for Required Target Valve for Re-adjustment...

  • Page 69: Charging Procedure Of Chemicals

    3.5 Charging Procedure of Chemicals (1) Li (chromic acid lithium) AT the service operation with 1/3 fuel consumption rate at full load, charge Li diluted with 50 liters of refrigerant (pure water) gradually from the discharge service valve of the refrigerant pump.

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