HITACHI Inspire the Next Featuring HFC134a Refrigerant HITACHI CENTRIFUGAL CHILLER HC-F-GSG Series, 1,407 - 4,395 kW (400 — 1,250 USRT) HC-F-GXG Series, 1,407 - 4,395 kW (400 — 1.250 USRT) TECHINICAL INFORMATIONLeute | ance a) Contents 1. Features and Scope of Supply Ll Features 1.2 Scope of Supply 2, Standard Spec ations 2.1 Standard Efficiency Type Specifications Table 2.2 High Eificiency Type Specifications Table 23 Standard Type Outline Drawing 2.4 Seandard Type Foundation Drawing 3. Model Selection Table 3.1 How to use the table (HC: SSGIGNG type) 4. Characteristics Information 4.1 Control Characteristies 4.1.1 Capacity controt characteristics (@) Pan load characteristics 4.1.2 Temperature control characteristics (@) Temperature control characteristics (b) Temperature characteristies at startup 4.2 Motor characteristics 4.2.1 Starting current characteristics 43 Noise 44 Vibration 5. Instrumentation and Control 5.1 Operation Control System $2 Safety Control Equipment ‘5.3 Sequential Operation with Pump and Cooling Tower Fan ‘54 control panel Indication S41 Display items 54.2 controt panel display 5.5 External Signal Tie-in 6. Start-up Panel (Starter) 7. Main Equipment Configuration and Main Options 7.1 Cycle Drawing 7.2 Compressor Unit7.3 Heat Exchanger Unit 7.4 Main Options 7.4.1 Marine-type water chamber case (option) 7.42 Hot gas by-pass valve control 7.4.3 Outdoor cover 8. Inspection 8.1 Inspection Etems and Points 9. Facility Design Considerations 9.1 Machinery Room and Maintenance Facilities 9.2 Notes for Operating the Chiller 9.2.1 Operatton in winter period 9.2.2 Standard range of operation 9.23 Other notes 93 Low Load Operation 9.3.1 Hot gas by-pass valve control 9.4 Vibration and Earthquake Prooting 9.4.1 Effect of vibration proofing 9.42 Earthquake proofing 9.5 Variable Flow Control (optional) 9.5.1 Cooling water variable flow control 9.52 Chilled water variable flow control 9.6 Controlling Number of Units 10. Constructional Considerations 10.1 Rigging Work 10.2 Insiallation Work 10.3 Water Piping Facily Work 10.5 Cold Insulation Work 11. Reference 11.1 Properties of refrigerant 11.2 Lubricating Oil 11.3 Maintenance tem List 11.4 Water Quality Control 11.5 Laws and RegulPreface ‘Laying the greatest emphasis on environmental protection of the earth, Hitachi has manufactured and offers you a centrifugal chiller featuring HBC- |34a refrigerant which has no effects on destroying the ozone layer. ‘Combining our expertise cultivated by a delivery record of about 6,300 chillers with our new technologies required for use of HFC- 34a refrigerant (such as fluid performance improved by the optimum impeller shape, heat transfer performance improved by a high-performance tube, and lubrication performance improved by a new lubricant), Hitachi provides high efficiency. performance and reliability Please use the Hitachi centrifugal chiller Featuring HFC-134a, as a future heat source for air conditioning or a cooling water manufacturing facility. This manual introduces the Standard-Efficiency type (HC-F400GSG to HC-FI250GSG ) and High4 Efficiency type (HC-F400GXG to HC-F1250GXG). For more information, please contact your nearest dealer.1. Features and Scope of Supply 1.1 Features ‘This chiller uses HFC134a refrigerant which has an ozone depletion potential of *zero* in 1] terms of protecting the ozone layer. higher than the atmospheric pressure at the startup/stop, thus requiring no purge unit and Using high-pressure refrigerant HFC134a always keeps the intemal pressure of equipment [2] ‘emitting less refrigerant to the air. ‘The ues of an economizer cycle, as compared with the conventional HC-F models, 3. | provides high efficiency and energy saving, and no purge unit is required for easy maintenance ‘The microcomputer packaged on the equipment provides highly functional operation control, 4 1.2 Scope of supply tem Delivered equipment or services 1. Chiler main unit | Compressor, main motor, lubricator, heat exchanger 2. Auxiliary Safety devioes, contol pane, starter Cindoor, nt explosion-proof), accessories, spares eee y pa G plosion-proof), 3 Testing Factory performance testing (when muliple chillers are ordered, only one is tested) ‘Main unit : Rus-proof painting. Control panel and starter cubicle : Finished with: Flat Munsell SY7/ 4 Painting: ial, ‘S.Transportation —_| Shipped on truck or trailer to the port in Japan without any transferring ‘Out of scope of supply : Unloading POB por, installation, cold insulation work, primary and secondary electrical wiring. foundation work, commissioning. pining2. Standard Specifications 2.1 Standard Efficiency Type Specifications Table (HC. Specifications (ARI temperature condition ) '400GSG to HC-F1250GSG) Chilled water inlet teraperature 123°C outlet temperature 6.7°C; Cooling water inlet temperature 20.4C. outlet temperature 34.8°C ypeING-F_ GSS) Funes | rewase | roesa | rewass | Paoocsa |] rrzsncss cin apy ww [aes uae eee | omen | [aan aan Fava we 26 [ms [ao | ms | oo |] e ag Pxmbooteoan [wef —@ [= | # |» |" | 6 mr [emma me Ty wo | 0 | om | am | ao iietwetteaes |= [2 2 2 z z z Towa Ae ing [Pessue Deaton [wo[ ee | oe mL ® [_® aw [emmeom ree To] aw | mw | ao | om | am | ao Nntwstranes[- |? 2 2 z 7 z Seater hpe wi aw [ [wep ef ee Tyeand OP => [= | == | = | se [om tat mm] ser [seo | ao | so | «oo | ae cnn |W 6 wm] 200 | 20m | 200 | 2000 | amo | acwo mensions | Height (C) mm 2.260 2.280 2.370 2830 2,600 3.040 Termite Pag Tabs [wm | e000 | som | amo | soo | sum | _anmo Opwanatasdhopen) | wm | na | os | ve | ea | va | me ms Carrying Mass (Approx.) | ton 8a 8 10.9 142 1% 08 Teton z Wim — ~L= |= |* |= |* | # Notes: 1 2 5 6 ‘.Spectications are subject to change widhout notice for technical improvement. This table fs applicable chilers manufactured for normal water Capacity conte range is 108 to approx. 208. Fouling factor is assumed to be 0.000036m?-=/W for both chilled and cooling water. Other oulng actors may be met upon request. ‘Standard main power sources: 400V AC, SO Hz, phase HC-F400GSG to F1250GS6, Capacites: HC-F400GSG to F1250G8G: 4 5kVA. Maximum working pressure i 0.7 Mpa for both chiled ane coating water. If higher maximum working pressure i roquiest Please speciy during inquiry. (tis possible to produce it up to 1.6 MPs} [For water piping connections, sae the dimensional auline drawing. (COP values fo nat incase auxdiary powerSpecifications (JIS temperature condition ) Chilled water inlet temperature 12°C, outlet temperature 7°C: Cooling water inlet temperamure 32°C, outlet temperature 37°C ype IHC-F_GSG} Faas | Fsoocse | Feoocse Fresoese. te 500 600 1.250 Pressure Drop (Approx) [kPa 7a 78 76 jater | Connection Pipe ees py] 200 200 280 ‘Number of Pasees = 2 2 2 Fiow Rate mim | 258 are a5 Pressure Dep ppon) [ora | 70 0 7 5 2 a Lag ep (APEX) | cm" fee Loup ae | om fm | m [oe |e ‘Number of Passes = 2 Expected motor Input Taneced cP tena wm seo | see zon | aon [ame etn | WAR wn] 200 | 20m | 2am | amo | ama | 0mm vrei) wm | 2a0 | za [2a | 20 [oma | ane Levan xara Tas [wm] sow | aon | anon | aaoo | awa | a0mn Se ee corieaess tower) [am | a 2 [we | we | = | = Tonge = ote Tuatng Awa |= 26 2 5 a Notes: This table is applicable to chilers manulactured for normal water Capacity contro range is 100 10 approx. 20% Fouling factor ie assumed tbe 0.000086" CW for Roth chited and cooling water. Other fouling factors may be met upon request. Standard main power sources: 400V AC, 50 Hz, Sphase HC-FaQ0GSG to F128005 Capactios: HC-FA00GSG to F1250GSG: 4.5kVA. Maximum working pressure 0./ Mpa for both chiled and cooling water. higher maximum working pressure requiast. Pease specify during inquiry. (ts possible to produce it up to 1.6 MPa) "TFor water piping connections, sae the dimensional otine drawing. 2, COP values fo not include aundiay power ‘9.Spectications are subject to change without notice for technical impraverent.2.2 High Efficiency Type Specifications Table (HC-F400GNG to HC-F1250GXG) Specifications (ARI temperature condition ) ‘Chilled water inkct temperature 12.3°C. outlet temperature 6.7°C; Cooling water inlet temperature 29).4°C_ outlet temperature 34.7°C pe HEF Gr rs cys ww | wwe | ve | paw | oes | aes [ aes Towa me Ce ag xeomomnteon [wef ef « | « |» |» [| = | or [eames ow | amo | wwe | oko | mw | aw | tw nie tfeaes | = | z z ; = wap ep we | | we | me a, Pam l=[ = [3 | « |= |» [= ine [Seencinee Toy Tame | aso | aso | ame | me | ao ea 2 2 7 Game roe wpe pe] ae] eee = =[ sa [sm | se | ea [eo [eo ‘eah wm [sso | aioe | seoo [sooo | saoo | a0 atin | rm |_2a0 | saw | aeso | ceo | amo | amo venensions | Height (C) mm. 2,350 2,380 2,600 2.600 3150 3180 teoghteratraTaoe [om | ae | aew | aooo | samo | ano | amo Gpeainanistorcns | em | ae | ne | wa [me _[_~ | = “= Camying Mass (Approx) | ton we 165 165 23.5 25 a | ese e a D*= )*= |=) |= Notes: 4. This table s applicable to chilers manufactured for normal water. 2. Capacity contol range is 100 t approx. 20%. 23. Fouling actors assumed to be 0.000086n”. = /W lot beth chiled and cooling water. Other fouling factors may be met upon request. 4, Standard main powar sources: 400V AC, 0 Hz, phase HC-FaQUGXG to F1259GXs. 5. Capactios: HC-FA00GXC to F1250GXG: 4-5KVA_ 6. Maximum wodking pressure if 0.7 Mpa for both child and casing water If higher maximum working pressure if request. Please specdy during inguty. (tis possible to produce it up 10 1.6 MPa) {L.For water ping connections, see the dimensional outine drawing 8. GOP values fo not include aurtiary power. {.Speciiestions are subject o change without notice fr technical improvement.Specifications _( JIS temperature condition ) Chilled water inlet temperature 12°C. outlet temperature TC; Cooling, waiter inlet temperature 32°C. outlet temperatare 37°C Sea NGF Gx] Faioone | remoxs | reocxe | remcxe | ravucxe | ror co] = | = | = | oo | oo | ia a Cay ww [var [ane [zee [aaa [ae [am Few wn| 2a [me [a [| os | Pen Ootome) [wa[ «| w# [« |» | # | « = wer [seman Tow | an | ooo | awe] a | | ae nnteretoenes | | 2 2 2 2 2 = wa] ae me ee ee reno [| sa] ele ple lo cin ae ar | acta Poe 5 ow] am | ao | ao | ao | ao | a tonne ste nenterfvenes [= [2 2 2 3 3 3 ——— wpe | ~ [ ae | a | ee pe Cagaced6OP =| [em | em | eo | ome |e aT wm [sao | asa [acon | emo | sam | caw ston | WHR wn | 200 | 2200 | 200 | omo | aan | saw Pensions | scignn(C) mm 2,380 2,380 2,600 2,600 3,350 3380 tah trPangtoc [am] sao | asco | = [= 1l*=)][#]=8 Notes: 1. This table is applicable to chillers manufactured for normal water 2. Capacty contol range is 1000 approx. 20%. 3. Fouling factor is assumed tobe 0.00006m" = for both chiled and cooling water. Other fouling factors may be met upon request. 4. Standard main power sources: 400V AC, SOH2,3-phase HC-F400GXG to F12S0CXG. ‘5. Capacitioe: HC-Fa00GKG o F1260GXG: 4 5KVA 6. Maximum working pressure if 0.7 Mpa for both chad and cooling water. If higher maximum working pressure # requiest Please speci during inquiry. (ts possible a produce it up in 1.6 MPa) {For water piping connections, soe the dimensional outine drawing 8. COP values fo not include auxtiary power {9 Specifications are subject to change without noice for technical improvement.2.3. Standard Type Outline Drawing ‘Tablel. Standard Efficiency Type (HC-F400GSG to HC-F1250GSG) ‘Model Fa0GsG [Fs00GsG [FeoGse [Fa00GsG | FooeGse | Fi25068G Outline Drawing |400V" Figure [Figure [Figure [Figure | Figure | Figure Figure Number 23.1 231 232 233 2.34 23.5 Table2, High Efficiency Type (HC-F400GXG to HC-F1000GXG) “Model | FAWGXG [FSQUGNG [FO30GXG | FS00GXG | FIOWUGXG Outline Drawing /400V Figure [Figure | Figure Figure —_—| Figure Figure Number: 2.3.6 23.7 2.3.8 2.3.9 23.10 2.4 Standard ‘Type Foundation Drawing ‘Tablel. Standard Efficiency Type (HHC-F400GSG to HC-F1250GSG) Model FAOGSG [FS00GSG | FOD0GSG | FROOGSG | F9NGNG Foundation Drawing |400V [Figure | Figure | Figure | Figure —_| Figure Figure Number 241 24el 2.4.2 243 244 245 Talbe2. High Efficiency Type (HC-F400GXG to HC-F1000GXG) (Model Fa00GXG | FS00GXG | F6R0GNG | F8O0GXG | FI000GXG Foundation Drawing [400V [Figure [Figure | Figure [Figure —_| Figure Figure Number 2.4.6 24.6 247 247 248DETAILS OF FLANGE (GB HG20593-97 ‘fk AT CENTER DiAMETER DIAMETER OF BOLT HOLE] 2 BOLT size 96 (TOTAL HEI TYPE WelGiT WEIGHT Te-Fo306% | nPPnOK. 19200 ny | APPROK. 16500 ug oc xT iavssonwes wn oreR comes on eve. ce coma. paw TION t 1430 bc OMe WOE 300 Con oF cont wate ‘TET oF cas wa ME OF CMM wT TR OF ONLLED TER tks "PPI FOR CALLED TER MD COLIN ATER SAL BE PRVLRD BF CST, ‘ust {THC IRE OUTLET OF ADT NTLED WATER AO CODING WATER SoD PRED AS IN THS DAN {LTH FECTIVE PIPE SUPPORTERS FORTHE CHULED ao DING TER ae REED 10 PROVIDE SO TAT THE WERETCAKE FORCE aD NOT ACT. TH PATON no CONNER TER HOES. 410 MH SRANERS SHULD BE SETED INT UPL PLING LIMES (OFTHE CLD 0 COLIN WATER SLONCRETE ORFACES WE SDE PLATES ARE PACED HOD AE FISD W FLAT ‘0 HRLZTHLY S CHAS PSSA. ‘LOMLLED TER 0 COOLING WATER UAT SOLD BE REGULATED OW TH OTL PUFING LI ‘LYALE Be FOL PES MASIRGMEVT tom E FROIED BY CTO WITHIN ee FEM CHLED JAD CONG WATER FE. 1 STRAIGT PPE OORE TH IROCATED_ ‘DIMNSLON_SAOME 8. PROVIDEL TO REPLACE areas fH EL a 109, 4000 3800 PITION St TTONB AlW ELECTRIC WOTOR UN GASE OF START ‘ue Fina" 210 ji { | | side eiLtew's vee suns Urgnarron ten..7a8 3 3 vont a is ral TON te, sale ge ose Twa 240 MAINTEUACE SPACE oss [Liaw 109 WALTENANCE SPACE | | L SPACE ON EITHER AOR B S102 al RE THAN 2470 Le _UreNBes RHE. sush We Ste or Sane DRAIN FOR WarNTENANCE a THIS ALANINE ROWS HE AAELE O2UENGIONE OF TE MET bcd PS0OURCEMTALA UAL MLL 2.10 REVERS ConRDGION OF THE LUGS OF ceRTMaFUGA SHULER. ull Ue Te FOUN? “ons, ACStRDENG, TOTS HAVENS, AMD Ene HAP THE BealhaGE 18 S090, 2.MKE 4 oharnace ov7cR araino THE chwrgiruGaL chine Reehi AMA Tok ge GeesaTeD PIC CHEAT TH AC HINESA THe SUREACE DF THE comoneTe QUNDATION tw EiNtaer Vion iat Sate base eae ao Taare orn {ND hs RoraL SCTALEN THE CENTER OFTHE TOR SusTace nes SLOPE Stati tom #08 nee vote ThGPALL ha CEMPtAFugie CHILLER. IPREPARE acuBtiis Linch! STV OIMCRETE-LAvINS MOM ANO THE WOETAR AND SRQUTINE woke Ave Guy OF Sure ue Tat Ash IRGERT RA OY LTH Te wae oe seer exc ce oF La aren SUES TY EASE OF OTMGR ENETEW GE FNL, 1, ANCHO 028, MTS WuSKERS, SOU PLATE 4X. fu SRE EAGLUGED FA AITACAT'§ SQPE OF SUFPLY Ie wishes ramaq WoRMpINOS L"p'Z ama OXDO08 Ol OXOOEIA-DH BU3. Model Selection Table 3.1 How to use the table (HC-F-GSG/GXG Type) (1) Mode! representation Hitachi Cenititugal Chiller models are represented by the standard refrigerating capacity of the compressor used. H C/-|F/||4)/0/0/}| GSG | | i T___ Chiller series eode | GSG-Standard efficiency type ‘Standard refrigerating capacity GXG:High efficiency type Name ot Applicable type for of the compressor chiller series _ alternate fleon {adopting HFC134a) (2) Formula for selecting an available model 1 USRT (US. refrigeration ton) = 3,024 kealth, = 3.516 KW 1 JRT (Japan refrigeration ton) = 3,320 kcalh = 3.86 KW Chilled water inlet temperature = Chilled water outlet temperature + Temperature difference between chilled water inlet and outlet Cooling water outlet temperature = Cooling water inlet temperature + Temperature difference between cooling water inlet and outlet Chilled water flow rate (m°%h)= Refrigerating capacity (RT) x 3.024 Chilled water temperature difference (3) Selection procedure and an example This technical information provides the ‘maximum capacity available for each model based on the fouling factor of 0.000086 m°K/W (0.0001 m*h°C ‘kcal) and within the range not exceeding the motor ‘output. If you wish to obtain lower power through any possible combination of devices, of you need any specifications of the range not offered in this technical information, please contact your nearest dealer. (a) Example specifications Power source : 50 Hz, 400 V Refrigerating capacity : 373 RT Chilled water temperature : 12°C at the inlet, TC atthe outlet Cooling water flow fate (m/h) [Rettigerating capacity (RT) x 3.024}+10.86xMotor input KW) Temperature dilferonee behween cooling water inlet and outlet Refrigerating capacity (RT) < 3.66 (High eliciency type)“ Temperature diference between cooling water inlet and outlet "13:72 (Standard type) Note : In this technical information, U.S. Refrigeration ton (USRT or RT) is used as the unit for expressing refrigerating capacity. Cooling water temperature : 32°C at the inlet, 37°C atthe outlet (b) Temperature aitterence calculation: Difference between at the inlet and the outlet of the chilled water: 12-7 =5 (©) Difference between at the inlet and the outlet of the cooling water: 37-32 = 5 (C) (€} Calculation of required power The power required for the desired specifications is calculated following the example given below atter ‘obtaining the correction factor from Figure 3.1. (KW of the motor represents the output)‘Specifications RT (373RT) Capacity ratio= —————. = 0,933 Capability RT (400RT) ‘The correction factor can be read as 0.95 in Figure 3.4 Therefore, Required power = Capability KW (240 kW). Correction factor (0.95) = 228 ki The required power obtained through the above calculation is only @ rough estimate and may be altered. For a more detailed value, please inquire via your nearest dealer. (2) Capacity control characters ‘The inlet guide vane incorporated in the compressor allows capacity control for a wide range ‘while maintaining a constant temperature at the chilled water outlet. Figure 4.1 in Chapter 4 illustrates the relationship between the refrigerating capacity and the required power; the required power varies with the temperature of the cooling water (an estimated value when the temperature at chilled water outlet and the water volume stay constant (e) Water flow rate and water head loss 3733.024 Chilled water flow 225.6 (mh rate 5 373x372 Cooling water flow = rate 5 Use the number of passes obtained in (c) and the above-mentioned water flow to calculate the water head loss from the water head loss curve in the capability table 277.5 (mith) Chilled water Cooling water 6.9 mAg 6.2mAq ‘Take the following points into account when calculating the water head loss: (1) The lower limit of the water head loss of the chilled water for the water flow of the specifications will be 4 ‘mAg or above depending on the operating condition ot the water cut-off relay. (2) Since the water head loss varies for each individual device, the water head loss of the chiller should be the value caleulated from the curve with 1 mAg or more allowance when selecting the specified water head of the pump. (8 Chilled water temperature condition ‘As for the specifications conditioned to have the temperature of less than 5°C. al the chilled water outlet, only a limited possible combination of devices or a limited ‘operation control system may be allowed to prevent freezing. Please inquire your nearest dealer. {g) Fouling factor ‘When the fouling factor is 0.000172 m?kiWw (0.0002 m*h*c/kcal), correct the temperature at the chilled water outlet to be lowered by 1°C and at the cooling water outlet higher by 1.5%. Then use the refrigerating capacity table with the corrected temperature conditions. For the fouling factors higher than this, inquire your nearest dealer. The appoximate correction factors are as follows: Lo $e Refrigerating Bao YZ) Water eon Motor Power Chilled water 0.94 1.0 Cooling water 0.96 1.0 0.9 _ f a i [CEE EEE O8 09 1.0 Capacity ratio = Spectication RT/Capabilty RT ‘Correction factor (P) Figure 3.1 Required power calculation4. Characteristics Infomation 4.4 Control Characteristics 4.1.4 Capacity control characteristics (a) Part load characteristics The capacity of the centrifugal chiller can be The inlet guide vane allows, using a chilled controlled by opening and closing the inlet guide vane ‘water outlet temperature regulator, 3 continuousty- installed at the iniet of the compressor to vary the stable capacity control within the range of 100% to amount of circulating refrigerant; the guide vane is approximately 20% of the refrigerating capacity, provided for assuring a constant temperature at the Figure 4.1 shows the relationship between the chilled water outiet, reffigerating capacity and the required power. 120) 100) 80) quiver power (2) —— Sofi ine: 286, GXG Type] Normal Specifications EeEELEAL ° . 20 30100120 Refrigerating capacity (%) Broken line: [(GXG Tyts] Option Specifications Figure 41 Example part load characteristics of the standard type @ Continuousiy operable without worry even on very het days Even when cooling water temperature rises on very hot days or condensing pressure increases due to stained tubes, the system continues to stably operate. the trouble of outage being minimized you can operate the system without worry ® _Low-load operation is available throughout the year without special devices ‘Conventionally the lower limit point: for capacity control has been set mechanically.so that the ‘capacity at the lower limit point increases in intermediate seasons or winter With the GXG series, operation is stable up to 20% even at low cooling water temperatures, without ‘any special devices(hot gas bypass vaive.ete.).due to microcomputer control. @ Even in seasons where extemal air temperature is low, the expanded operating range of single unit chiller assures a high energy saving effect. While conventional models require a controlling cooling water inlet temperature of 20°C or higher, GXG series can operate up to: cooling water inlet temperature of 12%, expanding further the capacity range. a4.1.2 Temperature control characterstics (a) Temperature control charactensties, Against such a load change, the temperature controller ‘The load changé ofthe standard type appears Will control the chilled water outlet temperature to be constant. asa change in the chilfed water inlet temperature, Acontrol example is given in Figure 4.3 below. given the chilled water flow is constant 70086 100 oad factor (7) tapout (rita) Figure 4.3 Temperature control characteristics: (p) Temperature characteristics at startup The follow-up characteristics of the standard quantity of heat of the chilled water system and the type depends on the relationship between the total capacity of the chiller See Figure 4.4 for an example = NG cua A 0 5 0 5 ‘Base ie (mt) ied water tripe (©) Figure 4.4 Example temperature characteristics at startup4.2 Motor Characteristic 4.2.1 Starting current characteristics The main motor for the hermetic centrifugal chiller has a squirrel-cage induction type structure which generally adopts the reduced voltage starting system to save the starting current. Various types of starting systems are used depending on source voltage and source capacity; the general characteristics of the starting current are shown in Figure 4.5 to49 For further information on the starter, see Section 6. ‘The starting current varies with the chilled water temperature immediately before starting up; the higher the temperature of the chilled water, more the transient current flows at startup. \Winen determining the source capacity, take such cifferences into consideration and make selection \with 130% or more of the value given in the figure,Table 4.1 Starting system and characteristics of the motor for the closed-type centrifugal chiller (1/2) Starting system Direct starter Starling compensator (Automatic compensator, Reactor starter (pou) condorfer) Applied voltage (V) 490,300,600 409,300,600 490,300,600 Starting voltage (%) 400 65 65 Starting current (%) (compared with rated 550~750 165~228 300~410 current) Starting torque(%) (compared with rated 200 60 60 torque, approx) Starting voltage change ‘Constant during startup Constant during startup Begin increasing from startup Motor terminal Starting time (til reaching the maximum rate) 3106 seconds 10 to 18 seconds 610.10 seconds Starter characteristics (in order of facitty cost incurred) Desirsbe in case where «large pacity is required for construction facilities et. (4) For facilities where minimized starting cumentis desires (5) 4) Circuit bs “Transterrer 775) sh i) %s, (ReacionTable 4.1 Starting system and characteristics of the motor for the closed-type centrifugal chiller (2/2) Starting system Open transition star-delta starter Closed transition star-delta starter torque, approx) Applied voitage (V) 400.3000 400 Starting voltage (%) 57.5 S75 Starting current (96) (compared with rated 180~250 180~280 current) Starting torque(%) (compared with rated 66 66 Starting voltage change Constant during startup Constant during startup Motor terminal 6 lead wire type only 6 lead wire type only Starting time (til reaching the maximum rate) 10 to 15 seconds a FE 10 to 15 seconds Starter characteristics Large rush current at ‘Small rush current at {in order of facility cost ‘switching ‘switching incurred) Star-delta (2) ‘Star-delta(3) bb beg, = t% ercuit Se IM rl SsStarting current (96) Starting current (%) Chilled water 25°C —— — Chilled water 15°C Time (second) Figure 4.5 Direct starting characteristics Chilled water 25°C ——— Chilled water 15°C Time (second) Figure 4.6 Reactor starting characteristics (65% tap) xRush cutrent of 1 to 2 Hz —— Chilled water 26°C (600 to 1500%) = == chilled water 15°C ve 0 gm oo 5m & 3 wm g =e B a0 y wo 10, is 0 8 lume (second) Figure 4.7 Automatic compensator starting characteristics (65% tap) 38/Rush current may occur due to the residual voltage in the starting transformaer at startup. Take this into account when selecting the primary over current relay. —— Chilled water 25°C — — = Chilled water 15°C Rush current of 1 to 2 Hz (600 to 1500%) (%) Starting current a 5 10 i 2 2% Time (second) 23eThe maximum value of the rush current when switching from 1 to D(A.) may be 15 times of the rated value. Take this into account when selecting the primary over current relay particularly for the 400V models. Figure 4.6 Open transition star-delta characteristics(%) Starting current Chilled water 26°C —— Chilled water 15°C g Beeee Bes 5 0 6 a s Figure 4.9 Closed transition star-detta starting characteristics43 Noise Noise (In case of HC-F400GSG ) — a ee |. | lL 5 oe A Figure 4.10 Noise measuring positions Table 4.2 Example noise measurements Unit dB Measuring position, Na) Measurement condition 4 2 3 4 5 6 Z 1 | Before Thermat insulation | 88 s6_| 81 | 88 | 87 a5 | 63 Note: 1. The measuring points are lacated at 1m from the side of the chiller and 1.5m above ground, 2. The table gives measurements for reference: actual values may dilfer depending on the eche of the machinary room, capability of individual machines. or the insulation condition. fp | | 40 = Noise measurements dB (4) | 63 5 (50S «1000S 2000» 4000» 8000 16000 Octave central frequency (Hz) Figure 4.11 Example noise frequency analysis,44 Vibration Vibration ( In case of HC-F400GSG ) Figure 4.12 Vibration measuring position Table 4.3 Example noise measurements Unit x (total amplitude) Tess @ @) @ @ @ ® @ a 2 B Measuring directa (Vertical direction) 4.0 | 15.0 60 3.0 | 12.0 7.0 JA(Axis direction) = = | Fa] = = | 11.0 40 40 HH erorzonta drecion | 40 | — | 8a |130| — | — | 40 40 Vibration during refrigerating operation (typical example) 6 4 i 2 »oL 0 50 100 150 Vibration frequency (Hz} Figure 4.13 Example vibration frequency analysis (50 Hz-specifications model) «5. Instrumentation and Control Operation Control System The Hitachi Centifugal Chiller adopts as standard entire autornatic operation system based on the micro computer incorporated in the console panel (@) Starup operation Pressing the start switch on the console panel first stars the oil purnp. About 20 seconds after the ol pressure has increased, the main contactor is ‘activated and the main motor is started via the reduced voltage starter. Once, after a certain period, it {is switched to full voltage setting with the rain motor in {ulspeced operation, the inlet qude vane (hereinafter referred to as the vane) is automatically started to ‘open via the temperature regulator circuit and the load limiter circuit without being overloaded. Then the Chiller gets into routine operation to keep the chilled water outlet temperature ata certain level (©) Stop operation Pressing the stop switch on the console pant ‘stops the operation of the Chills, after the minimum vane ‘openings, withthe vane automaticaly closed completely. The oil urn also automatically stops after about 4 minutes. (¢} Automatic temperature regulator (with load limiting function) ‘The temperature requlator provides stable ‘temperature control and load limiting control by applying the load limiting function to the entire circuit ‘and by adapting circuits unique to Hitachi such as ‘integration and differential control functions. onsole panel sich operation ‘The load limiting control operates in two phases; ‘one is to stop the vane opening action (limits opening ‘action only to stop the vane operation), and the other Isto force vane desing action. (9) Automatic start and stop ‘The signal detecting the chiked water outlet temperature is processed in the micro computer to activate the automatic start snd stop switch. Ifthe load is lowered below the range of capacity control, the automatic start and stop switch stops the chiller temporariy. After 15 minutes has passed and the load Js recovered, the chileris automatically restarted. (¢) Faiture stop In case the safety switch is activated, the chiller ‘stops operation with alarming beep while the cause of the failure is indicated on the console panel (9 Oilheater ‘To prevent foaming of oil at startup, the oil heater is automatically activated while the chiller fs out of operation so that the ois Kept at an appropriate temperature. (In order to do £0, electric source for contro ‘system will be activated even when the chiller is off) (a) Emergency stop Pressing the Emergency stop switch on the console ‘panel stops the operation ofthe Chiller with the vane ‘automaticaly closed completely. The oil pump also ‘automatically stops after about 4 minutes. sole panel sith off orzo |_| sacs] | soe] | ane |] seers’ [7] opm |_| amar = sored | 7m ‘oo |_| ws | |] ab are | Bieta —! Ticiini: —Apemicempee, — Lote Lend sin Linas mah emilee wn slp enact) lashes tt att ional cone Sead pe< OPERATIONAL FLOW DIAGRAM > 1..Normal startup (Startup operation) Tum start switch on [cba Sasi a [Operation light turns on (Thermostat tums on) Oil pamp normal Hck > | men _— [Main moor automatically tas) = (Protection circuits savas) [Dilber ns OFF ( [Galles in tomatic operation Avtoratic tart and stop at Vane damper is closed indicates the chile. 1 ——— ; =p (Refrigerating load increases) Oil pump stops. Oil heater turns ON] indies AND vot | (Chie water pete i) indicates OR circuit.2. Normal stop (Siop operation) Remo ~ seme ett Dire saga Tia NOR facie] [Chiller stops = | ied {Going wes pomp sos | Child wae up aps | [Vie dangers fay lxed] [Oil pump stops || [ Oil eater turns ON il supply pressure LOW iil pump OVER LOAD iil pump magnetic contactor OFF Chilled water SUSPENSION Coil temperature of main motor HIGH Starter ABNORMAL Chilled water OVER COOLED Oil supply temperature HIGH Condensing pressure HIGH Evaporation pressure LOW —— ey ‘Mode indicator and content indicator are displayed! Beep | = Sapna ight rs ON] [Tan oe wih aoe ON) Beep stops Failure cause survey | Chiller sons | Spring constant 9.4.2 Earthquake proofing As for earthquake proof basic strength, horizontal acceleration of 0.6 G and vertical acceleration of 0.3 G are spacified as standard earthquake factors. If earthquake factors higher than these values is required, contact your nearest dealer9.5 Variable Flow Control (optional) Be careful of the following in variable flow control of the chilled water and the cooling water. 9.5.1 Cooling water variable flow control Points to be noted when reducing the cooling water flow through variable flow control. (a) The performance of the condenser’ s heat transfer tube tends to deteriorate. Reducing the flow decreases the flow rate Within the heat transtar tube and thus lets the scales or times attach on the tube wall. This will reduce the performance of the condenser causing lower efficiency of the chiller or other troubles. Compressor tends to get into surging Ifthe cooling water flow is reduced with the ‘opening of the inlet guide vane kept constant, the head ‘of the compressor rises allowing the compressor to ‘easily get into surging. To prevent the compressor from getting into surging, program, when reducing the flow, to carry out the reduction while the cooling water inlet temperature is low enough. {e} Water head loss becomes great ‘The operation value of the water cut-off relay is required to be determined on the basis of the lower limit value of the flow variation. On the other hand, however, since the lower limit value of the operation density:0 O2giem thickness:SOmm salvanized shoot NS G3302A9511 2iypes thickess: 0.03-0.4mm [Aluminum shest 1S H4000 thickness: 0.6-0.8mm or more lstainloss shot 1S G4208 SUS304 Material thickness:0.amm or mere ton choot {169m or more fe tape 1S 21001 thickness:0.2mmn jatar proof hemp cloth IS L3405 No. F+JIS K2207 IPiacter 1S thicknase: Smm lstercit’ 1S 370g/m" oF more [Asphalt roting 1S ABOOS 17kg oF more per roll 21m) Metal ith IS ASSOS fat lath No.1, ib lath (A) No-t from ring IS G3532 galvanized iron Inanesive For polvstyrene: vinyl acetate type adhesive For rivet: chloroprene type synthetic rubber adhesive url fn ar onng CGahanizos shot unin shack (raion sao thot ts wot Foam poystrene on we ‘Acesvetape \-Asnatmofing _—_Asphatetng Stn “Wate prot hemp ch \\coton test #77. Example insulation ol piping saction Note: Foam polystyrene is tobe used for cooling, and the glass wool is to be used as the main cold, Insulator for the double-bundle condenser type.11. Reference 11.1 Properties of refrigerant ‘The reftigerant (HFC134s) used for this refrigerating ‘itchine as the following propecties (Gaseous at the normal temperature and normal pressure, Odorlees. @Noncombustible. HFC134a does not explode when ‘mixed with air at any ati. DHEC134a inthe liquid state is colorless and transparent. Snce it does net mix with water and is heavier than water, water floais in a layer on it. Pure HEC134a, in either iquid state or gas state, does not corrode metals. If any air enters the ‘etigerating machine, however, moisture inthe air ‘may rust the metals, particularly the orcinary ste Materialistic propertis of HEC134a Mineral lubricating oll dissolves in HEC'134a very lite at any ratio. Accordingly, special cl (ester cl) having come colubility must be used for the rettigerating machine which uses HFC134a. Harmless to men and animals. (Ventilete the machine room well, however.) |HFC134a in gas state is about 5 times as heavy as ait. Accordingly, when the reigerating machine is disassembled, the gas leaks fom the mactine flow ina layer on the floor. Molecular weight 102031 Boling point (under atomosphenc pressure) 26.18 C ‘Specific gravity in quid state (at 25°C) 1,208 kel A Spocife gravity in gas stato (atboling pein) | 6.26 kgiom® Soecifc heat in liquid state (at 25) 1.427 kska-K Latent heat of vaporzation (at 25°C) 478.7 kikg-K Latent heat of vaporization (at0°C) 199.2 kukg-K% Temperature =o) ‘Saturation curve of refrigerant (HFC134a) 11.2 Lubricating Oil The lubricating ol is required to have heat ‘stability, lubricity, as well 2s high insulation and ccompaiiiliy. Hitachi's using 2 synthesized cil dovoloped for HFC134a. If you wish to buy tho oilfor replenishment, please contact your neatest dealer. 11.3 Maintenance Item List Since maintenance and inspection ofthe chiller ‘substantially gover the service life ofthe machine, ‘The synthesis cil (ester ci) has high hygroscopic property. Make sure no water element in the air can be mixed with the oll when supplementing, Cr storing the oil Do not uso the samo oil tic. refer to Table 11-1 for providing proper maintenance ‘and inspection.Table 11.1 Maintenance and inspection item list - Period onneamann | onceayear Joren3ypas omen byes Remark tem Replacement of lubricating oil ° Replacement of oil strainer ° sossoxdwog, loverhaul ° Insuation measurement ° Jojou ule, Air gap measurement eae barat tes epedng [Cleaning of tube ° en the water quality conden. Water quality analysis ° |Contirmation ot water volume ° Pertcm twice a season or so. sasuapuog pure soreiodeng \conttmation of safty olay operation ° ately relay insuation measurement |Conttmaton of i pup insulation ° [Confirmation of oilheater |discontinuation and insulation [Confirmation of console fuse discontinuation ‘S@0v@p U}00R 101N0 Leakage inspeciton ° eum |ctezning ot retngerant strainer ° Replacement of fiter dryer ° S184 Perio a reqived acondng Retigerant analysis ° ome contin. Note: 1. Since the ist provides mere standard, the period may be shortened or lengthened according to your condition or use or inspection results, 2, The cpnditions of tubes should be investigated by non-destructive inspection with eddy current inspection apparatus if there Is crtcally contamination of the water.11.4 Water Quality Control Hitachi classifies fresh water as shown in Table 11-2, and recommends “normal fresh water” for ‘general use in the chiller. So long 2s the quality of the ‘water you use constantly stays within this range, no corrosion Is expacted. Therefore, control the water ‘Quality aiming the "normal fresh water’. ‘The extreme imit of the usable wateris “contaminated fresh water". Tne futher it goes beyond the limit, the worse the condition for corrosion will be. Perform regular water analysis of the water Used and control he quaity to stay within the range ot “normal fresh water" by implementing continual replacement and blow of the water. Especially, constant blowing is required for the ‘cooling water in the cooling tower. This is because the corrosive factor in the air may be condensed in the cooling water and expedite corrosion. Athough seme appropriate water treatment agent can give a certain cefect. replacement ot blow of the water is also necessary in order to make sure. ‘AS a means for checking the corrosion state inside the finned tube, the non-desttuctive examination using an eddy current test equioment is available, This method can provide @ fot of information on the condition ofthe tube in a relatively short time. Perform this examination reguarly as well as the water quality analysis ‘The water quaity and control standards are ven in Table 11-3. Prepare oriteria adequate for your Condition of use in order to impiernent effective water ualty control. Table 11.2 Water quality component table Cooling Water Quality Standarde ‘ot Wate yee tem ‘reuation Method | Sxbpeled | — Tendency owe | “Si | Patt [oven | tt HS) wsea_[ sose_| sean [7] + amionanmamee | se | sa | sa |, |, ; tsmase| Eom | Zam | Zia § | coioite ins ra OF) 20 seo | 7 3 | stuescsins ngsozn | = 20 ss B)reccraeginonanori |< ae 8 ; a hardness (mg CaCOs/ 1) = 200 = 70 = 70 “ cacimesnen rocco) | <1 [=o | <0 7 Dzau 9 04/9 = =x : Te (oF an ef 2 [es eos S03 so [4 8 | sutured acd iors (mg $7) ‘Undetected | Undetecied | Undetected | 7 8 [ eemeniumione (ra NHI) zi | sot | sto |v Elreamncostingco7) | sa» | sao | sao | Sey se tora _[- |.hilted Water Quality Standards Chited Water System Tendency Item Cretason water | Avcior so | cononen |, Sale (200 ess) ete rorneon BAO) v 7 Elecsical conductviy (mS/my25°0) ? z (uS/em) (25°C) a 8 conde ns (ng Cr) =6 v $3 Sut ais ons (mg SOM) =0 z Al rccexninges scart era) : | (racaco./) ili ae sf Total hardness (mg 620037) = Z Calum avdness (mg C2687) 20 z Torized calcu (ng $1037) “ Won (9 Fe) oe 7 Copper (ng Gu) S04 ‘ ‘Sured zed ens (ng $7) Undetesed | Undotoaod | ¥ “Ammonium ins (rg NH) z 10 201 v Residual sats (mgCi/1 203 z Free carbonic acd (1g COs i) 40 ¥ Stati inden ¥ z Note: “Lem names and units are based on JIS KO101-91. 2. Tho v symto! in ho abl inicatos a factor relating to corrosion oF scale formation tendoncios 3. The unis ornumerical values n (_) brackets are based on old units and are given for referance. 4. Inthe case of high temperatures (over 40°O), comfosiveness & generally heavy, and partculaty if on of ‘copper materials are indirect contact with water with no protective sheathing, it is desirable to carry out lari-corrosion measures such as adding an anti-corrosion agent or eating wth purging. 5. In.a cooling water system which uses an airtight ccoling tower, closed-circuit water and auxiiary supply ‘water are based on the water qualiy standard of iow order, hot water system, and sprinkling and its auxiliary ‘water supply are based on the water quality standard of a circulating-type cooling tower system, 6. Water sources used for water supply and auxiliary waier supply should be piped water (tap water), industial ‘water oF underground water. Pure water, intermediate water, eoltened water chould notbe ued.Table 11.3 Period Remark ype of conta Every ay | Every week [very month] Every year 1h | Biowng Make sure blowing is performed every day. ° [2 | water quaity alysis ‘See Notes (1) and (2). Depenairg on the water qually aralysis rest ° 3 | Replacement of water Perform as required according to the ° [4 | Cleaning of tube condition, 5 | Eddy curent test Consuit your service company. Je. | Water treatment Consuit your service company. Not (1) Perform a water analysis for the makeup water and the circulating water respeciively, and then determine the ‘number of times of replacement and blowing of the water. (2) Perform water qualty analysis seasonally (in spring, summer, fall, and winter) to prepare your criteria for judgomont 11.5 Law and Regulations For centrifugal chiller using high pressure Japanese standards. If any other local regulations, retngerant HEC124a, High Pressure Gas reguiation ‘pected, consult ne nearest branch of Fitacré in your, Laws are adopted in Japan. Therefore, Hitachi ‘country Centrifugal chiller is manufactured in accordance with