5.pressure tank(hitachi).pdf

Instruction Manual

Closed Type Diaphragm Expansion Tank

Object Model

For Hot Water Supply For Air-conditioning

AST Series AX Series

EX-LS Series EX-L Series

Hitachi Metals, Ltd. Please read this Instruction Manual thoroughly before use for correct operation.

Please read this Instruction Manual and keep it with care. Prepared in February 2011

Important information

{ Be sure to read this Manual before use. Moreover keep the manual at the place of easy access.

{ Be sure to thoroughly read this manual before construction and inspection, and use the tank correctly according to the instructions of safety information, precautions, and operation and handling methods.

{ Regularly operate the tank observing the operating range of each model described in the Manual.

{ Avoid executing construction or operation not covered in this Manual, using change parts not specified by us or attempting remodeling. Failure to do this may cause breakdown or fatal accident. We assume no responsibility for any accident resulting from such manner.

{ Contact our sales department for unclear expression or point in this manual if any. { We own the intellectual property right concerning the content of the description of this

manual. Avoid disclosing the whole or the part of the content to the third party without our consent.

{ The content described in this manual is subject to change without prior notice. { Inform our sales department promptly of the following if any abnormality occurs on the

product concerned. Name, model and manufacturing number of the product concerned (noted on the

nameplate or seal placed on the main body) Abnormal content (including the state before and after abnormal generation,

operation line and construction method, etc. in details as much as possible)

Precautions for the safety Be sure to thoroughly read this manual before construction, maintenance and inspection, and use it correctly. Thoroughly read this manual about safety information, precautions and equipment knowledge before operation. This Manual classifies the ranks of precautions for the safety into DANGER, WARNING and CAUTION.

Harm/damage Definition

Danger DANGER This indicates an immediately hazardous situation which, if disregarded causing wrong handling of the equipment, will result in death or serious injury.

Warning WARNING This indicates a potentially hazardous situation which, if disregarded causing wrong handling of the equipment, will result in death or serious injury.

Caution CAUTION This indicates a potentially hazardous situation which, if disregarded causing wrong handling of the equipment, will result in minor injury or property damage.

Prohibited PROHIBITED This prohibits the act indicated in handling the product.

Instructed FORCED This forces the act based on the instruction in handling the product.

WARNING

Usages The product concerned is the equipment for air-conditioning or hot water supplying. Do not use the product for the fluid other than air-conditioning or hot water supplying. Using this product for the purpose other than specified may cause serious injury or product damage. The expansion tank for air-conditioning cannot be used for hot water supply though the expansion tank for hot water supply can be used as an expansion tank for air-conditioning.

In piping Be sure to make connection to the product at the system connection port. Never connect it to the port other than the system connection port. Loosening an inspection port other than the system connection port will allow flying of parts possibly causing serious injury.

In use Loosening a connecting pipe or inspection port will allow flying of parts or blowing of hot water possibly causing serious injury. The water in the tank cannot be used for drinking.

CAUTION

In piping Wear appropriate protective gear when working. Moreover, do not take uneasy posture when working. Failure to do this may cause injury.

In use Loosening a connecting pipe or inspection port will allow flying of parts or blowing of hot water possibly causing serious injury.

PROHIBITED

In piping Do not make wrong piping connection when constructing. Wrong connection interrupts proper functioning of the product. Moreover, loosening the inspection port or bladder port will allow blowing of charged air or flying of parts possibly causing injury.

In use Loosening a connecting pipe or inspection port will allow flying of parts or blowing of hot water possibly causing serious injury.

FORCED

In piping Be sure to install a flexible joint, maintenance valve and water drain valve in the piping connection to the tank. Be sure to install a safety valve in the system piping. Without the safety valve installed, not only the tank but also the system will be damaged.

In use Be sure to conduct periodic voluntary inspection and periodic servicing once a year.

Thank you for purchasing the product. We thank you very much for purchasing our closed type diaphragm expansion tank. This tank has been designed and produced based on the technical tie-up with the US

Amtrol Incorporated. Read this manual to use the product more safely and correctly. The product specification is subject to change without prior notice. Acknowledge beforehand that the content and a part of this book might vary in that case.

Usage of closed type diaphragm expansion tank WARNING Usage of closed type diaphragm expansion tank The tank is used to absorb expansion water generated at water temperature rise in the closing system, suppress abnormal pressure rise and prevent damage on the equipment and piping.

* Do not use it as a water feed tank, for water hammer prevention, or other purposes.

WARNING It is necessary to check the tank by the selection calculation of the model.

Select the model by the selection form on P20 of this manual to check if the tank is proper for use when the selection calculation of the model has not been done.

* It is not possible to use the tank if it is not proper as a result of selection

calculation. Moreover, if not proper, the tank cannot only demonstrate its function but also possibly damage the piping and equipment. Contact our sales department for inquiry in the case of uncertain point if any.

Contents

1. Precautions for Handling ............................................................................................. 1

2. Product Warranty ......................................................................................................... 3

3. Service Life .................................................................................................................. 4

4. Check for Tank Acceptance ......................................................................................... 4

5. Label Display of Tank .................................................................................................. 4

6. Request at Installation and Piping Construction .......................................................... 5

7. About Charged Air Pressure ........................................................................................ 8

8 Charged Air Pressure Check and Adjust Procedure .................................................... 9

9. Hydraulic Pressure Test of System Piping ................................................................. 12

10. Trial Run .................................................................................................................... 13

11. Construction Example ............................................................................................... 14

12. Periodic Voluntary Inspection and Periodic Servicing ................................................ 15

13. Change Parts ............................................................................................................ 16

14. Treatment for Tank Storage (Stop) ............................................................................. 17

15. About Regulations of Tank ......................................................................................... 17

16. Closed type diaphragm expansion tank inspection record form ................................ 19

17. Air-conditioning and hot water supply expansion tank selection form ....................... 20

1. Precautions for Handling

WARNING

(1) Is a proper tank selected? When a mistake is made in the capacity

or withstand pressure of the tank, not only the tank but also the equipment of the system will be damaged.

Insufficient capacity

Insufficient withstand pressure

(2) Fill air to proper charged pressure. When charged pressure is low, the

diaphragm or bladder in the tank and other components may possibly be damaged.

When charged pressure is high, the safety valve of the system operates or the equipment will be damaged.

Too low. Proper Too high.

(3) Do not loosen the inspection port, hydraulic pressure test port or bladder port of the tank, or connect other piping.

Charged air in the charged tank blows off otherwise.

Loosening the inspection port or bladder port of the tank will allow blowing of charged air or flying of parts possibly causing injury.

(4) Do not allow entering of iron scrap, cutting chips or refuse into the tank.

Conduct flushing before connecting the piping to the tank.

Iron scrap (cutting chips or refuse, etc.) entered in the tank may damage the internal diaphragm or bladder.

Refuse Iron scrap

CAUTION

(5) Securely connect the piping from the system to the system connection port of the tank.

If the piping is connected to a wrong port, the tank cannot only demonstrate its function but also possibly allow blowing of charged air or damage the system equipment.

Wear appropriate protective gear when working. Moreover, do not take uneasy posture when working. Failure to do this may cause injury.

System connection port

* Install piping to the system.

The above label is applied at the system connection port of the tank. Be sure to check it.

-1-

CAUTION

(6) Secure the maintenance space for the air charging valve, pressure gauge, nameplate and the tank.

When the maintenance space is not secured, it is not possible to conduct periodic voluntary inspection within a year according to Article 88 of Ordinance on Safety against Boilers and Pressure Vessels.

(7) Use dry air containing no oil content when adjusting (correcting) the charged pressure of the tank.

When oil or humid air is charged, it causes deterioration of the diaphragm and bladder and inner corrosion of the tank.

(8) Securely fix the tank to the base or frame. Securely fix the tank with anchor bolts to

prevent falling. The tank is of the indoor type

specification. Be sure to provide treatment of waterproof (rain proofing) and rust prevention when installing the tank outdoors.

(9) Be sure to install a safety valve (relief

valve) in the system. Without the safety valve installed, not

only the tank but also the system will be damaged. Securely install the valve.

PROHIBITED

(10) Do not weld another material to the main body of the tank.

The diaphragm or bladder in the tank becomes damaged otherwise. Never make welding on the main body of the tank. Moreover, there is a possibility that the main body of the tank is damaged

-2-

2. Product Warranty We will supply a substitute tank or parts free of charge only when abnormality is caused on the tank by the defect recognized to be our responsibility during the warranty period after the delivery.

2-1. Warranty Period

12 months from the date of delivery 2-2. Warranty Information

We, however, will not be responsible for such supply in the following cases even in the above-mentioned period. (1) Trouble caused by improper handling during construction after delivery (2) Trouble caused by difference between each condition of the entire system when the tank

specification is decided and actual use conditions (3) Trouble caused by improper operation or handling (4) Trouble caused by inappropriate selection of the tank or wrong setting of charged pressure,

made by the third party (5) Trouble caused by iron scrap, cutting chips or refuse entered in the piping (6) Use of the tank for the fluid other than the below

Fluid pH Chlorine ion density (mg/Lit)

Free residual chlorine density

(mg/Lit)

Antifreeze liquid*1

For air-conditioning

Tap water or fresh water (recycled wastewater and well water) * Excluding recycled

wastewater for hot water supply.

5.8 to 8.6

200 max. 1 max. 50% max. density

For hot water supply*2 20 max. 0.1 max. -

*1 Antifreeze liquid: ethylene glycol or propylene glycol (Consult us before use.) *2 The tank for hot water supply can be used for air-conditioning within the range of conditions for air-conditioning.

(7) Use of the tank outside the following temperature range Fluid working temperature [-5C to 95C]

* Normal working temperature in the case of EX-LS series [60C] Working atmospheric temperature [0C to 43C] (Consult us when it lowers below 0C.)

(8) When periodic voluntary inspection and periodic servicing once a year are not conducted. 2-3. Warranty Range

(1) We give the warranty only to the trouble on the equipment body, and not to secondary damage caused by the failure of the equipment body.

We provide service for profit even in the above-mentioned warranty period in principle, for breakdowns caused by careless handling, by force majeure such as fire or natural disaster, by repair or remodeling by the user, by use or storage in improper environment, or in the case judged to be outside our responsibility.

(2) Exclusion of amends debt such as opportunity losses We will exclude the responsibility to profit loss and business stop or obstruction on the customer

side, and the warranty for bodily trouble and the property destruction, originated from the breakdown of the tank regardless of inside or outside the warranty period.

-3-

3. Service Life The diaphragm, bladder and hose (EX-L and EX-L S series) have the service life for ten years when the

periodic inspection described on P15 of this manual is executed while using the tank within the warranty condition range of section 2-1.

CAUTION

Foreign matter may flow out because of aged deterioration of the diaphragm, bladder or hose (EX-L and EX-LS series) when used exceeding the service life. Replace the tank body or bladder and hose.

Service life varies depending on using conditions.

4. Check for Tank Acceptance (1) Tank model Make a check on the nameplate (seal on some models). (2) Max. working pressure Make a check on the nameplate (seal on some models). (3) Charged air pressure Be sure to check that charged air pressure (Mpa) set at expansion tank model selection is

secured with the charged pressure marked value of the nameplate (seal on some models) attached to the tank or the pressure gauge or tire gauge equipped on the tank body.

(4) Painting Rustproof painting is standard on the exterior of the tank. Check the coating specification with the delivery specifications (drawing) when you specify the

final coating (option). (5) Appearance Visually check the overall appearance of the tank for any damaged part at the

acceptance of the tank (6) Others Check if your designations at the order have been securely provided.

5. Label Display of Tank (1) Inspection port, hydraulic pressure test port and bladder port Check that the label is applied as shown in Fig. 5-1.

WARNING The inspection port, hydraulic pressure test port and bladder port have been provided mainly according to the regulations of the pressure vessel structural standard. Do not remove or connect piping to the inspection port, hydraulic pressure test port or bladder port. It is dangerous since charged air blows out. Loosening the inspection port, hydraulic pressure test port or bladder port will allow blowing of charged air or flying of parts possibly causing injury.

(2) Air charging valve Check that the label is applied as shown in Fig. 5-2.

-4-

(3) System connection port

Check that the label is applied as shown in Fig. 5-3.

CAUTION Never touch here.

* Air comes off entirely.

Air charging valve

Pressure gauge

CAUTION Do not touch after charged

pressure adjusting.


* Install piping to the system.

(1) Inspection port, bladder port (2) Air charging valve, pressure gauge

(3) System connection port label

Fig. 5-1 Fig. 5-2 Fig. 5-3

6. Request at Installation and Piping Construction

(1) Secure the space around the tank for inspection.

CAUTION

Be sure to secure the space of 600 mm or more around the air charging valve. (Refer to Fig. 6-2.)

Be sure to secure the space of 1500 mm or more above the tank of EX-L and EX-LS series. (Refer to Fig. 6-1.) * Avoid running pipes and ducts above the tank. * Failure to do this interrupts replacing the tank body and bladder and hose parts.

1500 min. 600 min.

600 min. 600 min.

600 min. 600 min.

600 min.

Fig. 6-1 Front view Fig. 6-2 Top view

(2) Fix the tank. Fix the tank to the concrete foundation or the base securely with anchor bolts or bolts. The standard quake-resistance strength of the angle part of the tank is KH=1.0G and KV=0.5G. Check the specification with the delivery specifications (drawing) when you specify the strength

other than the standard.

-5-

(3) Connect the system piping with the system connection port of the tank. The position of system connection port of the tank varies by models. Check the model and install piping referring to the construction example on P14 of this manual.

FORCED (1) Be sure to install a maintenance valve,

water drain valve and flexible joint shown in Fig. 6-3 in the piping to the system connection port of the tank.

* The maintenance valve and water drain valve become necessary to prevent pressure from applying to the tank at hydraulic pressure test of the system piping and to measure charged air pressure of the tank.

The flexible joint is necessary for replacing the tank, bladder and hose parts (EX-L, EX-LS).

(2) Conduct flushing (to remove iron scrap, cutting chips or refuse) before connecting pipes to the tank.

Foreign matter, if caught inside the tank, may cause damaging the diaphragm or bladder.

Pressure gauge Air vent System piping

Valve

Fusible plug

Drain piping

(indirect drain)

Maintenance valve

Flexible joint


Air charging valve

Pressure gauge

Concrete foundation

Water drain valve

Fig. 6-3 (construction example)

CAUTION The fusible plug (dissolution plug) might be unnecessary depending on the type of heat source.

(3) The system connection port is provided with taper pipe thread. Check that no foreign matter (cutting chips, etc.) stays on the thread and spread proper

sealant before connecting securely. Refer to the value of Table 1 shown on P7 of this manual for clamp torque at screw-in

work.

FORCED Use two sets of pipe wrench for screw-in work. * Excessive force if applied to the tank connection port may damage the tank.

WARNING Strictly avoid touching the inspection port, hydraulic pressure test port and bladder port except the system connection port. Loosening the inspection port, hydraulic pressure test port or bladder port will allow blowing of charged air or flying of parts possibly causing injury. Contact our sales department for inquiry if you leak charged air by mistake.

(4) About hydraulic pressure test of the system piping

CAUTION Do not apply pressure to the tank at hydraulic pressure test of the system piping. * Securely close the maintenance valve located before the tank connection port.

There is a possibility that the diaphragm or bladder is damaged when the pressure of hydraulic pressure test of the system piping is applied to the tank.

-6-

(5) Heat insulation of tank Be sure to conduct heat insulation work when there is fear of freezing on the tank and connected

piping. * When freezing is encountered, the piping may possibly be damaged.

CAUTION Conduct heat insulation work for the tank, if required, so that the air charging valve, pressure gauge, hydraulic pressure test port, inspection port and nameplate can be checked from the outside.

(6) Others The tank is of the indoor type specification. Be sure to provide treatment of waterproof (rain proofing) and rust prevention when installing the

tank outdoors.

Standard clamp torque for tube fitting When screwing a tube fitting into pipe in piping work, it is necessary to know clamp torque by wrench. Table 1 shows the standard clamp torque though it actually differs somewhat according to using sealant etc. This clamp torque is not the maximum value but the value of clamping to the extent that fluid does not leak from the screw. For reference, Table 1 shows the number of tightening threads after hand clamping though the clamp torque cannot be measured in actual piping work.

Table 1 Standard clamp torque for tube fitting

Nominal size (B)

Number of clamp threads Standard clamp torque Number of

hand clamp

threads (Note 1)

Number of clamp

threads after hand clamp

(Note 2)

Torque Nm (kgfm)

Nominal wrench size force N

(kgf)

1/8 4.5 1.5 10 (1) 200 90 (9) 1/4 4.5 1.5 20 (2) 200 170 (17) 3/8 4.5 1.5 30 (3) 200 250 (25) 1/2 4.5 1.5 40 (4) 300 200 (20) 3/4 5.0 1.5 60 (6) 300 290 (29) 1 4.5 1.5 100 (10) 450 290 (29)

1 1/4 5.5 1.5 120 (12) 450 350 (35)1 1/2 5.5 1.5 150 (15) 600 320 (32)

2 7.0 2.0 200 (20) 600 420 (42)2 1/2 7.5 2.5 250 (25) 900 340 (34)

3 9.0 2.5 300 (30) 900 400 (40)4 11.0 3.0 400 (40) 950 530 (53)5 12.5 3.5 500 (50) 950 670 (67)6 12.5 3.5 600 (60) 1500 630 (63)

Note 1) Guide for number of clamp threads to reference diameter position

Note 2) Guide for number of clamp threads from reference diameter position

Remark: Nominal wrench size of 3 and under shows the nominal size of pipe wrench and 4 and over shows the nominal size of chain pipe wrench.

Reference: The minimum clamp torque is about 10% of the standard clamp torque.

-7-

7. About Charged Air Pressure Check the following before using the tank. (1) The tank charged air pressure must be the same as the highest make-up water pressure at the

tank installation position. * Set the tank charged air pressure to 0 to +5% of the highest make-up water pressure at the

tank installation position. (2) When the condition of (1) is not satisfied, check if the selection condition of the selection form

matches the using condition. (3) When conditions do not match in check of (2) above, conduct selection calculation after

correcting the condition. * The model may be changed.

(4) When the model is not changed as a result of selection calculation done in (3) above, adjust the charged pressure by Charged Air Pressure Check and Adjust Procedure on P9 of this manual according to model selection conditions.

CAUTION

(1) When the tank is used in the state where charged air pressure is lower than the highest make-up water pressure at the tank installation position:

It may cause the damage on the diaphragm or bladder. It will raise pressure in piping without absorbing the whole quantity of expansion water

possibly causing damage on the equipment or piping. It may cause the safety valve to blow off. It may shorten the life of diaphragm, bladder or hose parts.

(2) When the tank is used in the state where charged air pressure is higher than the highest make-up water pressure at the tank installation position:

It will raise pressure in piping without absorbing the whole quantity of expansion water possibly causing damage on the equipment or piping.

It may cause the safety valve to blow off. It may shorten the life of diaphragm, bladder or hose parts.

(3) Use the tank with charged air pressure set the same as the highest make-up water pressure at the tank installation position.

* The highest make-up water pressure at the tank installation position may become [highest make-up water pressure] + [circulation pump head] depending on the installation position of the circulation pump.

-8-

8 Charged Air Pressure Check and Adjust Procedure

FORCED Be sure to stop operating the system on which the tank is installed, when adjusting charged air pressure.

FORCED Wear appropriate protective gear before working. Moreover, do not take uneasy posture when working. Protective gear Protection glasses (goggle type), gloves and earplugs, etc.

FORCED Use proper tools for adjustment work. (1) Pressure gauge for charged air pressure measurement (optional) (2) Air chuck (optional) (3) Core driver (optional) (4) Soapy water or leakage test liquid (5) Waste cloth (6) Other tools seem to be necessary for work

* The valve core of the air charging valve of JIS D4211 (tire valve cores for automobiles) is used.

Charged air pressure check and adjust procedure

Possible

System stop 1

Yes (Refer to Fig. 8-1-1 and 8-1-2).

Check space 2

Yes (Refer to Fig. 8-2).

Maintenance valve3

Yes (Refer to Fig. 8-2).

Water drain valve No

No

No

Impossible

Check that the system has stopped.

Consult the manager in charge of system management about the day when the system can be stopped. Piping improvement construction may become necessary beforehand. Contact our sales department for detail.

Consult the manager in charge of system management about securing the space. Piping improvement construction may become necessary beforehand. Contact our sales department for detail.

Consult the manager in charge of system management about the possibility of valve installation. Piping improvement construction becomes necessary beforehand. Contact our sales department for detail.

4

To the next page

System stop 5

-9-

Pressure not applied.

6

Check system water

pressure to tank.

Pressure applied.

Be sure to wear protection glasses (goggle type).

Discontinue working and consult with the system manager when the system pressure is applied.

Close maintenance valve.

Gradually open the water drain valve, to drain water from piping between the water drain valve and the tank. Opening the valve at a time may cause drain water overflow. Be sure to wear protection glasses (goggle type).

Open water drain valve. 7

Be sure to check that system pressure does not apply to the tank.

Detach cap.

Detach the cap of the air charging valve.

8

9

Measure charged air pressure and

temperature. 10

(Refer to Photo 8-2.) Measure charged air pressure by applying the charged pressure gauge to the air charging valve. Moreover, measure the temperature of the place where the tank is installed at the same time.

When charged air pressure is low, the diaphragm or bladder in the tank and other components may possibly be damaged.

11 Record

Check pressure value.

12 When increasing

Record the measured value in the inspection record form on P19 of this manual.

When decreasing The difference with the charged pressure value marked on the nameplate (seal) should be 0% to +5%.


(Refer to Photo 8-2.) Check the difference with the charged pressure value marked on the nameplate (seal) of the tank.

Check if system pressure does not apply to the tank once again by following the procedures h - j.

(Refer to Photo 8-3.) Replenish (charge) dry air from the air charging valve. Replenish (charge) air by applying the air chuck to the aircharging valve.

Replenish charged air. 13

Measure charged air pressure.

14 (Refer to Photo 8-2.)

Measure charged air pressure by applying the charged pressure gauge to the air charging valve. Repeat procedures 13 and 14 so that the pressure becomes 0% to +5% of the charged pressure value marked on the nameplate (seal) of the tank.


Discontinue working and consult with the system manager when the system pressure is applied. Contact our sales department for detail.

To the next page

(Refer to Fig. 8-2.)

(Refer to Fig. 8-2.)

(Refer to Photo 8-1.)




-10-

No leakage

15

Leakage


Replacing the valve core is necessary. Contact our sales department for detail.

Spread soapy water or leakage test liquid.

Spread soapy water on the air charging valve.

Check leakage. 16 Check if there is leakage from air charging valve.

17 Tighten cap.

(Refer to Photo 8-4.) Tighten the cap of air charging valve.


18 Maintenance valve

[Open]

(Refer to Fig. 8-2.) Gradually open the valve.


18 Close water drain valve.

(Refer to Fig. 8-2.) Gradually close the valve.

Close the water drain valve after checking that air has comeout of the piping. Be sure to wear protection glasses (goggle type).

Check system operation. 20 Check if there is abnormality in system operation.

1500 min.

600 min. 600 min.

600 min.

600 min.600 min.

600 min.

Fig. 8-1-1 Front view (installation space)

Fig. 8-1-2 Top view (installation space)

Fig. 8-2 Example of piping construction

Photo 8-1 (work procedure)

Photo 8-2 (work procedure) Photo 8-3 (work procedure)

Photo 8-4 (work procedure)


Air vent

Valve

Fusible plug

Drain piping (indirect drain)

Pressure gauge

System piping

Maintenance valve

Flexible joint System connection port

Air charging valve

Pressure gauge

Concrete foundation

Water drain valve

-11-

9. Hydraulic Pressure Test of System Piping (* Refer to Fig. 9-1 for the example of piping construction and valve operation.)

WARNING When conducting hydraulic pressure test of the entire system, securely close the maintenance valve so that the pressure of hydraulic pressure test will not be applied to the tank. Moreover open the water drain valve.

CAUTION When the pressure of hydraulic pressure test is applied to the tank, the internal diaphragm or bladder may possibly be damaged. After hydraulic test, check that the pressure of hydraulic test is not applied and close the water drain valve. Then gradually open the maintenance valve.

2 WARNING Be sure to close valves when conducting hydraulic test.

Air vent

Valve

Pressure gauge

System piping

Maintenance valve

Flexible joint

Fusible plug

Drain piping

(indirect drain)


Pressure gauge

Concrete foundation

Water drain valve

Air charging valve



Be sure to close valves when conducting hydraulic test.

-12-

10. Trial Run (* Refer to Fig. 10-1 for the example of piping construction and valve operation.) (1) Check of tank charged air pressure c Close the maintenance valve and gradually open the water drain valve, to drain water from

the tank.

CAUTION Be sure to check that water pressure does not apply to the tank. d Observe the indicated pressure gauge value of the tank to check that the tank charged air

pressure is the same as the pressure marked on the nameplate. e After conducting d of (1), gradually open the maintenance valve to check that air is vented

from the water drain valve. Then close the water drain valve. (2) Check at system operation start c Check if the maintenance valve is opened and the water drain valve is closed. d Observe the indicated pressure gauge value of the tank to securely check that the tank

charged air pressure is the same as the highest make-up water pressure at the tank installation position.

* The highest make-up water pressure at the tank installation position may become [highest make-up water pressure] + [circulation pump head] depending on the installation position of the circulation pump.

e When c and d of (2) are checked, it is possible to start operation normally.

CAUTION If the pressure value is not the same in cases of c and d, contact our sales department.

(3) Check at system operation start (at heating start by heat source).

When warm water reaches the maximum working temperature in system operation, be sure to check that the indicated pressure gauge value of the tank is lower than the set pressure of safety valve.

If the value is higher than the set pressure of safety valve, inspect the safety valve and the system.

Moreover, check that the maximum working pressure of the tank is not exceeded.

* If abnormality is observed, stop operation and contact our sales department.

The equipment and piping, etc. may possibly be damaged if operation is continued in abnormal condition.

Pressure gauge Air vent

System piping

ValveMaintenance valve

Flexible joint

Fusible plug


Air charging valve

Water drain valvePressure gauge

Concrete foundationDrain

piping (indirect drain)



WARNING If system pressure rises abnormally at trial run, be sure to consult our sales department. Moreover, stop operating the system immediately when abnormality is observed.

-13-

11. Construction Example

* It does not correspond to the second class pressure vessel.

Air vent Valve


Pressure gauge

System piping Maintenance valve

Flexible joint System connection port

Air charging valve

Concrete foundation Water drain valve

Air vent

Air vent

Air vent

Air vent

Air vent

Pressure gauge

Pressure gauge Pressure gauge

Pressure gauge

Pressure gauge

Maintenance valve

Maintenance valve Maintenance valve

Maintenance valve

Maintenance valve

Valve

Valve

Valve

Valve

Valve

System piping

System piping

System piping

System piping

System piping

Flexible joint

Flexible joint

Flexible joint

Flexible joint

Flexible joint

Fusible plug

Fusible plug

Fusible plug

Fusible plug

Fusible plug Fusible plug

Water drain valve

Water drain valve

Water drain valve

Water drain valve

Water drain valve











Air charging valve

Air charging valve

Air charging valve

Air charging valve

Air charging valve

Concrete foundation

Concrete foundation

Pressure gauge

Pressure gauge

Concrete foundation

Concrete foundation

Concrete foundation

Pressure gauge

Pressure gauge

Pressure gauge

AX-42V to 50V

AST-30 to 60

AX-15, 20 AST-5, 12, 20

AX-110V to 200V

AX-62V to 80V

EX-200L to 2000L

EX-3000L to 5000L

EX-3000LS to 5000LS

EX-200LS to 2000LS

AST-95 to 210

AST-82 to 90


FORCED (1) Be sure to install a safety valve in the system piping. (2) Be sure to install the maintenance valve, water drain valve and flexible joint indicated in

the installation example. * Neither check of charged air pressure nor parts replacement can be done otherwise.

-14-

12. Periodic Voluntary Inspection and Periodic Servicing

FORCED Conduct periodic voluntary inspection and periodic servicing once a year. Be sure to stop operating the system on which the tank is installed, when conducting periodic voluntary inspection and periodic servicing. * Service life may possibly be shortened if neither periodical voluntary inspection nor periodic

servicing is executed. 12-1. Legal Inspection [Periodic Voluntary Inspection] ... Article 88 of Ordinance on

Safety against Boilers and Pressure Vessels Conduct inspection once a year. (1) Presence of damage on main body (2) Presence of wear-out of clamp bolt of cap (3) Presence of damage on tube and valve * The second class pressure vessel structural standard product is the vessel corresponding to

seventh clause of Article 1 of Industrial Safety and Health Act. Article 88 of Ordinance on Safety against Boilers and Pressure Vessels stipulates that periodic voluntary inspection should be conducted once a year after the start of the product use and that the result should be recorded and kept for three years.

12-2. Periodic Service

Be sure to execute the following checks according to above-mentioned legal inspection in using the tank. (1) 3-month inspection after operation start Check of tank charged air pressure Be sure to check that charged pressure value marked on the nameplate (seal) of the tank is the

same as the highest make-up water pressure at the tank installation position. Check it by Charged Air Pressure Check and Adjust Procedure on P9 of this manual.

CAUTION Contact our sales department when the pressure value is not the same.

(2) Annual inspection ... Conduct annual inspection at the time of legal inspection once a year. c Check and adjustment of charged air pressure

Be sure to check that charged pressure marked on the nameplate (seal) of the tank is the same as the highest make-up water pressure at the tank installation position.

Check it by Charged Air Pressure Check and Adjust Procedure on P9 of this manual.

CAUTION If the charged air pressure value is not the same, contact our sales department. Check it by Charged Air Pressure Check and Adjust Procedure on P9 of this manual, when the customer conducts adjusting the charged pressure.

FORCED State the changed pressure clearly on the nameplate (seal) when charged air pressure is changed at the site.

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d Presence of external abnormality on the body

Check if there is a trace of water leak or peel-off of painting. e Presence of leakage of charged air

Check the leakage of charged air at each part by spreading soapy water. f Water quality test

Conduct water quality test to check if the system water connected to the tank is used within the following range.

(a) pH (b) Chlorine ion density (c) Free residual chlorine density

Should be within the warranty condition range on P3 of this manual.

CAUTION Using the tank outside the range of (1) - (3) may cause occurrence of abnormality such as corrosion or deterioration of the part in contact with water. * Please contact our sales department when abnormality is observed in above-mentioned

cases c to f.

(3) Record of check result [Periodic voluntary inspection] and [Periodic servicing] Make copies of the inspection record form

on P19 of this manual to record the check result. * Keep the record for three years.

(4) Check on hoses of EX-L and EX-LS series Detach the upper flange of the tank to check the presence of no abnormality (break, crack or

swelling) on the hose. * Give the order to our maintenance section about the check for items concerned. (For profit) Give the order to us for periodic voluntary inspection and periodic servicing. (Inspection for

profit.) Contact our sales department for inquiry in detail. 12-3. Others

Conduct painting on the exterior once in 2 or 3 years to prevent corrosion from the outside.

13. Change Parts Object model: EX-200L to 5000L and EX-200LS to 5000LS Bladder and hose (Make changes every ten years after use for EX-200L to 2000L and EX-200LS to 2000LS). * Service lives of change parts differ depending on use conditions etc. Replace the bladder or hose even within the service life if abnormality is observed.

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CAUTION Foreign matter may flow out because of aged deterioration of the bladder or hose when used exceeding the service life. Contact our sales department near you for inquiry in detail.

14. Treatment for Tank Storage (Stop) Drain charged air pressure for storage exceeding the following period. When reusing, recharge the tank to the specified charged air pressure according to the Charged Air Pressure Check and Adjust Procedure on P9 of this manual. During storage, close the maintenance valve to prevent water entering into the tank. When storing (stopping) the tank without draining the charged air pressure, limit storing to the period of c or d according to charged air pressure. c When charged air pressure is 0.39 MPa or less. ... 1 year d When charged air pressure exceeds 0.39 MPa and less than 0.54 MPa ... 6 months

15. About Regulations of Tank 15-1. First Class Pressure Vessel

The first class pressure vessel includes hot water tanks, heat exchangers, warm water headers and closed type expansion tanks, etc. The diaphragm type expansion tank corresponds to the vessel containing the liquid that exceeds the boiling point in the atmospheric pressure, out of the ministerial ordinance. Small pressure vessel The person who manufactures the following pressure vessel out of the first class pressure vessel should receive individual authorization. c One with the maximum working pressure (MPa) inner volume (m3) to be 0.02 or less. d One with the maximum working pressure to be 0.1 (MPa) or less and inner volume 0.2 m3

(200 L) or less. e One with the maximum working pressure to be 0.1 (MPa) or less, inside diameter 500mm or

less, and length 1,000 mm or less. 15-2. Container Defined in 37th Clause of Article 13

Those other than the first class pressure vessel, if having contents corresponding to that of the first class pressure vessel, should have the standard or the safety device provided by the Minister of Labor in the following cases. c One with the maximum working pressure (MPa) inner volume (m3) to be 0.04 or less. d One with the maximum working pressure to be 0.1 (MPa) or less and inner volume 0.04 m3

(40 L) or less. e One with the maximum working pressure to be 0.1 (MPa) or less, inside diameter 200mm or

less, and length 1,000 mm or less.

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Pressure vessel excluded from application

c One with the maximum working pressure to be 0.1 (MPa) or less and inner volume 0.01 m3 (10 L) or less.

d One with the maximum working pressure (MPa) inner volume (m3) to be 0.001 or less.

15-3. Second Class Pressure Vessel The second class pressure vessel is a container storing gas internally and satisfying the following requirements. c One with gas pressure to be 0.2 (MPa) or over and inner volume 0.04 m3 (40L) or over. d One with pressure to be 0.2 (MPa) or over, barrel inside diameter 200mm or over, and length

1,000 mm or over.

15-4. Container Defined in 38th Clause of Article 13 The following vessels should have the standard or the safety device provided by the Minister of Labor.c One storing gas with pressure exceeding atmospheric pressure and with inner volume

exceeding 0.1 m3.

CAUTION Note that our closed type diaphragm expansion tank is excluded from the first class pressure vessel when provided with measure not exceeding 100C but not excluded from the second class pressure vessel. Be sure to install the safety valve (relief valve) that operates at pressure lower than the maximum working pressure of this container in the system when installing the above mentioned container.

15-5. Installation Example Not Exceeding 100C (a) Two devices that automatically intercept combustion when temperature of warm water reaches

the prescribed value. (One of these should not be electrically driven.) (b) One device that automatically intercepts combustion when temperature of warm water reaches

the prescribed value, and one piece of dissolution plug (bore 25mm or more) that automatically operates to drain hot water in the tank safely to the outside when temperature of warm water reaches the prescribed value.

(c) Two pieces of dissolution plug (bore 25mm or more) that automatically operate to drain hot water in the tank safely to the outside when temperature of warm water reaches the prescribed value.

* The dissolution plug should satisfy the following conditions in the above-mentioned cases (b) and (C). c The dissolution plug should function at the temperature within 5% increase of the

temperature (under 100C) displayed on it. d Extract two or more pieces of dissolution plug out of those produced under the same

condition. Then use one for which its function is checked by experiment.

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Closed type diaphragm expansion tank inspection record form

Date of work:

Worker:

Article name To:

Address Installation place

Main contractor (managing company) To: Equipment No.

Tank model Second class pressure vessel No. Mfg. year/month

Delivery condition

Line [Hot water supply, air-conditioning, others ( )] Charged pressure [ MPa]

Fluid [clean water, antifreeze (ethylene glycol, propylene glycol density: 50% or less)] Maximum working pressure [ MPa]

Operating state

Charged pressure (measurement) [ MPa]

Charged pressure (marked value) [ MPa] Pre-charged pressure [ MPa]

(*A) Highest make-up water pressure at tank installation position [ MPa]

Ambient temperature at tank installation position [ MPa]

Fluid temperature (-5C to 95C) [ C] pH value (5.8 to 8.6) [ C] Chlorine ion density (mg/L) (Air-conditioning: 200 or less, hot water supply: 20 or less)

[ mg/l] Free residual chlorine density (mg/L) (Air-conditioning: 1 or less, hot water supply: 0.1 or less)

[ mg/l]

(*B) Charged pressure at adjusting [ MPa] Difference of specified or last-adjusting charged pressure and measuring charged pressure [ MPa]

Inspecting and check items Judgment

Installation situation

Is the safety valve installed in the connection piping to the tank? Yes/No

Is the air vent valve installed in the connection piping to the tank? Yes/No

Is the drain valve for system water drain in the tank installed? Yes/No

Is the maintenance valve to disconnect the system and tank body installed? Yes/No

Is the connected piping to the tank going downward to prevent air catching in the tank? Yes/No

Is insulating racking provided for the tank body? Yes/No

Is there effective space for inspection? (Inspection, charged pressure measuring, bladder replacement, etc.) (Space over 600 mm around the tank, or space over 1500 mm above the tank in the case of EXL and EX-LS series) Yes/No

Check item

Appearance check (visually for damage, irregularity, paint peel-off, rusting or gauge breakage of the tank body) Good/bad

Bolt loosening or presence of leakage (tank body, flange, charged pressure adjust valve, or inspection port) Yes/No

State of attached pipes (damaged valves or leakage) Yes/No

Is charged pressure proper? (As per delivery specification condition or any of the following.) Good/bad

c Installation of model matched to specification (capacity, temperature, pressure) Good/bad

d Does the actual measurement satisfy the expression on the right? [(A) (B)] Is the pressure of (A) and (B) almost the same? (Fill in the reason on remarks when not the same.) Good/bad

e State of system (operation state of expansion tank) Good/bad

Remarks

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No.

Date:

Air-conditioning and hot water supply expansion tank selection form Design office In charge: Trader Article name 1. Total system water quantity (Lit) Remarks 2. Maximum working temperature (C) System flow diagram 3. Minimum working temperature (C)

4. Make-up water pressure (MPa) (Highest make-up water pressure at tank installation position)

5. Safety valve set pressure (MPa) 6. Circulation pump head P1 (MPa) P2 (MPa)

Object circulation pump of calculation (Mpa=0.001 kPa) (P1:1 P2:2)

7. Judgment of circulation pump pressure (YES:1 NO:2) c Pressure on tank d Pressure on safety valve

Selection of expansion tank 1. Minimum working pressure (Pf)

Pf = (make-up water pressure at tank installation position) + (circulation pump pressure) + 0.10 (MPa) Pf = __________ + __________ + 0.10 (MPa) Pf = __________ (MPaabs)

2. Permissible pressure increase (permissible pressure fluctuation band of safety valve) A: Safety valve set pressure __________ (MPa) B: Safety valve safety margin __________ (MPa) C: Make-up water pressure onto safety valve __________ (MPa) D: Circulation pump pressure __________ (MPa) (A: Setting within the range of maximum working pressure of equipment)

Pf = A (B + C +D)

Pm = ________ (________ + ________ +________) Pm = __________ (MPaG) 3. Max. working pressure (Po)

Po = Pf + Pm Po = ________ + ________ Po = __________ (MPaabs)

4. Expansion water volume (VE) VE = (System holding water volume) (coefficient of expansion) VE = ________ ________ VE = __________ (Lit)

5. Expansion tank capacity (V)

V = VE = V =__________ (Lit)

1- Pf 1- Po

6. Selection of expansion tank

Expansion tank capacity in calculation (V) tank capacity (catalog value) Expansion water volume in calculation (VE) maximum using receive water volume (catalog value) Set charged air pressure to gauge pressure (Pf-0.10) of minimum working pressure (Pf). Be sure to install the safety valve in the heat source equipment of the system. Pressure loss of the piping between each equipment is not taken into consideration for convenience

sake. When tank capacity is 40 L or more and pressure exceeds 0.20 MPa, use the second class pressure

vessel structural standard product. The upper limit of charged pressure at shipping from the factory is 0.54 MPa. Pressurize the tank right before operation start at the site when using it at higher pressure. Be sure to read through the manual about constructing procedure.

Selection tank model / specification Tank model

Tank capacity (Lit)Maximum using receive water

volume (Lit)

Maximum working pressure (Mpa)Size Mass (kg)

Second class pressure vessel structural standard

* Calculation of this form has been made based on the selection condition provided by the customer. Check the content of the form. Contact us when change in conditions is generated.

* Specify it at the order. Charged air pressure (MPaG) Necessity of fusible plug

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About maintenance

Our closed type diaphragm expansion tank requires maintenance once a year.Contact our sales department near you for inquiry in detail.

Hitachi Metals, Ltd. http://www.hitachi-metals.co.jp

Head Office Capital Region Fitting Sales Management Department, Piping Components Company SEAVANS North Building, 1-2-1, Shibaura, Minato-ku, Tokyo 105-8614 Tel. (03) 5765-4279 Fax. (03) 5765-8313

Kitanihon Sales Office Sendai Meihou Building, 2-10-30, Chuou, Aoba-ku, Sendai-shi, Miyagi-ken 980-0021 Tel. (022) 267-0216 Fax. (022) 266-7891

Hokkaido Sales Office Nissay Sapporo Building, 4-1, Kita-Sanjo Nishi, Chuo-ku, Sapporo-shi, Hokkaido 060-0003 Tel. (011) 221-1786 Fax. (011) 222-4273

Niigata Sales Office Hokuriku Building, 1-2-23, Higashi Ohdohri, Chuo-ku, Niigata-shi, Niigata-ken 950-0087 Tel. (025) 241-5421 Fax. (025) 243-2558

Kitakanto Sales Office Meijiyasuda Life Ohta Building, 1220-1, Iida-cho, Ohta-shi, Gunma-ken 373-0851 Tel. (0276) 46-6694 Fax. (0276) 46-3169

Chubu-Tokai Sales Office Kuwana Office 1200, Kuwabe, Kuwana-shi, Mie-ken 511-0923

Tel. (0594) 22-8393 Fax. (0594) 27-3452 Hokuriku Sales Office Imuzu Building, 2-13-1, Kurose Kita, Toyama-shi, Toyama-ken

939-8213 Tel. (076)420-2881 Fax. (076) 491-5201

Shizuoka Sales Office South Pot Shizuoka, 18-1, Minami-cho, Suruga-ku, Shizuoka-shi, Shizuoka-ken 422-8067 Tel. (054) 202-1580 Fax. (054) 202-1588

Kansai Sales Office Nissei Yodoya-bashi Building, 3-5-29, Kitahama, Chuo-ku, Osaka-shi, Osaka-fu 541-0041 Tel. (06) 6203-9704 Fax. (06) 6202-0730

Chugoku Sales Office Nihon Seimei Hiroshima No.2 Building, 16-11, Hacchobori, Naka-ku, Hiroshima-shi, Hiroshima-ken 730-0013 Tel. (082) 221-4486 Fax. (082) 221-4488

Kyushu branch Taisei Hakata Station East Building, 1-9-11, Hakata Station East, Hakata-ku, Fukuoka-shi, Fukuoka-ken 812-0013 Tel. (092) 432-8603 Fax. (092) 451-8620

Issue: February, 2011

-1-

1. Precautions for Handling2. Product Warranty2-1. Warranty Period2-2. Warranty Information2-3. Warranty Range

3. Service Life4. Check for Tank Acceptance5. Label Display of Tank6. Request at Installation and Piping Construction7. About Charged Air Pressure8 Charged Air Pressure Check and Adjust ProcedureCharged air pressure check and adjust procedure

9. Hydraulic Pressure Test of System Piping10. Trial Run11. Construction Example12. Periodic Voluntary Inspection and Periodic Servicing12-1. Legal Inspection [Periodic Voluntary Inspection] ... Article 88 of Ordinance on Safety against Boilers and Pressure Vessels12-2. Periodic Service12-3. Others

13. Change Parts14. Treatment for Tank Storage (Stop)15. About Regulations of Tank15-1. First Class Pressure Vessel15-2. Container Defined in 37th Clause of Article 13Pressure vessel excluded from application15-3. Second Class Pressure Vessel15-4. Container Defined in 38th Clause of Article 1315-5. Installation Example Not Exceeding 100(C

Closed type diaphragm expansion tank inspection record formAir-conditioning and hot water supply expansion tank selection form

5.pressure tank(hitachi).pdf

Documents

product damage

wrong handling

warning warning

serious injury

handling methods

hot water supply

equipment knowledge

operation line