Daikin EWWQ-AJYNN Service Manual
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Daikin EWWQ-AJYNN Service Manual

Daikin EWWQ-AJYNN Service Manual

Water-cooled screw chillers
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ESIE07-05
Service Manual
EWWQ-AJYNN
Water-cooled screw chillers

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  • Page 1 ESIE07-05 Service Manual EWWQ-AJYNN Water-cooled screw chillers...
  • Page 2 IMPORTANT NOTICE This manual for the EWWQ-AJYNN chillers is a draft. Not all information on this chiller is already present in this service manual. However, together with the installation & operation manual and the databook, this manual should provide you with enough information to do maintenance and...
  • Page 4 Responsibilities Daikin declines all present and future responsibilities referred to injuries to people and damage to things and unit, coming from operators negligence, the unrespected installation/maintenance data carrier in this manual, the lacking of the current regulations respect referred to the safety of the equipment and the qualified personnel.
  • Page 5 Daikin introduces their newest water cooled screw chillers equipped with new single screw compressors. Daikin water cooled EWWQ-AJYNN chillers equipped with 1, 2, 3 and 4 screw compressors are a new range of the unit using the StarGateTM Frame 4 single screw compressors. They are manufactured by Daikin to satisfy the requirements of the consultants and the end user.
  • Page 6 Introduction ESIE 07-05 Safety Measures The unit must be suitably clamped to the ground. It is necessary to follow these cautions and warnings: ■ The unit must be lifted only by using the proper tools able to support the weight of the unit. ■...
  • Page 7 Atmospheric air contains many contaminants which increases the need for water treatment. The use of untreated water may result in corrosion, erosion, sliming, scaling, or algae formation. A water treatment service is recommended. Daikin is not responsible for damage or faulty operation from untreated or improperly treated water.
  • Page 8 Direct acting water regulating valve Condenser Temperature and EWWQ-AJYNN units are designed to operate in conditions from -8 °C to +15 °C leaving water waterflow temperature on the evaporator side and +15 °C to +55 °C entering water temperature on the limitations condenser side.
  • Page 9 Prior to insulating the piping and filling the system, a preliminary leak check should be made. Chilled water The EWWQ-AJYNN water-cooled chiller is equipped with the MicroTech II leaving water controller. Be thermostat careful when working around the unit to avoid damaging lead wires and sensor cables. Check lead wires before running the unit.
  • Page 10 Introduction ESIE 07-05 Standard Accessories (furnished on basic unit) Star Delta Compressors starter For low inrush current and reduced starting torque. Phase monitor The phase monitor controls the voltage values on the supply line stopping the unit when the calibration threshold is reached (±...
  • Page 11 Condenser power factor correction Installed on the electrical control panel to ensure it (OPPF) conforms to the plant rules. (DAIKIN advises maximum 0.9). Suction line shut off valve (OP12) Suction shut-off valve installed on the suction port of the compressor to facilitate maintenance operation.

  • Page 12: See Page

    ESIE07-05 Part 2 Functional Description Introduction This part gives more detailed information on the functions and controls of the unit. This information is used as background information for troubleshooting. An extensive overview of the functioning of the controller is also given in this part. Knowledge of the controller is essential to gather information prior to servicing and troubleshooting.
  • Page 13 ESIE07-05 2–2 Part 2 – Functional Description...

  • Page 14: Table Of Contents

    ESIE07-05 The Digital Controller Part 2 The Digital Controller What Is in This Chapter? Introduction This chapter gives more detailed information about the controller and the software. Understanding these functions is vital when diagnosing a malfunction, which is related to system architecture or software.

  • Page 15: General Description

    The Digital Controller ESIE07-05 General Description Introduction The Microtech II C Plus control panel contains a microprocessor based controller which provides all monitoring and control functions required for the safe, efficient operation of the Chiller. The operator can monitor all operating conditions by using the panel's built in 4 line by 20 character keypad/display or by using an IBM compatible computer running MicroPlant monitor software release 2.0 and later.

  • Page 16: Main Control Software Features

    ESIE07-05 The Digital Controller Main Control Software Features ■ Control of evaporator outlet or condenser outlet or both temperature. ■ Control of leaving water within a ± 0.1 °C (with a steady-state load). ■ Management of sudden load reduction up to 50% with max 3°C controlled temperature obscillation ■...

  • Page 17: Component Description Digital Controller

    The Digital Controller ESIE07-05 Component Description Digital controller Overview This chapter contains the following topics: Topic See page 1.4.1–Control Panel 2–7 1.4.2–Main Board 2–8 1.4.3–EEXV Valve Driver 2–10 1.4.4–Meaning of the Driver EEXV Status LEDs 2–12 1.4.5–Addressing of pLAN 2–13 1.4.6–Controller Input/Output 2–14 1.4.7–Display and Keypad...
  • Page 18 ESIE07-05 The Digital Controller 1.4.1 Control Panel Introduction The Control Panel is constituted by the backlight display 4 line by 20 character and by the 15 key keypad. In this chapter we will described this functions. Frontal and back view Backlight Display Keys Trimmer for brightness...
  • Page 19 The Digital Controller ESIE07-05 1.4.2 Main Board Introduction The control board contains the hardware and the software necessary to monitor and to control the unit. Main Board The figure below shows the main board: Power supply G (+), G0 (-) Status LED Fuse 250Vac Universal analog inputs (NTC, 0/1V, 0/10V,0/20mA, 4/20mA)
  • Page 20 ESIE07-05 The Digital Controller pLAN addressing microswitches R G V Part 2 – Functional Description 2–9...
  • Page 21 The Digital Controller ESIE07-05 1.4.3 EEXV Valve Driver Introduction The valve drivers contain the software for the control of the electronic expansion valve and are connected to the battery group which provide to close valve in case of power failure. Driver Status Led Inside of driver...
  • Page 22 ESIE07-05 The Digital Controller Battery assembly Battery charger Chargeable Battery 10 Amp Fuse Part 2 – Functional Description 2–11...
  • Page 23 The Digital Controller ESIE07-05 1.4.4 Meaning of the Driver EEXV Status LEDs Normal conditions Under normal conditions five(5) LED indicates: ■ POWER: (yellow) remains On in presence of supply. Remains Off in case of battery operation ■ OPEN: (green) Flashing during the valve opening. On when valve is fully open. ■...
  • Page 24 ESIE07-05 The Digital Controller 1.4.5 Addressing of pLAN To get the correct functionality of the pLAN net system, it is necessary to address correctly all the installed components. Each component has a series of microswitches that must be set as specified in the table below.
  • Page 25 ESIE07-05 The Digital Controller 1.4.7 Display and Keypad Introduction The display and the keypad are the main elements of interface between operator and unit. All the operational conditions, the alarms and the setpoints can be monitored with this display and all the values of setpoint can be modified through the keypad.
  • Page 26 The Digital Controller ESIE07-05 It allows to adjust the setpoints within the limits previously set in prog. Date and time setting. Input/Output and corresponding circuit functions visualization. Print (not available). (=print) By the Password it is possible to access the maintenance functions. (=maint) It allows to visualize the main menu.
  • Page 27 ESIE07-05 The Digital Controller It enables the set values. Screen categories Using the keypad you can access the different menus of the program. In particular there are 9 screen categories, shortly introduced in the following table with the keys to use to access them and with the type of operation they allow.

  • Page 28: Controller Menu's

    The Digital Controller ESIE07-05 Controller Menu’s Overview This chapter contains the following topics: Topic See page 1.5.1–Main Menu 2–23 1.5.2–User Menu 2–26 1.5.3–Setting Menu 2–30 1.5.4–Input/Output Menu (I/O Menu) 2–31 1.5.5–Manufacturer Menu 2–33 1.5.6–Maintenance Menu 2–38 1.5.7–Service Menu 2–41 1.5.8–Alarm Menu 2–42 1.5.9–Buffer Alarm Menu 2–43...

  • Page 29: Part

    ESIE07-05 The Digital Controller 1.5.1 Main Menu Introduction This menu shows only the output parameters throughout the screens listed below (the passage from one to another is allowed by the arrow key). Current date, time and weekday, setpoint origin and unit status in percent with the possibilities listed below.
  • Page 30 The Digital Controller ESIE07-05 Condenser outlet This screen shows the Condenser outlet water temperature (in heat pump or pursuit mode) water temperature Water Temperatures LVG Rec xxx ˚C Percent This screen shows the Percent compressor status compressor status Comp. #1 Status: Auto xxx%...
  • Page 31 ESIE07-05 The Digital Controller Compressor status This screen shows the Compressor status Staging Staging Down Staging Fixed Compressor ■ ■ standby ■ load ■ download Part 2 – Functional Description 2–25...

  • Page 32: Esie07

    The Digital Controller ESIE07-05 1.5.2 User Menu In this menu you can set the parameters by entering the password and acceding the following masks: Item description Default U.m. Cooling Temperature SetPoint Limits 4.0-10.0 °C ChLW Temperature setpoint limits xx.x ˚C High xx.x ˚C...
  • Page 33 ESIE07-05 The Digital Controller Item description Default U.m. Regulating Band °C Regul. band xx.x ˚C band Neutral xx.x ˚C Max Pull Down Rate xx.x ˚C/min Dead Band °C Max Pulldown Rate °C/min StartUp DT °C Startup xx.x ˚C Shutdn xx.x ˚C ShutDown DT °C...
  • Page 34 The Digital Controller ESIE07-05 Item description Default U.m. Outside ambient temperature lockout °C Ambient temperature setpoint °C Ambient temperature differential Ambient Lockout Unit limiting NONE Unit Limiting NONE/Superv. Demand/Currnent Limit Demand Limit Delay time between main pump and compressor start Time between main...
  • Page 35 ESIE07-05 The Digital Controller Item description Default U.m. Switch off unit on external alarm Switch unit External Alarm Time scheduling Enable Time Scheduling Working time from monday to friday Working time for saturday Working time for sunday If enabled Start Stop Mon-Fri xx:xx...

  • Page 36: Setting Menu

    The Digital Controller ESIE07-05 1.5.3 Setting Menu Introduction In this menu you can set and display the setpoint values. Cooling Setpoint This screen shows the Cooling Setpoint (°C) Cooling setpoint xx.x ˚C Heating setpoint xx.x ˚C Active setpoint These screens show the Active setpoint (if the "DOUBLE SETPOINT" function is enabled or "RESET SETPOINT"...

  • Page 37: Input/Output Menu (I/O Menu)

    ESIE07-05 The Digital Controller 1.5.4 Input/Output Menu (I/O Menu) Introduction This menu shows the parameters listed below. Software type, This screen shows the Software type, release release software version Code: xxxx xxxx xxxx 1.xxx xx/xx/xx Digital Input and This screen shows the Digital Input and Output status (C, O) Output status (C, O) Digital inputs xxxxxxxxxxxxxxxxxxxxxxx...
  • Page 38 The Digital Controller ESIE07-05 Modem Status, This screen shows: Controller Bios, ■ Modem Status Boot version and ■ Controller Bios and Boot version and date date, SoftLoad Status ■ SoftLoad Status Bios Version xxx.x Bios Date xx/xx/xx Boot Version xxx.x Boot Date xx/xx/xx EXV Firmware...

  • Page 39: Manufacturer Menu

    ESIE07-05 The Digital Controller 1.5.5 Manufacturer Menu Introduction In this menu you can set all manufacturer data. Password is required before the operation. The parameters can be modified only by trained persons. Warning: Improper Setpoint or value, can cause erratic chiller operation and damage to the chiller.
  • Page 40 The Digital Controller ESIE07-05 Compressor configuration ■ N. OF COMPRESSOR: 1/2/3/4 ■ N. OF EVAPORATORS (if compressor number >2) Compressors config. N. of compressors ■ Max number of pulses to load compressor ■ Max number of pulses to unload compressor Number of pulses to load comp.
  • Page 41 ESIE07-05 The Digital Controller Compressor loading pulse time ■ PULSE TIME = 0.3 s ■ MIN. PULSE PERIOD = 20 s ■ MAX. PULSE PERIOD = 90 s Compressor Loading Pulse time 00.3 Min pulse period Max pulse period Pumpdown configuration ■...
  • Page 42 The Digital Controller ESIE07-05 Enable evaporator flow alarm YES (MASTER); NO (SLAVES) Enable condenser flow alarm YES (MASTER); NO (SLAVES) Solo WHS ■ Evaporator flow alarm delay (if STARTUP DELAY = 20 s enabled) ■ OPERATING DELAY = 5 s ■...
  • Page 43 ESIE07-05 The Digital Controller Delay low oil pressure alarm ■ STARTUP DELAY = 300 s ■ OPERATING DELAY = 90 s Oil low pressure alarm delays Startup delay Run delay Delay high oil pressure differential 20 sec Oil high pressure diff.

  • Page 44: Maintenance Menu

    The Digital Controller ESIE07-05 1.5.6 Maintenance Menu Introduction In this menu you can set the maintenance parameters acceding the masks listed below. To set the maintenance parameters input, insert the maintenance password that gives access to the masks. Working time of This screen shows the Workingtime of evaporator pump/condenser pump.
  • Page 45 ESIE07-05 The Digital Controller EXV driver state This screen shows the EXV driver state. EXV Driver State Batt. Resist. xxx.x Batt. Voltage xx.x Pressure and These screens show the Pressure and temperature sensors correction. temperature Input probes sensors correction offset Input probes offset Compressor run...
  • Page 46 The Digital Controller ESIE07-05 Compressors This screen shows the Compressors minimum load. minimum load Comp. Min load Time download This screen shows the Time download compressor. compressor Time to download compressor This screen shows the Minimum evaporator ∆T. Minimum evaporator ∆T Min Evap DT ˚C Max Time...

  • Page 47: Service Menu

    ESIE07-05 The Digital Controller 1.5.7 Service Menu Introduction In this menu you can set the service parameters by entering the password and acceding the masks listed below. Compressor This screen shows the Compressor control (OFF/AUTO/MANUAL) and compressor load in manual control and mode.

  • Page 48: Alarm Menu

    The Digital Controller ESIE07-05 1.5.8 Alarm Menu Introduction When an alarm condition occurs, the display buzzer starts. Pressing the alarm key displays the current fault. Pressing the alarm key twice stops the buzzer while pressing it thrice removes the alarm. Remark: Sometimes, when an alarm occurs, another spurious alarm of star/delta transition failure also occurs.

  • Page 49: Buffer Alarm Menu

    ESIE07-05 The Digital Controller 1.5.9 Buffer Alarm Menu Introduction Using this menu you can consult the last ten alarms of every chiller circuit. Each mask displays the date, time and description of the alarm. Pressing the enter key when an alarm description is displayed shows the operating conditions at the time the alarm occurred (temperatures, pressures, expansion valve status and compressor load).

  • Page 50: Alarm List

    The Digital Controller ESIE07-05 1.5.10 Alarm List Introduction The table below shows the list of the possible alarms with the identifier number, the cause and the reset type (A = auto, M = manual). Alarm table - Chiller Compressor Pump System Reset Code...
  • Page 51 ESIE07-05 The Digital Controller Alarm table - Driver1 Compressor Pump System Reset Code Alarm description Fan off Delay Enabling (auto/man) AL60 Driver1 - Probe error *Circuit selectable AL61 Driver1 - Step motor error *Circuit AL62 Driver1 - Eeprom error *Circuit selectable AL63 Driver1 - Battery error...
  • Page 52 The Digital Controller ESIE07-05 2–46 Part 2 – Functional Description...
  • Page 53 ESIE07-05 Functional Control Part 2 Functional Control What Is In This Chapter? Introduction This chapter will give more detailed information about the functions used to control the system. Understanding these functions is vital when diagnosing a malfunction, which is related to functional control.
  • Page 54 Functional Control ESIE07-05 ON / OFF Management Introduction There are four ways of switching the unit on and off: ■ Through the local key of the controller ■ Through a remote switch ■ Through a supervision system (BMS) ■ Through a time schedule Power on ■...

  • Page 55: Thermostat Control

    ESIE07-05 Functional Control Thermostat Control Introduction The thermostat control is used to generate a load-up or load-down according to the active PID regulation. Continuous loading and unloading uses 2 solenoid valves to control the screw compressor slide and thus its capacity. Control is performed by outlet temperature. Unit and In the following flow chart the unit startup, management and shutdown procedures are shown, as well compressor...
  • Page 56 Functional Control ESIE07-05 Unit shutdown Unit S hutdown request Compressors shutdown (see compressors shutdown in startup and management procedure) Flow switch opening within 180 s UNIT ALARM 005 (user set) (Evap Flow Alarm) Evaporator pump shutdown Compressors start up and loading management Step n.
  • Page 57 ESIE07-05 Functional Control Step n. Leader Comp. Lag 1 Comp. Lag 2 Comp. Lag 3 Comp. 16a (T in unload Fixed at 75% Fixed at 75% Unload up to 50% Start band) 16b (T out unload Fixed at 75% Fixed at 75% Fixed at 75% Start band)
  • Page 58 Functional Control ESIE07-05 Step n. Leader Comp. Lag 1 Comp. Lag 2 Comp. Lag 3 Comp. 18a (T in load Load up to 75% Stop band) 18b (T not in load Fixed at 50% Stop band) Unload up to 25% If T is approaching SetP –...
  • Page 59 ESIE07-05 Functional Control Start up ∆T : 2.7°C ■ Other settings Shutdown ∆T : 1.7°C ■ ■ Regulation band : 3°C EXAMPLE: Upload ■ If the water temperature is above 9.7°C the chiller can start (below 9.7°C the chiller will wait) ■...

  • Page 60: Setpoint Reset Of The Chilled Water

    Functional Control ESIE07-05 Setpoint Reset of the Chilled Water Introduction Among the MicroTech NC controllers options, there are also several possibilities to regulate the unit with particular logics or outside signals. The setpoint reset function gives the possibility to modify the local setpoint of the chilled water according to the following logics: ■...
  • Page 61 ESIE07-05 Functional Control Lvg Water Temp Setpoint Reset 4-20mA chLWT Setpoint Override Limits Setp. Diff. 03.0 ˚C Part 2 – Functional Description 2–55...

  • Page 62: Return Water Reset

    Functional Control ESIE07-05 Return Water Reset Introduction When return water is selected as the reset mode, the MicroTech controller will adjust the leaving chilled water setpoint to maintain a constant return water temperature equal to the return water setpoint. The return water temperature is sampled every 5 minutes and a proportional correction is made to the leaving chilled water setpoint.

  • Page 63: Freeze-Up Control

    ESIE07-05 Functional Control Freeze-up Control Introduction Freeze up control is used to protect the evaporator against accidentally freezing. Two protections are present: freeze-up prevention and Anti-freeze alarm. Freeze-up Freeze-up prevention will request a load-down when the temperature of the evaporator outlet gets prevention below 3°C (default freeze prevention setpoint).
  • Page 64 Functional Control ESIE07-05 Function description Outlet Temp. possible for the compressor to upload 4 ∞C possible to reset Anti-freeze Alarm 3 ∞C Freeze Prevention Setpoint Freeze up prevention (load down) 2 ∞C Anti-freeze Alarm Setpoint Anti-freeze Alarm (shutdown) Time Anti-Freeze Alarm Setpoint 02.0 ˚C Diff.

  • Page 65: Enable Soft Load

    ESIE07-05 Functional Control Enable Soft Load Function The Soft load function can be enabled by keyboard in the user menu. The Soft load function limits the description unit load to a predetermined value (Max stage) for a set period (Max time). This function finds wide application where the water temperature is high at the start up but without having a consistent thermal load.

  • Page 66: Unit Load Limiting

    Functional Control ESIE07-05 Unit Load Limiting Introduction The Unit load limiting function finds application in all those situations when it is necessary to reduce the electric absorption of the unit, in determined periods of the day. Load limiting It is possible to limit the unit absorption using one of the two options available under user menu. ■...

  • Page 67: Start Up With High Evaporator Water Temperature

    ESIE07-05 Functional Control Start Up With High Evaporator Water Temperature Function This function limits the load of each compressor to a set value (default 70%) until the outlet water description temperature is below the set value (default 25°C). This function helps the start up of the unit when the water temperature is very high (35°C - 40°C) avoiding dangerous overheating of the motor and disagreeable interventions for high pressure protection.

  • Page 68: Pump Control

    Functional Control ESIE07-05 2.10 Pump Control Introduction To prevent the chiller to start up without flow, safety checks are performed. First there is a check to make sure that water flows through the system. The pump control of the user menu allows the user to define the pump lead and the pump lag time. Pump lead time Time Between Main Pump / Fan and Comp.

  • Page 69: Auto Restart After Power Failure Function

    ESIE07-05 Functional Control 2.11 Auto Restart after Power Failure Function Function The Auto restart after power failure allows the unit to restart after a power failure. description ■ When the Auto restart is enabled the unit will automatically restart after the power failure. ■...

  • Page 70: Liquid Injection

    Functional Control ESIE07-05 2.12 Liquid Injection Function description Liq. Inj. ON Liq. Inj. OFF (del Temp.) Oil Temp. ■ When the oil temperature (PT1000; del. temp.) is higher than 85°C (default) the liquid injection will be activated. ■ When the oil temperature decreases to 75°C the liquid injection will be disabled. Liquid Injection Setpoint 085 ˚C...

  • Page 71: Exv Pre Opening

    ESIE07-05 Functional Control 2.13 EXV Pre Opening Function Because the unit stops with a pump down, it will restart with a pre-purge (opening - closing of the description expansion valve). At start up the valve will open (up to 50%) and close to the evaporator with a certain amount of liquid. EXV PreOpening 50 % Part 2 –...

  • Page 72: Compressor Configuration

    Functional Control ESIE07-05 2.14 Compressor Configuration Function This controller screen will allow you to modify the number of compressors and evaporators on the unit. description The selection of the compressors and evaporators has to be done according to the unit. Compressor Configuration Numbers of Compressors 2 - 4...

  • Page 73: Compressor Management

    ESIE07-05 Functional Control 2.15 Compressor Management Introduction The compressor sequencing mode determines which circuit starts up first in case of a capacity demand. It prevents the unit from always starting the same circuit. Also, compressor timers are implemented to avoid too many compressor starts in 1 hour. Compressor The compressor sequence of starting up can be selected in the user menu.
  • Page 74 Functional Control ESIE07-05 Function description Min time between same comp start Min time comp ON Min time comp OFF Comp 1 Comp 1 Comp 1 Comp 1 Min time between diff comp starts Comp 1 Comp 1 Comp 2 Comp 2 2–68 Part 2 –...

  • Page 75: High Pressure Setback

    ESIE07-05 Functional Control 2.16 High Pressure Setback Introduction This is a safety prevention function, when high pressure is near to the high pressure switch setpoint. The unit will hold same capacity or will load-down to prevent the unit from tripping on the high pressure switch or transducer high pressure alarm.

  • Page 76: Lp Prevention

    Functional Control ESIE07-05 2.17 LP Prevention Introduction This is a safety prevention function, when the low pressure is near to the low pressure switch. The unit will hold same capacity or will load down to prevent the unit from tripping on the low pressure switch. Function description LP (bar)

  • Page 77: Capacity Control

    ESIE07-05 Functional Control 2.18 Capacity Control Introduction Cooling capacity control is infinitely variable by means of a capacity slide controlled by a microprocessor system. Each unit has infinitely variable capacity control from 100% down to 6.25% (four compressor units), to 8.3% (three compressor units) to 12.5% (two compressor units). This modulation allows the compressor capacity to exactly match the building-cooling load.
  • Page 78 Functional Control ESIE07-05 Pulse time The time of the pulse time is fixed (default 0.3 s). The interval time between two pulses is proportional to the PID (proportional + integral + derivative) unit request. Fixed Variable upload/download pulses Compressor Unloading Pulse Time 00.3 s Min Pulse Period...
  • Page 79 ESIE07-05 Functional Control Graph 2 The derivative part of the logic controls how the temperature reaches the setpoint. If it is getting closer – increases the time between intervals, or if it is far from the setpoint – decreases the time between intervals.

  • Page 80: Pump Down Configuration At Compressor Stop

    Functional Control ESIE07-05 2.19 Pump Down Configuration at Compressor Stop Introduction When the unit is switched off (local, remote, thermostat) the pump down procedure will be executed. Function Pump down procedure: description ■ request to shut down compressor ■ close electronic expansion valve ■...

  • Page 81: Pressure Safeties

    ESIE07-05 Functional Control 2.20 Pressure Safeties 2.20.1 Transducer high pressure alarm Introduction This is a software safety function. When high pressure is near to the high pressure switch setpoint, the unit will shutdown and trip on transducer high pressure alarm. Function description HP Alarm...
  • Page 82 Functional Control ESIE07-05 2.20.2 Transducer low pressure alarm Function description If LP is below possible this value to reset LP Alarm Setpoint Time ■ When the low pressure is below the LP setpoint (for the LP alarm delay time), the unit will go into LP alarm.

  • Page 83: Lp Alarm Delay

    ESIE07-05 Functional Control 2.21 LP alarm delay Function Delay timer before the unit goes into LP alarm. description ■ start delay: At start up the unit has a delay of 120 seconds before the unit can trip on LP alarm (low pressure bypass timer) ■...

  • Page 84: Oil Management Safeties

    Functional Control ESIE07-05 2.22 Oil Management Safeties 2.22.1 Pressure ratio alarm Introduction Because the capacity control is done by oil pressure it is very important to have a minimum pressure difference between LP and HP to be able to move the sliding vane. Function When the pressure ratio is too small for a specified time, the controller will give an alarm.
  • Page 85 ESIE07-05 Functional Control 2.22.2 Pressure ratio alarm delay Function Delay time before the unit goes into pressure ratio alarm. description ■ start up delay: At start up the unit will start to check the pressure ratio after the 180 seconds start up delay timer.
  • Page 86 Functional Control ESIE07-05 2–80 Part 2 – Functional Description...

  • Page 87: What Is In This Part? This Part Contains The Following Chapters

    ESIE07-05 Part 3 Troubleshooting Introduction When a problem occurs, all possible faults have to be checked. This chapter gives a general idea of where to look for faults. Furthermore the general procedures for refrigeration circuit repair and for electrical circuit repair are explained. Remark Not all repair procedures are described.
  • Page 88 ESIE07-05 3–2 Part 3 – Troubleshooting...
  • Page 89 ESIE07-05 Procedure for Software Upload/Download Part 3 Procedure for Software Upload/Download What Is in This Chapter? Overview This chapter contains the following topics: Topic See page 1.2–Copy from the Software Key to pCO² 3–4 1.3–Copy from pCO² to the Software Key 3–5 1.4–Installation of Winload32 on the PC and Programming a Controller 3–6...
  • Page 90 Procedure for Software Upload/Download ESIE07-05 Copy from the Software Key to pCO² ■ Switch off the pCO and remove the "expansion memory" cover with a screwdriver (see "Copy from pCO² to the Software Key" on page 3–5/Fig. 1) ■ Set the key selector on ■...
  • Page 91 ESIE07-05 Procedure for Software Upload/Download Copy from pCO² to the Software Key ■ Switch off the pCO and remove the "expansion memory" cover with a screwdriver (see Fig. 1) ■ Set the key selector on ■ Insert the key in the corresponding pin connector as shown. (see Fig. 2) ■...
  • Page 92 Create 2 folders 1: Carel to place progam winload in this folder 2: Carel_upload to place software program files in this folder 1. Go to the Daikin Extranet website 2. Select Software downloads 3. Select Service software 3–6 Part 3 – Troubleshooting...
  • Page 93 ESIE07-05 Procedure for Software Upload/Download Step Action Select Chiller PCO² page 1. Go to the WinLoad32 program page Part 3 – Troubleshooting 3–7...
  • Page 94 Procedure for Software Upload/Download ESIE07-05 Step Action 1. Click on winload32 to download the file 2. “file download” screen will appear 3. Click on save Download the file to your hard disk 1. Browse to the place were you want to save the file Example: save on C-drive 2.
  • Page 95 ESIE07-05 Procedure for Software Upload/Download Step Action The file “Winload32 v3.30” is now saved on the hard disk of your PC 1. Double click on the file Winzip will open : 1. Select winload32.exe 2. Press on extract Part 3 – Troubleshooting 3–9...
  • Page 96 Procedure for Software Upload/Download ESIE07-05 Step Action 1. Browse to the Carel folder 2. Press Extract. 1. Do the same (see previous screens) for the Carel drivers 2. Save the carel drivers in the Carel folder on your PC. 3. Follow the PDF instruction file in the zip archive to install the driver.
  • Page 97 ESIE07-05 Procedure for Software Upload/Download Step Action 1. Go back to the PCO² software download page on the extranet 2. Click on the model name Click to download the file Select save to download the file to your PC Part 3 – Troubleshooting 3–11...
  • Page 98 Procedure for Software Upload/Download ESIE07-05 Step Action Open the saved zip file Select the file for the unit (capacity Press extract Choose a location where you want to save the file (example: C-drive) Click extract The file is now save on the hard disk of your PC 1.
  • Page 99 ESIE07-05 Procedure for Software Upload/Download Step Action Winzip will open : 1. Select the files • If you have a 2Mb controller you can upload all languages (*.iup-files) • If you have a 1Mb controller only 2 languages can be uploaded, only extract 2 languages (*.iup-files) to the upload folder.
  • Page 100 Procedure for Software Upload/Download ESIE07-05 Step Action All program files are placed into the upload folder now Remark: • No old or other files may be placed into this (only program-files) • If you copy the files from a CD to this folder then the property of this files is “read only”...
  • Page 101 ESIE07-05 Procedure for Software Upload/Download Step Action 1. Go to the shortcut “shortcut to winload32” 2. Select properties 1. Go to target and type C:\Carel\WinLoad32.exe "C:\carel_upload" "EASY_BOOT " don’t forget the place ‘spaces’ 2. Press apply 3. Press OK Part 3 – Troubleshooting 3–15...
  • Page 102 Procedure for Software Upload/Download ESIE07-05 Step Action 1. Go to the Carel folder 2. Open Winload32 1. Go to the tab: “Application” 2. Open the Carel_upload folder to activate 3. If OK you will see the files that are in the Carel_upload folder 5.
  • Page 103 ESIE07-05 Procedure for Software Upload/Download Step Action 1. Go to the tab: “Bios” 2. Open the Carel_upload folder to activate 3. If OK you will see the BIOS file that is in the Carel_upload folder 1. Go to the tab: “Boot” 2.
  • Page 104 Procedure for Software Upload/Download ESIE07-05 Step Action 1. Go to the tab: “Public Variables” 2. Open the Carel_upload folder to activate 1. Go to the tab: “LogProject” 2. Open the Carel_upload folder to activate This is the folder where you can find the “program report” to check if uploading was successfully done.
  • Page 105 ESIE07-05 Procedure for Software Upload/Download Step Action 1. Double click “shortcut to winload32” 2. The white screen will appear and the program is now waiting for the controller. 3. When you see this screen you can now put power supply to the controller. 4.
  • Page 106 Procedure for Software Upload/Download ESIE07-05 Step Action Please check that you have 4 times “UPLOAD COMPLETED SUCCESSFULLY” 3–20 Part 3 – Troubleshooting...
  • Page 107 ESIE07-05 Procedure for Software Upload/Download Copy Software from WinLoad32 to the Software Key Optional: Carel RS Converter (software Winload + drivers: are available on intranet) ■ Switch off the pCO and remove the "expansion memory" cover with a screwdriver (see "Copy from pCO²...
  • Page 108 Procedure for Software Upload/Download ESIE07-05 3–22 Part 3 – Troubleshooting...
  • Page 109 ESIE07-05 pLAN Setting Part 3 pLAN Setting What Is in This Chapter? Overview This chapter contains the following topics: Topic See page 2.2–pLAN Setting 3–24 Part 3 – Troubleshooting 3–23...
  • Page 110 pLAN Setting ESIE07-05 pLAN Setting Procedure To add a terminal in the pLAN or change the settings, follow this procedure: 1 Press the UP, DOWN and ENTER buttons for at least 10 seconds. 2 A screen will appear with the terminal address and with the address of the board in examination. Terminal Adr: I/O Board Adr: 3 You can choose between the different boards (1, 2, 3, 4 for the compressors and 5, 7, 9, 11 for the...
  • Page 111 ESIE07-05 Part 4 Commissioning and Test Run Introduction Commissioning and test run are well known practices in service engineering. This part contains a systematic approach on test run checks and test values, which guarantees a high quality installation and operation of the units. What is in this part? This part contains the following chapters: Chapter...
  • Page 112 ESIE07-05 4–2 Part 4 – Commissioning and Test Run...
  • Page 113 ESIE07-05 Part 5 Maintenance Introduction Preventive maintenance should be set up for operation at maximum capacity or to avoid damage. The following chapters explain how to or when to maintain the units. What is in this part? This part contains the following chapters: Chapter See page 1–Maintenance...
  • Page 114 ESIE07-05 5–2 Part 5 – Maintenance...
  • Page 115 ESIE07-05 Maintenance Part 5 Maintenance What Is in This Chapter Introduction As shown in the table below, we have grouped the maintenance in maintenance of the main parts (condenser, compressor and evaporator) and periodical checks. Precautions Correct choices and decisions have to be made before any maintenance is done. Opening the refrigerant circuit may cause a loss of refrigerant or lead to system contamination.

  • Page 116: Screw Compressors

    Oil injection is used for these compressors in order to get high COP at high condensing pressure. EWWQ-AJYNN units are provided with an high efficiency oil separator to maximise oil extraction. Compressors have a infinitely variable capacity control down to 25% of its total capacity. This control is made by means of capacity slides controlled by microprocessors.

  • Page 117: Standard Controls

    ESIE07-05 Maintenance Standard Controls High pressure The high pressure switch will shut-down the compressor when the discharge pressure exceeds the control setting point value. Warning: during testing, stand by the emergency stop switch on control panel, to shut the unit down should the safety control malfunction.

  • Page 118: System Maintenance

    Maintenance ESIE07-05 System Maintenance General To ensure proper operation at peak capacity and to avoid damage to package components, a program of periodic inspections should be set up and followed. The following items are intended as a guide and are to be used during inspection and must be combined with sound coming from compressor and electrical practices to ensure troublefree performance.
  • Page 119 Open the suction line valve. A leak check is recommended before returning the unit to operation. Electronic The EWWQ-AJYNN water cooled chiller is equipped with the most advanced electronic expansion expansion valve valve to achieve precise control of refrigerant mass flow. As today’s system requires improved energy...
  • Page 120 Maintenance ESIE07-05 Lubrificating oils Besides lubrificating the bearing and other moving parts, the oil has the equally important task of sealing the clearances between the rotors and other potential leakage paths thereby improving pumping efficiency; the oil also assists in dissipating the heat of compression. The amount of oil injected is therefore well in excess of that required for lubrification only.

  • Page 121: Preventive Maintenance Schedule

    ESIE07-05 Maintenance Preventive Maintenance Schedule Overview SCHEDULE Operation TYPE OF OPERATION Six- Ref. No. Weekly Monthly Yearly Monthly Reading and recording of suction pressure Reading and recording of discharge pressure Reading and recording of supply voltage Reading and recording of current intensity Check refrigerant charge and possible moisture in the circuit refrigerant through the liquid sight glass...

  • Page 122: Refrigerant

    ESIE07-05 Refrigerant Refrigerant EWWQ-AJYNN water cooled screw chillers are shipped factory charged with a full operating charge charging of refrigerant but there may be times that a unit must be recharged at the jobsite. Follow these recommendations when field charging.
  • Page 123 ESIE07-05 Appendix B Part 6 Appendix B What Is in This Chapter Overview This chapter covers the following topics: Topic See page 2.2–General Chiller Start-up Guide 5–20 Part 5 – Maintenance 6–19...
  • Page 124 Detailed procedures will vary from chiller to chiller, but this guide is intended to indicate the principle items to be checked on any Daikin chiller to ensure that the commissioning process is adequate. It is not exhaustive and could be added to if necessary, particularly where optional accessories are included.
  • Page 125 ■ Make a close visual inspection of the chiller for transport damage and general condition. Inform the Daikin Europe Logistic Department in case of transport damage. ■ Carry out a refrigerant leak check of the whole unit, report and fix any leaks.
  • Page 126 If the unit incorporates heat-recovery or heat pump operation, repeat the unit operation checks in heating mode and, again, take a full log. Complete the standard log sheets and return to Daikin Europe Service Department. If heating operation is not possible at the time of commissioning, arrange with the client to return when it is possible.
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