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Summary of Contents for Daikin EWWD170~600G-SS
- Page 1 Installation, Operation and Maintenance Manual D–EIMWC00208-16EN Water-cooled screw chillers EWWD170~600G-SS EWWD190~650G-XS EWLD160~550G-SS 50Hz – Refrigerant: R-134a Original Instructions...
- Page 2 This Manual is a technical aid and does not represent a binding offer for Daikin. Daikin has drawn up this Manual to the best of its knowledge. The content cannot be held as explicitly or implicitly guaranteed as complete, precise or reliable.
- Page 3 Two compressors unit Label Identification 1 – Lifting instructions 6 – Non flammable gas symbol 2 – Unit nameplate data 7 – Manufacturer’s logo 3 – Hazardous Voltage warning 8 – Emergency stop 4 – Cable tightening warning 9 – Water circuit filling warning 5 –...
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Page 4: Table Of Contents
Contents General information ................................6 Warnings for the operator ..............................6 Assistance ..................................6 Spare parts ..................................6 Receiving the machine ............................... 6 Checks ....................................6 Purpose of this manual ............................... 7 Important information on the refrigerant used ........................7 Mechanical Installation ............................... - Page 5 Electrical measurements ..............................39 Service and limited warranty............................40 Obligatory routine checks and starting up apparatuses under pressure ..............41 Important information regarding the refrigerant used ....................41 Table contents Table 1 - Acceptable water quality limits ....................11 Table 2 - Equivalent Lengths (in meters) ....................15 Table 3 - Liquid line sizes ..........................
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Page 6: General Information
Specifications are subject to change without prior notice. Refer to the data communicated at the time of the order as per the “Documents Certified” such as “Dimensional Drawings”, “Wiring diagrams” and “Nameplate”. Daikin explicitly rejects any liability for any direct or indirect damage, in the broadest sense, arising from or related to the use and/or interpretation of this Installation and Maintenance Manual. -
Page 7: Purpose Of This Manual
Before accepting the machine, please verify every single component in the consignment. Check for any damage. In the event that the machine has been damaged, do not remove the damaged material. A set of photographs are helpful in ascertaining responsibility. Immediately report the extent of the damage to the transportation company and request that they inspect the machine. -
Page 8: Mechanical Installation
Mechanical Installation Shipping The stability of the machine during shipping must be ensured. If the machine is shipped with a wooden crossplank on its base, the crossplank must be removed only after the final destination has been reached. Responsibility The manufacturer declines all responsibility, present and future, for any damage to persons, animals or property caused by negligence of operators failing to follow the installation and maintenance instructions in this manual. -
Page 9: Positioning And Assembly
Fig. 1 - Lifting the unit WARNING Both the lifting ropes and the spacing bar and/or scales must be strong enough to support the machine safely. Please check the unit’s weight on the machine’s nameplate. The weights shown in the "Technical data" tables in the "General Information" chapter refer to standard units. Some specific machines might have accessories that increase their overall weight (heat recovery, etc.) WARNING The machine must be lifted with the utmost attention and care. -
Page 10: Minimum Space Requirements
Minimum space requirements Every side of the machine must be accessible for all postinstallation maintenance activities. Figure 2 shows the minimum space necessary. Fig. 2 - Minimum clearance requirements for machine maintenance Ventilation The temperature of the room where the unit is placed should be always maintained between 0°C and 40°C. Sound protection When sound levels require special control, great care must be exercised to isolate the machine from its base by appropriately applying antivibration elements (supplied as an option). -
Page 11: Water Treatment
Fig. 3 - Water piping connections for evaporator Fig. 4 - Water piping connection for heat recovery exchangers Install a mechanical filter on the inlet to each heat exchanger. Failure to install a mechanical filter allows solid particles and/or welding slag to enter the exchanger. Installation of a filter with a mesh size not exceeding 0.5 mm in diameter is advised. -
Page 12: Evaporator And Exchangers Antifreeze Protection
Evaporator and exchangers antifreeze protection Two or more of below protection methods should be considered when designing the system as a whole: Continuous water flow circulation inside piping and exchangers. Addition of an appropriate amount of glycol inside the water circuit. Additional heat insulation and heating of exposed piping. -
Page 13: Guidelines For Remote Condenser Application
After the equipment is correctly installed, leak tested and evacuated, it can be charged with R134a refrigerant and started under the supervision of Daikin authorized technician. Charge will be added until the liquid line sight glass is clear, with no bubbles flowing into the expansion valve. Total... -
Page 14: Fig. 7 Condenser Located Above Chiller Unit
Fig. 7 Condenser Located above Chiller Unit Fig. 8 Condenser Located below Chiller Unit D-EIMWC00208-16EN - 14/48... - Page 15 Determining Equivalent Line Length To determine the appropriate size for field installed liquid and discharge lines, it is first necessary to establish the equivalent length of pipe for each line. The equivalent length is the actual friction loss from the linear run of pipe plus t he added friction loss of elbows, valves, etc.
- Page 16 Table 3 - Liquid line sizes Circuit Total Equivalent Length (meters) Capacity 11/8 11/8 13/8 13/8 13/8 13/8 13/8 15/8 15/8 11/8 13/8 13/8 13/8 13/8 13/8 15/8 15/8 15/8 11/8 13/8 13/8 13/8 13/8 15/8 15/8 15/8 15/8 11/8 13/8 13/8 13/8...
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Page 17: Electrical Installation
Electrical Installation General specifications CAUTION All electrical connections to the machine must be carried out in compliance with laws and regulations in force. All installation, operating and maintenance activities must be carried out by qualified personnel. Please refer to the specific wiring diagram for the machine that you have purchased and which was sent with the unit. Should the wiring diagram not appear on the machine or should it have been lost, please contact your dealer who will provide for a copy to be forwarded. -
Page 18: Electrical Components
Electrical components All power and interface electrical connections are specified in the wiring diagram that is shipped with the machine. The installer must supply the following components: Power supply wires (dedicated conduit) Interconnection and interface wires (dedicated conduit) Thermalmagnetic circuit breaker of suitable size (please see electrical data). Electrical wiring Power circuit: Connect the electrical power supply cables to the terminals of the general circuit breaker on the machine’s... -
Page 19: Unit Limitation Electrical Wiring (Optional)
Unit limitation Electrical wiring (Optional) The machine’s microprocessor allows to limit the capacity by means of two separate criteria: >Load limitation: The load can be varied by means of a 420 mA external signal from a BMS. The signal cable must be directly connected to terminals 36 and 37 of the M3 terminal board. The signal cable must be of the shielded type and must not be laid in the vicinity of the power cables, so as not to induce interference with the electronic controller. -
Page 20: Operation
Operation Operator’s responsibilities It is important that the operator is appropriately trained and becomes familiar with the system before operating the machine. In addition to reading this manual, the operator must study the microprocessor operating manual and the wiring diagram in order to understand startup sequence, operation, shutdown sequence and operation of all the safety devices. During the machine’s initial startup phase, a technician authorized by the manufacturer is available to answer any questions and to give instructions as to the correct operating procedures. -
Page 21: Fig. 10 - Refrigeration Cycle Ewwd G-Ss, Ewwd G-Xs
Fig. 10 - Refrigeration cycle EWWD G-SS / EWWD G-XS 23,5 bar D-EIMWC00208-16EN - 21/48... -
Page 22: Fig. 11 - Refrigeration Cycle Ewwd G-Ss, Ewwd G-Xs Partial Heat Recovery
Fig. 11 - Refrigeration cycle EWWD G-SS, EWWD G-XS Partial Heat recovery 23,5 bar D-EIMWC00208-16EN - 22/48... -
Page 23: Fig. 12 - Refrigeration Cycle Ewld G-Ss
Fig. 12 - Refrigeration cycle EWLD G-SS OPTIONAL 23,5 bar D-EIMWC00208-16EN - 23/48... -
Page 24: Description Of The Refrigeration Cycle With Partial Heat Recovery
Description of the refrigeration cycle with partial heat recovery The lowtemperature refrigerant gas from the evaporator is drawn by the compressor through the electric motor, which is cooled by the refrigerant. It is subsequently compressed and during this process the refrigerant mixes with the oil from the oil separator. -
Page 25: Compression Process
Fig. 13 - Picture of Fr3200 compressor In the Fr3200. series compressor, access to internal parts is allowed by two covers positioned sidewise. Compression process With the singlescrew compressor the suction, compression and discharge process takes place in a continuous manner thanks to the upper satellite. -
Page 26: Fig. 14 - Compression Process
1. E 2. Suction Main rotor flutes ‘a’, ‘b’ and ‘c’ are in communication at one end with the suction chamber and are sealed at the other end by the upper satellite teeth. As the main rotor turns, the effective length of the flutes increases, thus increasing the volume open to the suction chamber. -
Page 27: Fig. 15 - Refrigeration Capacity Control Mechanism Of Compressor Fr3200
FR3200 Compressor Oil vent Oil supply Load Unload Yoke Slide Spring Piston Permanent vent to suction Fig. 15 - Refrigeration capacity control mechanism of compressor Fr3200 D-EIMWC00208-16EN - 27/48... -
Page 28: Fig. 16 - Capacity Control Mechanism
Oil supply Oil vent Energised De-Energised (open) (closed) Unload Compressor unloading Permanent vent to suction Spring Force + Oil Pressure Suction/Discharge Differential Pressure = Slide valve moves toward unload Oil supply Oil vent De-Energised Energised (closed) (open) Load Compressor loading Permanent vent to suction Suction/Discharge Differential Pressure >... -
Page 29: Prestartup Checks
Prestartup checks General Once the machine has been installed, use the following procedure to check that it has been done correctly: CAUTION Switch off the power supply of the machine before performing any checks. Failure to open the power switches at this stage can result in serious injury to the operator or even death. Inspect all the electrical connections to the power circuits and to the compressors, including the contactors, fuse carriers and electrical terminals and check that they are clean and well secured. -
Page 30: Units With External Water Pump
Units with external water pump Start the water pump and check the water system for any leaks; repair these if necessary. While the water pump is in operation, adjust the water flow until the design pressure drop for the evaporator is reached. Adjust the flow switch trigger point (not factorysupplied), to ensure operation of the machine within a ... -
Page 31: Startup Procedure
Startup procedure Turning on the machine With the general disconnecting switch Q10 closed, check that switches Q0, Q1, Q2 and Q12 are in the Off (or 0) position. Close the thermalmagnetic switch Q12 and wait for the microprocessor and the control to start. Check that the oil temperature is warm enough. -
Page 32: Seasonal Shutdown
IMPORTANT If the machine is not supplied with a builtin pump, do not shut down the external pump before 3 minutes have elapsed after the last compressor has shut down. Early shutdown of the pump triggers a waterflow failure alarm. Seasonal shutdown Turn switches Q1 and Q2 to the Off (or 0) position to shut down the compressors, using the normal pumpdown procedure. -
Page 33: System Maintenance
System maintenance WARNING All routine and non-routine maintenance activities on the machine must be carried out solely by qualified personnel who are familiar with the machine characteristics, operation and maintenance procedures, and who are aware of the safety requirements and risks involved. WARNING It 's absolutely forbidden to remove all the protections of the moving parts of the unit WARNING... -
Page 34: Routine Maintenance
ECONOMIZER PORT ECONOMIZER PORT LIFTING HIGH PRESSURE SWITCH LIFTING DISCHARGE OIL CHARGE LOADING SOLENOID VALVE UNLOADING COCK SOLENOID VALVE TRANSDUCER FOR HIGH PRESSURE OIL FILTER OIL FILTER TEMPERATURE SENSOR POSITION TRANSDUCER FOR OIL PRESSURE HEATER SHEATH FOR OIL SUMP TRANSDUCER FOR OIL PRESSURE Fig. -
Page 35: Replacement Of Filter Dryer
Monthly activities include alle the weekly ones The annual (or early season) activities include all weekly and monthly activities Machine operating values should be read on a daily basis thus keeping high observation standards Replace the oil filter when the pressure drop across it reaches 2.0 bar Check for any dissolved metals 0.10 : No action TAN (Total Acid Number) :... -
Page 36: Replacement Of The Oil Filter
Replacement of the oil filter ATTENTION The lubrication system has been designed to keep most of the oil charge inside the compressor. During operation, however, a small amount of oil circulates freely in the system, conveyed by the refrigerant. The amount of replacement oil going into the compressor should therefore be equal to the quantity removed rather than the amount stated on the nameplate;... -
Page 37: Refrigerant Charge
Refrigerant charge ATTENTION The units have been designed to operate with R134A refrigerant. So DO NOT USE refrigerants other than R134A. ATTENTION When refrigerant gas is added to or removed from the system, ensure proper water flow through the evaporator for the entire charge/discharge time. -
Page 38: Standard Checks
Standard Checks Temperature and pressure sensors The unit comes factoryequipped with all the sensors listed below. Periodically check that their measurements are correct by means of reference instruments (manometers, thermometers); correct the wrong readings as necessary using the microprocessor keypad. Wellcalibrated sensors ensure better efficiency for the machine and a longer lifetime. Note: Refer to the microprocessor use and maintenance manual for a complete description of applications, settings and adjustments. -
Page 39: Test Sheet
Test sheet It is recommended that the following operation data are recorded periodically in order to verify correct operation of the machine over time. These data will also be extremely useful to the technicians who will be performing routine and/or nonroutine maintenance on the machine. -
Page 40: Service And Limited Warranty
Service and limited warranty All machines are factorytested and guaranteed for 12 months as of the first startup or 18 months as of delivery. These machines have been developed and constructed according to high quality standards ensuring years of failurefree operation. -
Page 41: Obligatory Routine Checks And Starting Up Apparatuses Under Pressure
Obligatory routine checks and starting up apparatuses under pressure The units are included in category IV of the classification according to European Directive PED 2014/68/EU. For chillers belonging to this category, some local regulations require a periodic inspection by an authorized agency. Please check with your local requirements. - Page 42 Factory and Field charged units instructions (Important information regarding the refrigerant used) The refrigerant system will be charged with fluorinated greenhouse gases. Do not vent gases into the atmosphere. 1 Fill in with indelible ink the refrigerant charge label supplied with the product as following instructions: the refrigerant charge for each circuit (1;...
- Page 43 Field charged units instructions (Important information regarding the refrigerant used) The refrigerant system will be charged with fluorinated greenhouse gases. Do not vent gases into the atmosphere. 1 Fill in with indelible ink the refrigerant charge label supplied with the product as following instructions: the refrigerant charge for each circuit (1;...
- Page 44 Disposal The unit is made of metal and plastic parts. All these parts must be disposed of in accordance with the local regulations in terms of disposal. Lead batteries must be collected and taken to specific refuse collection centres. D-EIMWC00208-16EN - 44/48...
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- Page 48 The present publication is drawn up by of information only and does not constitute an offer binding upon Daikin Applied Europe S.p.A.. Daikin Applied Europe S.p.A. has compiled the content of this publication to the best of its knowledge. No express or implied warranty is given for the completeness, accuracy, reliability or fitness for particular purpose of its content, and the products and services presented therein.
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