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Summary of Contents for Daikin EWWD320
- Page 1 Installation, Operation and Maintenance Manual Installation, Operation and Maintenance Manual Installation, Operation and Maintenance Manual D-EIMWC00908-16EN Frictionless Centrifugal Chiller EWWD320 ÷ C10FZXS Cooling capacity from 114 to 1048 kW 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 Description of the labels applied to the electrical panel for 1 and 2 compressors unit Label Identification 1 – Non flammable gas symbol 6 – Cable tightening warning 2 – Manufacturer’s logo 7 – Water circuit filling warning 3 – Gas type 8 –...
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Page 4: Table Of Contents
Index General information ................................6 Purpose of this manual ..............................6 General description ................................ 6 Receiving the machine ..............................6 Checks ................................... 6 Technical Specifications ..............................8 Operating limits ................................. 9 Storage ................................... 9 Operation ..................................9 Mechanical installation ..............................11 Shipping .................................. - Page 5 Start/Stop Switching ............................38 Annual Unit Startup/Shutdown ............................. 39 Annual Shutdown ..............................39 Annual Startup ..............................39 Operating parameters ............................39 System maintenance............................... 41 General ..................................41 Compressor maintenance ............................41 Routine maintenance ..............................42 Refrigerant charge ................................ 42 Procedure to replenish refrigerant ..........................44 Standard checks ................................
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Page 6: General Information
DOCUMENTS AND AS A PART OF THIS MANUAL In case of any discrepancy between this manual and the equipment’s document refer to on board documents. For any doubt ask Daikin or authorized centers Compressor manuals may may be downloaded from turbocor website www.turbocor.com... - Page 7 e) Immediately report the extent of the damage to the manufacturer representative, so that arrangements can be made for the required repairs. In no case must the damage be repaired before the machine has been inspected by the representative of the transportation company. Nomenclature E W W D 3 9 10 11 12 13 14...
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Page 8: Technical Specifications
Technical Specifications EWWD 320FZ 430FZ 520FZ 640FZ 660FZ C10FZ Cooling Capacity 1048 Capacity control Type Variable speed centrifugal compressor Minimum capacity Unit power input At min capacity 21.6 27.7 33.1 21.6 27.7 33.1 At max capacity 65.9 85.7 104.2 132.3 171.1 205.5 At min capacity... -
Page 9: Operating Limits
Storing in condensing atmosphere may damage the electronic components. Operation ATTENTION Daikin EWWD FZ chillers are suitable for stationary installations only. For any moving or marine applications, contact the factory. ATTENTION Operation limits of Frictionless Centrifugal compressor strongly depend from requested duty, so refer to selection tool to be sure unit can operate at requested condition. -
Page 10: Figure 1 - Operating Limits
Figure 1 - Operating limits Other limits are: Maximum startup evaporator inlet fluid temperature, 32°C Maximum non-operating inlet fluid temperature, 38°C D-EIMWC00908-16EN - 10/52... -
Page 11: Mechanical Installation
Mechanical installation Shipping The stability and the absence of any kind of deformation of the unit during shipping must be ensured. If the machine is shipped with a wooden cross-plank on its base, this cross-plank must only be removed after the final destination has been reached. -
Page 12: Positioning And Assembly
All units of the series are supplied with lifting points indicated in the figure below. Only these points may be used for lifting the unit, as shown in the following figure. Figure 2 - Lifting the unit This picture is for reference only. Lifting tools (bars, ropes, etc) are not supplied. WARNING Both the lifting ropes and the spacing bar and/or scales must be strong enough to support the machine safely. -
Page 13: Ventilation
Minimum clearance at all sides, including the top, is (1 meter); local regulation may require larger clearance. 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 anti-vibration elements (supplied as an option). -
Page 14: Water Treatment
Water treatment Before putting the machine into operation, clean the water circuit. Dirt, scale, corrosion residue and other foreign material can accumulate inside the heat exchanger and reduce its heat exchanging capacity. Pressure drop can increase as well, thus reducing water flow. Proper water treatment therefore reduces the risk of corrosion, erosion, scaling, etc. The most appropriate water treatment must be determined locally, according to the type of system and local characteristics of the process water. -
Page 15: Loss Of Flow Protection
Unless the heat exchangers are completely emptied and cleaned with anti-freeze solution, they have to be protected against freezing. Two or more of below protection methods should be considered when designing the system as a whole: 1. Continuous water flow circulation inside piping and exchangers 2. -
Page 16: Figure 4 - Evaporator Pressure Drop
Figure 4 - Evaporator pressure drop D-EIMWC00908-16EN - 16/52... - Page 17 D-EIMWC00908-16EN - 17/52...
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Page 18: Figure 5 - Condenser Pressure Drop
Figure 5 - Condenser pressure drop D-EIMWC00908-16EN - 18/52... - Page 19 Figure 4 and 5 legend Label Size Label Size 320FZ 640FZ 430FZ 860FZ 520FZ C10FZ D-EIMWC00908-16EN - 19/52...
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Page 20: Refrigerating Circuit Safety Valves
Refrigerating circuit safety valves Each system comes with safety valves that are installed, both on the evaporator and on the condenser. The purpose of the valves is to release the refrigerant inside the refrigerating circuit in the event of certain malfunctions. ATTENTION This unit is designed for indoor installation. -
Page 21: 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, management and maintenance activities must be carried out by qualified personnel. 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 nearest manufacturer office, who will send you a copy. -
Page 22: Electrical Components
EWWD FZ units use variable speed compressors that may operate at different rated conditions; the above listed electrical data are for reference only, please refer to selection to to have specific unit electrical data. 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 cables (dedicated conduit) Interconnection and interface cables (dedicated conduit) -
Page 23: Figure 6 - Field Wiring Diagram
Figure 6 – Field wiring diagram Digital Input Terminals Evap Flow Switch Condens Flow Switch Remote Start/Stop Mode Switch Analog Input Terminals Leaving Water Reset Demand Limit Evap GPM Condens GPM Digital Output Terminals Evap Water Pump #1-2 Condens Water Pump #1-2 Tower Stage #1-4 Alarm NO Alarm NC... -
Page 24: Field Wiring Diagram Notes
Field Wiring Diagram Notes Power wiring between the terminal box and compressor terminals is factory installed. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance. Standard. Supply voltage must be +/- 10% of compressor nameplate voltage. A customer furnished 115 Vac power for alarm relay coil may be connected between MC115 terminals 519 power and 506 neutral of the control panel. -
Page 25: Harmonic Filter
Harmonic Filter The harmonic filter is an option for field mounting and wiring outside of the power panel. It works in conjunction with the line reactor to further minimize harmonic distortion. It is wired between a compressor’s power supply and the circuit breaker (manual disconnect). -
Page 26: Table 4 - Electrical Data
4. Connect chillers together (RS485 wiring) as shown in Figure 7. The first chiller in the connection can be designated as Chiller A. The isolation board is attached to the DIN rail adjacent to the Chiller A unit controller. The isolation board has a pigtail that is plugged into J10 on the controller. -
Page 27: Microtech Ii Operator Interface Touch Screen (Oits) Settings
MicroTech II Operator Interface Touch Screen (OITS) Settings Settings for any type of linked multiple compressor operation must be made to the MicroTech II controller. Settings on a dual compressor unit are made in the factory prior to shipment, but must be verified in the field before startup. Settings for multiple chiller installations are set in the field on the Operator Interface Touch Screen as follows: Maximum Compressors ON –... -
Page 28: 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 start-up sequence, operation, shutdown sequence and operation of all the safety devices. During the machine’s initial start-up phase, a technician authorized by the manufacturer is available to answer any questions and to give instructions as to the correct operating procedures. -
Page 29: Use With On-Site Generators
The necessary procedure for reconnecting power from the generator back to the utility grid is shown below. These procedures are not peculiar to Daikin units only, but should be observed for any chiller manufacturer. 1. Set the generator to always run five minutes longer than the unit start-to-start timer, which could be set from 15 to 60 minutes. -
Page 30: Description Of The Refrigeration Cycle
1. Elctrical panel: Contains all electrical (main disconnect, inductances, filters, fuses) and electronic components. 2. Compressors: State of the art frictionless two-stages centrifugal compressor, magnetic bearing, of the Dafoss Turbocor series 3. Evaporator: Flooded shell and tube heat exchanger for all models, with chilled water flowing inside tubes and refrigerant changing phase from liquid to vapour shellside. -
Page 31: Figure 9 - Refrigeration Cycle
Figure 9 - Refrigeration cycle a) Single compressor unit b) Dual compressor unit D-EIMWC00908-16EN - 31/52... - Page 32 Legend Compressor Evaporator Condenser Drier filter Electronic expansion valve Sight glass Evaporator and condenser differential pressure switches Safety valve Valve Mechanical filter ¼ flare connection Check valve Condenser leaving water centerature sensor Condenser water inlet temperature sensor Evaporator leaving water centerature sensor Evaporator water inlet temperature sensor D-EIMWC00908-16EN - 32/52...
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Page 33: Compressor
Compressor Daikin EWWD FZXS chiller use Danfoss Turbocor family of compressors (TT300, TT350 and TT400), a totally oil-free compressors, specifically designed HVAC industry. The convergence of proven magnetic bearing, variable-speed centrifugal compression and digital electronic technologies enables the Turbocor family of compressors to achieve the highest compressor efficiencies for middle-market chillers. -
Page 34: Figure 12 - Compressor Overview
Figure 12 – Compressor overview D-EIMWC00908-16EN - 34/52... -
Page 35: Pre-Startup Checks
Pre-startup checks General Once the machine has been installed, use the following procedure to check that is has been done properly: ATTENTION Switch off the power supply of the machine before performing any checks. Since there are dc link electrolytic capacitors inside the VFD, there is voltage downstream of the inverter for several minutes after the electricity supply has been switched off. -
Page 36: Electrical Power Supply
Electrical power supply The machine’s power supply voltage must be the same as that specified on the nameplate 10% while the voltage unbalance between phases must not be in excess of 3%. Measure the voltage between phases and if the value does not fall within the established limits, correct it before starting the machine. -
Page 37: Prestart System Checklist
Prestart System Checklist Chilled Water Piping complete..................…………………………. Water system filled, vented..............………………………… Pumps installed, (rotation checked), strainers cleaned......………………………… Controls (3-way, face and bypass dampers, bypass valves, etc.) operable ……………………….. Strainer installed at evaporator inlet............…………………………. ... -
Page 38: Operation
Operation Capacity Control System The capacity of the chiller is controlled by: 1. Staging the compressors on and off; 2. By adjusting the capacity of each compressor by opening or closing the inlet vanes to control the quantity of refrigerant entering the impeller; and, 3. -
Page 39: Annual Unit Startup/Shutdown
3. BAS, BAS input is field-wired into a communication module that is factory-installed on the unit controller. 4. Control Panel Switches Three On/Off switches are located in the main Control Panel and have the following function: UNIT shuts down the chiller through the normal shutdown cycle of unloading the compressors. ... - Page 40 IMPORTANT The symptoms of a low refrigerant charge, that may be due to refrigerant leak, are: low evaporation pressure high suction and discharge superheat low super-cooling value Additionally a low level of liquid refrigerant inside the evaporator may be recognized. In this case, add R134a refrigerant only.
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Page 41: System Maintenance
System maintenance WARNING All routine and extraordinary maintenance activities on the machine must be carried out only 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 The causes of repeated shutdowns deriving from triggering of safety devices must be investigated and corrected. -
Page 42: Routine Maintenance
Routine maintenance Table 6 - Routine maintenance programme List of Activities Weekly Monthly Yearly (Note 1) (Note 2) General: Reading of operating data (Note 3) Visual inspection of machine for any damage and/or loosening Verification of thermal insulation integrity Clean and paint where necessary Analysis of water (5) Electrical: Verification of control sequence... - Page 43 appropriate materials for this unit. Unsuitable maintenance can result in uncontrolled losses in pressure and fluid. Do not disperse the refrigerant and lubricating oil in the environment. Always be equipped with a suitable recovery system. The units ship with a full refrigerant charge, but in some cases it might be necessary to adjust the machine in the field. ATTENTION Always verify the causes of a loss of refrigerant.
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Page 44: Procedure To Replenish Refrigerant
Procedure to replenish refrigerant If the machine has lost refrigerant, it is necessary to first find the causes before carrying out any replenishment operation. The leak must be found and repaired. Searching with soap/water solution is a good method and simple methos for medium to large leaks, while an electronic leak detector is required to find small leaks. -
Page 45: Standard Checks
Standard checks Temperature and pressure sensors The unit comes factory-equipped 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 operator interface panel. Well-calibrated sensors ensure better efficiency for the machine and a longer lifetime. Note: refer to operating manual for a complete description of applications, settings and adjustments. -
Page 46: Test Sheet
Test sheet It is recommended that the following operation data are recorded periodically in order to verify the correct function of the machine over the time. These data will also be extremely useful to the technicians who will be performing routine and/or extraordinary maintenance on the machine. -
Page 47: Service And Limited Warranty
Service and limited warranty All machines are factory-tested and guaranteed for 12 months as of the first start-up or 18 months as of delivery. These machines have been developed and constructed according to high quality standards ensuring years of failure-free operation. - Page 48 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 49 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-EIMWC00908-16EN - 49/52...
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- Page 52 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.