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Summary of Contents for Daikin EWWD 340
- Page 1 Installation, Operation and Maintenance Manual D–EIMWC00408-16EN Water-cooled screw chillers EWWD 340 ÷ C18 I-SS EWWD 360 ÷ C12 I-XS EWLD 320 ÷ C17 I-SS 50Hz – Refrigerant: R-134a Original Instructions...
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Page 2: Table Of Contents
Contents Contents ..................................... 2 General information ................................6 Warnings for the operator ..............................6 Assistance ..................................6 Spare parts ..................................6 Receiving the machine ..............................6 Checks ..................................... 7 Purpose of this manual ..............................7 Important information on the refrigerant used ........................7 Operating limits ................................. - Page 3 Fr4200 compressor ................................ 49 Oil filter replacement procedure ............................. 49 Procedure to replace oil filter ............................49 Refrigerant charge ................................50 Refrigerant filling procedure ............................50 Standard Checks ................................51 Temperature and pressure sensors ..........................51 Test sheet ..................................52 Water side measurements ..............................
- Page 4 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 reject 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 5 Two Compressors Unit 1 – Unit nameplate data 6 – Non flammable gas symbol 2 – Lifting instructions 7 – Manufacturer’s logo 3 – Hazardous Voltage warning 8 – Gas type 4 – Cable tightening warning 9 – Electrical hazard symbol 5 –...
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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 reject 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: Checks
Checks To prevent the possibility of incomplete delivery (missing parts) or transportation damage, please perform the following checks upon receipt of the machine: 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. -
Page 8: Operating Limits
Operating limits Storage The units can be stored under the following environmental conditions: Minimum ambient temperature -20°C Maximum ambient temperature 53°C Maximum relative humidity 95% non-condensing ATTENTION Storage at a lower temperature than the minimum indicated can cause damage to certain parts including the electronic control unit and its LCD display. -
Page 9: Mechanical Installation
Mechanical Installation Shipping The stability of the machine during shipping must be ensured. If the machine is shipped with a wooden cross-plank on its base, the cross-plank 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 10: 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 11: Minimum Space Requirements
Make sure to provide a strong and solid foundation to reduce noise and vibration as much as possible.The water in the system must be particularly clean and all traces of oil or rust must be removed. A mechanical water filter must be installed on the machine’s inlet piping. -
Page 12: Fig. 3 - Water Piping Connection For Evaporator
Fig. 3 - Minimum clearance requirements for machine maintenance Fig. 4 - Water piping connection for condenser and heat recovery D–EIMWC00408-16EN - 12/60... -
Page 13: Water Treatment
ATTENTION 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 – 1 mm in diameter is advised. -
Page 14: General Specifications
3” 83 mm 4” 107 mm 5” 134 mm 6” 162 mm 5 mm For 3” - 6” piping Adjusting flow switch’s Use paddle b = 29 mm trigger sensitivity Fig. 5 - Adjusting the safety flow switch Refrigerating circuit safety valves Each system comes with safety valves that are installed on each circuit, both on the evaporator and on the condenser. - Page 15 CAUTION Use copper conductors only. Use of conductors in any material other than copper could cause overheating or corrosion at the connection points and damage the unit. To avoid interference, all control wires must be installed separately from the power cables. Use separate electrical conduits for this purpose.
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Page 16: 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) Thermal-magnetic 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 17: 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 4-20 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 18: 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 19: Determining Equivalent Line Length
Fig. 8 - Condenser Located above Chiller Unit Fig. 9 - Condenser Located below Chiller Unit 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 the added friction loss of elbows, valves, etc. -
Page 20: Liquid Line Sizing
Note: When calculating the equivalent length, do not include piping of the chiller unit. Only field piping must be considered. Table 2 - Equivalent Lengths (in meters) Line Size Angle Short Long OD (inches) Valve Radius Radius EL 1-1/8 1-3/8 10.1 1-5/8 10.4... -
Page 21: Oil Charge
Total friction loss for discharge line from 20 to 40 kPa is considered good design. Carefully consideration must be given for sizing each section of piping so that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is to low, considerable oil can collect in the riser and horizontal header, causing compressor to lose oil and it can result in compressor damage due to lack of oil. -
Page 22: 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 23: Controlling The Partial Recovery Circuit And Installation Recommendations
These condensers, with partial heat recovery tubes, have crowns with special couplings by which they can be connected to the hot water pipes. When partial recovery is activated, condenser performance is improved since the condenser temperature is lowered further in as much as the surface dedicated to heat discharge is greater. After passing through the cooling tubes, the gas starts to condense in the central part of the condenser. -
Page 24: Fig. 10 - Refrigeration Cycle Of The Ewwd I-Ss Single Circuit
Fig. 10 - Refrigeration cycle of the EWWD I-SS Single Circuit LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH PARTIAL HEAT RECOVERY GAS CHARGE PORT (OPTIONAL) 15,5 bar SOLENOID VALVE 23,5 bar 23,5 bar... -
Page 25: Fig. 11 - Refrigeration Cycle Of The Ewld I-Ss Single Circuit
Fig. 11 - Refrigeration cycle of the EWLD I-SS Single Circuit LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE DISHARGE LINE CHECK VALVE CONNECTION SIGHT GLASS 23,5 bar 24.5 BAR SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH 15,5 bar GAS CHARGE PORT 23,5 bar SOLENOID VALVE... -
Page 26: Fig. 12 - Refrigeration Cycle Of The Ewld I-Ss + Liquid Receiver Single Circuit
Fig. 12 - Refrigeration cycle of the EWLD I-SS Single Circuit LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE DISHARGE LINE CONNECTION SIGHT GLASS 23,5 bar 24.5 BAR SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH GAS CHARGE PORT 15,5 bar SOLENOID VALVE 23,5 bar... -
Page 27: Fig. 13 - Refrigeration Cycle Of The Ewwd Single Circuit - Total Heat Recovery
Fig. 13 - Refrigeration cycle of the EWWD Single Circuit – Total heat recovery LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE 15,5 bar CHECK VALVE 23,5 bar 23,5 bar 23,5 bar SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH GAS CHARGE PORT SOLENOID VALVE... -
Page 28: Fig. 14 - Refrigeration Cycle Of The Ewwd I-Xs Single Circuit
Fig. 14 - Refrigeration cycle of the EWWD I-XS Single Circuit LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH PARTIAL HEAT RECOVERY GAS CHARGE PORT (OPTIONAL) 15,5 bar SOLENOID VALVE 23,5 bar 23,5 bar... -
Page 29: Fig.15 - Refrigeration Cycle Of The Ewwd I-Ss Double Circuits
Fig.15 - Refrigeration cycle of the EWWD I-SS Double Circuits PARTIAL HEAT RECOVERY (OPTIONAL) 15,5 bar 23,5 bar 23,5 bar 23,5 bar LEGEND COMPRESSOR IN/OUT EVAPORATOR WATER PARTIAL RECOVERY CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE 23,5 bar... -
Page 30: Fig. 16 - Refrigeration Cycle Of The Ewld I-Ss Double Circuits
Fig. 16 - Refrigeration cycle of the EWLD I-SS Double Circuits DISHARGE LINE CONNECTION 23,5 bar 15,5 bar 23,5 bar LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE LIQUID LINE CHECK VALVE CONNECTION SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH LIQUID LINE... -
Page 31: Fig. 17 - Refrigeration Cycle Of The Ewld I-Ss + Liquid Receiver Double Circuits
Fig. 17 - Refrigeration cycle of the EWLD I-SS Double Circuits 23,5 bar DISHARGE LINE CONNECTION 15,5 bar 23,5 bar LEGEND 23,5 bar COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE LIQUID 23,5 bar LINE CHECK VALVE CONNECTION SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH... -
Page 32: Fig. 18 - Refrigeration Cycle Of The Ewwd Double Circuits - Total Heat Recovery
Fig. 18 - Refrigeration cycle of the EWWD Double Circuits – Total heat recovery 23,5 bar DISHARGE LINE CONNECTION 15,5 bar 23,5 bar LEGEND 23,5 bar COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE LIQUID 23,5 bar LINE CHECK VALVE CONNECTION SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE... -
Page 33: Fig. 19 - Refrigeration Cycle Of The Ewwd I-Xs Double Circuits
Fig. 19 - Refrigeration cycle of the EWWD I-XS Double Circuits PARTIAL HEAT RECOVERY (OPTIONAL) 15,5 bar 23,5 bar 23,5 bar 23,5 bar LEGEND COMPRESSOR IN/OUT EVAPORATOR WATER PARTIAL RECOVERY CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH... -
Page 34: Fig.20 - Refrigeration Cycle Of The Ewwd I-Ss Trial Circuits
Fig.20 - Refrigeration cycle of the EWWD I-SS Trial Circuits 15,5 bar 23,5 bar 23,5 bar 23,5 bar LEGEND IN/OUT WATER COMPRESSOR PARTIAL RECOVERY EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE 23,5 bar 23,5 bar SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH... -
Page 35: Fig. 21 - Refrigeration Cycle Of The Ewld I-Ss Trial Circuits
Fig. 21 - Refrigeration cycle of the EWLD I-SS Trial Circuits 15,5 bar 23,5 bar 23,5 bar 23,5 bar LEGEND IN/OUT WATER COMPRESSOR PARTIAL RECOVERY EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE 23,5 bar 23,5 bar SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH... -
Page 36: Fig. 22 - Refrigeration Cycle Of The Ewld I-Ss + Liquid Receiver Trial Circuits
Fig. 22 - Refrigeration cycle of the EWLD I-SS Trial Circuits 23,5 bar DISHARGE LINE CONNECTION 15,5 bar 23,5 bar 23,5 bar LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR 23,5 bar EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH GAS CHARGE PORT... -
Page 37: Fig. 23 - Refrigeration Cycle Of The Ewwd Trial Circuits- Total Heat Recovery
Fig. 23 - Refrigeration cycle of the EWWD Trial Circuits– Total heat recovery 15,5 bar 23,5 bar 23,5 bar 23,5 bar LEGEND COMPRESSOR EVAPORATOR CONDENSER OIL SEPARATOR EXPANSION VALVE CHECK VALVE SIGHT GLASS SAFETY VALVE 23,5 bar 23,5 bar SHUT-OFF VALVE 2 WAY ANGLE VALVE WITH GAS CHARGE PORT... -
Page 38: Compression Process
Compressor The single-screw compressor is of the semi-hermetic type with an asyncronous three-phase, two-pole motor which is directly splined on the main shaft. The suction gas from the evaporator cools the electric motor before entering the suction ports. There are temperature sensors inside the electric motor which are completely covered by the coil winding and constantly monitor motor temperature. -
Page 39: Fig. 25 - 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 suction chamber. -
Page 40: Fig. 26 - Refrigeration Capacity Control Mechanism Of Compressor Fr4
Load Unload Fig. 26 - Refrigeration capacity control mechanism of compressor Fr4 D–EIMWC00408-16EN - 40/60... -
Page 41: Pre-Startup Checks
Pre-startup 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 holders and electrical terminals and check that they are clean and well secured. -
Page 42: 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 factory-supplied), to ensure operation of the machine within a ... -
Page 43: 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 thermal-magnetic switch Q12 and wait for the microprocessor and the control to start. Check that the oil temperature is warm enough. -
Page 44: Seasonal Shutdown
IMPORTANT If the machine is not supplied with a built-in 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 water-flow failure alarm. Seasonal shutdown Turn switches Q1 and Q2 to the Off (or 0) position to shut down the compressors, using the normal pump-down procedure. -
Page 45: 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 ATTENTION... -
Page 46: Fig. 27 - Installation Of Control Devices For Fr4 Compressor
Fig. 27 - Installation of control devices for Fr4 compressor D–EIMWC00408-16EN - 46/60... -
Page 47: Routine Maintenance
Routine maintenance Table 6 – Routine maintenance programme (Note 2) 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 (Note 5) Electrical: Verification of control sequence... -
Page 48: Replacement Of The Oil Filter
Shut down the relevant compressor by turning the Q1 or Q2 switch to Off. Wait until the compressor has stopped and close the valve located on the liquid line. Once the compressor has stopped, place a label on the compressor start-up switch, to prevent undesired start-ups. -
Page 49: Fr4200 Compressor
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 50: Refrigerant Charge
Refrigerant charge ATTENTION The units have been designed to operate with R134a refrigerant. DO NOT USE refrigerants other than R134a. WARNING The addition or removal of refrigerant gas must be carried out in compliance with the laws and regulations in force. 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 51: 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 microprocessor keypad. Well-calibrated 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 52: 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 non- routine maintenance on the machine. - Page 53 Analysis of the unit’s voltage unbalance: Phases: _____ V _____ V _____ V Vaverage _____ Unbalance %: Vaverage Compressors current – Phases: Compressor #1 _____ A _____ A _____ A Compressor #2 _____ A _____ A _____ A Compressor #3 _____ A _____ A...
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Page 54: 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 55: 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 56 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 57 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 58 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–EIMWC00408-16EN - 58/60...
- Page 59 D–EIMWC00408-16EN - 59/60...
- Page 60 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.