Page 1 ESIE10-01 Service Manual EWAD620-C17C-SS/SL/SR EWAD740-C19C-XS/XL/XR EWAD810-C14C-PS/PL/PR Air-cooled chiller EWAD~CJ...
Page 3 ESIE10-01 Table of Contents Part 1 System Outline General Outline What Is in This Chapter? ................ 1–3 Features ....................1–5 Nomenclature..................1–8 General Characteristics ................1–9 Technical Specifications: EWAD~C-SS ..........1–15 Technical Specifications: EWAD~C-SL ..........1–18 Technical Specifications: EWAD~C-SR..........1–21 Technical Specifications: EWAD~C-XS ..........
Page 4: Table Of Contents
ESIE10-01 Part 2 Functional Description The Digital Controller What Is in This Chapter? ................. 2–3 System Architecture................. 2–4 Customer Interfaces ................2–6 Display and Keypad ................. 2–10 Functional Control What Is In This Chapter? ................. 2–23 Unit Functions ..................2–24 Circuit Functions ..................
Page 5: Troubleshooting
ESIE10-01 Procedure for Software Programming What is in This Chapter?................. 3–67 Software Programming with SD Card ............. 3–68 Procedure to Protect Compressor in Case of Frozen Evaporator What is in This Chapter?................. 3–71 Procedure to Protect Compressor in Case of Frozen Evaporator... 3–72 Procedure to Clear the Refrigerant Circuit in Case of Frozen Evaporators...
Page 6 ESIE10-01 Part 5 Maintenance Maintenance What Is in This Chapter ................5–3 System Maintenance ................5–4 Standard Checks ..................5–10 Table of Contents...
Page 7 ESIE10-01 Part 1 System Outline Introduction This part contains an outline of all the relevant elements in the EWAD-CJ air-cooled units. What is in this part? This part contains the following chapters: Chapter See page 1–General Outline 1–3 Part 1 – System Outline 1–1...
Page 8 ESIE10-01 1–2 Part 1 – System Outline...
Page 9 ESIE10-01 General Outline Part 1 General Outline What Is in This Chapter? Introduction This chapter contains the following information: Technical specifications Electrical specifications Capacity tables Correction factors Heat recovery ratings Wiring diagrams Overview This chapter contains the following topics: Topic See page 1.2–Features 1–5...
Page 10 General Outline ESIE10-01 Topic See page 1.27–Water Content in Cooling Circuits 1–78 1.28–Heat Recovery Ratings 1–79 1.29–Evaporator Pressure Drops 1–80 1.30–Condensor Pressure Drops 1–83 1.31–Operation Range 1–84 1.32–Mechanical Installation 1–85 1.33–Dimensional Drawing 1–90 1.34–Electrical Installation 1–92 1.35–Operation 1–95 1.36–Wiring Diagrams - EWAD-CJYNN 1–103 1–4 Part 1 –...
Page 11 ESIE10-01 General Outline Features Low operating cost EWAD is the result of careful design, aimed to optimizing the energy efficiency of the chillers, with the objective of bringing down operating costs and improving profitability, effectiveness and economical management. The EWAD chillers use the New very high efficiency McQuay single rotor screw compressor design, large condenser coil surface area for maximum heat transfer and low discharge pressure, advanced technology condenser fans, a single-pass pure conterflow shell&tube direct-expansion evaporator with low refrigerant pressure drops.
Page 12 General Outline ESIE10-01 Superior control The new MicroTech III controller provides an easy to use control environmental. The control logic is logic designed to provide maximum efficiency, to continue operation in unusual operating conditions and to provide a history of unit operation. One of the greatest benefits is the easy interface with LonWorks, Bacnet, Ethernet TCP/IP or Modbus communications.
Page 13 ESIE10-01 General Outline XN: Extra Low Noise Condenser fan rotating at 710 rpm, rubber antivibration on compressor, compressor sound enclo- sure. Part 1 – System Outline 1–7...
Page 14 General Outline ESIE10-01 Nomenclature Name Digits Machine type EWA = Air-cooled chiller, cooling only EWY = Air-cooled chiller, heat pump EWL = Remote condenser chiller ERA = Air-cooled condensing unit EWW = Water-cooled chiller, cooling only EWC = Air-cooled chiller, cooling only with centrifugal fan EWR = Air-cooled chiller, cooling only with heat recovery Refrigerant D = R-134a...
Page 15 ESIE10-01 General Outline General Characteristics Cabinet and The cabinet is made of galvanized steel sheet and painted to provide a high resistance to corrosion. structure Colour Ivory White (Munsell code 5Y7.5/1) (±RAL7044). The base frame has eye-hook for lifting the unit with ropes for an easy installation.
Page 16 General Outline ESIE10-01 Refrigerant circuit Each unit has 2 or 3 independent refrigerant circuits and each one includes: Compressor with integrated oil separator. Air Cooled Condenser. Electronic expansion valve. Evaporator. Discharge line shut off valve. Liquid line shut off valve. Suction line shut off valve (optional).
Page 17 ESIE10-01 General Outline Control section - main features Management of the compressor stepless capacity and fans modulation. Chillers enabled to work in partial failure condition. Full routine operation at condition of: • high ambient temperature value. • high thermal load. •...
Page 18 General Outline ESIE10-01 Regulation type Proportional + integral + derivative regulation on the leaving water evaporator output probe. Condensing pressure Condensing pressure can be controlled in according to the entering air temperature to the condenser coil. The fans can be managed either with steps, or with a 0/10 V modulating signal or with a mixed 0/10 V + Steps strategy to cover all possible operational conditions.
Page 19 ESIE10-01 General Outline Compressor hour run meter. General fault - Alarm relay. Set-point reset - The leaving water temperature set-point can be overwritten with the following options: 4-20 mA from external source (by user); outside ambient temperature; evaporator water temperature Δt. Demand limit - User can limit the load of the unit by 4-20 mA signal or by network system.
Page 20 General Outline ESIE10-01 Evaporator Flow switch - Supplied separately to be wired and installed on the evaporator water piping (by the customer). Suction line shut off valves - Installed on the suction port of the compressor to facilitate maintenance operation. High pressure gauges. Kit container.
Page 21 ESIE10-01 General Outline Technical Specifications: EWAD~C-SS Technical The table below contains the technical specifications. specifications Model EWAD~C-SS Capacity (1) Cooling Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 2.93 2.84 2.78 2.87 2.76...
Page 22 General Outline ESIE10-01 Model EWAD~C-SS Capacity (1) Cooling 1064 1152 1419 1538 1622 1714 Capacity control Type Stepless Minimum capacity 12.5 12.5 Unit power input (1) Cooling EER (1) 2.82 2.86 2.84 2.79 2.77 ESEER 3.88 3.84 3.88 3.87 3.78 IPLV 4.17 4.19...
Page 23 ESIE10-01 General Outline Notes (1) Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator 12/7°C; ambient 35°C, unit at full load operation. (2) The values are according to ISO 3744 and are referred to: evaporator 12/7°C, ambient 35°C, full load operation.
Page 24 General Outline ESIE10-01 Technical Specifications: EWAD~C-SL Technical The table below contains the technical specifications. specifications Model EWAD~C-SL Capacity (1) Cooling Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 2.93 2.84 2.78 2.87 2.76...
Page 25 ESIE10-01 General Outline Model EWAD~C-SL Capacity (1) Cooling 1064 1152 1419 1538 1622 1714 Capacity control Type Stepless Minimum capacity 12.5 12.5 Unit power input (1) Cooling EER (1) 2.82 2.86 2.84 2.79 2.77 ESEER 3.88 3.84 3.88 3.87 3.78 IPLV 4.17 4.19...
Page 26 General Outline ESIE10-01 Notes (1) Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator 12/7°C; ambient 35°C, unit at full load operation. (2) The values are according to ISO 3744 and are referred to: evaporator 12/7°C, ambient 35°C, full load operation.
Page 27 ESIE10-01 General Outline Technical Specifications: EWAD~C-SR Technical The table below contains the technical specifications. specifications Model EWAD~C-SR Capacity (1) Cooling Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 2.77 2.62 2.51 2.65 ESEER...
Page 28 General Outline ESIE10-01 Model EWAD~C-SR Capacity (1) Cooling 1020 1112 1367 1471 1556 1623 Capacity control Type Stepless Minimum capacity 12.5 12.5 Unit power input (1) Cooling EER (1) 2.59 2.67 2.64 2.55 2.58 2.51 ESEER 3.96 3.96 3.87 3.83 IPLV 4.20 4.29...
Page 29 ESIE10-01 General Outline Notes (1) Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator 12/7°C; ambient 35°C, unit at full load operation. (2) The values are according to ISO 3744 and are referred to: evaporator 12/7°C, ambient 35°C, full load operation.
Page 30 General Outline ESIE10-01 Technical Specifications: EWAD~C-XS Technical The table below contains the technical specifications. specifications Model EWAD~C-XS Capacity (1) Cooling 1001 Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 3.25 3.28 3.26 ESEER 4.02...
Page 31 ESIE10-01 General Outline Model EWAD~C-XS Capacity (1) Cooling 1074 1196 1280 1349 1409 Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 3.18 3.29 3.29 3.23 ESEER 4.05 4.14 4.02 4.28 4.23 IPLV 4.44 4.51...
Page 32 General Outline ESIE10-01 Model EWAD~C-XS Capacity (1) Cooling 1526 1596 1685 1768 1858 Capacity control Type Stepless Minimum capacity Unit power input (1) Cooling EER (1) 3.22 3.17 3.16 3.15 3.15 ESEER 4.19 4.17 4.16 4.13 4.13 IPLV 4.54 4.52 4.52 4.47 4.47...
Page 33 ESIE10-01 General Outline Notes (1) Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator 12/7°C; ambient 35°C, unit at full load operation. (2) The values are according to ISO 3744 and are referred to: evaporator 12/7°C, ambient 35°C, full load operation.
Page 34 General Outline ESIE10-01 Technical Specifications: EWAD~C-XL Technical The table below contains the technical specifications. specifications Model EWAD~C-XL Capacity (1) Cooling 1001 Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 3.25 3.28 3.26 ESEER 4.02...
Page 35 ESIE10-01 General Outline Model EWAD~C-XL Capacity (1) Cooling 1074 1196 1280 1349 1409 Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 3.18 3.29 3.29 3.23 ESEER 4.05 4.14 4.02 4.28 4.23 IPLV 4.44 4.51...
Page 36 General Outline ESIE10-01 Model EWAD~C-XL Capacity (1) Cooling 1526 1596 1685 1768 1858 Capacity control Type Stepless Minimum capacity Unit power input (1) Cooling EER (1) 3.22 3.17 3.16 3.15 3.15 ESEER 4.19 4.17 4.16 4.13 4.13 IPLV 4.54 4.52 4.52 4.47 4.47...
Page 37 ESIE10-01 General Outline Notes (1) Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator 12/7°C; ambient 35°C, unit at full load operation. (2) The values are according to ISO 3744 and are referred to: evaporator 12/7°C, ambient 35°C, full load operation.
Page 38 General Outline ESIE10-01 1.10 Technical Specifications: EWAD~C-XR Technical The table below contains the technical specifications. specifications Model EWAD~C-XR Capacity (1) Cooling Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 3.14 3.08 3.15 ESEER 4.29...
Page 39 ESIE10-01 General Outline Model EWAD~C-XR Capacity (1) Cooling 1041 1168 1247 1302 1378 Capacity control Type Stepless Minimum capacity 12.5 12.5 12.5 12.5 Unit power input (1) Cooling EER (1) 3.03 3.08 3.14 3.15 ESEER 4.24 4.38 4.25 4.33 4.34 IPLV 4.54 4.65...
Page 40 General Outline ESIE10-01 Model EWAD~C-XR Capacity (1) Cooling 1486 1550 1639 1722 1813 Capacity control Type Stepless Minimum capacity Unit power input (1) Cooling EER (1) 3.03 3.03 3.04 3.04 ESEER 4.26 4.26 4.21 IPLV 4.65 4.60 4.59 4.59 4.57 Casing Colour Ivory White...
Page 41 ESIE10-01 General Outline Notes (1) Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator 12/7°C; ambient 35°C, unit at full load operation. (2) The values are according to ISO 3744 and are referred to: evaporator 12/7°C, ambient 35°C, full load operation.
Page 42 General Outline ESIE10-01 1.11 Technical Specifications: EWAD~C-PS Technical The table below contains the technical specifications. specifications Model EWAD~C-PS Capacity (1) Cooling 1074 1158 1279 1390 Capacity control Type Stepless Minimum capacity 12.5 Unit power input (1) Cooling EER (1) 3.64 3.58 3.56 3.56...
Page 43 ESIE10-01 General Outline Model EWAD~C-PS Safety devices High discharge pressure (pressure switch) High discharge pressure (pressure transducer) Low suction pressure (pressure transducer) Compressor motor protection High discharge temperature Low oil pressure Low pressure ratio High oil filter pressure drop Phase monitor Emergency stop button Water freeze protection controller Notes...
Page 44 General Outline ESIE10-01 1.12 Technical Specifications: EWAD~C-PL Technical The table below contains the technical specifications. specifications Model EWAD~C-PL Capacity (1) Cooling 1074 1158 1279 1390 Capacity control Type Stepless Minimum capacity 12.5 Unit power input (1) Cooling EER (1) 3.64 3.58 3.56 3.56...
Page 45 ESIE10-01 General Outline Model EWAD~C-PL Safety devices High discharge pressure (pressure switch) High discharge pressure (pressure transducer) Low suction pressure (pressure transducer) Compressor motor protection High discharge temperature Low oil pressure Low pressure ratio High oil filter pressure drop Phase monitor Emergency stop button Water freeze protection controller Notes...
Page 46 General Outline ESIE10-01 1.13 Technical Specifications: EWAD~C-PR Technical The table below contains the technical specifications. specifications Model EWAD~C-PR Capacity (1) Cooling 1053 1132 1251 1359 Capacity control Type Stepless Minimum capacity 12.5 Unit power input (1) Cooling EER (1) 3.58 3.51 3.52 3.43...
Page 47 ESIE10-01 General Outline Model EWAD~C-PR Safety devices High discharge pressure (pressure switch) High discharge pressure (pressure transducer) Low suction pressure (pressure transducer) Compressor motor protection High discharge temperature Low oil pressure Low pressure ratio High oil filter pressure drop Phase monitor Emergency stop button Water freeze protection controller Notes...
Page 48 General Outline ESIE10-01 1.14 Electrical Specifications: EWAD~C-SS Electrical The table below contains the electrical specifications. specifications Model EWAD~C-SS Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 628.4 665.2 665.2 904.2 949.8 Nominal running current cooling Maximum running current Maximum current for wires sizing Fans...
Page 49 ESIE10-01 General Outline 1.15 Electrical Specifications: EWAD~C-SL Electrical The table below contains the electrical specifications specifications Model EWAD~C-SL Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 628.4 665.2 665.2 904.2 949.8 Nominal running current cooling Maximum running current Maximum current for wires sizing Fans...
Page 50 General Outline ESIE10-01 1.16 Electrical Specifications: EWAD~C-SR Electrical The table below contains the electrical specifications specifications Model EWAD~C-SR Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 614.4 651.2 651.2 887.4 Nominal running current cooling Maximum running current Maximum current for wires sizing Fans...
Page 51 ESIE10-01 General Outline 1.17 Electrical Specifications: EWAD~C-XS Electrical The table below contains the electrical specifications specifications Model EWAD~C-XS Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 636.4 681.2 681.2 920.2 Nominal running current cooling Maximum running current Maximum current for wires sizing Fans...
Page 52 General Outline ESIE10-01 Model EWAD~C-XS Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 1213 1258.6 1317.8 1377 1385 Nominal running current cooling Maximum running current 1017 1074 1146 1218 1290 Maximum current for wires sizing 1119 1181 1261...
Page 53 ESIE10-01 General Outline 1.18 Electrical Specifications: EWAD~C-XL Electrical The table below contains the electrical specifications specifications Model EWAD~C-XL Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 636.4 681.2 681.2 920.2 Nominal running current cooling Maximum running current Maximum current for wires sizing Fans...
Page 54 General Outline ESIE10-01 Model EWAD~C-XL Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 1213 1258.6 1317.8 1377 1385 Nominal running current cooling Maximum running current 1017 1074 1146 1218 1290 Maximum current for wires sizing 1119 1181 1261...
Page 55 ESIE10-01 General Outline 1.19 Electrical Specifications: EWAD~C-XR Electrical The table below contains the electrical specifications. specifications Model EWAD~C-XR Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 619.6 661.6 661.6 897.8 Nominal running current cooling Maximum running current Maximum current for wires sizing Fans...
Page 56 General Outline ESIE10-01 Model EWAD~C-XR Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 1179.4 1225 1281.4 1337.8 1343 Nominal running current cooling 1001 Maximum running current 1040 1110 1179 1248 Maximum current for wires sizing 1082 1144 1221...
Page 57 ESIE10-01 General Outline 1.20 Electrical Specifications: EWAD~C-PS Electrical The table below contains the electrical specifications specifications Model EWAD~C-PS Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 660.4 697.2 697.2 936.2 981.8 1041 1049 Nominal running current cooling Maximum running current Maximum current for wires siz-...
Page 58 General Outline ESIE10-01 1.21 Electrical Specifications: EWAD~C-PL Electrical The table below contains the electrical specifications specifications Model EWAD~C-PL Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 660.4 697.2 697.2 936.2 981.8 1041 1049 Nominal running current cooling Maximum running current Maximum current for wires siz-...
Page 59 ESIE10-01 General Outline 1.22 Electrical Specifications: EWAD~C-PR Electrical The table below contains the electrical specifications specifications Model EWAD~C-PR Power Supply Phase Frequency Voltage Voltage Tolerance Minimum -10% Maximum +10% Unit Maximum starting current 635.2 908.2 953.8 1010.2 1015.4 Nominal running current cooling Maximum running current Maximum current for wires siz- Fans...
Page 60 General Outline ESIE10-01 1.23 Cooling Capacity Tables EWAD~C-SS / EWAD~C-SL Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,007 1,031 1,055 1,021 1,079 1,044 1,000 1–54 Part 1 –...
Page 61 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,021 1,046 1,017 1,071 1,042 1,005 1,097 1,066 1,028 1,123 1,091 1,052 1,002 1,149 1,117 1,076 1,022 1,175...
Page 62 General Outline ESIE10-01 Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,391 1,355 1,311 1,253 1,225 1,194 1,155 1,429 1,392 1,347 1,287 1,258 1,226 1,177 1,468 1,429 1,382 1,321...
Page 63 ESIE10-01 General Outline Cc (cooling capacity) – Pi (unit power input) – ELWT (evaporator leaving water temperature – Δt 5°C). Notes Data are referred to 0,0176 m °C/kW evaporator fouling factor. EWAD~C-SR Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW)
Page 64 General Outline ESIE10-01 Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,018 1,042 1,006 1,066 1,028 1,090 1,051 1,002 1,115 1,074 1,015 1,139 1,097 1,027 1,006 1,030 1,054 1,015...
Page 65 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,363 1,322 1,268 1,227 1,197 1,144 1,400 1,357 1,300 1,259 1,227 1,172 1,437 1,392 1,334 1,291 1,258 1,196...
Page 66 General Outline ESIE10-01 Cc (cooling capacity) – Pi (unit power input) – ELWT (evaporator leaving water temperature – Δt 5°C). Notes Data are referred to 0,0176 m °C/kW evaporator fouling factor. EWAD~C-XS / EWAD~C-XL Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW)
Page 67 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,001 1,031 1,003 1,060 1,032 1,001 1,090 1,062 1,030 1,121 1,092 1,059 1,017 1,151 1,122 1,088 1,046 1,182...
Page 68 General Outline ESIE10-01 Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,311 1,275 1,233 1,182 1,100 1,066 1,352 1,314 1,271 1,218 1,133 1,099 1,007 1,393 1,354 1,310 1,255 1,168...
Page 69 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,641 1,599 1,552 1,493 1,397 1,357 1,313 1,686 1,644 1,596 1,535 1,436 1,396 1,351 1,732 1,689 1,640 1,577...
Page 70 General Outline ESIE10-01 EWAD~C-XR Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,001 1,024 1,046 1,020 1,015 1,038 1,012 1,061 1,034 1,001 1,084 1,056 1,022 1,107 1,079 1,044 1,012...
Page 71 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,026 1,056 1,024 1,086 1,053 1,013 1,117 1,083 1,041 1,147 1,113 1,070 1,015 1,177 1,143 1,099 1,042 1,208...
Page 72 General Outline ESIE10-01 Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,348 1,313 1,272 1,218 1,131 1,064 1,385 1,350 1,307 1,252 1,163 1,087 1,423 1,386 1,343 1,287 1,185 1,109...
Page 73 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,692 1,646 1,590 1,517 1,399 1,278 1,085 1,738 1,692 1,634 1,558 1,433 1,279 1,097 1,786 1,737 1,678 1,600...
Page 74 General Outline ESIE10-01 EWAD~C-PS / EWAD~C-PL Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,002 1,030 1,004 1,058 1,032 1,005 1,086 1,060 1,032 1,000 1024 1053 1026 1082 1055...
Page 75 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,120 1,089 1,057 1,019 1,154 1,123 1,090 1,050 1,189 1,158 1,124 1,083 1,019 1,225 1,192 1,158 1,116 1,050...
Page 76 General Outline ESIE10-01 EWAD~C-PR Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,015 1,042 1,016 1,070 1,043 1,014 1,009 1,037 1,010 1,065 1,038 1,007 1,094 1,066 1,035 1,123 1,094...
Page 77 ESIE10-01 General Outline Condenser Inlet Air Temperature (°C) ELWT Size (°C) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) (kW) 1,101 1,071 1,036 1,135 1,104 1,067 1,022 1,169 1,137 1,100 1,053 1,204 1,171 1,132 1,084 1,008 1,239 1,205...
Page 78 General Outline ESIE10-01 1.24 Capacity Correction Factor EWAD~C- Evaporator fouling factors Fouling factors Cooling capacity Power input correction EER correction factor correction factor factor °C / kW 0.0176 1.000 1.000 1.000 0.0440 0.978 0.986 0.992 0.0880 0.957 0.974 0.983 0.1320 0.938 0.962 0.975...
Page 79 ESIE10-01 General Outline Correction factors for water and glycol Ethylene Glycol (%) mixture Cooling Capacity 0.991 0.982 0.972 0.961 0.946 Compressor Power Input 0.996 0.992 0.986 0.976 0.966 Ethylene Glycol Δ 1.013 1.040 1.074 1.121 1.178 Flow Rate ( Evaporator Pressure Drop 1.070 1.129 1.181...
Page 80 General Outline ESIE10-01 Mixture Water and Glycol - Evaporator leaving water temperature < 4°C • Depending on the type and percentage (%) of glycol filled in the circuit (see table "Minimum glycol percentage for low water temperature" on page 1–72 and table "Minimum glycol per- centage for low air temperature"...
Page 81 ESIE10-01 General Outline 1.25 Available Fan Static Pressure Correction Factors EWAD~C-SS / EWAD~C-XS / EWAD~C-PR EWAD~C-PS / Type EWAD~C-SL EWAD~C-XL EWAD~C-PL External Static Pressure (Pa) Cooling Capacity (kW) Correc- 1.000 0.998 0.996 0.995 0.993 0.992 0.991 0.989 0.986 0.985 0.982 tion factor Compr.
Page 82 General Outline ESIE10-01 1.26 Water Charge, Flow and Quality Cooling Water Cooled Water Circulating System Once Flow Items (1)(5) Circulating Supply Supply Circulating Flowing water water water water water [Below 20°C] at 25°C 6.5~8.2 6.0~8.0 6.0~8.0 6.0~8.0 6.0~8.0 Electrical conductivity [mS/m] at 25°C Below 80 Below 30...
Page 83 ESIE10-01 General Outline Notes (1) Names, definitions and units are according to JIS K 0101. Units and figures between brackets are old units published as reference only. (2) In case of using heated water (more than 40°C), corrosion is generally noticeable. Especially when the iron materials is in direct contact with water without any protection shields, it is desirable to give the valid measure for corrosion.
Page 84 General Outline ESIE10-01 1.27 Water Content in Cooling Circuits The cooled water distribution circuits should have minimum water content to avoid excessive compressors start and stop. In fact, each time the compressor starts up, an excessive quantity of oil goes from the compressor sump and simultaneously there is a rise in the temperature of the compressor motor’s stator due to the inrush current during the start-up.
Page 85 ESIE10-01 General Outline 1.28 Heat Recovery Ratings Water Pump Kit - Combination Matrix Single Pump Double Pump Version Size SPK1 SPK2 SPK3 DPK1 DPK2 DPK3 DPK4 Water Pump Kit - Technical Information Pump Motor Pump Motor Power Supply Motor Insulation Working Power (kW) Current (A)
Page 86 General Outline ESIE10-01 1.29 Evaporator Pressure Drops EWAD~C-SS EWAD~C-SL Cooling Capacity (kW) 1064 1152 1419 1538 1622 1714 Water Flow (l/s) 30.90 35.56 39.74 43.60 46.21 50.85 55.04 67.78 73.5 77.51 81.89 Pressure Drops (kPa) Water flow and pressure drop referred to nominal condition: evaporator water in/out: 12/7°C – condenser air inlet: 35°C.
Page 87 ESIE10-01 General Outline EWAD~C-PS EWAD~C-PL Cooling Capacity (kW) 1074 1158 1279 1390 Water Flow (l/s) 39.22 42.53 46.6 51.30 55.31 61.12 66.41 Pressure Drops (kPa) Water flow and pressure drop referred to nominal condition: evaporator water in/out: 12/7°C – condenser air inlet: 35°C. EWAD~C-PR Cooling Capacity (kW) 1053...
Page 88 General Outline ESIE10-01 The pressure drop at the selected working condition will be: 25.61 (l/s) (kPa) = 73 (kPa) x 30.90 (l/s) (kPa) = 52 (kPa) Notes: If the calculated evaporator water pressure drop is below 10 kPa or above 100 kPa please contact the factory for dedicated evaporator.
Page 89 ESIE10-01 General Outline 1.30 Condensor Pressure Drops Water Pump Kit - Discharge Head Single Pump (2 poles) - Discharge Head SPK 3 SPK 2 SPK 1 Water Flow (l/s) Notes: The above curves are referred to the discharge head of the pump only. When selecting the pump you have to consider the installation and evaporator pressure drops.
Page 90 General Outline ESIE10-01 1.31 Operation Range EWAD~C- Standard Efficiency High Efficiency Premium Efficiency Operation with Glycol (below 4°C Evap LWT) Fan Speed Regulation required (below 10°C Amb. Temp) Speedtroll required (below -10°C Amb. Temp) Evaporator Leaving Water Temp. (°C) Evaporator minimum and Δ...
Page 91 ESIE10-01 General Outline 1.32 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.
Page 92 General Outline ESIE10-01 In case of sudden stop of the unit, follow the instructions on the Control Panel Operating Manual which is part of the on-board documentation delivered to the end user with this manual. It is recommended to perform installation and maintenance with other people. In case of accidental injury or unease, it is necessary to: Keep calm.
Page 93 ESIE10-01 General Outline Warning: Both the lifting ropes and the spacing bar and/or scales must be sized to support the machine weight 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, without any added accessories.
Page 94 General Outline ESIE10-01 1800 2000 1500 1800 Clearance requirements for machine maintenance When two or more machines are positioned side by side, a space of at least 3,600 mm is recommended between the condensation banks. For further solutions, please consult authorised technicians.
Page 95 ESIE10-01 General Outline 3600 Recommended minimum installation clearance Attention: The minimum installation clearance spaces described previously are indicative only and not a fundamental requirement. Each installation must be carefully evaluated according to the specific environmental parameters. For example: should you fail to consider dominant wind at the point of installation, this can affect overall machine function, even where the recommended minimum installation clearance spaces are left.
Page 96 General Outline ESIE10-01 1.33 Dimensional Drawing Dimensions EWAD~C- (2 circuits) EWAD-C~ Dimensions Size Size Fans 650 ÷ 830 SS/SL 620 ÷ 720 SR 2285 6185 2540 2412 Nr 10 910 ÷ 970 SS/SL 880 ÷ 920 SR 2285 6185 2540 2412 Nr 12 C11 SS/SL...
Page 97 ESIE10-01 General Outline Dimensions EWAD~C- (3 circuits) EWAD-C~ Dimensions Size Size Fans C14 ÷ C15 SS/SL C13 ÷ C14 SR 2285 10185 2540 4440 2360 Nr 20 C16 ÷ C17 SS/SL C15 ÷ C16 SR 2285 11085 2540 5340 2360 Nr 22 C14 XS/XL C14 XR...
Page 98 General Outline ESIE10-01 1.34 Electrical Installation General Caution: specifications 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.
Page 99 ESIE10-01 General Outline Control circuit: Every machine of the series is supplied with an auxiliary 400/115 V control circuit transformer. No additional cable for the control system power supply is thus required. Only if the optional separate accumulation tank is requested, the electrical antifreeze resistance must have a separate power supply.
Page 100 General Outline ESIE10-01 Unit limitation - The machine's microprocessor allows for the limitation of capacity by means of two separate criteria: Electrical wiring Load limitation (optional) The load can be varied directly by means of 4-20 external signal or directly from a BMS. The sig- nal cable must be directly connected to terminals 37 and 38 of the M5 terminal board.
Page 101 ESIE10-01 General Outline 1.35 Operation Operator's It is important that the operator is appropriately trained and becomes familiar with the system before responsibilities 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 the start-up sequence, operation, shut-down sequence and operation of all safety devices.
Page 102 General Outline ESIE10-01 Legend Name Compressor 2-way discharge valve High-pressure transducer Schrader valve High-pressure safety valve Fans 1–96 Part 1 – System Outline...
Page 103 ESIE10-01 General Outline Condensation bank Load valve 2-way angle valve Filter dryer Sight glass Solenoid valve Thermostatic expansion valve Non-return valve Electronic expansion valve Water outlet temp. transducer Evaporator Water inlet temp. transducer Low-pressure safety valve Suction valve (optional) Suction gas temp. transducer Suction gas press.
Page 104 General Outline ESIE10-01 Controlling the The partial heat recovery system is not managed and/or controlled by the machine. The installer partial recovery should follow the suggestions below for best system performance and reliability: circuit and 1. Install a mechanical filter on the heat exchanger inlet pipe. installation 2.
Page 105 ESIE10-01 General Outline Legend Name Compressor 2-way discharge valve High-pressure transducer Schrader valve High-pressure safety valve Part 1 – System Outline 1–99...
Page 106 General Outline ESIE10-01 Fans Condensation bank Load valve 2-way angle valve Filter dryer Sight glass Solenoid valve Thermostatic expansion valve Non-return valve Electronic expansion valve Water outlet temp. transducer Evaporator Water inlet temp. transducer Low-pressure safety valve Suction valve (optional) Suction gas temp.
Page 107 ESIE10-01 General Outline Compression With the single-screw compressor, the suction, compression and discharge process takes place in a process continuous manner thanks to the two satellites. In this process, the suction gas penetrates into the profile between the rotor, teeth of the upper satellite and the compressor body. The volume is gradually reduced by compression of the refrigerant.
Page 108 General Outline ESIE10-01 Modulating box The operating diagram of the modulating box is shown in the following figure. The system is controlled by three solenoids, A, B, C, which are normally closed if not powered, and by a spring assembled directly onto the slide.
Page 109 ESIE10-01 General Outline 1.36 Wiring Diagrams - EWAD-CJYNN Overview This chapter contains the following topics: Topic See page 1.36.1–Power Compressor 1-2 1–105 1.36.2–Power Compressor 3 1–106 1.36.3–Kit Pumps 1–107 1.36.4–Circuit Fan Power Supply 1 1–108 1.36.5–Circuit Fan Power Supply 1 1–109 1.36.6–Circuit Fan Power Supply 2 1–110...
Page 110 General Outline ESIE10-01 Symbols The following symbols are used on the wiring diagrams: Optional equipments Equipment installed Electrical equipment installed on compressor terminals box Field wiring connections Remove this wire or MJ if the option is requested Manual reset 1–104 Part 1 –...
Page 111 ESIE10-01 General Outline 1.36.1 Power Compressor 1-2 Part 1 – System Outline 1–105...
Page 112 General Outline ESIE10-01 1.36.2 Power Compressor 3 1–106 Part 1 – System Outline...
Page 113 ESIE10-01 General Outline 1.36.3 Kit Pumps Part 1 – System Outline 1–107...
Page 114 General Outline ESIE10-01 1.36.4 Circuit Fan Power Supply 1 1–108 Part 1 – System Outline...
Page 115 ESIE10-01 General Outline 1.36.5 Circuit Fan Power Supply 1 Part 1 – System Outline 1–109...
Page 116 General Outline ESIE10-01 1.36.6 Circuit Fan Power Supply 2 1–110 Part 1 – System Outline...
Page 117 ESIE10-01 General Outline 1.36.7 Circuit Fan Power Supply 2 Part 1 – System Outline 1–111...
Page 118 General Outline ESIE10-01 1.36.8 Circuit Fan Power Supply 3 1–112 Part 1 – System Outline...
Page 119 ESIE10-01 General Outline 1.36.9 Circuit Fan Power Supply 3 Part 1 – System Outline 1–113...
Page 120 General Outline ESIE10-01 1.36.10 Unit Control Circuit Power Supply 1–114 Part 1 – System Outline...
Page 121 ESIE10-01 General Outline 1.36.11 Analog Inputs-Output Board Part 1 – System Outline 1–115...
Page 122 General Outline ESIE10-01 1.36.12 Digital Inputs Board 1–116 Part 1 – System Outline...
Page 123 ESIE10-01 General Outline 1.36.13 Digital Outputs Board Part 1 – System Outline 1–117...
Page 124 General Outline ESIE10-01 1.36.14 Digital Outputs Board 1–118 Part 1 – System Outline...
Page 125 ESIE10-01 General Outline 1.36.15 Extension Control Fans 1&2 Part 1 – System Outline 1–119...
Page 126 General Outline ESIE10-01 1.36.16 Extension Control Fans 3 1–120 Part 1 – System Outline...
Page 127 ESIE10-01 General Outline 1.36.17 Extension Control Fans 4 Part 1 – System Outline 1–121...
Page 128 General Outline ESIE10-01 1.36.18 Expansion Input / Output Unit Alarm & Limiting 1–122 Part 1 – System Outline...
Page 129 ESIE10-01 General Outline 1.36.19 Expansion Control Compressor 1 Part 1 – System Outline 1–123...
Page 130 General Outline ESIE10-01 1.36.20 Expansion Control Compressor 1 1–124 Part 1 – System Outline...
Page 131 ESIE10-01 General Outline 1.36.21 EEXV Compressor 1 Part 1 – System Outline 1–125...
Page 132 General Outline ESIE10-01 1.36.22 Expansion Control Compressor 2 1–126 Part 1 – System Outline...
Page 133 ESIE10-01 General Outline 1.36.23 Expansion Control Compressor 2 Part 1 – System Outline 1–127...
Page 134 General Outline ESIE10-01 1.36.24 EEXV Compressor 2 1–128 Part 1 – System Outline...
Page 135 ESIE10-01 General Outline 1.36.25 Expansion Control Compressor 3 Part 1 – System Outline 1–129...
Page 136 General Outline ESIE10-01 1.36.26 Expansion Control Compressor 3 1–130 Part 1 – System Outline...
Page 137 ESIE10-01 General Outline 1.36.27 EEXV Compressor 3 Part 1 – System Outline 1–131...
Page 138 General Outline ESIE10-01 1.36.28 Pumps Control 1–132 Part 1 – System Outline...
Page 139 ESIE10-01 General Outline 1.36.29 Terminals M1 - M2 Part 1 – System Outline 1–133...
Page 140 General Outline ESIE10-01 1.36.30 Terminals M3 1–134 Part 1 – System Outline...
Page 141 ESIE10-01 General Outline 1.36.31 Terminals M5 - MQ Part 1 – System Outline 1–135...
Page 142 General Outline ESIE10-01 1.36.32 Legend Item Description A.C. Alarm Control Power Factor Correction Power Factor Correction Power Factor Correction C.C.1 Control Compressor (Siemens) C.C.2 Control Compressor (Siemens) C.C.3 Control Compressor (Siemens) CP-1 Condenser Pressure Transducer Cir. 1 CP-2 Condenser Pressure Transducer Cir. 2 CP-3 Condenser Pressure Transducer Cir.
Page 143 ESIE10-01 General Outline Item Description F13-2 Mech. High Pressure Switch Cir. 1 F13-3 Mech. High Pressure Switch Cir. 3 F130A Under/Overvoltage Control Fuse F59-1 Auxiliary Circuit Fuse F59-2 Auxiliary Circuit Fuse F59-3 Auxiliary Circuit Fuse F13A-1 Mech. High Pressure Switch Cir. 1 F13A-2 Mech.
Page 144 General Outline ESIE10-01 Item Description KT1-1 Delay Relay KT1-2 Delay Relay KT1-3 Delay Relay KT13-1 Time Delay Relay KT13-2 Time Delay Relay KT13-3 Time Delay Relay Compressor 1 Compressor 2 Compressor 1 M101 Fan Motor M102 Fan Motor M103 Fan Motor M104 Fan Motor M105...
Page 145 ESIE10-01 General Outline Item Description Circuit Switch 1 Circuit Switch 2 Main Switch Emergency Stop Automatic Circuit Breaker Q101 Fan Circuit Breaker Q102 Fan Circuit Breaker Q103 Fan Circuit Breaker Q105 Fan Circuit Breaker Q107 Fan Circuit Breaker Q110 Fan Circuit Breaker Q201 Fan Circuit Breaker Q202...
Page 146 General Outline ESIE10-01 Item Description Y3B-3 Unloader Sol. Valve Cir. 1 YJ-1 Oil By-Pass Solenoid Valve Circ. 1 YJ-2 Oil By-Pass Solenoid Valve Circ. 1 YJ-3 Oil By-Pass Solenoid Valve Circ. 1 YT-1 Oil By-Pass Solenoid Valve Circ. 1 YT-2 Oil By-Pass Solenoid Valve Circ.
Page 147 ESIE10-01 General Outline 1.36.33 Field Wiring Connection Part 1 – System Outline 1–141...
Page 148 General Outline ESIE10-01 1–142 Part 1 – System Outline...
Page 149 ESIE10-01 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 150 ESIE10-01 2–2 Part 2 – Functional Description...
Page 151 ESIE10-01 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 152: System Architecture
The Digital Controller ESIE10-01 System Architecture The overall controls architecture shall use the following: One Microtech III main controller ■ I/O extensions as needed depending on the configuration of the unit ■ BMS interface as selected ■ All modules are connected with a BUS system throughout the unit ■...
Page 153: Part 2
ESIE10-01 The Digital Controller Configuration of chiller Remote Operator Interface MicroTech III Unit Controller BACnet/ BACnet/ MSTP Communication MODbus Extension I/O Modules Part 2 – Functional Description 2–5...
Page 154: Customer Interfaces
The Digital Controller ESIE10-01 Customer Interfaces Overview This chapter contains the following topics: Topic See page 1.3.1–Control Panel 2–7 1.3.2–Addresses Used In System 2–8 1.3.3–Communication Modules 2–9 2–6 Part 2 – Functional Description...
Page 155 ESIE10-01 The Digital Controller 1.3.1 Control Panel General description Layout of controller Alarm button Menu button Back button Navigation wheel Display Part 2 – Functional Description 2–7...
Page 156 The Digital Controller ESIE10-01 1.3.2 Addresses Used In System ADDRESS=6 Each module in the system has it’s own address (mentioned in wiring diagram). Special way to configure address: Do not use dipswitch 6 ■ Start configuring the address from dipswitch 5 ■...
Page 157 ESIE10-01 The Digital Controller 1.3.3 Communication Modules Any of the following modules can be connected directly to the left side of the main controller to allow a BMS interface to function. Module Siemens Description of Expansion Boards Usage BacNet/IP POL908.00/MCQ Optional POL906.00/MCQ Optional...
Page 158: Display And Keypad
The Digital Controller ESIE10-01 Display and Keypad Overview This chapter contains the following topics: Topic See page 1.4.1–General Description 2–11 1.4.2–Set Point 2–16 2–10 Part 2 – Functional Description...
Page 159 ESIE10-01 The Digital Controller 1.4.1 General Description Layout of screen View/Set Unit Status/Settings Set Up Temperature Date/Time/Schedule Menu title ■ A parameter (setpoint, value, …) ■ Link to further menu (arrow on right side) ■ Part 2 – Functional Description 2–11...
Page 160 The Digital Controller ESIE10-01 View/Set Unit Home Page Status/Settings > Enter Password Set-Up > Continue W/O Password Temperatures > Date/Time/Schedules > Power Conservation > LON Setup Main Menu BACnet IP Setup View/Set - Unit > BACnet MSTP Setup View/Set - Circuit >...
Page 161 ESIE10-01 The Digital Controller View/Set Unit Status/Settings (view/set unit) Status/Settings > Unit Status Set-Up > Chiller Enable Temperatures > Control Source Date/Time/Schedules > Next Circuit On Power Conservation > Chiller Enable Setpoint - LON Setup > Chiller Mode Setpoint - Network BACnet IP Setup >...
Page 162 The Digital Controller ESIE10-01 View/Set Unit Power Conservation (view/set) Status/Settings > Unit Capacity Set-Up > Unit Current Temperatures > Demand Limit Enable Date/Time/Schedules > Demand Limit Value Power Conservation > Current @ 20mA LON Setup > Current Limit Setpoint BACnet IP Setup >...
Page 163 ESIE10-01 The Digital Controller View/Set Unit AWM Setup (view/set unit) Status/Settings > Apply Changes Set-Up > DHCP Temperatures > Actual IP Address Date/Time/Schedules > Actual Mask Power Conservation > Actual Gateway LON Setup > Given IP Address BACnet IP Setup >...
Page 164 The Digital Controller ESIE10-01 1.4.2 Set Point Set point table The following set points are remembered during power off, are factory set to the Default value, and can be adjusted to any value in the Range column. Warning: These values are the default settings; however they might not be correct ones to provide a correct operation of the unit in any given situation.
Page 165 ESIE10-01 The Digital Controller Current Limit Off, On Current @ 20 mA 800 Amp 0 to 2000 Amp = 4 to 20 mA Current limit Set Point 800 Amp 0 to 2000 Amp # of Circuits 2-3-4 Ice Time Delay 1-23 hours Clear Ice Timer No, Yes...
Page 166 The Digital Controller ESIE10-01 Slide Load Delay Maximum 150 seconds 60 to 300 seconds Slide Unload Delay Minimum 10 seconds 5 to 20 seconds Slide Unload Delay Maximum 50 seconds 30 to 75 seconds Liquid Injection Activation 85°C 75 to 90°C Liquid Line Solenoid Valves No, Yes Alarm Limits...
Page 167 ESIE10-01 The Digital Controller Cond pressure offset 0 KPA -100 to 100 KPA Oil pressure offset 0 KPA -100 to 100 KPA Suction temp offset 0°C -5.0 to 5.0°C Discharge temp offset 0°C -5.0 to 5.0°C Fans Fan VFD enable Off, On Number of fans 5 to 12...
Page 168 The Digital Controller ESIE10-01 Auto adjusted Some settings have different ranges of adjustment based on other settings. ranges Cool LWT 1 and Cool LWT 2 Available Mode Selection Range SI Without Glycol 4 to 15°C With Glycol -4 to 15°C Evaporator Water Freeze Available Mode Selection Range SI...
Page 169 ESIE10-01 The Digital Controller Dynamic default The fan staging dead bands have different default values based on the vfd enable set point. When the values vfd enable set point is changed, a set of default values for the fan staging dead bands is loaded as follows: VFD is enabled VFD is disabled...
Page 170 The Digital Controller ESIE10-01 2–22 Part 2 – Functional Description...
Page 171: What Is In This Chapter
ESIE10-01 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 172: Unit Functions
Functional Control ESIE10-01 Unit Functions Overview This chapter contains the following topics: Topic See page 2.2.1–Unit Enable 2–25 2.2.2–Unit Mode Selection 2–26 2.2.3–Unit Control States 2–27 2.2.4–Unit Status 2–28 2.2.5–Ice Mode Start Delay 2–29 2.2.6–Evaporator Pump Control 2–30 2.2.7–Noise Reduction 2–31 2.2.8–LWT Target 2–32...
Page 173 ESIE10-01 Functional Control 2.2.1 Unit Enable There are different ways to start and stop a unit. Enabling and disabling the chiller is accomplished using set points and inputs to the chiller. The unit switch, remote switch input, and Unit Enable Set Point all are required to be 'on' for the unit to be enabled when the control source is set to 'local'.
Page 174 Functional Control ESIE10-01 2.2.2 Unit Mode Selection The operating mode of the unit is determined by set points and inputs to the chiller. The Available Modes Set Point determines what modes of operation can be used. This set point also determines whether the unit is configured for glycol use.
Page 175 ESIE10-01 Functional Control 2.2.3 Unit Control States The unit will always be in one of three states: Off – Unit is not enabled to run. ■ Auto – Unit is enabled to run. ■ Pumpdown – Unit is doing a normal shutdown. ■...
Page 176 Functional Control ESIE10-01 2.2.4 Unit Status The displayed unit status is determined by the conditions in the following table: Enum Status Conditions Auto Unit State = Auto Off:Ice Mode Timer Unit State = Off, Unit Mode = Ice, and Ice Delay = Active Off:OAT Lockout Unit State = Off and Low OAT Lockout is active Off:All Cir Disabled...
Page 177 ESIE10-01 Functional Control 2.2.5 Ice Mode Start Delay An adjustable start to start ice delay timer will limit the frequency with which the chiller may start in Ice mode. The timer starts when the first compressor starts while the unit is in ice mode. While this timer is active, the chiller cannot restart in Ice mode.
Page 178 Functional Control ESIE10-01 2.2.6 Evaporator Pump Control For control of the evaporator pumps, three evaporator pump control states are possible: Off – No pump on. ■ Start – Pump is on, water loop is being recirculated. ■ Run – Pump is on, water loop has been recirculated. ■...
Page 179 ESIE10-01 Functional Control 2.2.7 Noise Reduction Noise Reduction should be enabled only when the Noise Reduction set point is ‘enable’. Noise Reduction is in effect when enabled via the set point, the unit mode is cool, and the unit controller clock time is between the Noise Reduction start time and end time.
Page 180 Functional Control ESIE10-01 2.2.8 LWT Target The LWT Target varies based on settings and inputs. The base LWT Target is selected as follows: Control Source Mode Available Modes Set Base LWT Target Set Point Input Request Point Local COOL Cool Set Point 1 Local COOL Cool Set Point 2...
Page 181 ESIE10-01 Functional Control Actual Setpoint reset Local or Dual Setpoint ΔT on evaporator start ΔT Reset Type – 4-20 mA ■ The Active Leaving Water variable is adjusted by the 4 to 20 mA reset analog input. Parameters used: 1. Cool LWT set point. 2.
Page 182 Functional Control ESIE10-01 OAT Reset Cool LWT + Max Reset (54) Active Max Reset (10) (°F) Cool LWT Set Point (44) OAT (°F) 2–34 Part 2 – Functional Description...
Page 183 ESIE10-01 Functional Control 2.2.9 Unit Capacity Control Unit capacity control will be performed as described in this section. All unit capacity limits described in following sections must be applied as described. Compressor staging in cool mode Load Load + Start Start first Unload Stop Last...
Page 184 Functional Control ESIE10-01 Staging sequence This section defines which compressor is the next one to start or stop. In general, compressors with fewer starts will normally start first, and compressors with more run hours will normally stop first. Compressor staging sequence can also be determined by an operator defined sequence via set points.
Page 185 ESIE10-01 Functional Control Load/unload This section defines which compressor is the next one to load or unload. sequence Next To Load ■ The next compressor to load must meet the following requirements: Lowest capacity of the running compressors that can load up: If capacities are equal, it must have the highest sequence number of the compressors that are ■...
Page 186 Functional Control ESIE10-01 2.2.10 Unit Capacity Overrides Unit capacity limits can be used to limit total unit capacity in Cool mode only. Multiple limits may be active at any time, and the lowest limit is always used in the unit capacity control. Soft load, demand limit, and network limit should use a deadband around the actual limit value, such that unit capacity increase is not allowed within this deadband.
Page 187 ESIE10-01 Functional Control High water If the evaporator LWT exceeds 18°C, compressor load shall be limited to a maximum of 75%. temperature Compressors shall unload to 75% or less if running at greater than 75% load when the LWT exceeds capacity limit the limit.
Page 188: Circuit Functions
Functional Control ESIE10-01 Circuit Functions Overview This chapter contains the following topics: Topic See page 2.3.1–Circuit Control Logic 2–41 2.3.2–Circuit Status 2–43 2.3.3–Compressor Control 2–44 2.3.4–Condenser Fan Control 2–46 2.3.5–EXV Control 2–48 2.3.6–Economizer Control 2–50 2.3.7–Liquid Injection 2–51 2–40 Part 2 – Functional Description...
Page 189 ESIE10-01 Functional Control 2.3.1 Circuit Control Logic Circuit availability A circuit should be available to start if the following conditions are true: Circuit switch is closed. ■ No circuit alarms are active. ■ Circuit Mode set point is set to Enable. ■...
Page 190 Functional Control ESIE10-01 Stopping Normal Shutdown ■ A normal shutdown requires the circuit to pumpdown before the compressor is turned off. This is to be done by closing the EXV, and closing the liquid line solenoid (if present) while the compres- sor is running.
Page 191 ESIE10-01 Functional Control 2.3.2 Circuit Status The displayed circuit status should be determined by the conditions in the following table: Enum Status Conditions Off:Ready Circuit is ready to start when needed. Off:Stage Up Delay Circuit is off and cannot start due to stage up delay. Off:Cycle Timer Circuit is off and cannot start due to active cycle timer.
Page 192 Functional Control ESIE10-01 2.3.3 Compressor Control The compressor should run only when the circuit is in a run or pumpdown state. This means the compressor should not be running any time the circuit is off or preopening the EXV. Cycle timers A minimum time between starts of the compressor and a minimum time between shutdown and start of the compressor shall be enforced.
Page 193 ESIE10-01 Functional Control Capacity overrides - The following conditions shall override automatic capacity control when the chiller is in COOL mode. limits of operation These overrides keep the circuit from entering a condition in which it is not designed to run. Low Evaporator Pressure ■...
Page 194 Functional Control ESIE10-01 2.3.4 Condenser Fan Control Saturated The condenser fan control logic will attempt to control the saturated condenser temperature to a condenser calculated target. A base condenser target is calculated based on evaporator saturated temperature. temperature target The equation is: Base saturated condenser target = 5/6 (saturated evaporator temperature) + 3.5°C.
Page 195 ESIE10-01 Functional Control The Stage Down Error Step is added to Stage Down Accumulator once every Stage Down Error Delay seconds. When the Stage Down Error Accumulator is greater than the Stage Down Error Set Point another stage of condenser fans is removed. When one fan is running, a fixed point is used in place of a deadband.
Page 196 Functional Control ESIE10-01 2.3.5 EXV Control The EXV moves at a rate of 150 steps per second, with a total range of 3810 steps. Positioning should be determined as described in the following sections, with adjustments made in increments of 0.1% of the total range.
Page 197 ESIE10-01 Functional Control Manual control The EXV position can be set manually. Manual control can only be selected when the EXV state is Pressure or Superheat control. At any other time, the EXV control set point is forced to auto. When EXV control is set to manual, the EXV position is equal to the manual EXV position setting.
Page 198 Functional Control ESIE10-01 2.3.6 Economizer Control The economizer shall be activated when the circuit is in a run state and the capacity exceeds 95%. It shall turn back off when either the load drops below 60% or the circuit is no longer in a run state. Economizer Compressor Capacity 2–50...
Page 199 ESIE10-01 Functional Control 2.3.7 Liquid Injection Liquid injection shall be activated when the circuit is in a run state and the discharge temperature rises above the Liquid Injection Activation set point. Liquid injection should be turned off when the discharge temperature decreases below the activation set point by a differential of 10°C.
Page 200 Functional Control ESIE10-01 2–52 Part 2 – Functional Description...
Page 201 ESIE10-01 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 202 ESIE10-01 3–2 Part 3 – Troubleshooting...
Page 203: What Is In This Chapter
ESIE10-01 Alarms and Events Part 3 Alarms and Events What Is in This Chapter? Introduction Situations may arise that require some action from the chiller or that should be logged for future reference. A condition that requires a shutdown and/or lockout is an alarm. Alarms may cause a normal stop or a rapid stop.
Page 204 Alarms and Events ESIE10-01 Unit Stop Alarms The alarm output should be on constantly when any stop alarm occurs. It shall be turned off when all alarms have been cleared. Overview This chapter contains the following topics: Topic See page 1.2.1–Phase Volts Loss/GFP Fault 3–5 1.2.2–Evaporator Flow Loss...
Page 205 ESIE10-01 Alarms and Events 1.2.1 Phase Volts Loss/GFP Fault Alarm description (as shown on screen): Unit PVM/GFP Fault. Trigger: PVM set point is set to Single Point and PVM/GFP input is low. Action Taken: Rapid stop all circuits. Reset: Auto reset when PVM input is high or PVM set point does not equal single point for at least 5 seconds.
Page 206 Alarms and Events ESIE10-01 1.2.2 Evaporator Flow Loss Alarm description (as shown on screen): Evap Water Flow Loss. Trigger: 1. Evaporator Pump State = Run AND Evaporator Flow Digital Input = No Flow for time > Flow Proof Set Point AND at least one compressor running. 2.
Page 207 ESIE10-01 Alarms and Events 1.2.3 Evaporator Water Freeze Protect Alarm description (as shown on screen): Evap Water Freeze. Trigger: Evaporator LWT or EWT drops below evaporator freeze protect set point. If the sensor fault is active for either LWT or EWT, then that sensor value cannot trigger the alarm. Action Taken: Rapid stop all circuits.
Page 208 Alarms and Events ESIE10-01 1.2.4 Evaporator Water Temperatures Inverted Alarm description (as shown on screen): Evap Water Inverted. Trigger: [Evap EWT < Evap LWT - 1 deg C AND at least one circuit is running AND EWT sensor fault not active AND LWT sensor fault not active] for 30 seconds. Action Taken: Pumpdown stop on all circuits.
Page 209 ESIE10-01 Alarms and Events 1.2.5 Leaving Evaporator Water Temperature Sensor Fault Alarm description (as shown on screen): Evap LWT Sens Fault. Trigger: Sensor shorted or open. Action Taken: Rapid stop all circuits. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. Part 3 –...
Page 210 Alarms and Events ESIE10-01 1.2.6 AC Comm Failure Alarm description (as shown on screen): AC Comm. Fail. Trigger: Communication with the I/O extension module has failed. Action Taken: Rapid stop of all running circuits. Reset: This alarm can be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds.
Page 211 ESIE10-01 Alarms and Events 1.2.7 Outdoor Air Temperature Sensor Fault Alarm description (as shown on screen): OAT Sensor Fault. Trigger: Sensor shorted or open and Low Ambient Lockout is enabled. Action Taken: Normal shutdown of all circuits. Reset: This alarm can be cleared manually via the keypad if the sensor is back in range or Low Ambient Lockout is disabled.
Page 212 Alarms and Events ESIE10-01 1.2.8 External Alarm Alarm description (as shown on screen): External Alarm. Trigger: External Alarm/Event input is open for at least 5 seconds and external fault input is configured as an alarm. Action Taken: Rapid stop of all circuits. Reset: Auto clear when digital input is closed.
Page 213 ESIE10-01 Alarms and Events 1.2.9 Emergency Stop Alarm Alarm description (as shown on screen): Emergency Stop Switch. Trigger: Emergency Stop input is open. Action Taken: Rapid stop of all circuits. Reset: This alarm can be cleared manually via the keypad, but only if the emergency switch is closed. Part 3 –...
Page 214 Alarms and Events ESIE10-01 Unit Events The following unit events are logged in the event log with a time stamp. Overview This chapter contains the following topics: Topic See page 1.3.1–Entering Evaporator Water Temperature Sensor Fault 3–15 1.3.2–External Event 3–16 1.3.3–Low Ambient Lockout 3–17 3–14...
Page 215 ESIE10-01 Alarms and Events 1.3.1 Entering Evaporator Water Temperature Sensor Fault Event description (as shown on screen): EWT Sensor Fail. Trigger: Sensor shorted or open. Action Taken: Return water reset cannot be used. Reset: Auto reset when sensor is back in range. Part 3 –...
Page 216 Alarms and Events ESIE10-01 1.3.2 External Event Alarm description (as shown on screen): External Event. Trigger: External Alarm/Event input is open for at least 5 seconds and external fault is configured as an event. Action Taken: None. Reset: Auto clear when digital input is closed. 3–16 Part 3 –...
Page 217 ESIE10-01 Alarms and Events 1.3.3 Low Ambient Lockout Alarm description (as shown on screen): Low Ambient Lockout. Trigger: The OAT drops below the low ambient lockout set point and low ambient lockout is enabled. Ambient reset ambient lockout and restart unit diff.
Page 218: Circuit Stop Alarms
Alarms and Events ESIE10-01 Circuit Stop Alarms All circuit stop alarms require shutdown of the circuit on which they occur. Rapid stop alarms do not do a pumpdown before shutting off. All other alarms will do a pumpdown. When one or more circuit alarms are active and no unit alarms are active, the alarm output should be switched on and off on 5 second intervals.
Page 219 ESIE10-01 Alarms and Events 1.4.1 Phase Volts Loss/GFP Fault Alarm description (as shown on screen): PVM/GFP Fault N. Trigger: PVM input is low and PVM set point = Multi Point. Action Taken: Rapid stop circuits. Reset: Auto reset when PVM input is high or PVM set point does not equal multi point for at least 5 seconds.
Page 220 Alarms and Events ESIE10-01 1.4.2 Low Evaporator Pressure Alarm description (as shown on screen): Evap Press Low N. Trigger: [Freezestat trip AND Circuit State = Run] OR Evaporator Press < 0.7 bar. Freezestat logic allows the circuit to run for varying times at low pressures. The lower the pressure, the shorter the time the compressor can run.
Page 221 ESIE10-01 Alarms and Events 1.4.3 Low Pressure Start Fail Alarm description (as shown on screen): LowPressStartFail N. Trigger: Circuit state is in the 'start'-status for time greater than Startup Time set point. Action Taken: Rapid stop circuit. Reset: This alarm can be cleared manually via the Unit Controller keypad. Part 3 –...
Page 222 Alarms and Events ESIE10-01 1.4.4 Mechanical Low Pressure Switch Alarm description (as shown on screen): Mech Low Pressure Sw N. Trigger: Mechanical Low Pressure switch input is low. Action Taken: Rapid stop circuit. Reset: This alarm can be cleared manually via the Unit Controller keypad if the MLP switch input is high.
Page 223 ESIE10-01 Alarms and Events 1.4.5 High Condenser Pressure Alarm description (as shown on screen): Cond Pressure High N. Trigger: Condenser Saturated Temperature is higher than the Max Saturated Condenser Value for time longer than High Cond Delay set point. Setpoint HP Alarm 20.5 If HP is below...
Page 224 Alarms and Events ESIE10-01 1.4.6 Low Pressure Ratio Alarm description (as shown on screen): Low Pressure Ratio N. Trigger: Pressure ratio is lower than calculated limit for a time longer than Low Pressure Ratio Delay set point after circuit startup has completed. The calculated limit will vary from 1.4 to 1.8 as the compressor's capacity varies from 25% to 100%.
Page 225 ESIE10-01 Alarms and Events 1.4.7 Mechanical High Pressure Switch Alarm description (as shown on screen): Mech High Pressure Sw N. Trigger: Mechanical High Pressure switch input is low AND Emergency Stop Alarm is not active. (Opening emergency stop switch kills power to MHP switches). Action Taken: Rapid stop circuit.
Page 226 Alarms and Events ESIE10-01 1.4.8 High Discharge Temperature Alarm description (as shown on screen): Disc Temp High N. Trigger: Discharge Temperature > High Discharge Temperature set point AND compressor is running. Alarm cannot trigger if discharge temperature sensor fault is active. Action Taken: Rapid stop circuit.
Page 227 ESIE10-01 Alarms and Events 1.4.9 High Oil Pressure Difference Alarm description (as shown on screen): Oil Pres Diff High N. Trigger: When the Oil Pressure Differential measured over the oil filter is bigger then the High Oil Pressure Differential set point for a time greater than Oil Pressure Differential Delay, the unit will trip on high oil pressure difference.
Page 228 Alarms and Events ESIE10-01 1.4.10 Compressor Starter Fault Alarm description (as shown on screen): Starter Fault N. Trigger: If PVM set point = None(SSS): any time starter fault input is open. ■ If PVM set point = Single Point or Multi Point: compressor has been running for at least 14 seconds ■...
Page 229 ESIE10-01 Alarms and Events 1.4.11 High Motor Temperature Alarm description (as shown on screen): Motor Temp High. Trigger: In the windings of the compressor, a temperature sensitive resistor is installed. If the value for the resistor is 4500 ohms or higher, the unit will trip on high motor temperature alarm. Action Taken: Rapid stop circuit.
Page 230 Alarms and Events ESIE10-01 1.4.12 Low OAT Restart Fault Alarm description (as shown on screen): LowOATRestart Fail N. Trigger: Circuit has failed three low OAT start attempts. Action Taken: Rapid stop circuit. Reset: This alarm can be cleared manually via the Unit Controller keypad. 3–30 Part 3 –...
Page 231 ESIE10-01 Alarms and Events 1.4.13 No Pressure Change After Start Alarm description (as shown on screen): NoPressChgAtStrt N. Trigger: After start of compressor, at least a 1 psi drop in evaporator pressure OR 5 psi increase in condenser pressure has not occurred after 15 seconds. Action Taken: Rapid stop circuit.
Page 232 Alarms and Events ESIE10-01 1.4.14 No Pressure At Startup Alarm description (as shown on screen): No Press At Start N. Trigger: [Evap Pressure < 5 psi OR Cond Pressure < 5 psi] AND Compressor start requested AND circuit does not have a fan VFD. Action Taken: Rapid stop circuit.
Page 233 ESIE10-01 Alarms and Events 1.4.15 CC Comm Failure N Alarm description (as shown on screen): CC Comm. Fail N. Trigger: Communication with the I/O extension module has failed. Action Taken: Rapid stop of affected circuit. Reset: This alarm can be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds.
Page 234 Alarms and Events ESIE10-01 1.4.16 FC Comm Failure Circuit 1/2 Alarm description (as shown on screen): FC Comm Fail Cir 1/2. Trigger: [Circuit 1 or Circuit 2 have more than 6 fans OR PVM Config = Multi Point] and communication with the I/O extension module has failed. Action Taken: Rapid stop of circuit 1 and 2.
Page 235 ESIE10-01 Alarms and Events 1.4.17 FC Comm Failure Circuit 3 Alarm description (as shown on screen): FC Comm Fail Cir 3. Trigger: Number of Circuits set point is greater than 2 and communication with the I/O extension module has failed. Action Taken: Rapid stop of circuit 3.
Page 236 Alarms and Events ESIE10-01 1.4.18 FC Comm Failure Circuit 4 Alarm description (as shown on screen): FC Comm. Fail Cir 4. Trigger: Number of Circuits set point is greater than 3 and communication with the I/O extension module has failed. Action Taken: Rapid stop of circuit 4.
Page 237 ESIE10-01 Alarms and Events 1.4.19 FC Comm Failure Circuit 3/4 Alarm description (as shown on screen): FC Comm. Fail Cir 3/4. Trigger: Circuit 3 or circuit 4 have more than 6 fans and communication with the I/O extension module has failed. Action Taken: Rapid stop of circuit 3 and 4.
Page 238 Alarms and Events ESIE10-01 1.4.20 EEXV Comm Failure N Alarm description (as shown on screen): EEXV Comm. Fail N. Trigger: Communication with the I/O extension module has failed. Alarm on Circuit #3 will be enabled if Number of Circuits set point > 2; alarm on Circuit #4 will be enabled if Number of Circuits set point >...
Page 239 ESIE10-01 Alarms and Events 1.4.21 Evaporator Pressure Sensor Fault Alarm description (as shown on screen): EvapPressSensFault N. Trigger: Sensor shorted or open. Action Taken: Rapid stop circuit. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. Part 3 –...
Page 240 Alarms and Events ESIE10-01 1.4.22 Condenser Pressure Sensor Fault Alarm description (as shown on screen): CondPressSensFault N. Trigger: Sensor shorted or open. Action Taken: Rapid stop circuit. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. 3–40 Part 3 –...
Page 241 ESIE10-01 Alarms and Events 1.4.23 Oil Pressure Sensor Fault Alarm description (as shown on screen): OilPressSensFault N. Trigger: Sensor shorted or open. Action Taken: Normal shutdown of circuit. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. Part 3 –...
Page 242 Alarms and Events ESIE10-01 1.4.24 Suction Temperature Sensor Fault Alarm description (as shown on screen): SuctTempSensFault N. Trigger: Sensor shorted or open. Action Taken: Normal shutdown of circuit. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. 3–42 Part 3 –...
Page 243 ESIE10-01 Alarms and Events 1.4.25 Discharge Temperature Sensor Fault Alarm description (as shown on screen): DiscTempSensFault N. Trigger: Sensor shorted or open. Action Taken: Normal shutdown of circuit. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. Part 3 –...
Page 244 Alarms and Events ESIE10-01 1.4.26 Motor Temperature Sensor Fault Alarm description (as shown on screen): MotorTempSensFault N. Trigger: Sensor shorted or open. Action Taken: Rapid stop circuit. Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. 3–44 Part 3 –...
Page 245: Circuit Events
ESIE10-01 Alarms and Events Circuit Events The following events limit operation of the circuit in some way as described in the Action Taken column. The occurrence of a circuit event only affects the circuit on which it occurred. Circuit events are logged in the event log on the unit controller.
Page 246 Alarms and Events ESIE10-01 1.5.1 Low Evaporator Pressure - Hold Event description (as shown on screen): EvapPress Low Hold N. Trigger: This event is not enabled until the circuit startup is complete and the unit mode is Cool. Then, while running, if evaporator pressure <= Low Evaporator Pressure Hold set point the event is triggered. The event is not to be triggered for 90 seconds following the capacity change of the compressor from 50% to 60%.
Page 247 ESIE10-01 Alarms and Events 1.5.2 Low Evaporator Pressure - Unload Event description (as shown on screen): EvapPressLowUnload N. Trigger: This event is not enabled until the circuit startup is complete and the unit mode is Cool. Then, while running, if evaporator pressure <= Low Evaporator Pressure Unload set point the event is triggered.
Page 248 Alarms and Events ESIE10-01 1.5.3 High Condenser Pressure - Hold Event description (as shown on screen): CondPressHigh Hold N. Trigger: While the compressor is running and unit mode is Cool, if saturated condenser temperature is higher or equal to the High Saturated Condenser Hold Value, the event is triggered. Action Taken: Inhibit loading.
Page 249 ESIE10-01 Alarms and Events 1.5.4 High Condenser Pressure - Unload Event description (as shown on screen): CondPressHighUnloadN. Trigger: While the compressor is running and unit mode is Cool, if saturated condenser temperature is higher or equal to High Saturated Condenser Unload Value, the event is triggered. Action Taken: Unload the compressor by decreasing the capacity by one step every 5 seconds until the evaporator pressure rises above the High Condensing Pressure Unload set point.
Page 250 Alarms and Events ESIE10-01 1.5.5 Failed Pumpdown Event description (as shown on screen): Pumpdown Fail Cir N. Trigger: If the circuit state is 'pumpdown' for a time longer then the pumpdown time setpoint, the alarm is triggered. Action Taken: Shutdown circuit. Reset: N/A.
Page 251 ESIE10-01 Alarms and Events 1.5.6 Power Loss While Running Event description (as shown on screen): Run Power Loss Cir N. Trigger: Circuit controller is powered up after losing power while compressor was running. Action Taken: N/A. Reset: N/A. Part 3 – Troubleshooting 3–51...
Page 252: Alarm Logging
Alarms and Events ESIE10-01 Alarm Logging When an alarm occurs, the alarm type, date, and time are stored in the active alarm buffer corresponding to that alarm (viewed on the Alarm Active screens) also in the alarm history buffer (viewed on the Alarm Log screens). The active alarm buffers hold a record of all current alarms. The active alarms can be cleared by pressing the Edit key when the end of the list has been reached by scrolling.
Page 253: Event Logging
ESIE10-01 Alarms and Events Event Logging An event log similar to the alarm log holds the last 25 events to occur. When an event occurs, it is put into the first slot in the event log and all other entries are moved down one, dropping the last event. Each entry in the event log includes an event description as well as the time and date of the occurrence.
Page 254 Alarms and Events ESIE10-01 3–54 Part 3 – Troubleshooting...
Page 255: What Is In This Chapter
ESIE10-01 Controller Inputs and Outputs Part 3 Controller Inputs and Outputs What is in This Chapter? Introduction This chapter gives information of the configuration of the input and output channels. Overview This chapter contains the following topics: Topic See page 2.2–Main Board Controller (POL687.70/MCQ) 3–56 2.3–Expansion I/O Compressor #1 to #4 (POL965.00/MCQ)
Page 256: Main Board Controller (Pol687.70/Mcq)
Controller Inputs and Outputs ESIE10-01 Main Board Controller (POL687.70/MCQ) Analog inputs Description Signal Source Expected Range Evaporator Entering Water Temp NTC Thermister (10K@25°C) -50°C – 120°C Evaporator Leaving Water Temp NTC Thermister (10K@25°C) -50°C – 120°C Evaporator #1 Leaving Water Temp (*) NTC Thermister (10K@25°C) -50°C –...
Page 257 ESIE10-01 Controller Inputs and Outputs Digital outputs Description Output OFF Output ON Evaporator Water Pump Pump Off Pump On Unit Alarm Alarm not Active Alarm Active (Flashing= circuit alarm) Circuit #1 Fan Step #1 Fan Off Fan On Circuit #1 Fan Step #2 Fan Off Fan On Circuit #1 Fan Step #3...
Page 258: Expansion I/O Compressor #1 To #4 (Pol965.00/Mcq)
Controller Inputs and Outputs ESIE10-01 Expansion I/O Compressor #1 to #4 (POL965.00/MCQ) Analog inputs Description Signal Source Expected Range Discharge Temperature NTC Thermister (10K@25°C) -50°C – 120°C Evaporator Pressure Ratiometric (0,5-4,5 Vdc) 0 to 5 Vdc Oil Pressure Ratiometric (0,5-4,5 Vdc) 0 to 5 Vdc Condenser Pressure Ratiometric (0,5-4,5 Vdc)
Page 259 ESIE10-01 Controller Inputs and Outputs Digital outputs Outputs DO3, DO4, and XO8 are configured based on Manufacturing Location. Europe Configuration ■ Description Output Off Output On Start Compressor Compressor Off Compressor On Economizer Solenoid Closed Solenoid Open Non-modulating Slide Load/Unload Solenoid Closed Solenoid Open Liquid Injection...
Page 260: Expansion I/O Exv Circuit #1 To #4 (Pol94U.00/Mcq)
Controller Inputs and Outputs ESIE10-01 Expansion I/O EXV Circuit #1 to #4 (POL94U.00/MCQ) Analog inputs Description Signal Source Expected Range Suction Temperature NTC Thermister 10K@25°C) -50°C – 120°C Analog outputs Description Output Signal Range Not Needed Digital inputs Description Signal Off Signal On Low Pressure switch Fault...
Page 261: Expansion I/O Fan Module Circuit #1 & #2 (Pol945.00/Mcq)
ESIE10-01 Controller Inputs and Outputs Expansion I/O Fan Module Circuit #1 & #2 (POL945.00/MCQ) Digital inputs Description Output Off Output On PVM/GFP Circuit #1 Fault No fault PVM/GFP Circuit #2 Fault No fault Digital outputs Description Output Off Output On Circuit #1 Fan Step #5 Fan Off Fan On...
Page 262: Expansion I/O Fan Module Circuit #3 (Pol945.00/Mcq)
Controller Inputs and Outputs ESIE10-01 Expansion I/O Fan Module Circuit #3 (POL945.00/MCQ) Digital inputs Description Output Off Output On PVM/GFP Circuit #3 Fault No fault Digital outputs Description Output Off Output On Circuit #3 Fan Step #1 Fan Off Fan On Circuit #3 Fan Step #2 Fan Off Fan On...
Page 263: Expansion I/O Fan Module Circuit #4 (Pol945.00/Mcq)
ESIE10-01 Controller Inputs and Outputs Expansion I/O Fan Module Circuit #4 (POL945.00/MCQ) Digital inputs Description Output Off Output On PVM/GFP Circuit #4 Fault No fault Digital outputs Description Output Off Output On Circuit #4 Fan Step #1 Fan Off Fan On Circuit #4 Fan Step #2 Fan Off Fan On...
Page 264: Expansion I/O Fan Module Circuit #3 & #4 (Pol945.00/Mcq)
Controller Inputs and Outputs ESIE10-01 Expansion I/O Fan Module Circuit #3 & #4 (POL945.00/MCQ) Digital outputs Description Output Off Output On Circuit #3 Fan Step #5 Fan Off Fan On Circuit #3 Fan Step #6 Fan Off Fan On Circuit #4 Fan Step #5 Fan Off Fan On Circuit #4 Fan Step #6...
Page 265: Expansion I/O Unit Alarm & Limiting (Pol965.00/Mcq)
ESIE10-01 Controller Inputs and Outputs Expansion I/O Unit Alarm & Limiting (POL965.00/MCQ) Analog inputs Description Signal Source Range Demand Limit 4-20 mA 1 to 23 mA Unit Current 4-20 mA 1 to 23 mA Analog outputs Description Output Signal Range Not Needed Digital inputs Description...
Page 266 Controller Inputs and Outputs ESIE10-01 3–66 Part 3 – Troubleshooting...
Page 267: What Is In This Chapter
ESIE10-01 Procedure for Software Programming Part 3 Procedure for Software Programming What is in This Chapter? Overview This chapter contains the following topics: Topic See page 3.2–Software Programming with SD Card 3–68 Part 3 – Troubleshooting 3–67...
Page 268: Software Programming With Sd Card
Procedure for Software Programming ESIE10-01 Software Programming with SD Card Controllers are programmed with a SD card. You’ll need following things: SD card with software (not new fast SD card). ■ Pin. ■ Controller. ■ Put the SD card in the controller in the correct position. 3–68 Part 3 –...
Page 269 ESIE10-01 Procedure for Software Programming Put the pin in the small hole in the controller and push. Switch on power. Part 3 – Troubleshooting 3–69...
Page 270 Procedure for Software Programming ESIE10-01 Remove pin when LED becomes orange. Then LED will start to blink red/green. Programming complete when LED is orange again. 1. Pin till orange. 2. Remove pin. 3. Blinking till orange. 4. Power off and remove SD card. 3–70 Part 3 –...
Page 271: What Is In This Chapter
ESIE10-01 Procedure to Protect Compressor in Case of Frozen Evaporator Part 3 Procedure to Protect Compressor in Case of Frozen Evaporator What is in This Chapter? Overview This chapter contains the following topics: Topic See page 4.2–Procedure to Protect Compressor in Case of Frozen Evaporator 3–72 Part 3 –...
Page 272 Procedure to Protect Compressor in Case of Frozen Evaporator ESIE10-01 Procedure to Protect Compressor in Case of Frozen Evaporator If water is detected in the compressor after an evaporator damage, the following procedure should be executed within the first day. Step Action Supply the compressor crank case heater.
Page 273: What Is In This Chapter
ESIE10-01 Procedure to Clear the Refrigerant Circuit in Case of Frozen Evaporators Part 3 Procedure to Clear the Refrigerant Circuit in Case of Frozen Evaporators What Is in This Chapter? Overview This chapter contains the following topics: Topic See page 5.2–Procedure to Clean the Refrigerant Circuit in Case of Frozen Evaporators 3–74 Part 3 –...
Page 274 Procedure to Clear the Refrigerant Circuit in Case of Frozen Evaporators ESIE10-01 Procedure to Clean the Refrigerant Circuit in Case of Frozen Evaporators If water is detected in the refrigerant circuit after an evaporator damage, the following procedure should be executed to clear the system. Step Action Inspection and cleaning of compressor.
Page 275: Troubleshooting Chart
ESIE10-01 Troubleshooting Chart Part 3 Troubleshooting Chart What is in This Chapter? Overview This chapter contains the following topics: Topic See page 6.2–Troubleshooting Chart 3–76 Part 3 – Troubleshooting 3–75...
Page 276 Troubleshooting Chart ESIE10-01 Troubleshooting Chart Problem Possible causes Possible corrective steps 1 Main power switch is open. 1 Close switch. 2 Unit system switch is open. 2 Check the unit status on the control panel. Close switch. 3 Circuit switch is in pump-down 3 Check the circuit status on the position.
Page 277 5 There is high discharge 5 See corrective steps for high pressure. discharge pressure. 1 There is a compressor internal 1 Contact Daikin. Compressor problem. noisy or vibrating 2 The oil injection is not adequate. 2 Contact Daikin.
Page 278 Troubleshooting Chart ESIE10-01 1 There is wind effect at low 1 Protect the unit against ambient. excessive wind into the vertical coils. 2 The condenser fan control is not 2 Check if the unit set-up in the correct. microprocessor matches the unit Low discharge model number.
Page 279 ESIE10-01 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 280 ESIE10-01 4–2 Part 4 – Commissioning and Test Run...
Page 281 ESIE10-01 Pre-Test Run Checks Part 4 Pre-Test Run Checks What Is in This Chapter? Introduction This chapter contains checks you have to carry out before every test run. Overview This chapter contains the following topics: Topic See page 1.2–Pre-Start Commissioning Check List 4–4 1.3–General Checks 4–5...
Page 282: Pre-Start Commissioning Check List
Pre-Test Run Checks ESIE10-01 Pre-Start Commissioning Check List Unit type: Serial n°: General Minimum system load sufficient for testing at 100% for approx. 1h Operation and service space are according to installation manual Oil heaters energized at least 24h before startup Hydraulic circuit Check if there is refrigerant pressure before connecting water circuit (if no pressure, do not connect)
Page 283: General Checks
ESIE10-01 Pre-Test Run Checks General Checks Checklist The table below contains the general checklist. Step Check whether... There is external damage. The unit is properly supported and/or has a proper foundation. The unit is installed horizontally with a deviation of maximum 1°. Anti-vibration pads are required.
Page 284: Water Piping Checks
Pre-Test Run Checks ESIE10-01 Water Piping Checks Checklist The table below contains the water piping checklist. Step Check whether... A filter is installed in front (less than 1 meter) of the water inlet of the heat exchanger. The heat exchangers are sensitive to dirt and small particles (maximum filter mesh of 1mm). The water volume is within the limits.
Page 285 ESIE10-01 Pre-Test Run Checks Evaporator Condenser The water pressure should not exceed the maximum working pressure of 10 bar. Part 4 – Commissioning and Test Run 4–7...
Page 286 Pre-Test Run Checks ESIE10-01 4–8 Part 4 – Commissioning and Test Run...
Page 287: What Is In This Chapter
ESIE10-01 Running Data Part 4 Running Data What Is in This Chapter? Introduction This chapter contains the typical operating data. Overview This chapter contains the following topics: Topic See page 2.2–Typical Operating Data 4–10 Part 4 – Commissioning and Test Run 4–9...
Page 288: Typical Operating Data
Running Data ESIE10-01 Typical Operating Data Standard eff with Nominal Conditions: OAT 35°C – Ent/Leav. Water Temp. 12/7°C – 100% ST/LN Operating Value Standard Noise Low Noise Condensing Temperature 52-53°C 54-56°C Evaporating Temperature 2-3°C 2-3°C Total Liquid Sub Cooling 4-6°C 4-6°C Suction Superheat 4-6°C...
Page 289 ESIE10-01 Running Data Part 4 – Commissioning and Test Run 4–11...
Page 290 Running Data ESIE10-01 4–12 Part 4 – Commissioning and Test Run...
Page 291 Preventive maintenance should be set up for operation at maximum capacity or to avoid damage. The following chapter explain how to or when to maintain the units. It is also applicable on other types of Daikin chillers. What is in this part?
Page 292 ESIE10-01 5–2 Part 5 – Maintenance...
Page 293 ESIE10-01 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 system and standard 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 294 Maintenance ESIE10-01 System Maintenance Warning: All routine and non-routine maintenance activities on the machine must be carried out solely by ■ qualified personnel who have been suitably trained and are familiar with the device, its operation and maintenance, and who are aware of the safety requirements and risks involved. It is absolutely forbidden to remove all the protections of the moving parts of the unit.
Page 295 ESIE10-01 Maintenance Solenoid load valve Solenoid disc High-pressure pressure switch High-pressure transducer Oil filter Oil and delivery temperature transducer Oil load/discharge valve position Maximum oil level Position of electric resistance for oil Minimum oil level heating Installation of F4AL compressor control devices Ordinary The following table shows the ordinary maintenance schedule: maintenance...
Page 296 Maintenance ESIE10-01 Monthly Yearly List of activities Weekly (Note 1) (Note 2) Check refrigerant flow using the liquid sight glass - Sight glass full Check filter dryer pressure drop Check oil filter pressure drop (Note 5) Analyse compressor vibrations Analyse compressor oil acidity (7) Condenser section: Clean the condensation banks (Note 4) Check that the fans are properly fastened...
Page 297 ESIE10-01 Maintenance Filter dryer Attention: Ensure proper water flow through the evaporator during the entire servicing period. cartridge Interrupting the water flow during this procedure would cause the evaporator to freeze, with replacement consequent breakage of internal piping. procedure Shut down the relevant compressor turning the Q1 or Q2 switch to off. Wait until the compressor has stopped and close the valve located on the liquid line.
Page 298 Maintenance ESIE10-01 Oil filter replacement procedure: Shut down both compressors by turning the Q1 and Q2 switches to the off position. Turn the Q0 switch to off, wait for the circulation pump to turn off and open the general discon- necting switch Q10 to cut off the machine's electrical power supply.
Page 299 ESIE10-01 Maintenance N.B.: As the load changes and the number of active fans changes, subcooling also changes and ■ takes a few minutes to stabilise. In any case, it must never go below 3°C in any condition. Furthermore, the subcooling value may change slightly as the water temperature and suction superheating vary.
Page 300 Maintenance ESIE10-01 Standard Checks Temperature and The unit comes factory-equipped with all the sensors listed below. Periodically check that their pressure sensors measurements are correct by means of reference instruments (manometers, thermometers) and correct any wrong readings as necessary, using the microprocessor keypad. Well-calibrated sensors guarantee greater machine efficiency and a longer life.
Page 301 ESIE10-01 Index 3–10 AC Comm Failure ..............3–52 Alarm Logging .
Page 302 ESIE10-01 3–38 EEXV Comm Failure N ............1–92 Electrical Installation .
Page 303 ESIE10-01 Mechanical Installation 1–87 Clearance ..............1–86 Moving And Lifting .
Page 304 ESIE10-01 1–76 Water Charge, Flow And Quality ........... . 1–78 Water Content In Cooling Circuits .

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Daikin EWAD620-C17C-SS Service Manual

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