Daikin ZUWCM/DM Installation And Maintenance Manual
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Daikin ZUWCM/DM Installation And Maintenance Manual

Single screw chillers
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Engineering Data
(Installation, Maintenance Manual)
Single Screw Chillers
This manual is applicable to following models and their derived and
modified models.
ZUWCM/DM ZUW.C-B ZUWY ZUWV ZUW-HCA
Thanks for purchasing DAIKIN chiller.
The Manual specifies safety, installation and maintenance precautions.
Please read through the manual before installation and use.
For future reference, please be sure to keep it safe.
Engineered for Flexibility and performance
IMM Chiller universal part
Category: Single Screw Chiller
Date: Mar. 2019
New Part No.: Z8100180-09
Prior Part No.: Z8100180-08

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Summary of Contents for Daikin ZUWCM/DM

  • Page 1 Prior Part No.: Z8100180-08 This manual is applicable to following models and their derived and modified models. ZUWCM/DM ZUW.C-B ZUWY ZUWV ZUW-HCA Thanks for purchasing DAIKIN chiller. The Manual specifies safety, installation and maintenance precautions. Please read through the manual before installation and use.
  • Page 3 Safety Matters Single screw chiller can serve safely and reliably under design conditions. Good judgment and safety precaution measures shall be available for operating the chiller to avoid losses of equipment and property or personal in-juries. Operators must understand and abide by the operation procedures and safety precaution measures in the installation operation and maintenance manual.
  • Page 4 Notes: It’s forbidden to clean the pipe or pressure chiller with oxygen and compressed air. Only refrigerant or dry nitrogen other than air is allowed to use for leakage test. Walking on the chiller pipeline is prohibited in order to prevent pipeline damage and personal injury caused by refrigerant leakage.

  • Page 5: Table Of Contents

    SINGLE SCREW CHILLERS IMM Contents ■1. NOMENCLATURE ........................3 ●1.1 W ) ..............3 ATER OOLED INGLE CREW HILLER LOODED ●1.2 W ) .............. 3 ATER OOLED INGLE CREW HILLER ALLING FILM ●1.3 W ZUW-HCA) ........3 ATER OOLED INGLE CREW HILLER LATFORM FOR...
  • Page 6 SINGLE SCREW CHILLERS IMM ●11.3 W ....................34 ATER UALITY FOR CHILLER ■APPENDIX A..........................36 ■APPENDIX B ..........................37 ■APPENDIX C ..........................43 ●1. D ....................43 IMENSION OF WITCHES ●2. O ................43 PERATING ONDITIONS OF WITCHES ●3. F ......................

  • Page 7: Nomenclature

    SINGLE SCREW CHILLERS IMM 1. Nomenclature 1.1 Water Cooled Single Screw Chiller (Flooded) 1.2 Water Cooled Single Screw Chiller (Falling-film) Application Code Water Cooled Single Screw Chiller Condenser Pass:2-pass Starting Method: Y:Star-detla V:Variable frequency Condenser Tube Type Code Compressor Code Condenser Code Power Supply: Evaporator Pass ：...

  • Page 8: Major Component Locations

    SINGLE SCREW CHILLERS IMM 2. Major Component Locations Single screw chillers are classified into the single-compressor, double-compressor chillers according to the quantity of compressors, taking the double-compressor chiller(as shown in Fig.2-2),ZUWY6Q2OFLHE3LDL2N falling-film chiller(as shown Fig.2-3) ZUWY6Q2OSF-HCA Falling-film chiller with Flash-tank Economizer (as shown in Fig.2-4) as examples to introduce each component of chiller.
  • Page 9 SINGLE SCREW CHILLERS IMM A View Fig.2-2 Engineered for Flexibility and Performance...
  • Page 10 SINGLE SCREW CHILLERS IMM A View Fig.2-3 Engineered for Flexibility and Performance...
  • Page 11 SINGLE SCREW CHILLERS IMM Flash-tank Economizer compressor starter cabinet Evaporator condenser A View control cabinet screen evaporator outlet condenser outlet evaporator inlet condenser inlet Fig.2-4 Engineered for Flexibility and Performance...

  • Page 12: Working Principles

    SINGLE SCREW CHILLERS IMM 3. Working Principles 3.1 Working principles of single screw chiller without Flash-tank Economizer 1. Low temp/pressure refrigerant gas enters the compressor. After compression, the gas will be discharged into oil separator in high temp/pressure; 2. Oil is separated from refrigerant in oil separator. The former goes back to compressor and the later goes to condenser;...
  • Page 13 SINGLE SCREW CHILLERS IMM 3.2 Working principles of single screw chiller with Flash-tank Economizer 1. Low temp/pressure refrigerant gas enters the compressor. After compression, the gas will be discharged into oil separator in high temp/pressure; 2. Oil is separated from refrigerant in oil separator. The former goes back to compressor and the later goes to condenser;...

  • Page 14: Safety (Please Follow The Following Content Strictly)

    SINGLE SCREW CHILLERS IMM 4. Safety (Please follow the following content strictly) Precautions in this section include: Warning: a faulty operation that may cause death or serious injuries. Caution: a faulty operation that may cause injuries or equipment failure. It may lead to even more serious consequences according to severity.
  • Page 15 SINGLE SCREW CHILLERS IMM horizontal line horizontal line Fig.4-1 G) Chiller shall be installed in indoor space If chiller is installed in rainy or water dropping place, electric leakage \ shock might happen. H) Use specified cable and ensure the connections are firm Ensure the connections of cables are firm.
  • Page 16 SINGLE SCREW CHILLERS IMM H) It is prohibited to locate chiller in severe environment Hot well, coast area, etc. will cause chiller corrosion which might cause shock or fire accident. The water (cooling water\chilled water) in chiller system shall follow the criteria of local water quality standard.
  • Page 17 4.2 Precautions during Use Warning: A) If chiller running abnormally (e.g. smell of burning), please cut off the power and contact local Daikin office or distributors. Running the chiller after abnormity happen might damage the chiller or shock and fire accidents.

  • Page 18: Precautions During Relocation And Repair

    B) Chiller relocation shall be done by chiller vender. Inappropriate relocation will cause electrical shock or fire accident. C) It is prohibited to modify the chiller without Daikin authorization. Unauthorized chiller alteration will cause electrical shock or fire accident. Attention: A) Client shall follow the local regulations or rules when handling the wasted chilled water, cleaning agent and refrigerant.

  • Page 19: Notes For Relief Valve

    Fig.4-2 If local regulations required, so in the safety valve to connect one emptying pipe to the outdoor (Daikin advices that customers installation emptying pipe). Refer to below; the connected pipe of relief valve must use flexible connectors. Engineered for Flexibility and Performance...
  • Page 20 SINGLE SCREW CHILLERS IMM Fig.4-3 Note: Before connect the pipe, Need to remove the plastic plug in the valve (if any), According to the local regulations. When the emptying pipe is installed to the relief valve, the dimension of emptying pipe is based on the size of one relief valve.

  • Page 21: Chiller Transit

    If you requires differential pressure controller configuration, it has been installed on the machine for you; Daikin will offer flange or Victaulic groove on evaporator & condenser pipes for customer water system connection. 5.2 Chiller Lifting The lifting mode is shown in Fig.5-1.

  • Page 22: Horizontal Transiting

    SINGLE SCREW CHILLERS IMM G) During lifting, use fabric to cover the chiller so as to protect it from injury. Warning: A) Do not use compressor or starter lift lug to lift the entire chiller B) The lifting cable shall not contact chiller pipes. It might crack the pipes. 5.4 Horizontal transiting To prevent bending of chiller main foundation, please pay special attention when handling.

  • Page 23: Installation

    SINGLE SCREW CHILLERS IMM 6. Installation 6.1 Chiller location and foundation A) Chiller shall not be located in rainy or exposed directly under the sun. If chiller is placed near beach or chemical plant etc., corrosion might occur to electronic parts or chiller painting. Special condition is required as per special chiller design.
  • Page 24 SINGLE SCREW CHILLERS IMM Fig.6-1 If chiller is installed in the building of the middle layer where excessive vibration may occur, please use the spring anti-vibration device. Daikin offers spring isolators according to the user's requirements. Chiller Foot Adjusting bolt Foundation Fig.6-2...

  • Page 25: Knockdown Of Chiller

    SINGLE SCREW CHILLERS IMM 6.2 Knockdown of Chiller The chiller is delivered in three states: 1. complete chiller with refrigerant and lubricating oil; 2. complete chiller without refrigerant, but with lubricating oil; 3. the chiller is partially or fully dismantled. Reinstallation of the chiller in the second or third state shall be performed by professional operator as per the General Assembly Schematic Map of the chiller.

  • Page 26: Piping Of The Chillers

    SINGLE SCREW CHILLERS IMM 6.3 Piping of the chillers The schematic map (Fig. 6-3) of water connecting pipe for single screw chiller is provided only as a reference. Fig.6-3 A) Anti-Vibration 1. To limit the spread of vibration which would affect other equipment, flexible joints for the unit connection pipe installation are suggested.
  • Page 27 Otherwise Daikin won’t be responsible for any loss caused by this. C) Eliminate the impurities in water loop 1.

  • Page 28: Electric Works

    3. Chiller plant room might equip heater to prevent water freezing in chiller unit. 4. If chiller seasonally stop in the plant room where temperature goes below 0℃, operator must drain the water in chiller tubes. Otherwise Daikin won’t be responsible for the damage or loss caused by this.
  • Page 29 SINGLE SCREW CHILLERS IMM Attention: Ground cable shall be kept certain distance with natural gas \lightening rod and telephone cables. And don’t connect water pipes to ground cable. Gas pipeline – gas leakage may cause explosion and fire. Water pipe – the grounding will be invalid if the water pipe is made of hard ethylene materials. Telephone grounding wire and lightning rod –...

  • Page 30: Matters To Be Confirmed Before Test Run

    It is necessary to read [4.Safety] to ensure safety for equipment. If the inspection results failed to conform to relevant requirements, the test run shall not be performed, and a negotiation with Daikin shall be conducted. 7.1 Inspect the power circuit (please confirm before it being powered up) A) Insulation resistance of power circuit It must be confirmed before being powered up.

  • Page 31: Water System Check

    SINGLE SCREW CHILLERS IMM B) Power on more than 8 hours before operation. In order to start compressor smoothly, starter cabinet should be powered on more than 8 hours to energize oil heater to heat the oil. 7.4 Water system check A) Water should be filled in pump.

  • Page 32: Panel Setting Check

    SINGLE SCREW CHILLERS IMM Installation Position※ Description of Valve Application On-off State Upper Part of Evaporator Safety Valve On ※※ Upper Part of Evaporator Refrigerant charging valve Lower Part of Evaporator Pollution discharging valve Bottom of evaporator head Drain valve Top of evaporator head Vent valve Rear of Evap.

  • Page 33: Functions Of Chiller

    SINGLE SCREW CHILLERS IMM 8. Functions of Chiller 8.1 Automatic control of water-temperature for the chillers The single screw chiller utilizes PID control so that ELWT is automatically close to setting value. Compressors utilize the stepless control to adapt cooling load change to ensure constant ELWT in a short time.

  • Page 34: Limits Of Start/Stop

    SINGLE SCREW CHILLERS IMM It will lead to frequent start/stop of the chiller if the equipment water flow is below minimum retention flow. In this circumstance, the “Stop Temperature Difference” can be enlarged (by following “Setting Menu” – “chiller Setting” – “Stop Temperature Difference”) If the water flow is too smaller, then, enlarging the “Stop Temperature Difference”...

  • Page 35: Maintenance

    The chiller’s operation status varies largely with the cooling load, cooling water temperature and flow. The customer is recommended to sign a maintenance contract with the Daikin service branch. Please contact with the dealer for detailed information. 9.5 About Refrigerant and refrigeration Oil The type and charging quantity is shown by chiller nameplate.

  • Page 36: Routine Maintenance

    SINGLE SCREW CHILLERS IMM 9.6 Routine Maintenance In order to keep chiller running, regularly maintenance with adjustment and record is required. Maintenance table is shown in appendix A See Appendix B for screw chiller maintenance and inspection cycle. Engineered for Flexibility and Performance...

  • Page 37: Precautions For Long-Time Stop

    Select antifreeze that doesn’t react with iron, copper and neoprene. ● Re-operation after long-time stop Please check the following before re-operation after a long-time stop and contact with the local Daikin service branch.  1. Test insulation resistance before chiller starts. (More than 2 M...

  • Page 38: Operating Range

    Installation: indoor installation without direct exposure to the rain and the sun (if it shall be installed outdoor or in the such atmospheric environments with high concentration of corrosive gas as seaside or chemical plant, please contact the local Daikin branch office and dealers) 11.2 Minimum Retaining Water Capacity of System...
  • Page 39 3. If water quality can’t meet the requirements showed above, please handle the water according to GB50050-2007 Code for design of industrial recirculating cooling water treatment We recommend you add water process device and contact Daikin professional servicer to deal with it. Engineered for Flexibility and Performance...
  • Page 40 SINGLE SCREW CHILLERS IMM Appendix A 8:00 10:00 12:00 14:00 16:00 18:00 20:00 Condenser/ Heat Recoverer Condensing pressure (kPa) Entering water temperature(℃) Leaving water temperature(℃) Enter/Leaving water pressure drop(kPa) Evaporator Entering water temperature ℃) Leaving water temperature(℃) Enter/Leaving water pressure drop(kPa) Entering water temperature ℃) Others...
  • Page 41 SINGLE SCREW CHILLERS IMM Appendix B Replacing Interval Month Month Years Years Years Years Years Years Years Years Years Years Years Years criteria when Year Years Years Later Later Later Later Later Later Later Later Later Later Later Later abnormal Items Start 2500...
  • Page 42 SINGLE SCREW CHILLERS IMM Abnormal insulation Motor ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ▲ resistance is detected Injection Abnormal expansion ○ ○ ○ ○ ▲ ○ ○ ○ ○ ○ ○ ○...
  • Page 43 SINGLE SCREW CHILLERS IMM Obvious black suspended substance, floc and oil sludge, ○ ○ ○ ○ ▲ ○ ○ ○ ○ ▲ ○ ○ ○ ▲ ○ ○ ○ ▲ lubricant oil acidity>0.04 (mg KOH/g), water content >400 Heat transfer Cleaning temperature tubes:...
  • Page 44 SINGLE SCREW CHILLERS IMM No flowing fluid during Solenoid valve starting or ○ ○ ○ ○ ○ ○ ○ ○ ▲ ○ ○ ○ ○ ○ ○ ○ ▲ (abnormal fluid flows open or close) during closing the chiller The input or output of ○...
  • Page 45 SINGLE SCREW CHILLERS IMM Abnormal operation is detected, Timing ○ ○ ○ ○ ○ ○ ▲ ○ ○ ○ ○ ▲ ○ ○ ○ ○ ▲ Time relay deviation exceeds the maximum range of 10% The cut-off value exceeds High voltage ○...
  • Page 46 Daikin professionals. Please refer to GB18430.1-2007 for water quality and it is recommended to add water treatment devices and contact with Daikin professionals in case of poor water quality. Engineered for Flexibility and Performance...

  • Page 47: Dimension Of Flow Switches

    SINGLE SCREW CHILLERS IMM Appendix C (Informative Appendix) Instructions for Flow Switches 1. Dimension of Flow Switches Fig.1 Dimension 2. Operating Conditions of Flow Switches Fig.2 Switches Motion When sufficient liquid passes through the pipe and turns the flow switch on, the circuit between red to yellow points is connected.

  • Page 48: Flowing Direction Sheet

    SINGLE SCREW CHILLERS IMM 3. Flowing direction sheet Fig.3 Trimming Template Sketch Map of Flowing Direction Sheet Fig.3 is a trimming template sketch map and please refers to the trimming template of flow switch during the practical operation. User can install the removable flowing direction sheet 1, 2, 3 and 6 of flow switches allocated by the factory according to actual needs.
  • Page 49 SINGLE SCREW CHILLERS IMM Fig.5 4.2 The flow switch shall be installed in the horizontal pipeline or vertical pipeline in the direction of liquid flows other than the pipeline of downward direction of liquid flows. If it has been installed in the pipeline in upward direction of liquid flows, the gravity effect shall be taken into account to adjust the values higher slightly than the typical flow values in the Table 1.

  • Page 50: Switch Adjustment

    SINGLE SCREW CHILLERS IMM 5. Switch Adjustment The procedures for setting adjusting flow switches: A. Remove the casing of flow switches: B. Turn up the flow and rotate the adjusting screw in clockwise direction. After turning up the ex-factory set value, rotate the adjusting screw in counterclockwise director to turn down the flow value (as shown in Fig.1).

  • Page 51: Fault Elimination

    SINGLE SCREW CHILLERS IMM 7. Fault Elimination Phenomena or Problems Solutions The bellows is damaged and the Replacement liquid leaks into the casing. Scraps have stuck Clear the scraps in the mechanical parts and test for mechanical parts of switches several times to ensure its normal operation.
  • Page 52 SINGLE SCREW CHILLERS IMM Appendix D Field Wiring Diagram of Control cable Note: 1． This drawing has DC wires and 220VAC wires; it is recommended that DC wires be run separately from 220VAC wires. 2． Only heat Recovery Unit need to connect this signal. 3．...
  • Page 53 SINGLE SCREW CHILLERS IMM function, the cabinet supplies a passive contactor between No. 17 and No.18 terminals. 8． Users need to connect the grounding bus bar of the cabinet to the ground. 9． If users order the Ice/ Heat function, connect the switch (user supply) to the corresponding terminals to switch the modes.
  • Page 54 ★ Printing may be different from real products and product in this document, please refer to the real chiller when purchasing. ★ All material is carefully reviewed. In case of any printing errors, DAIKIN bears no responsibility. ★ Models, parameters and performance may change due to product improvement without further...

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