Daikin EWAQ016CAW, EWAQ021CAW, EWAQ025CAW, EWAQ032CAW, EWAQ040CAW Installer reference guide
...
Installer and user
reference guide
Packaged air-cooled water chiller
EWAQ016CAW
EWAQ021CAW
EWAQ025CAW
EWAQ032CAW
EWAQ040CAW
EWAQ050CAW
EWAQ064CAW
EWYQ016CAW
EWYQ021CAW
EWYQ025CAW
EWYQ032CAW
EWYQ040CAW
EWYQ050CAW
EWYQ064CAW
Installer and user reference guide
Packaged air-cooled water chiller
English
Table of contents
Table of contents
1 General safety precautions 3
1.1 About the documentation .......................................................... 3
1.1.1 Meaning of warnings and symbols.............................. 3
1.2 For the user ............................................................................... 3
1.3 For the installer.......................................................................... 4
1.3.1 General ....................................................................... 4
1.3.2 Installation site ............................................................ 4
1.3.3 Refrigerant .................................................................. 4
1.3.4 Brine............................................................................ 5
1.3.5 Water .......................................................................... 5
1.3.6 Electrical ..................................................................... 5
2 About the documentation 6
2.1 About this document.................................................................. 6
For the installer 7
3 About the box 7
3.1 Overview: About the box ........................................................... 7
3.2 Outdoor unit............................................................................... 7
3.2.1 To unpack the outdoor unit ......................................... 7
3.2.2 To remove the accessories from the outdoor unit....... 7
4 About the units and options 8
4.1 Overview: About the units and options...................................... 8
4.2 Identification label: Outdoor unit................................................ 8
4.3 About the outdoor unit ............................................................... 8
4.4 Operation range ........................................................................ 8
4.5 System layout............................................................................ 9
4.6 Combining units and options ..................................................... 9
4.6.1 About combining units and options............................. 9
4.6.2 Possible options for the outdoor unit........................... 9
5 Preparation 9
5.1 Overview: Preparation............................................................... 9
5.2 Preparing installation site .......................................................... 9
5.2.1 Installation site requirements of the outdoor unit ........ 9
5.2.2 Additional installation site requirements of the
outdoor unit in cold climates ....................................... 10
5.3 Preparing water piping .............................................................. 10
5.3.1 Water circuit requirements .......................................... 10
5.3.2 Formula to calculate the expansion vessel pre-
pressure ...................................................................... 11
5.3.3 To check the water volume and expansion vessel
pre-pressure................................................................ 11
5.3.4 Changing the pre-pressure of the expansion vessel... 13
5.3.5 To check the water volume: Examples ....................... 13
5.4 Preparing electrical wiring ......................................................... 13
5.4.1 About electrical compliance ........................................ 13
5.4.2 Cable requirements..................................................... 13
5.4.3 Safety device requirements ........................................ 13
6.4.3 To fill the water circuit .................................................. 16
6.4.4 To protect the water circuit against freezing ................ 16
6.4.5 To insulate the water piping ......................................... 17
6.5 Connecting the electrical wiring.................................................. 17
6.5.1 Precautions when connecting electrical wiring ............ 17
6.5.2 Field wiring: Overview.................................................. 18
6.5.3 About the electrical wiring ............................................ 18
6.5.4 To route and fix the power supply................................ 18
6.5.5 To install the main switch handle ................................. 18
6.5.6 To connect the power supply and transmission
cables........................................................................... 19
6.5.7 To install the remote controller..................................... 19
6.5.8 To install optional equipment ....................................... 20
7 Configuration 20
7.1 Overview: Configuration ............................................................. 20
7.2 Making field settings................................................................... 20
7.2.1 About making field settings .......................................... 20
7.2.2 Field setting components ............................................. 20
7.2.3 To access the field setting components....................... 21
7.2.4 To access mode 1 or 2 ................................................ 21
7.2.5 To use mode 1 ............................................................. 21
7.2.6 To use mode 2 ............................................................. 21
7.2.7 Mode 1: Monitoring settings......................................... 22
7.2.8 Mode 2: Field settings.................................................. 22
7.2.9 Field settings on the remote controller......................... 23
7.3 Switching between cooling and heating ..................................... 27
8 Commissioning 28
8.1 Overview: Commissioning.......................................................... 28
8.2 Precautions when commissioning .............................................. 28
8.3 Checklist before commissioning................................................. 28
8.4 Final check ................................................................................. 29
8.5 Checklist handover to the user................................................... 29
8.6 To complete the model fill-in ...................................................... 29
9 Maintenance and service 29
9.1 Overview: Maintenance and service .......................................... 29
9.2 Maintenance safety precautions................................................. 30
9.3 Checklist for yearly maintenance of the outdoor unit ................. 30
10 Troubleshooting 30
10.1 Overview: Troubleshooting......................................................... 30
10.2 Error codes: Overview ................................................................ 30
11 Disposal 31
12 Technical data 32
12.1 Overview: Technical data ........................................................... 32
12.2 Service space: Outdoor unit ....................................................... 32
12.3 Piping diagram: Outdoor module................................................ 33
12.4 Wiring diagram: Outdoor unit ..................................................... 34
12.5 Technical specifications: Outdoor unit........................................ 35
12.6 Field settings on the remote controller – overview ..................... 36
12.7 Field settings on the outdoor module ......................................... 38
12.8 ESP curve: Outdoor unit............................................................. 39
6 Installation 14
6.1 Overview: Installation ................................................................ 14
6.2 Opening the units ...................................................................... 14
6.2.1 To open the outdoor unit............................................. 14
6.2.2 To open the electrical component box of the outdoor
unit .............................................................................. 14
6.3 Mounting the outdoor unit.......................................................... 14
6.3.1 About mounting the outdoor unit................................. 14
6.3.2 To provide the installation structure ............................ 14
6.3.3 Precautions when mounting the outdoor unit.............. 15
6.4 Connecting the water piping...................................................... 15
6.4.1 About connecting the water piping.............................. 15
6.4.2 Precautions when connecting the water piping........... 15
Installer and user reference guide
2
For the user 42
13 About the system 42
13.1 System layout ............................................................................. 42
14 User interface 42
15 Before operation 43
16 Operation 43
16.1 Operation range ......................................................................... 43
16.2 Quick start-up ............................................................................. 43
16.3 Operating the system ................................................................. 44
16.3.1 About the clock ............................................................ 44
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
1 General safety precautions
16.3.2 About operating the system ........................................ 45
16.3.3 Space cooling operation ............................................. 45
16.3.4 Space heating operation ............................................. 45
16.3.5 Other operation modes ............................................... 46
16.3.6 Schedule timer ............................................................ 46
16.3.7 Operating the optional demand PCB .......................... 50
16.3.8 Operating the optional external control adapter .......... 51
16.3.9 Operating the optional remote controller..................... 51
17 Maintenance and service 51
17.1 About the refrigerant.................................................................. 51
17.2 After-sales service and warranty ............................................... 51
17.2.1 Warranty period .......................................................... 51
17.2.2 Recommended maintenance and inspection .............. 51
17.2.3 Recommended maintenance and inspection cycles ... 51
18 Troubleshooting 52
18.1 Error codes: Overview ............................................................... 52
19 Relocation 52
20 Disposal 52
21 Glossary 52
55
1 General safety precautions
1.1 About the documentation
▪ The original documentation is written in English. All other
languages are translations.
▪ The precautions described in this document cover very important
topics, follow them carefully.
▪ The installation of the system, and all activities described in the
installation manual and the installer reference guide must be
performed by an authorised installer.
INFORMATION
Indicates useful tips or additional information.
Symbol Explanation
Before installation, read the installation and
operation manual, and the wiring instruction sheet.
Before performing maintenance and service tasks,
read the service manual.
For more information, see the installer and user
reference guide.
1.2 For the user
▪ If you are not sure how to operate the unit, contact your installer.
▪ This appliance can be used by children aged from 8 years and
above and persons with reduced physical, sensory or mental
capabilities or lack of experience and knowledge if they have been
given supervision or instruction concerning use of the appliance in
a safe way and understand the hazards involved. Children shall
not play with the appliance. Cleaning and user maintenance shall
not be made by children without supervision.
WARNING
To prevent electric shocks or fire:
▪ Do NOT rinse the unit.
▪ Do NOT operate the unit with wet hands.
▪ Do NOT place any objects containing water on the unit.
NOTICE
▪ Do NOT place any objects or equipment on top of the
unit.
▪ Do NOT sit, climb or stand on the unit.
▪ Units are marked with the following symbol:
1.1.1 Meaning of warnings and symbols
DANGER
Indicates a situation that results in death or serious injury.
DANGER: RISK OF ELECTROCUTION
Indicates a situation that could result in electrocution.
DANGER: RISK OF BURNING
Indicates a situation that could result in burning because of
extreme hot or cold temperatures.
DANGER: RISK OF EXPLOSION
Indicates a situation that could result in explosion.
WARNING
Indicates a situation that could result in death or serious
injury.
WARNING: FLAMMABLE MATERIAL
CAUTION
Indicates a situation that could result in minor or moderate
injury.
NOTICE
Indicates a situation that could result in equipment or
property damage.
This means that electrical and electronic products may not be
mixed with unsorted household waste. Do NOT try to dismantle
the system yourself: the dismantling of the system, treatment of
the refrigerant, of oil and of other parts must be done by an
authorized installer and must comply with applicable legislation.
Units must be treated at a specialized treatment facility for reuse,
recycling and recovery. By ensuring this product is disposed of
correctly, you will help to prevent potential negative consequences
for the environment and human health. For more information,
contact your installer or local authority.
▪ Batteries are marked with the following symbol:
This means that the batteries may not be mixed with unsorted
household waste. If a chemical symbol is printed beneath the
symbol, this chemical symbol means that the battery contains a
heavy metal above a certain concentration.
Possible chemical symbols are: Pb: lead (>0.004%).
Waste batteries must be treated at a specialized treatment facility
for reuse. By ensuring waste batteries are disposed of correctly,
you will help to prevent potential negative consequences for the
environment and human health.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
Installer and user reference guide
3
1 General safety precautions
1.3 For the installer
1.3.1 General
If you are not sure how to install or operate the unit, contact your
dealer.
NOTICE
Improper installation or attachment of equipment or
accessories could result in electric shock, short-circuit,
leaks, fire or other damage to the equipment. Only use
accessories, optional equipment and spare parts made or
approved by Daikin.
WARNING
Make sure installation, testing and applied materials
comply with applicable legislation (on top of the
instructions described in the Daikin documentation).
CAUTION
Wear adequate personal protective equipment (protective
gloves, safety glasses,…) when installing, maintaining or
servicing the system.
WARNING
Tear apart and throw away plastic packaging bags so that
nobody, especially children, can play with them. Possible
risk: suffocation.
DANGER: RISK OF BURNING
▪ Do NOT touch the refrigerant piping, water piping or
internal parts during and immediately after operation. It
could be too hot or too cold. Give it time to return to
normal temperature. If you must touch it, wear
protective gloves.
▪ Do NOT touch any accidental leaking refrigerant.
WARNING
Provide adequate measures to prevent that the unit can be
used as a shelter by small animals. Small animals that
make contact with electrical parts can cause malfunctions,
smoke or fire.
CAUTION
Do NOT touch the air inlet or aluminium fins of the unit.
NOTICE
▪ Do NOT place any objects or equipment on top of the
unit.
▪ Do NOT sit, climb or stand on the unit.
NOTICE
Works executed on the outdoor unit are best done under
dry weather conditions to avoid water ingress.
CAUTION
For use of units in applications with schedule timer mode, it
is advised to foresee a delay of 10 to 15 minutes for
signalling the alarm in case the schedule timer is
exceeded. The unit may stop for several minutes during
normal operation for "defrosting of the unit" or when in
"thermostat-stop" operation.
In accordance with the applicable legislation, it might be necessary
to provide a logbook with the product containing at least: information
on maintenance, repair work, results of tests, stand-by periods,…
Also, at least, following information must be provided at an
accessible place at the product:
▪ Instructions for shutting down the system in case of an emergency
▪ Name and address of fire department, police and hospital
▪ Name, address and day and night telephone numbers for
obtaining service
In Europe, EN378 provides the necessary guidance for this logbook.
1.3.2 Installation site
▪ Provide sufficient space around the unit for servicing and air
circulation.
▪ Make sure the installation site withstands the unit's weight and
vibration.
▪ Make sure the area is well ventilated. Do NOT block any
ventilation openings.
▪ Make sure the unit is level.
Do NOT install the unit in the following places:
▪ In potentially explosive atmospheres.
▪ In places where there is machinery that emits electromagnetic
waves. Electromagnetic waves may disturb the control system,
and cause malfunction of the equipment.
▪ In places where there is a risk of fire due to the leakage of
flammable gases (example: thinner or gasoline), carbon fibre,
ignitable dust.
▪ In places where corrosive gas (example: sulphurous acid gas) is
produced. Corrosion of copper pipes or soldered parts may cause
the refrigerant to leak.
1.3.3 Refrigerant
If applicable. See the installation manual or installer reference guide
of your application for more information.
NOTICE
Make sure refrigerant piping installation complies with
applicable legislation. In Europe, EN378 is the applicable
standard.
NOTICE
Make sure the field piping and connections are not
subjected to stress.
WARNING
During tests, NEVER pressurize the product with a
pressure higher than the maximum allowable pressure (as
indicated on the nameplate of the unit).
WARNING
Take sufficient precautions in case of refrigerant leakage. If
refrigerant gas leaks, ventilate the area immediately.
Possible risks:
▪ Excessive refrigerant concentrations in a closed room
can lead to oxygen deficiency.
▪ Toxic gas may be produced if refrigerant gas comes
into contact with fire.
Installer and user reference guide
4
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
1 General safety precautions
DANGER: RISK OF EXPLOSION
Pump down – Refrigerant leakage. If you want to pump
down the system, and there is a leakage in the refrigerant
circuit:
▪ Do NOT use the unit's automatic pump down function,
with which you can collect all refrigerant from the
system into the outdoor unit. Possible consequence:
Self-combustion and explosion of the compressor
because of air going into the operating compressor.
▪ Use a separate recovery system so that the unit's
compressor does NOT have to operate.
WARNING
Always recover the refrigerant. Do NOT release them
directly into the environment. Use a vacuum pump to
evacuate the installation.
NOTICE
After all the piping has been connected, make sure there is
no gas leak. Use nitrogen to perform a gas leak detection.
NOTICE
▪ To avoid compressor breakdown, do NOT charge more
than the specified amount of refrigerant.
▪ When the refrigerant system is to be opened,
refrigerant must be treated according to the applicable
legislation.
WARNING
Make sure there is no oxygen in the system. Refrigerant
may only be charged after performing the leak test and the
vacuum drying.
▪ In case re-charge is required, refer to the nameplate of the unit. It
states the type of refrigerant and necessary amount.
▪ The unit is factory charged with refrigerant and depending on pipe
sizes and pipe lengths some systems require additional charging
of refrigerant.
▪ Only use tools exclusively for the refrigerant type used in the
system, this to ensure pressure resistance and prevent foreign
materials from entering into the system.
▪ Charge the liquid refrigerant as follows:
If Then
A siphon tube is present
(i.e., the cylinder is marked with
"Liquid filling siphon attached")
A siphon tube is NOT present Charge with the cylinder upside
Charge with the cylinder upright.
down.
CAUTION
When the refrigerant charging procedure is done or when
pausing, close the valve of the refrigerant tank
immediately. If the valve is not closed immediately,
remaining pressure might charge additional refrigerant.
Possible consequence: Incorrect refrigerant amount.
1.3.4 Brine
If applicable. See the installation manual or installer reference guide
of your application for more information.
WARNING
The selection of the brine MUST be in accordance with the
applicable legislation.
WARNING
Take sufficient precautions in case of brine leakage. If
brine leaks, ventilate the area immediately and contact
your local dealer.
WARNING
The ambient temperature inside the unit can get much
higher than that of the room, e.g. 70°C. In case of a brine
leak, hot parts inside the unit can create a hazardous
situation.
WARNING
The use and installation of the application MUST comply
with the safety and environmental precautions specified in
the applicable legislation.
1.3.5 Water
If applicable. See the installation manual or installer reference guide
of your application for more information.
NOTICE
Make sure water quality complies with EU directive
98/83EC.
1.3.6 Electrical
DANGER: RISK OF ELECTROCUTION
▪ Turn OFF all power supply before removing the
switch box cover, connecting electrical wiring or
touching electrical parts.
▪ Disconnect the power supply for more than 1 minute,
and measure the voltage at the terminals of main circuit
capacitors or electrical components before servicing.
The voltage MUST be less than 50 V DC before you
can touch electrical components. For the location of the
terminals, see the wiring diagram.
▪ Do NOT touch electrical components with wet hands.
▪ Do NOT leave the unit unattended when the service
cover is removed.
▪ Open refrigerant cylinders slowly.
▪ Charge the refrigerant in liquid form. Adding it in gas form may
prevent normal operation.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
WARNING
If NOT factory installed, a main switch or other means for
disconnection, having a contact separation in all poles
providing full disconnection under overvoltage category III
condition, MUST be installed in the fixed wiring.
Installer and user reference guide
5
2 About the documentation
WARNING
▪ ONLY use copper wires.
▪ Make sure the field wiring complies with the applicable
legislation.
▪ All field wiring must be performed in accordance with
the wiring diagram supplied with the product.
▪ NEVER squeeze bundled cables and make sure they
do not come in contact with the piping and sharp
edges. Make sure no external pressure is applied to the
terminal connections.
▪ Make sure to install earth wiring. Do NOT earth the unit
to a utility pipe, surge absorber, or telephone earth.
Incomplete earth may cause electrical shock.
▪ Make sure to use a dedicated power circuit. NEVER
use a power supply shared by another appliance.
▪ Make sure to install the required fuses or circuit
breakers.
▪ Make sure to install an earth leakage protector. Failure
to do so may cause electric shock or fire.
▪ When installing the earth leakage protector, make sure
it is compatible with the inverter (resistant to high
frequency electric noise) to avoid unnecessary opening
of the earth leakage protector.
NOTICE
Precautions when laying power wiring:
▪ Do not connect wiring of different thicknesses to the
power terminal block (slack in the power wiring may
cause abnormal heat).
▪ When connecting wiring which is the same thickness,
do as shown in the figure below.
▪ For wiring, use the designated power wire and connect
firmly, then secure to prevent outside pressure being
exerted on the terminal board.
▪ Use an appropriate screwdriver for tightening the
terminal screws. A screwdriver with a small head will
damage the head and make proper tightening
impossible.
▪ Over-tightening the terminal screws may break them.
Install power cables at least 1metre away from televisions or radios
to prevent interference. Depending on the radio waves, a distance of
1metre may not be sufficient.
WARNING
▪ After finishing the electrical work, confirm that each
electrical component and terminal inside the electrical
components box is connected securely.
▪ Make sure all covers are closed before starting up the
unit.
NOTICE
Only applicable if the power supply is three‑phase, and the
compressor has an ON/OFF starting method.
If there exists the possibility of reversed phase after a
momentary black out and the power goes on and off while
the product is operating, attach a reversed phase
protection circuit locally. Running the product in reversed
phase can break the compressor and other parts.
2 About the documentation
2.1 About this document
INFORMATION
Make sure that the user has the printed documentation and
ask him/her to keep it for future reference.
Target audience
Authorised installers + end users
INFORMATION
This appliance is intended to be used by expert or trained
users in shops, in light industry and on farms, or for
commercial use by lay persons.
Documentation set
This document is part of a documentation set. The complete set
consists of:
▪ General safety precautions:
▪ Safety instructions that you must read before installing
▪ Format: Paper (in the box of the outdoor unit)
▪ Outdoor unit installation and operation manual:
▪ Installation and operation instructions
▪ Format: Paper (in the box of the outdoor unit)
▪ Installer and user reference guide:
▪ Preparation of the installation, reference data,…
▪ Detailed step-by-step instructions and background information
for basic and advanced usage
▪ Format: Digital files on http://www.daikineurope.com/support-
and-manuals/product-information/
Latest revisions of the supplied documentation may be available on
the regional Daikin website or via your dealer.
The original documentation is written in English. All other languages
are translations.
Technical engineering data
▪ A subset of the latest technical data is available on the regional
Daikin website (publicly accessible).
▪ The full set of latest technical data is available on the Daikin
extranet (authentication required).
Installer and user reference guide
6
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
For the installer
e
d
a
c
c
b
1× 8×
a d ec
1×
b
1× 1×
f g
h
2× 1×
i
1×1×/2×
3 About the box
3.1 Overview: About the box
This chapter describes what you have to do after the box with the
outdoor unit is delivered on-site.
It contains information about:
▪ Unpacking and handling the outdoor unit
▪ Removing the accessories from the unit
Keep the following in mind:
▪ At delivery, the unit must be checked for damage. Any damage
must be reported immediately to the carrier's claims agent.
▪ Bring the packed unit as close as possible to its final installation
position to prevent damage during transport.
▪ When handling the unit, take into account the following:
Fragile, handle the unit with care.
Keep the unit upright in order to avoid compressor
damage.
3 About the box
▪ Prepare the path along which you want to bring the unit inside in
advance.
▪ Lift the unit preferably with a crane and 2 belts of at least 8m long
as shown in the figure below. Always use protectors to prevent
belt damage and pay attention to the position of the unit's centre
of gravity.
a Packaging material
b Belt sling
c Protector
d Opening
e Forklift
NOTICE
Use a belt sling of ≤20mm wide that adequately bears the
weight of the unit.
▪ A forklift can only be used for transport as long as the unit remains
on its pallet as shown above.
3.2 Outdoor unit
3.2.2 To remove the accessories from the outdoor unit
Make sure that all accessories are available in the unit.
3.2.1 To unpack the outdoor unit
Remove the packaging material from the unit:
▪ Take care not to damage the unit when removing the shrink foil
with a cutter.
▪ Remove the 4 bolts fixing the unit to its pallet.
WARNING
Tear apart and throw away plastic packaging bags so that
nobody, especially children, can play with them. Possible
risk: suffocation.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
a General safety precautions
b Installation manual and operation manual (panel 3)
c Remote controller (panel 3)
d Main switch handle (panel 1)
e Tie wraps (panel 3)
f Shut-off valves (panel 3)
Installer and user reference guide
7
4 About the units and options
43
–5
–15
0
–10 0 5 20 25
LWE
T
A
A B C
D
B— —
Glycol
30%
B— —
Glycol
40%
C
0
35
25
5
–15
5 (EWC) 20 25 35 50
LWC
T
A
A B
g Threaded connection (panel 3) (1× for EWAQ
+EWYQ016~032, 2× for EWAQ+EWYQ040~064)
h Filter (panel 3)
i Elbow (panel 3)
4 About the units and options
4.1 Overview: About the units and options
This chapter contains information about:
▪ Identification of the outdoor unit
▪ Where the outdoor unit fits in the system layout
▪ With which indoor units and options you can combine the outdoor
units
4.2 Identification label: Outdoor unit
Location
The main components are the compressor, the air heat exchanger,
and the water heat exchanger.
The compressor circulates refrigerant into the heat exchangers.
▪ In cooling mode, the refrigerant transports the heat taken from the
water heat exchanger to the air heat exchanger where the heat is
released to the air.
▪ In heating mode, the refrigerant transports the heat taken from the
air heat exchanger to the water heat exchanger where the heat is
released to the water.
4.4 Operation range
Cooling
Model identification
Example: EW A Q 016 CA W P —H—
Code Explanation
EW Chiller
A/Y A=Air-to-water cooling-only model
Y=Air-to-water heat pump model
Q Refrigerant R410A
016 Capacity class
CA Model series
W Power supply: 3P, 400V
P/H Complete hydraulic package
N Basic hydraulic package
—H— Depends on option
4.3 About the outdoor unit
This installation manual concerns the packaged air-cooled water
chiller. The unit is intended for outdoor installation and can be
combined with fan coil units for air conditioning purposes, or it can
be used for supplying water for process cooling applications.
The units are available in 7 standard sizes with nominal capacities
ranging from 16.8 to 63 kW. All sizes are available as cooling only
unit (EWAQ) and as heat pump unit (EWYQ: cooling/heating).
The unit is designed to work in heating mode at ambient
temperatures from –15°C to 35°C and in cooling mode at ambient
temperatures from –15°C to 43°C.
Installer and user reference guide
8
TAAmbient temperature (°CDB)
LWE Leaving water evaporator temperature (°C)
OPB Option B— —
A Optional water + glycol operation range
B Standard water operation range
C Pull down area
D Protect the system against freezing by installing an optional
water piping heater tape or by filling up the system with a
glycol solution.
Glycol Glycol
Heating
TAAmbient temperature (°CDB)
LWC Leaving water condenser temperature (°C)
EWC Entering water condenser temperature (°C)
A Pull up area
B Standard water operation range
C Protect the system against freezing by installing an optional
water piping heater tape or by filling the system with a
glycol solution.
Glycol Glycol
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
5 Preparation
RC
RT1M1RT2M2RT3
M3
FC1 FC2 FC3
a b c e
e f
i
f f
g
d
4.5 System layout
a Outdoor unit
b Plate heat exchanger
c Expansion vessel
d Pump
e Shut-off valve
f Motorized valve
g Bypass valve
FC1…3 Fancoil unit (field supply)
RC Remote controller
RT1…3 Room thermostat
4.6 Combining units and options
4.6.1 About combining units and options
This packaged air-cooled water chiller can be combined with fan coil
units and is intended for R410A use only.
The demand PCB is used to remotely
▪ switch the unit on/off,
▪ select cooling/heating,
▪ select thermo on/off.
For installation instructions, see the installation manual of the
demand PCB and addendum book for optional equipment.
Electronic gauge kit (BHGP26A1)
To monitor pressures in the refrigerant system.
External control adaptor (DTA104A62)
To instruct specific operation with an external input coming from a
central control, the external control adaptor can be used. Instructions
(group or individual) can be given for low noise operation and power
consumption limitation operation.
5 Preparation
5.1 Overview: Preparation
This chapter describes what you have to do and know before going
on-site.
It contains information about:
▪ Preparing the installation site
▪ Preparing the water piping
▪ Preparing the electrical wiring
4.6.2 Possible options for the outdoor unit
INFORMATION
Refer to the technical engineering data for the latest option
names.
Factory mounted options Description
Hydraulic package (N) N (standard) contains flow
Hydraulic package (P) Identical to N plus pump,
High static pump (H) Identical to P but allows
Water piping heater tape (—H—) The water piping heater tape
Low temperature cooling (B— —) Allows to cool glycol solution
Low temperature cooling + water
piping heater tape (BH—)
Optional kits that are ordered with the unit will be delivered in a
separate box together with their specific manuals.
Remote controller (EKRUAHTB)
A second remote controller to control the unit from 2 locations.
Demand PCB (EKRP1AHTA)
To enable the power saving consumption control by digital inputs
you must install the demand PCB.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
switch, filter, shut-off valves,
pressure ports, drain/fill valve.
expansion vessel, safety valve,
pressure gauge.
operation in applications with
high pressure drops inside the
hydraulic system.
warms up to prevent freezing of
water inside the unit during
winter while the unit is at a
standstill.
(ethylene/propylene glycol +
water) down to –10°C.
Combination of the above
2options.
5.2 Preparing installation site
5.2.1 Installation site requirements of the outdoor unit
▪ Provide sufficient space around the unit for servicing and air
circulation.
▪ Make sure the installation site withstands the unit's weight and
vibration.
▪ Make sure the unit is level.
▪ Select a place where rain can be avoided as much as possible.
▪ Select the location of the unit in such a way that the sound
generated by the unit does not disturb anyone, and the location is
selected according the applicable legislation.
Do NOT install the unit in the following places:
▪ In potentially explosive atmospheres.
▪ In places where there is machinery that emits electromagnetic
waves. Electromagnetic waves may disturb the control system,
and cause malfunction of the equipment.
▪ In places where there is a risk of fire due to the leakage of
flammable gases (example: thinner or gasoline), carbon fibre,
ignitable dust.
▪ In places where corrosive gas (example: sulphurous acid gas) is
produced. Corrosion of copper pipes or soldered parts may cause
the refrigerant to leak.
▪ In places where a mineral oil mist, spray or vapour may be
present in the atmosphere. Plastic parts may deteriorate and fall
off or cause water leakage.
Installer and user reference guide
9
5 Preparation
b
c
a
a
b
c
d
c
d
c
NOTICE
This is a class A product. In a domestic environment this
product may cause radio interference in which case the
user may be required to take adequate measures.
CAUTION
Appliance NOT accessible to the general public, install it in
a secured area, protected from easy access.
This unit is suitable for installation in a commercial and
light industrial environment.
▪ When installing, take strong winds, typhoons or earthquakes into
account, improper installation may result in the unit turning over.
▪ Take care that in the event of a water leak, water cannot cause
any damage to the installation space and surroundings.
▪ Be sure that the air inlet of the unit is not positioned towards the
main wind direction. Frontal wind will disturb the operation of the
unit. If necessary, use a screen to block the wind.
▪ Ensure that water cannot cause any damage to the location by
adding water drains to the foundation and prevent water traps in
the construction.
Seaside installation. Make sure the outdoor unit is NOT directly
exposed to sea winds. This is to prevent corrosion caused by high
levels of salt in the air, which might shorten the life of the unit.
Install the outdoor unit away from direct sea winds.
Example: Behind the building.
▪ To prevent exposure to wind and snow, install a baffle plate on the
air side of the outdoor unit:
In heavy snowfall areas it is very important to select an installation
site where the snow will NOT affect the unit. If lateral snowfall is
possible, make sure that the heat exchanger coil is NOT affected by
the snow. If necessary, install a snow cover or shed and a pedestal.
If the outdoor unit is exposed to direct sea winds, install a
windbreaker.
▪ Height of windbreaker≥1.5×height of outdoor unit
▪ Mind the service space requirements when installing the
windbreaker.
a Sea wind
b Building
c Outdoor unit
d Windbreaker
5.2.2 Additional installation site requirements of the outdoor unit in cold climates
INFORMATION
For instructions on how to install the snow cover, contact
your dealer.
NOTICE
When installing the snow cover, do NOT obstruct the air
flow of the unit.
5.3 Preparing water piping
5.3.1 Water circuit requirements
INFORMATION
Also read the precautions and requirements in the
"General safety precautions" chapter.
NOTICE
In case of plastic pipes, make sure they are fully oxygen
diffusion tight according to DIN 4726. The diffusion of
oxygen into the piping can lead to excessive corrosion.
▪ Connecting piping – Legislation. Make all piping connections in
accordance with the applicable legislation and the instructions in
the "Installation" chapter, respecting the water inlet and outlet.
▪ Connecting piping – Force. Do NOT use excessive force when
connecting the piping. Deformation of the piping can cause
malfunctioning of the unit.
▪ Connecting piping – Tools. Only use appropriate tooling to
handle brass, which is a soft material. If NOT, pipes will get
damaged.
NOTICE
When operating the unit in a low outdoor ambient
temperature, be sure to follow the instructions described
below.
Installer and user reference guide
10
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
5 Preparation
a
b
a
c
d
b
▪ Connecting piping – Air, moisture, dust. If air, moisture or dust
gets into the circuit, problems may occur. To prevent this:
▪ Only use clean pipes
▪ Hold the pipe end downwards when removing burrs.
▪ Cover the pipe end when inserting it through a wall, to prevent
dust and/or particles entering the pipe.
▪ Use a decent thread sealant to seal connections.
NOTICE
If glycol is present in the system, make sure the thread
sealant used is resistant to glycol.
▪ Closed circuit. Use the outdoor unit ONLY in a closed water
system. Using the system in an open water system will lead to
excessive corrosion.
▪ Water flow. You can find the minimum required water flow in the
following table. In all cases, this flow needs to be guaranteed.
When the flow is lower, operation will stop and error
displayed.
Capacity class Minimum required flow rate
016+021+025 23 l/min
032 36 l/min
040+050 46 l/min
064 72 l/min
▪ Field supply components – Water pressure and temperature.
Check that all components in the field piping can withstand the
water pressure and water temperature.
▪ Drainage – Low points. Provide drain taps at all low points of the
system in order to allow complete drainage of the water circuit.
▪ Non-brass metallic piping. When using non-brass metallic
piping, insulate the brass and non-brass properly so that they do
NOT make contact with each other. This to prevent galvanic
corrosion.
▪ Shut-off valves. Two shut-off valves are delivered with the unit.
Install them as shown in the following figure.
will be
NOTICE
If the bend is not used during installation, replace it with an
extension (5cm long for a 1¼"filter, and 6 cm long for a
2"filter) to ensure proper cleaning operation of the filter.
NOTICE
Be sure to install the filter properly. Failure to install or
incorrect installation will damage the plate heat exchanger
permanently.
▪ Drain taps. Drain taps must be provided at all low points of the
system to permit complete drainage of the circuit. A drain valve is
provided inside the unit.
▪ Air vents. Provide air vents at all high points of the system, which
must also be easily accessible for servicing. An automatic air
purge valve is provided inside the unit. Check that this air purge
valve is NOT tightened too much, so that automatic release of air
from the water circuit is possible. Refer to field setting[E‑04] in
"7.2.9Field settings on the remote controller"on page23.
▪ Water pressure. Take care that the components installed in the
field piping can withstand the water pressure (maximum 3 bar +
static pressure of the pump). Refer to "12.8ESP curve: Outdoor
unit"on page39.
WARNING
▪ For correct operation of the system, a regulating valve
must be installed in the water system. The regulating
valve is to be used to regulate the water flow in the
system (field supply).
▪ Selecting a flow outside the curves can cause
malfunction or damage to the unit. Also refer to the
Technical specifications.
▪ The maximum water piping temperature is 50°C according to
safety device setting.
▪ Always use materials which are compatible with the water used in
the system and with the materials used in the unit. (The unit piping
fittings are made of brass, the plate heat exchangers are made of
stainless steel 316 plates brazed together with copper and the
optional pump housing is made of cast iron.)
▪ Select the piping diameter in relation to the required water flow
and available external static pressure (ESP) of the pump. See the
following table for the recommended water piping diameter.
a Adapter piece (on the inlet only in case of EWAQ
+EWYQ040~064)
b Shut-off valve
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
c Bend
d Filter
NOTICE
Before mounting the bend, attach the filter to it.
Capacity class Water piping diameter
016~032 1-1/4"
040~064 2"
NOTICE
It is strongly recommended to install an additional filter on
the water circuit. Especially to remove metallic particles
from the field water piping, it is advised to use a magnetic
or cyclone filter which can remove small particles. Small
particles can damage the unit and will not be removed by
the standard filter of the unit.
5.3.2 Formula to calculate the expansion vessel pre-pressure
The pre-pressure (Pg) of the vessel depends on the installation
height difference (H):
Pg=0.3+(H/10) (bar)
5.3.3 To check the water volume and expansion vessel pre-pressure
The unit has an expansion vessel of 12 litre with a default prepressure of 1bar.
Installer and user reference guide
11
5 Preparation
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5
9
a
b
0
0,5
1
1,5
2
2,5
3
0 50 100 150 200 250 300 350 400 450 500 550 600
A
B
F
C
E
33
b
D
a
To make sure that the unit operates properly:
▪ You must check the minimum and maximum water volume.
▪ You might need to adjust the pre-pressure of the expansion
vessel.
Minimum water volume
Cooling only model Minimum total water volume (l)
016~032 33
040~064 66
Heat pump model Minimum total water volume (l)
016~025 76
032 110
040+050 152
064 220
INFORMATION
In critical processes, or in rooms with a high heat load,
extra water might be required.
INFORMATION
The temperature step difference can be modified using
settings [A‑02] and [F‑00]. This has an impact on the
minimum water volume required when the unit operates in
cooling.
By default, the unit is set to have a water temperature
difference of 3.5 K which allows it to operate with the
minimum volume mentioned in the previous table.
However, if a smaller temperature differential is set, as in
the case of process cooling applications where
temperature fluctuations must be avoided, a larger
minimum water volume will be required.
To ensure proper operation of the unit when changing the
values of setting [F‑00] (for cooling mode), the minimum
water volume has to be corrected. If this volume exceeds
the range allowed in the unit, an additional expansion
vessel or a buffer tank must be installed in the field piping.
Example:
To illustrate the impact on the system when modifying the setting
[F‑00], we will consider a unit with a minimum allowable water
volume of 66l. The unit is installed 5m below the highest point in
the water circuit and is charged with 30% of ethylene glycol.
Assuming that the setting [F‑00] is changed from 5°C (default value)
to 0°C. From the below table we see that 5°C corresponds to a
temperature differential of 3.5K and 0°C to 1K, which is actually the
lowest value we can set.
[F‑00] value (°C) Temperature differential (K)
14 8
15 8.5
The water volume correction factor according to the curve shown in
the below graph is 3.5; this means that the minimum volume will be
3.5 times larger.
Correction factor curve for minimum water volume
a Water volume correction factor
b Temperature differential (K)
When multiplying 64 l by the correction factor, we get 224 l, which
will be the minimum water volume allowed in the installation if a
temperature differential of 1K is used.
Now it is very important to check that for the height difference of the
system, the volume in the system is less than the maximum allowed
value at that pre-pressure (Pg). If we take a look at the ethylene
glycol concentration curve of 30%, for 1 bar of pre-pressure the
maximum volume allowed is 240l.
The total volume in the system will definitely be larger after adding
the internal volume of the unit. In this case, some pre-pressure can
be applied or an additional expansion vessel or buffer tank must be
installed in the field piping.
Maximum water volume
Use the following graph to determine the maximum water volume for
the calculated pre-pressure.
[F‑00] value (°C) Temperature differential (K)
0 1
1 1.5
2 2
3 2.5
4 3
5 3.5
6 4
7 4.5
8 5
9 5.5
10 6
11 6.5
12 7
13 7.5
Installer and user reference guide
12
a Pre-pressure (bar)
b Maximum water volume (l) (water or water + glycol)
A System without glycol
B System with 30% ethylene glycol
C System with 40% ethylene glycol
D System with 30% propylene glycol
E System with 40% propylene glycol
F Default
If the total water volume in the entire circuit exceeds the maximum
allowed water volume (see graph), an additional expansion vessel
must be installed in the field piping.
The default value of pre-pressure (Pg) is for a height difference of
7m.
If the height difference of the system is lower than 7 m AND the
volume in the system is less than the maximum allowed value at that
pre-pressure (Pg) (see graph), then NO pre-pressure (Pg)
adjustment is required.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
5 Preparation
a
5.3.4 Changing the pre-pressure of the expansion vessel
NOTICE
Only a licensed installer may adjust the pre-pressure of the
expansion vessel.
When changing the default pre-pressure of the expansion vessel
(1bar) is required, take following guidelines into account:
▪ Only use dry nitrogen to set the expansion vessel pre-pressure.
▪ Inappropriate setting of the expansion vessel pre-pressure will
lead to malfunction of the system.
Changing the pre-pressure of the expansion vessel should be done
by releasing or increasing nitrogen pressure through the Schrader
valve of the expansion vessel.
a Schrader valve
5.3.5 To check the water volume: Examples
Example 1
The unit is installed 5m below the highest point in the water circuit.
The total water volume in the water circuit is 250l.
No actions or adjustments are required.
Example 2
The unit is installed at the highest point in the water circuit. The total
water volume in the water circuit (no glycol used) is 420l.
Actions:
▪ Because the total water volume (420l) is more than the default
water volume (340l), the pre-pressure must be decreased.
▪ The required pre-pressure is:
Pg=(0.3+(H/10))bar=(0.3+(0/10))bar=0.3bar
▪ The corresponding maximum water volume is approximately 490l
(see graph).
▪ Because 420 l is lower than 490 l, the expansion vessel is
appropriate for the installation.
5.4 Preparing electrical wiring
5.4.1 About electrical compliance
This equipment complies with:
▪ EN/IEC 61000‑3‑11 provided that the system impedance Z
less than or equal to Z
at the interface point between the user's
max
is
sys
supply and the public system.
▪ EN/IEC 61000‑3‑11 = European/International Technical
Standard setting the limits for voltage changes, voltage
fluctuations and flicker in public low-voltage supply systems for
equipment with rated current ≤75A.
▪ It is the responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply
with a system impedance Z
less than or equal to Z
sys
max
.
▪ EN/IEC 61000‑3‑12 provided that the short-circuit power Ssc is
greater than or equal to the minimum Ssc value at the interface
point between the user's supply and the public system.
▪ EN/IEC 61000‑3‑12 = European/International Technical
Standard setting the limits for harmonic currents produced by
equipment connected to public low-voltage systems with input
current >16A and ≤75A per phase.
▪ It is the responsibility of the installer or user of the equipment to
ensure, by consultation with the distribution network operator if
necessary, that the equipment is connected only to a supply
with a short-circuit power Ssc greater than or equal to the
minimum Ssc value.
Model Z
(Ω) Minimum Ssc value
max
(kVA)
EWAQ/EWYQ016 — 1016
EWAQ/EWYQ021 0.27 820
EWAQ/EWYQ025 0.27 821
EWAQ/EWYQ032 0.24 874
EWAQ/EWYQ040 0.25 1639
EWAQ/EWYQ050 0.25 1630
EWAQ/EWYQ064 0.22 1747
5.4.2 Cable requirements
Item Cable
bundle
1 PS Power supply 4+GND
2 LV Standard remote controller (F1/F2) 2
3 LV Secondary remote controller (F1/F2)
4 LV Thermostat ON/OFF signal
5 LV Thermostat cooling/heating signal
6 LV Operation ON signal
7 LV Operation OFF signal
8 HV Cooling/heating output 2 0.3 A
9 HV Operation ON/OFF output 2 0.3 A
10 HV Error output 2 0.3 A
11 HV Water piping heater output 2 1 A
12 HV Pump ON/OFF output 2 0.3 A
(a) Optional
(b) Refer to the nameplate on the unit or to the technical data
book.
(c) Minimum cable section 0.75mm2.
(d) Only for models with pump (EWAQ*CAW(P/H)* and
EWYQ*CAW(P/H)* units).
PS Power supply
LV Low voltage
HV High voltage
Description Required
(a)
(a)
(a)
(a)
(a)
number of
conductors
2
2
2
2
2
Maximum
running
current
(b)
(c)
(c)
(c)
(c)
(c)
(c)
(d)
5.4.3 Safety device requirements
The power supply must be protected with the required safety
devices, i.e. a main switch, a slow blow fuse on each phase and an
earth leakage protector in accordance with the applicable legislation.
Selection and sizing of the wiring should be done in accordance with
the applicable legislation based on the information mentioned in the
table below.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
Installer and user reference guide
13
6 Installation
1
3
2
4
5
4
5
INFORMATION
Multi units are standard combinations.
Model Recommended fuses
EWAQ/EWYQ016 25A
EWAQ/EWYQ021 32A
EWAQ/EWYQ025 32A
EWAQ/EWYQ032 40A
EWAQ/EWYQ040 50A
EWAQ/EWYQ050 63A
EWAQ/EWYQ064 80A
NOTICE
When using residual current operated circuit breakers, be
sure to use a high-speed type 300 mA rated residual
operating current.
6 Installation
6.1 Overview: Installation
This chapter describes what you have to do and know on-site to
install the system.
Typical workflow
Installation typically consists of the following stages:
▪ Mounting the outdoor unit
▪ Connecting the water piping
▪ Connecting the electrical wiring
Panel
4 Outdoor module (left panel)
5 Outdoor module (right panel)
Once the front plates open, the electrical component box can be
accessed. See "6.2.2 To open the electrical component box of the
outdoor unit"on page14.
For service purposes, the pushbuttons on the main PCB need to be
accessed. To access these pushbuttons, the electrical component
box cover does not need to be opened. See "7.2.3To access the
field setting components"on page21.
6.2.2 To open the electrical component box of the outdoor unit
NOTICE
Do NOT apply excessive force when opening the
electronic component box cover. Excessive force can
deform the cover, resulting in entering of water to cause
equipment failure.
6.2 Opening the units
6.2.1 To open the outdoor unit
DANGER: RISK OF ELECTROCUTION
DANGER: RISK OF BURNING
To gain access to the unit, front plates need to be opened as follows:
Panel
1 Electrical parts of the hydro module
2 Hydro module (side panel)
3 Hydro module (front panel)
Installer and user reference guide
14
6.3 Mounting the outdoor unit
6.3.1 About mounting the outdoor unit
When
You have to mount the outdoor unit before you can connect the
water piping.
Typical workflow
Mounting the outdoor unit typically consists of the following stages:
1 Providing the installation structure.
2 Installing the outdoor unit.
3 Providing drainage.
4 Protecting the unit against snow and wind by installing a snow
cover and baffle plates. See "Preparing installation site" in
"5Preparation"on page9.
6.3.2 To provide the installation structure
Make sure the unit is installed level on a sufficiently strong base to
prevent vibration and noise.
NOTICE
When the installation height of the unit needs to be
increased, do NOT use stands to only support the corners.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
≥100 ≥100
≥100 ≥100
X Not allowed
729
765
765
631
A
B
729
765
765
631
A
B
C B
a
b
c
d
e
f
c
a
b
c
d
e
f
c
440
440
20 mm
a
O Allowed (* = preferred installation)
▪ The height of the foundation must at least be 150 mm from the
floor. In heavy snowfall areas, this height should be increased,
depending on the installation place and condition.
▪ The preferred installation is on a solid longitudinal foundation
(steel beam frame or concrete). The foundation must be larger
than the grey marked area.
6 Installation
NOTICE
▪ Prepare a water drainage channel around the
foundation to drain waste water from around the unit.
During heating operation and when the outdoor
temperatures are negative, the drained water from the
outdoor unit will freeze up. If the water drainage is not
taken care of, the area around the unit might be very
slippery.
▪ When installed in a corrosive environment, use a nut
with plastic washer (a) to protect the nut tightening part
from rust.
6.3.3 Precautions when mounting the outdoor unit
INFORMATION
Also read the precautions and requirements in the
following chapters:
▪ General safety precautions
▪ Preparation
Minimum foundation
a Hole for foundation bolt
b Base inner dimension
c Distance between foundation bolt holes
d Depth of unit
e Base outer dimension
f Longitudinal foundation dimension
kW A B C
16~25 1340 792 —
32 1650 1102 —
40+50 2320 792 192
64 2940 1102 192
▪ Fasten the unit in place using four foundation bolts M12. It is best
to screw in the foundation bolts until their length remains 20mm
above the foundation surface.
6.4 Connecting the water piping
6.4.1 About connecting the water piping
Before connecting the water piping
Make sure the outdoor unit is mounted.
Typical workflow
Connecting the water piping typically consists of the following
stages:
1 Connecting the water piping of the outdoor unit.
2 Filling the water circuit.
3 Protecting the water circuit against freezing (addition of glycol).
4 Insulating the water piping.
6.4.2 Precautions when connecting the water piping
INFORMATION
Also read the precautions and requirements in the
following chapters:
▪ General safety precautions
▪ Preparation
To connect the water piping
Water connections must be made in accordance with all applicable
legislations and the outlook drawing delivered with the unit,
respecting the water inlet and outlet.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
NOTICE
Do NOT use excessive force when connecting the piping.
Deformation of the piping can cause malfunctioning of the
unit.
If dirt gets in the water circuit, problems may occur. Therefore,
always take into account the following when connecting the water
circuit:
Installer and user reference guide
15
6 Installation
▪ Use clean pipes only.
▪ Hold the pipe end downwards when removing burrs.
▪ Cover the pipe end when inserting it through a wall so that no dust
and dirt enter.
▪ Use a good thread sealant for the sealing of the connections. The
sealing must be able to withstand the pressures and temperatures
of the system; it must also be resistant to the used glycol in the
water.
▪ When using non-brass metallic piping, make sure to insulate both
materials from each other to prevent galvanic corrosion.
▪ Make sure to provide a proper drain for the pressure relief valve.
▪ Because brass is a soft material, use appropriate tooling for
connecting the water circuit. Inappropriate tooling will cause
damage to the pipes.
▪ For correct operation of the system, a regulating valve must be
installed in the water system. The regulating valve is to be used to
regulate the water flow in the system (field supply).
6.4.3 To fill the water circuit
1 Connect the water supply to the drain and fill valve.
2 Make sure the automatic air purge valve is open (at least 2
turns).
3 Fill with water until the pressure gauge indicates a pressure of
approximately 2.0 bar. Remove air in the circuit as much as
possible using the air purge valves (refer to field setting [E‑04]
in "7.2.9Field settings on the remote controller"on page23).
NOTICE
▪ Air in the water circuit can cause malfunctioning. During
filling, it may not be possible to remove all the air from
the circuit. Remaining air will be removed through the
automatic air purge valves during the initial operating
hours of the system. Additional filling with water
afterwards may be required.
▪ To purge the system, use the special function as
described in "8Commissioning"on page28.
NOTICE
The water pressure indicated on the manometer will vary
depending on the water temperature (higher pressure at
higher water temperature).
However, at all times water pressure shall remain above
1bar to avoid air entering the circuit.
NOTICE
Make sure water quality complies with EU directive
98/83EC.
6.4.4 To protect the water circuit against freezing
Frost can damage the system. For this reason, if negative ambient
temperatures are expected, make sure the water circuit is sufficiently
protected against freezing.
Heater tape (optional)
A heater tape is wound around the piping to protect vital parts of the
hydraulic system inside the unit.
This heater tape will only protect internal parts of the unit. It can not
protect field installed parts outside the unit.
Field heater tapes must be provided by the installer.
NOTICE
In case of a power failure or if the power supply is
disconnected during winter, the optional heater tape
cannot protect the unit from freezing. If a power failure can
happen at times the unit is unattended, if the power supply
is disconnected during winter, or if you did not select this
option, it is recommended to add glycol to the water
system.
Glycol
Refer to field setting [8‑04] in "7.2.9 Field settings on the remote
controller"on page23.
INFORMATION
The concentrations mentioned in the table below will
prevent the piping from bursting, but will not prevent the
liquid in the piping from freezing.
Depending on the expected lowest outdoor temperature, make sure
the water system is filled with a weight concentration of glycol as
mentioned in the following table.
Minimum outdoor
temperature
–5°C 10% 15%
–10°C 15% 20%
–15°C 20% 35%
WARNING
Ethylene glycol is toxic.
NOTICE
The above mentioned concentrations are applicable only
when the unit is at a standstill.
CAUTION
▪ In case of over-pressure when using glycol, be sure to
connect the safety valve to a drain pan in order to
recover the glycol. Connecting a drain pipe is not
required if no glycol is used. The discharged water is
then drained via the bottom of the unit.
▪ Using more than 40% glycol will damage the unit.
Ethylene glycol Propylene glycol
INFORMATION
The unit may dispose of some excessive water through the
pressure relief valve.
NOTICE
In case of a power supply failure or pump failure, and NO
glycol was added to the system, drain the system. When
water is at standstill inside the system, the system is very
likely to freeze and get damaged.
Installer and user reference guide
16
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
6 Installation
WARNING
Due to presence of glycol, corrosion of the system is
possible. Uninhibited glycol will turn acidic under the
influence of oxygen. This process is accelerated by the
presence of copper and high temperatures. The acidic
uninhibited glycol attacks metal surfaces and forms
galvanic corrosion cells that cause severe damage to the
system. Therefore it is important that:
▪ the water treatment is correctly executed by a qualified
water specialist,
▪ a glycol with corrosion inhibitors is selected to
counteract acids formed by the oxidation of glycols,
▪ no automotive glycol is used because their corrosion
inhibitors have a limited lifetime and contain silicates
which can foul or plug the system,
▪ galvanized pipes are NOT used in glycol systems since
the presence may lead to the precipitation of certain
components in the glycol's corrosion inhibitor.
NOTICE
Glycol absorbs water from its environment. Therefore do
NOT add glycol that has been exposed to air. Leaving the
cap off the glycol container causes the concentration of
water to increase. The glycol concentration is then lower
than assumed. As a result, the hydraulic components
might freeze up after all. Take preventive actions to ensure
a minimal exposure of the glycol to air.
See also "8.4Final check"on page29.
6.4.5 To insulate the water piping
The complete water circuit, inclusive all piping, must be insulated to
prevent condensation during cooling operation and reduction of the
heating and cooling capacity as well as prevention of freezing of the
outside water piping during winter time. The thickness of the
insulation materials must be at least 13 mm with λ=0.039W/mK in
order to prevent freezing of the outside water piping at ambient
temperature of –15°C.
If the temperature is higher than 30°C and the humidity is higher
than RH 80%, the thickness of the insulation materials should be at
least 20 mm to prevent condensation on the surface of the
insulation.
6.5 Connecting the electrical wiring
6.5.1 Precautions when connecting electrical wiring
DANGER: RISK OF ELECTROCUTION
WARNING
▪ ONLY use copper wires.
▪ Make sure the field wiring complies with the applicable
legislation.
▪ All field wiring must be performed in accordance with
the wiring diagram supplied with the product.
▪ NEVER squeeze bundled cables and make sure they
do not come in contact with the piping and sharp
edges. Make sure no external pressure is applied to the
terminal connections.
▪ Make sure to install earth wiring. Do NOT earth the unit
to a utility pipe, surge absorber, or telephone earth.
Incomplete earth may cause electrical shock.
▪ Make sure to use a dedicated power circuit. NEVER
use a power supply shared by another appliance.
▪ Make sure to install the required fuses or circuit
breakers.
▪ Make sure to install an earth leakage protector. Failure
to do so may cause electric shock or fire.
▪ When installing the earth leakage protector, make sure
it is compatible with the inverter (resistant to high
frequency electric noise) to avoid unnecessary opening
of the earth leakage protector.
Install power cables at least 1metre away from televisions or radios
to prevent interference. Depending on the radio waves, a distance of
1metre may not be sufficient.
WARNING
▪ After finishing the electrical work, confirm that each
electrical component and terminal inside the electrical
components box is connected securely.
▪ Make sure all covers are closed before starting up the
unit.
NOTICE
Do NOT operate the unit until the refrigerant piping is
complete. Running the unit before the piping is ready will
break the compressor.
NOTICE
If the power supply has a missing or wrong N-phase,
equipment will break down.
NOTICE
Do NOT install a phase advancing capacitor, because this
unit is equipped with an inverter. A phase advancing
capacitor will reduce performance and may cause
accidents.
WARNING
All field wiring and components must be installed by a
licensed electrician and must comply with the applicable
legislation.
WARNING
If NOT factory installed, a main switch or other means for
disconnection, having a contact separation in all poles
providing full disconnection under overvoltage category III
condition, MUST be installed in the fixed wiring.
EWAQ016~064CAW + EWYQ016~064CAW
Packaged air-cooled water chiller
4P497339-1 – 2017.07
NOTICE
NEVER remove a thermistor, sensor, etc., when
connecting power wiring and transmission wiring. (If
operated without thermistor, sensor, etc., the compressor
may break down.)
Installer and user reference guide
17
Loading...