Daikin EWWD 120 MBYNN, EWWD 180 MBYNN, EWWD 240 MBYNN, EWWD 280 MBYNN, EWWD 360 MBYNN Operation manuals

...
0 (0)

OPERATION MANUAL

Packaged water-cooled water chillers

EWWD120MBYNN

EWWD180MBYNN

EWWD240MBYNN

EWWD280MBYNN

EWWD360MBYNN

EWWD440MBYNN

EWWD500MBYNN

EWWD520MBYNN

EWWD540MBYNN

EWWD120MBYNN EWWD280MBYNN EWWD500MBYNN EWWD180MBYNN EWWD360MBYNN EWWD520MBYNN EWWD240MBYNN EWWD440MBYNN EWWD540MBYNN

Packaged water-cooled water chillers

Operation manual

CONTENTS

Page

Introduction .......................................................................................

1

Technical specifications .............................................................................

1

Electrical specifications .............................................................................

2

Description ........................................................................................

3

Function of the main components..............................................................

4

Safety devices............................................................................................

5

Internal wiring - Parts table........................................................................

5

Before operation................................................................................

6

Checks before initial start-up .....................................................................

6

Water supply..............................................................................................

7

Power supply connection and crankcase heating......................................

7

General recommendations ........................................................................

7

Operation ..........................................................................................

7

Digital controller .........................................................................................

7

Working with the unit .................................................................................

8

Advanced features of the digital controller...............................................

11

Troubleshooting ...............................................................................

17

Maintenance....................................................................................

20

Maintenance activities .............................................................................

20

Disposal requirements .............................................................................

20

READ THIS MANUAL ATTENTIVELY BEFORE STARTING UP THE UNIT. DO NOT THROW IT AWAY. KEEP IT IN YOUR FILES FOR FUTURE REFERENCE.

INTRODUCTION

This operation manual concerns packaged water-cooled water chillers of the Daikin EWWD-MBYNN series. These units are provided for indoor installation and used for cooling applications. The EWWD units can be combined with Daikin fan coil units or air handling units for air conditioning purposes. They can also be used for supplying water for process cooling.

This manual has been prepared to ensure adequate operation and maintenance of the unit. It will tell you how to use the unit properly and will provide help if problems occur. The unit is equipped with safety devices, but they will not necessarily prevent all problems caused by improper operation or inadequate maintenance.

In case of persisting problems contact your local Daikin Dealer.

Before starting up the unit for the first time, make sure that it has been properly installed. It is therefore necessary to carefully read the installation manual supplied with the unit and the recommendations listed in "Checks before initial start-up" on page 6.

Technical specifications(1)

General EWWD

 

120

180

240

Dimensions HxWxD

(mm)

 

1014x2672x930

 

Weight

 

 

 

 

• machine weight

(kg)

1000

1273

1527

• operation weight

(kg)

1032

1318

1588

Connections

 

 

 

 

• chilled water inlet

(inch)

3" OD

3" (88.9 mm OD)

and outlet(a)

(76 mm OD)

• condenser water inlet

(inch)

2-1/2"

3" (88.9 mm OD)

and outlet(a)

• pressure relief valve

(inch)

1x 1"

1x 1"

2x 1"

condenser

 

 

 

 

Compressor

 

 

 

 

Type

 

semi-hermetic single screw

Qtyxmodel

 

1x

1x

1x

 

ZHA5LMGUYE

ZHA7MSGUYE

ZHA7WSGUYE

 

 

Speed

(rpm)

 

2880

 

Oil type

 

 

FVC 68D

 

Oil charge volume

(l)

7.5+0–0.5

10+0–0.5

10+0–0.5

Condensor

 

 

 

 

Type

 

 

shell & tube

 

Qty x model

 

1x CDEW215

1x CDEW260

1x CDEW400

Evaporator

 

 

 

 

Type

 

brased plate heatexchanger

Qtyxmodel

 

1x AC120EQ-NP156 1x AC250EQ-NP96 1x AC250EQ-NP128

 

 

 

 

 

General EWWD

 

280

360

440

Dimensions HxWxD

(mm)

1014x2672x

2000x2672x930

 

930

 

 

 

 

Weight

 

 

 

 

• machine weight

(kg)

1623

2546

2800

• operation weight

(kg)

1693

2636

2906

Connections

 

 

 

 

• chilled water inlet

(inch)

3"

2x 3" (2x 88.9 mm OD)

and outlet(a)

(88.9 mm OD)

• condenser water inlet

(inch)

3"

2x 3" (2x 88.9 mm OD)

and outlet(a)

(88.9 mm OD)

• pressure relief valve

(inch)

2x 1"

2x 1"

3x 1"

condenser

 

 

 

 

Compressor

 

 

 

 

Type

 

semi-hermetic single screw

Qtyxmodel

 

1x

2x

1x ZHA7MSGUYE+

 

ZHA9LSGUYE

ZHA7MSGUYE

1x ZHA7WSGUYE

 

 

Speed

(rpm)

 

2880

 

Oil type

 

 

FVC 68D

 

Oil charge volume

(l)

14+0.5

2x 10+0.5

2x 10+0.5

 

 

–0

–0

–0

Condensor

 

 

 

 

Type

 

 

shell & tube

 

Qtyxmodel

 

1x CDEW450

2x CDEW260

1x CDEW400

 

1x CDEW260

 

 

 

 

Evaporator

 

 

 

 

Type

 

brased plate heatexchanger

Qtyxmodel

 

1x AC250EQ-NP162 2x AC250EQ-NP96

1x AC250EQ-NP96

 

 

 

 

1x AC250EQ-NP128

(a) Victaulic® coupling

 

(1) Refer to the engineering data book for the complete list of specifications.

 

 

Operation manual

EWWD120~540MBYNN

1

Packaged water-cooled water chillers

4PW22685-1

General EWWD

 

500

520

540

Dimensions HxWxD

(mm)

 

2000x2672x930

 

Weight

 

 

 

 

• machine weight

(kg)

3034

3150

3346

• operation weight

(kg)

3156

3281

3485

Connections

 

 

 

 

• chilled water inlet

(inch)

2x 3" (2x 88.9 mm OD)

and outlet(a)

• condenser water inlet

(inch)

2x 3" (2x 88.9 mm OD)

and outlet(a)

• pressure relief valve

(inch)

 

4x 1"

 

condenser

 

 

 

 

 

 

Compressor

 

 

 

 

Type

 

semi-hermetic single screw

Qtyxmodel

 

2x

1x ZHA7WSGUYE+

2x

 

ZHA7WSGUYE

1x ZHA9LSGUYE

ZHA9LSGUYE

 

 

Speed

(rpm)

 

2880

 

Oil type

 

 

FVC 68D

 

Oil charge volume

(l)

2x 10+0–0.5

10+0–0.5 +14+0–0.5

2x 14+0–0.5

Condensor

 

 

 

 

Type

 

 

shell & tube

 

Qtyxmodel

 

2x CDEW400

1x CDEW400

2x CDEW450

 

1x CDEW450

 

 

 

 

Evaporator

 

 

 

 

Type

 

brased plate heatexchanger

Qtyxmodel

 

2x AC250EQ-NP128

1x AC250EQ-NP128

2x AC250EQ-NP162

 

1x AC250EQ-NP162

 

 

 

 

 

(a) Victaulic® coupling

Electrical specifications(1)

Model EWWD

 

120

180

240

280

360

440

500

520

540

 

Power supply

 

 

 

 

 

 

 

 

 

 

 

• Phase

 

 

 

 

 

 

3~

 

 

 

 

• Frequency

 

(Hz)

 

 

 

 

50

 

 

 

 

• Voltage

 

(V)

 

 

 

 

400

 

 

 

 

• Voltage tolerance

 

(%)

 

 

 

 

±10

 

 

 

 

Unit

 

 

 

 

 

 

 

 

 

 

 

• Nominal running

 

(A)

48

78

108

118

156

186

216

226

236

current

 

 

 

 

 

 

 

 

 

 

 

 

• Maximum running

 

(A)

76

120

174

184

240

294

348

358

368

current

 

 

 

 

 

 

 

 

 

 

 

 

• Recommended fuses

 

(gL)

3x 100

3x 160

3x 200

3x 200

2x 3x 200

3x 200+3x 250

2x 3x 250

2x 3x 250

2x 3x 250

according to IEC 269-2

 

 

 

 

 

 

 

 

 

 

 

 

Compressor

 

 

 

 

 

 

 

 

 

 

 

• Phase

 

 

 

 

 

 

3~

 

 

 

 

• Frequency

 

(Hz)

 

 

 

 

50

 

 

 

 

• Voltage

 

(V)

 

 

 

 

400

 

 

 

 

• Nominal running current

(A)

48

78

108

118

78+78

78+108

108+108

108+118

118+118

Control and fan motor

 

 

 

 

 

 

 

 

 

 

• Phase

 

 

 

 

 

 

1~

 

 

 

 

• Frequency

 

(Hz)

 

 

 

 

50

 

 

 

 

• Voltage

 

(V)

 

 

 

 

230

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(1) Refer to the engineering data book for the complete list of specifications.

EWWD120~540MBYNN

Operation manual

Packaged water-cooled water chillers

2

4PW22685-1

DESCRIPTION

The EWWD water-cooled water chillers are available in 9 standard sizes.

 

300

 

700

<![if ! IE]>

<![endif]>850

<![if ! IE]>

<![endif]>500

16

 

9

900

 

18

 

<![if ! IE]>

<![endif]>1000 600

 

7

6

 

 

11 8

 

 

9

 

 

 

 

3

 

 

 

 

22

4 21 20

23

 

 

 

5

10

1

2

30 28 29

13

12

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

<![if ! IE]>

<![endif]>EWWD360~540

 

<![if ! IE]>

<![endif]>EWWD120~280

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

19

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

26

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

29

 

 

 

 

 

 

 

 

 

 

17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30 28 29

 

 

 

 

 

19

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

7

26

11 8 24

 

 

9

3

24

22

27

4

 

 

23

 

25

5

10

1

2

29

 

 

 

12

13

17

 

 

 

 

Figure - Main components

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

Compressor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

17

 

Leaving water temperature sensor

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

Evaporator

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

18

 

Discharge stopvalve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

Condenser

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

19

 

Condensor entering water temperature sensor

 

 

 

 

 

 

 

 

 

 

4

 

 

Switchbox

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

20

 

Digital display controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

Compressor switchbox

 

 

 

 

 

 

 

 

 

 

 

 

21

 

Emergency stop

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

Air purge condenser

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

 

Power supply intake

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

 

Water drain condenser

 

 

 

 

 

 

 

 

 

 

 

 

23

 

Field wiring intake

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

Charge valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24

 

Holes for lifting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

Safety valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

25

 

Transportbeam

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

High pressure switch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

26

 

Ballvalve liquid pipe

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

11

 

Drier

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

27

 

Main isolator switch (optional)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12

 

Chilled water in (Victaulic® coupling)

 

 

 

 

 

 

 

 

28

 

Filter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13

 

Chilled water out (Victaulic® coupling)

 

 

 

 

 

 

 

 

29

 

Counterpipe for welding

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14

 

Condenser water out

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30

 

Flowswitch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

15

 

Condenser water in

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

Entering water temperature sensor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Required space around the unit for service

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Operation manual

EWWD120~540MBYNN

3

Packaged water-cooled water chillers

4PW22685-1

Daikin EWWD 120 MBYNN, EWWD 180 MBYNN, EWWD 240 MBYNN, EWWD 280 MBYNN, EWWD 360 MBYNN Operation manuals

Function of the main components

 

 

 

 

 

 

 

 

 

 

A

B1P

B

B3P

C

B1P

D

B4P

E

B6P

F

H

 

 

 

13

 

13

 

13

 

13

 

13

 

 

 

 

 

 

R9T

 

 

 

 

 

 

 

R10T

 

 

 

 

 

 

 

 

 

 

 

 

 

11

11

11

 

 

 

 

 

 

 

 

 

 

 

G

J

 

 

 

12

 

14

 

12

 

12

 

14

11

11

11

 

 

Y11S

 

 

 

 

 

 

 

 

 

 

Y21S

 

S1PH

S14PH

 

 

 

 

 

 

 

 

 

 

S2PH

S15PH

 

 

 

M1C

 

 

 

 

 

 

 

M2C

 

 

 

 

 

 

 

15

16

 

 

 

 

 

 

 

Y15S

 

 

(*)

 

R3T

 

 

 

(*)

 

Y25S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

9

5

 

 

 

 

4

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B2P

 

Y16S

 

 

 

 

 

 

 

 

Y26S

 

B5P

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

3

 

 

 

 

 

 

 

 

 

 

 

R4T

 

 

R6T

 

 

 

 

 

7

8

10

2

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R5T

 

 

 

 

 

 

 

S3T

 

 

 

 

 

 

 

 

 

 

 

 

S4T

 

 

 

 

 

(**)

 

 

 

 

(***)

 

 

 

 

 

EWWD120~280

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

EWWD360~540

 

 

 

 

 

Figure - Functional diagram

1

Evaporator

12

Expansion valve

(*)

See A~E

2

Condenser

13

Suction stop valve (option)

(**)

- Standard

3

Water out

14

Electronic expansion valve

 

(see F and G) only for EWWD120~180,360

 

- Dual pressure relief valve (OP03)

4

Water in

15

Flowswitch

 

 

(see H and J) only for EWWD240~280)

 

 

 

 

 

5

Drier

16

Filter

 

 

6

Discharge stop valve

 

 

(***)

- Standard

7

Charge valve

A

only for EWWD120~180

 

(see F and G) only for EWWD360 and 440

 

- Dual pressure relief valve (OP03)

8

Stop valve

B

only for EWWD240~280, EWWD440~540

 

 

(see H and J) only for EWWD500~540)

 

 

 

 

 

9

Strainer

C

only for EWWD360

 

 

10

Sightglass

D

only for EWWD440

 

 

11

Safety valve

E

only for EWWD500~540

 

 

As the refrigerant circulates through the unit, changes in its state or condition occur. These changes are caused by the following main components:

Compressor

The compressor (M*C) acts as a pump and circulates the refrigerant in the refrigeration circuit. It compresses the refrigerant vapour coming from the evaporator at the pressure at which it can easily be liquefied in the condenser.

Condenser

The function of the condenser is to change the state of the refrigerant from gaseous to liquid. The heat gained by the gas in the evaporator is discharged through the condenser to the ambient air, and the vapour condenses to liquid.

Filter / drier

The filter installed behind the condenser removes small particles from the refrigerant to prevent blockage of the tubes.

The drier takes water out of the system.

Expansion valve

The liquid refrigerant coming from the condenser enters the evaporator via an expansion valve. The expansion valve brings the liquid refrigerant to a pressure at which it can easily be evaporated in the evaporator.

Evaporator

The main function of the evaporator is to take heat from the water that flows through it. This is done by turning the liquid refrigerant, coming from the condenser, into gaseous refrigerant.

Water in/outlet connection

The water inlet and outlet connection allow an easy connection of the unit to the water circuit of the air handling unit or industrial equipment.

Flowswitch

The flowswitch protects the evaporator of the unit against freezing when there is no waterflow or when the waterflow is too low.

Waterfilter

The waterfilter protects the evaporator against clogging.

EWWD120~540MBYNN

Operation manual

Packaged water-cooled water chillers

4

4PW22685-1

Safety devices

The unit is equipped with three kinds of safety devices:

1General safety devices

General safety devices shut down all circuits and stop the whole unit. For this reason the unit has to be manually put on again after a general safety occurred.

2Circuit safety devices

Circuit safety devices shut down the circuit they protect. For this reason the unit does not need to be manually put on again after a circuit safety occurred.

3Part safety devices

Part safety devices shut down the part they protect.

An overview of all safety devices is given below.

Overcurrent relay

The overcurrent relays (K*S) are located in the switchbox of the unit and protect the compressor motors in case of overload, phase failure or too low voltage. The relays are factory-set and may not be adjusted. When activated, they must be reset manually, followed by a reset of the controller.

Compressor thermal protectors

The compressor motors are equipped with thermal protectors (Q*M). The protectors are activated when the compressor motor temperature becomes too high.

When temperature returns to normal, the protectors reset automatically, but the controller needs to be reset manually.

Flowswitch

The unit is protected by a flowswitch (S8L).

When the water flow becomes lower than the minimum allowed water flow, the flowswitch shuts down the unit. When the water flow becomes normal, the protection resets automatically but the controller still needs to be reset manually.

Discharge thermal protectors

The unit is equipped with discharge thermal protectors (S*T). The protectors are activated when the temperature of the refrigerant leaving the compressor becomes too high. When the temperature returns to normal the protector resets automatically and the controller needs to be reset manually.

Freeze-up protection

The freeze-up protection prevents the water in the evaporator from freezing during operation. When the outlet water temperature is too low, the controller shuts down the circuit. When the outlet water temperature returns to normal, the unit can start up again.

When freeze-up protection occurs several times in a certain period, the freeze-up alarm will be activated and the unit will be shut down. The cause of freezing up should be investigated and after outlet water temperature has risen enough, the alarm indicator on the controller needs to be reset manually.

Low pressure safety

When the suction pressure of a circuit is too low, the circuit controller shuts down the circuit. When the pressure returns to normal, the safety device can be reset on the controller.

Pressure relief safety valve

The safety valve is activated when the pressure in the refrigerant circuit becomes too high. If this occurs, shut down the unit and contact your local dealer.

High pressure switch

Each circuit is protected by two high pressure switches (S*PH) which measure the condenser pressure (pressure at the outlet of the compressor). They are installed in the compressor housing of the circuit. When the pressure becomes too high, the pressure switches are activated and the circuit stops.

The switches are factory-set and may not be adjusted. When activated, they must be reset by means of a screwdriver. The controller still needs to be reset.

Reverse phase protector

The reverse phase protectors (R*P) prevent the screw compressors from running in the wrong direction. If the compressors do not start, two phases of the power supply must be inverted.

Internal wiring - Parts table

Refer to the internal wiring diagram supplied with the unit. The abbreviations used are listed below:

A1,A2..........

** .......

Current transfo circuit 1, circuit 2

A1P........................

 

PCB-controller

A2P,A3P.................

 

PCB-EEV driver circuit 1, circuit 2

A11P......................

 

Expansion board controller

 

 

(only for EWWD360~540)

B1P,B4P.................

 

Low pressure transmitter for circuit 1, circuit 2

B2P,B5P.................

 

High pressure transmitter for circuit 1, circuit 2

B3P,B6P.................

 

Low pressure transmitter EEV for circuit 1 (A2P),

 

 

circuit 2 (A3P)

C11,C21 ................

 

Capacitor for capacity control

 

 

(only for EWWD360~540)

E1HC,E2HC

..........

Crankcase heater compressor circuit 1, circuit 2

F1R,F2R ................

 

Fuses for reverse phase protector circuit 1,

 

 

circuit 2

F1U~F3U....

# ........

Main fuses

F6B,F11B ..............

 

Fuse for primary of TR1

F7B ........................

 

Fuse for secondary of TR1

F8B ........................

 

Fuse for EEV driver

F8U........................

 

Surge proof fuse for A1P

F9B ........................

 

Surge proof fuse for secondary of TR2

F10B,F14B ............

 

Autofuse for secondary of TR2

F10S,F11S ............

 

Circuit breakers with fuses for circuit 1, circuit 2

 

 

(only for EWWD360~540)

F11U~F13U...........

 

Main fuses (only for EWWD360~540)

F21U~F23U...........

 

Main fuses (only for EWWD360~540)

H1P.............

*.........

Indication lamp general operation

H2P.............

*.........

Indication lamp alarm

H3P.............

*.........

Indication lamp operation compressor 1

H4P.............

*.........

Indication lamp operation compressor 2

 

 

(only for EWWD360~540)

H4P,H5P .....

*.........

Changeable output (only for EWWD120~280)

H5P,H6P .....

*.........

Changeable output (only for EWWD360~540)

J1...........................

 

Power supply

J2,J3,J6,J20

..........

Analog input

J4...........................

 

Analog output

J5,J7,J8,J19

..........

Digital input

J11.........................

 

RS485 connection

J12~J18,J21,J22 ...

Digital output

K1A,K4A ................

 

Auxiliary relay for safeties circuit 1, circuit 2

K1M,K4M...............

 

Linecontactor for circuit 1, circuit 2

K2A,K5A ................

 

Auxiliary relay compressor thermal protector

 

 

circuit 1, circuit 2

K2M,K5M...............

 

Deltacontactor for circuit 1, circuit 2

K3A,K6A ................

 

Auxiliary relay for discharge thermal protector

 

 

circuit 1, circuit 2

K3M,K6M...............

 

Starcontactor for circuit 1, circuit 2

K7A,K8A ................

 

Auxiliary relay for high pressure circuit 1, circuit 2

K17S,K18S ............

 

Overcurrent relay for circuit 1, circuit 2

L1,L2,L3.................

 

Main supply terminals

M1C,M2C ..............

 

Compressor motor circuit 1, circuit 2

Operation manual

EWWD120~540MBYNN

5

Packaged water-cooled water chillers

4PW22685-1

M1S,M2S...............

 

Stepless capacity control for compressor

 

 

circuit 1, circuit 2

 

PE..........................

 

Main earth terminal

 

Q1M,Q2M ..............

 

Thermal protector compressor motor

R1,R2 ....................

 

Auxiliary resistance for feedback

R1F,R2F.................

 

Feedback resistance for compressor circuit 1,

 

 

circuit 2

 

R1P,R2P ................

 

Reverse phase protector

 

R3T........................

 

Sensor for evaporator inlet water temperature

R4T,R6T ................

 

Sensor for evaporator outlet water temperature

 

 

circuit 1, circuit 2

 

R5T........................

 

Sensor for condensor inlet water temperature

R7T........................

 

Mixed outlet water temperature sensor (only for

 

 

EWWD360~540)

 

R8T........................

 

Sensor for evaporator outlet water in a DICN

 

 

system

 

R9T,R10T ..............

 

Temperature sensor EEV for circuit 1 (A2P),

 

 

circuit 2 (A3P)

 

S1PH,S2PH...........

 

High pressure switch circuit 1, circuit 2

S3T,S4T.................

 

Discharge thermal protector circuit 1, circuit 2

S5E........................

 

Emergency stop push button

S6S.............

*.........

Changeable switch for remote function

 

 

(e.g. remote start/stop)

 

S8L,S10L...............

 

Flowswicth circuit 1, circuit 2

S9L,S11L....

# ........

Contact that closes if the pump is working

S10S...........

*.........

Changeable switch for remote function

 

 

(e.g. dual setpoint)

 

S11S...........

*.........

Changeable switch for remote function

 

 

(e.g. enable/disable capacity limitation 1)

S12S...........

*.........

Changeable switch for remote function

 

 

(e.g. enable/disable capacity limitation 2)

S13S...........

## ......

Main isolator switch

 

S14PH,S15PH.......

High pressure switch

 

TC01,TC02 ............

 

Optocoupler (analog to digital signal) (only for

 

 

EWWD360~540)

 

TR1........................

 

Transfo control circuit

 

TR2........................

 

Transfo supply controller + digital inputs

V1 ...............

** .......

V-meter

 

V1F ........................

 

Filter for EEV

 

V2C~V5C ..............

 

Ferrite for EEV

 

X2A~X4A...............

 

Connector 24, 20, 16 pole to main switchbox

 

 

(only for EWWD360~540)

 

Y1E,Y2E ................

 

Electronic expantion valve circuit 1, circuit 2

Y11S,Y21S ............

 

12% capacity step for compressor circuit 1,

 

 

circuit 2

 

Y15S,Y25S ............

 

Liquid injection valve of the compressor circuit 1,

 

 

circuit 2

 

Y16S,Y26S ............

 

Liquid line solenoid valve circuit 1, circuit 2

 

 

 

 

 

 

Not included with standard unit

 

 

 

 

 

 

Not possible as option

 

Possible as option

 

 

 

 

Obligatory

#

 

##

 

 

 

 

Not obligatory

*

 

**

 

 

 

 

 

BEFORE OPERATION

Checks before initial start-up

Make sure that the circuit breaker on the power supply panel of the unit is switched off.

After the installation of the unit, check the following before switching on the circuit breaker:

1Field wiring

Make sure that the field wiring between the local supply panel and the unit has been carried out according to the instructions described in the installation manual, according to the wiring diagrams and according to European and national regulations.

2Additional pump interlock contact

Additional pump interlock contact (S9L) must be provided. Make sure that the contact has been installed between the appropriate terminals (refer to the wiring diagram supplied with the unit). The contact must be a normal open contact.

3Fuses or protection devices

Check that the fuses or the locally installed protection devices are of the size and type specified in the installation manual. Make sure that neither a fuse nor a protection device has been bypassed.

4Earth wiring

Make sure that the earth wires have been connected properly and that the earth terminals are tightened.

5Internal wiring

Visually check the switch box on loose connections or damaged electrical components.

6Fixation

Check that the unit is properly fixed, to avoid abnormal noises and vibrations when starting up the unit.

7Damaged equipment

Check the inside of the unit on damaged components or squeezed pipes.

8Refrigerant leak

Check the inside of the unit on refrigerant leakage. If there is a refrigerant leak, call your local dealer.

9Oil leak

Check the compressor on oil leakage. If there is an oil leak, call your local dealer.

10Stop valves

Open the liquid line, discharge and suction (if provided) stopvalves completely.

11Power supply voltage

Check the power supply voltage on the local supply panel. The voltage must correspond to the voltage on the identification label of the unit.

12Water connection

Check water piping system and circulating pumps.

Check if the filter kit that was supplied with the unit separately is installed correctly in front of the evaporator water inlet.

13Water sensors

Check that all the water sensors are correctly fixed into the pipes connected to the evaporator.

EWWD120~540MBYNN

Operation manual

Packaged water-cooled water chillers

6

4PW22685-1

Water supply

Fill the water piping, taking into account the minimum water volume required by the unit. Refer to the "installation manual".

Make sure that the water is of the quality as mentioned in the installation manual.

Purge the air at the high points of the system and check the operation of the circulation pump and the flowswitch.

Power supply connection and crankcase heating

In order to avoid compressor damage, it is necessary to switch on the crankcase heater for at least 8 hours before starting the compressor after a long period of standstill.

To switch on the crankcase heater proceed as follows:

1Switch on the circuit breaker on the local supply panel. Make sure that the unit is "OFF".

2The crankcase heater is switched on automatically.

3Check the supply voltage on the supply terminals L1, L2, L3, by means of a voltmeter. The voltage must correspond to the voltage indicated on the identification label of the unit. If the voltmeter reads values which are not within the ranges specified in the technical data, check the field wiring and replace the supply cables if necessary.

4Check the LED on the reverse phase protectors. If it lights up, the phase order is correct. If not, switch off the circuit breaker and call a licensed electrician to connect the wires of the power supply cable in the correct phase order.

5Check if the crankcaseheaters are warming up.

After 8 hours, the unit is ready for operation.

General recommendations

Before switching on the unit, read following recommendations:

1When the complete installation and all necessary settings have been carried out, close all front panels of the unit.

2The service panels of the switch boxes may only be opened by a licensed electrician for maintenance purposes.

3To prevent the evaporator from freezing and to avoid damage to the LCD displays of the digital controller, never switch off the power supply during winter.

Legibility of the alphanumeric display may decrease at low temperatures.

OPERATION

The EWWD120~540 units are equipped with a digital controller offering a user-friendly way to set up, use and maintain the unit.

This part of the manual has a task-oriented, modular structure. Apart from the first section, which gives a brief description of the controller itself, each section or subsection deals with a specific task you can perform with the unit.

Depending on the model there are one or two cooling circuits in the system. The models EWWD360~540 exist out of two circuits, whereas the models EWWD120~280 only have one circuit. These circuits are generally named C1 and C2 in the following descriptions. So all information about circuit 2 ( ) is not applicable for EWWD120~280 models.

Digital controller

User interface

The digital controller consists of an alphanumeric display, labelled keys which you can press and a number of LEDs.

Digital built-in controller

Figure - Digital built-in controller

Keys:

fkey, to enter the main menu

okey, to start up or to shut down the unit.

pkey, to enter the safeties menu or to reset an alarm.

g

keys, to scroll up or down through the screens of a menu

(only in case W, X or C appears) or to raise, respectively

h

lower a setting.

 

qkey, to confirm a selection or a setting.

Digital remote controller (to be ordered separately)

Figure - Digital controller

okey, to start up or to shut down the unit.

pkey, to enter the safeties menu or to reset an alarm.

kkey, to scroll through the screens of a menu (only in case W, X or C appears) or to raise, respectively lower a setting.

qkey, to confirm a selection or a setting.

ukey, to enter the readout menu.

skey, to enter the setpoints menu.

zkey, to enter the user settings menu.

ekey, to enter the timers menu.

rkey, to enter the history menu.

tkey, to enter the info menu.

ykey, to enter the input/output status menu.

Operation manual

EWWD120~540MBYNN

7

Packaged water-cooled water chillers

4PW22685-1

Loading...
+ 16 hidden pages