Daikin EWWP045KAW1M, EWWP055KAW1M, EWWP065KAW1M, ECB2MUAW, ECB3MUAW Operation manuals

OPERATION MANUAL

Packaged water-cooled water chillers

EWWP045KAW1M EWWP055KAW1M EWWP065KAW1M

ECB2MUAW ECB3MUAW

EWWP045KAW1M EWWP055KAW1M ECB2MUAW EWWP065KAW1M ECB3MUAW

Packaged water-cooled water chillers

Operation manual

CONTENTS Page

Introduction ....................................................................................... 1

Technical speciﬁcations ............................................................................. 2

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.............................................................................................. 6

General recommendations ........................................................................ 6

Operation 32~72 Hp.......................................................................... 6

Digital controller......................................................................................... 6

Working with the 32~72 Hp units............................................................... 6

Advanced features of the digital controller................................................. 9

Troubleshooting............................................................................... 14

Maintenance.................................................................................... 15

Important information regarding the refrigerant used .............................. 15

Maintenance activities ............................................................................. 15

Disposal requirements............................................................................. 15

READ THIS MANUAL ATTENTIVELY BEFORE STARTING UP THE UNIT. DO NOT THROW THIS MANUAL AWAY. KEEP IT IN YOUR FILES FOR FUTURE REFERENCE. Read the chapter "User settings menu" on page 9 before changing the parameters.

INTRODUCTION

This operation manual concerns packaged water-cooled water chillers of the Daikin EWWP-KA series. These units are provided for indoor installation and used for cooling and/or heating applications. The 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 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.

The English text is the original instruction. Other languages are translations of the original instructions.

This appliance is not intended for use by persons, including children, with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

Operation manual

EWWP045~065KAW1M + ECB2+3MUAW

Packaged water-cooled water chillers

4PW61664-1A - 2012.04

Technical speciﬁcations

General

Nominal cooling

(a)

capacity

Nominal input Dimensions HxWxD Machine weight

(b)

(1)

Hp 32 36 40 44 48 52 56 60 64 68 72

(kW)

86 99 112 121 130 142 155 168 177 186 195

(kW)

24.2 28.1 32.0 34.3 36.6 40.2 44.1 48.0 50.3 52.6 54.9

(mm)

(kg)

600 620 640 654 668 920 940 960 974 988 1002

1200x600x1200 1800x600x1200

Connections

• water inlet (inch)

• water outlet (inch)

2x 2x G 1-1/2 3x 2x G 1-1/2 2x 2x G 1-1/2 3x 2x G 1-1/2

Compressor

Ty pe hermetically sealed scroll

Qty x model

Speed

(rpm)

JT212DA-YE

JT212DA-YE +

2x JT300DA-YE

JT300DA-YE

JT300DA-YE +

2x JT335DA-YE

JT335DA-YE

JT212DA-YE

+ 2x

JT300DA-YE

JT212DA-YE

+ 4x

JT300DA-YE

2900 2900

JT300DA-YE

+ 2x

JT335DA-YE

JT300DA-YE

+ 4x

JT335DA-YE

Oil type FVC 68D FVC 68D Oil charge volume

(l)

4x 2.7 6x 2.7

Evaporator

Ty pe brased plate heat exchanger Qty 23 Nominal water ﬂow Water ﬂow range

(l/min)

247 284 321 347 373 407 444 482 507 533 559

202 - 493 232 - 568 262 - 642 283 - 694 304 - 745 333 - 814 363 - 889 393 -963 414 - 1015 435 - 1066 456 - 1118

Condenser

Ty pe brased plate heat exchanger Qty 23 Nominal water ﬂow Water ﬂow range

(a) The nominal cooling capacity is based on:

(b) The nominal input includes total input of the unit: compressor, control circuit and water pumps.

(l/min)

314 362 410 442 474 519 567 614 647 679 711

157 - 629 181 -724 205 - 819 221 - 883 237 - 948

- entering water temperature of 12°C

- chilled water temperature of 7°C

- condenser in/out water temperature of 30/35°C

260-1038 283-1133 307-1229 323-1293 339-1357 355-1422

Electrical speciﬁcations

General

Power supply

• Phase

• Frequency (Hz)

• Voltage (V)

• Voltage tolerance (%)

Unit

• Nominal running current

• Maximum running current

• Recommended fuses according to IEC 269-2

Compressor

• Phase

• Frequency (Hz)

• Voltage (V)

• Nominal running current

Hp 32 36 40 44 48 52 56 60 64 68 72

(A)

(1)

3N~ 3N~

50 50 400 400 ±10 ±10

41.6 47.0 52.4 56.2 60.0 67.8 73.2 78.6 82.4 86.2 90.0

56 64 72 76 80 92 100 108 112 116 120

3x 63 3x 63 3x 80 3x 80 3x 80 3x 100 3x 100 3x 125 3x 125 3x 125 3x 125

3~ 3~

50 50 400 400

10.4 10.4/13.1 13.1 13.1/15 15

10.4/13.1 10.4/13.1

13.1 13.1/15 13.1/15 15

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

EWWP045~065KAW1M + ECB2+3MUAW

Packaged water-cooled water chillers

4PW61664-1A - 2012.04

Operation manual

DESCRIPTION

32~48 Hp

52~72 Hp

17 26 11 23

14 20

15 21

25 16

2 3

500 500

500

Figure -

Main components

1 Compressor 15 Condenser water in 2

2 Evaporator 16 Condenser water in 3

3 Condenser 17 Evaporator entering water temperature sensor 1

4 Switchbox 18 Evaporator entering water temperature sensor 2

5 Chilled water in 1 19 Evaporator entering water temperature sensor 3

6 Chilled water in 2 20 Freeze up sensor 1

7 Chilled water in 3 21 Freeze up sensor 2

8 Chilled water out 1 22 Freeze up sensor 3

9 Chilled water out 2 23 Condenser entering water temperature sensor 1

10 Chilled water out 3 24 Condenser entering water temperature sensor 2

11 Condenser water out 1 25 Condenser entering water temperature sensor 3

12 Condenser water out 2 26 Digital display controller 32~72 Hp

13 Condenser water out 3 27 Power supply intake

14 Condenser water in 1

Required space around the unit for service

Operation manual

EWWP045~065KAW1M + ECB2+3MUAW

Packaged water-cooled water chillers

4PW61664-1A - 2012.04

Function of the main components

Water

inlet

Water

outlet

Condenser

S1HP

S2HP

Filter

Compressor

Q1D

Compressor

Q2D

M1C

M2C

S4LP

S5LP

Evaporator

R4TR5T

Water outlet

R3T

Water inlet

32~48 Hp

52~72 Hp

S1HP

S2HP

S1HP

S2HP

M1C

Q1D

M2C

Q2D

M1C

Q1D

M2C

Q2D

S4LP

R4TR5T

R3T

S5LP

S4LP

R4TR5T

R3T

S5LP

Figure -

Functional diagram

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 to a pressure at which it can easily be liquiﬁed 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 and the vapour condenses to liquid.

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

EWWP045~065KAW1M + ECB2+3MUAW

Packaged water-cooled water chillers

4PW61664-1A - 2012.04

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

Operation manual

Safety devices

■ Overcurrent relay The overcurrent relay (K*S) is located in the switch box of the unit and protects the compressor motor in case of overload, phase failure or too low voltage. The relay is factory-set and may not be adjusted. When activated, the overcurrent relay has to be reset in the switch box and the controller needs to be reset manually.

■ High-pressure switch The high-pressure switch (S*HP) is installed on the discharge pipe of the unit and measures the condenser pressure (pressure at the outlet of the compressor). When the pressure is too high, the pressure switch is activated and the circuit stops. When activated, it resets automatically, but the controller needs to be reset manually.

■ Low pressure switch The low-pressure switch (S*LP) is installed on the suction pipe of the unit and measures the evaporator pressure (pressure at the inlet of the compressor). When the pressure is too low, the pressure switch is activated and the circuit stops. When activated, it resets automatically, but the controller needs to be reset manually.

■ Reverse phase protector The reverse phase protector (R1P) is installed in the switch box of the unit. It prevents the compressor from running in the wrong direction. If the unit does not start, two phases of the power supply must be inverted.

■ Discharge thermal protector The discharge thermal protector (Q*D) is activated when the temperature of the refrigerant leaving the compressor becomes too high. When the temperature returns to normal, the protector resets automatically, but 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 disables the circuit. When the outlet water temperature returns to normal, the circuit can start up again. When freeze-up protection occurs several times in a certain period, the freeze-up alarm will be activated and the circuit 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.

■ Additional interlock contact To avoid that the unit could be started or run without water circulating through the water heat exchanger, an interlock contact (S11L) of e.g. a ﬂow switch must be installed in the startup circuit of the unit.

Internal wiring - Parts table

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

A1P ........................PCB terminal unit

A2P ................** ....PCB address card

F1,2,3U ..........#.....Main fuses for the unit

F5B,F6B .................Automatic fuse for the control circuit/secondary

of TR1

F8U ........................Surge-proof fuse

F9U ................ ##...Surge-proof fuse

H1P ................ *......Indication lamp alarm

H3P ................ *......Indication lamp operation compressor (M1C)

H4P ........................Indication lamp operation compressor (M2C)

K1A ........................auxiliary contactor for high pressure

K1M........................ Compressor contactor (M1C)

K1P ................*......Pumpcontactor

K2M........................ Compressor contactor (M2C)

K4S.........................Overcurrent relay (M1C)

K5S.........................Overcurrent relay (M2C)

K19T.......................Timer, time delay for M2C

M1C,M2C ...............Compressor motor

PE...........................Main earth terminal

Q1D........................Discharge thermal protector (M1C)

Q2D........................Discharge thermal protector (M2C)

R1P ........................Reverse phase protector

R3T.........................Evaporator inlet water temperature sensor

R4T.........................Evaporator outlet water temperature sensor

(Freeze up sensor)

R5T.........................Condenser inlet temperature sensor

S1HP,S2HP ............High pressure switch

S4LP,S5LP .............Low pressure switch

S7S.........................Changeable digital input 1

S9S.................*......Changeable digital input 2

S10L...............#.....Flowswitch

S11L...............#.....Contact that closes if the pump is working

S12S...............# .....Main isolator switch

TR1.........................Transfo 230 V ➞ 24 V for power supply of

controllers

Y1R ........................Reversing valve

Y1S.........................Solenoid valve for injection line

...........................Connector for digital inputs, analog inputs, analog

outputs and for power supply controller (A1P)

X2...........................Connector for digital outputs (A1P)

X3...........................Connector for (A1P)

X4,X5,X6 ................Interconnection connector Main ↔ Control

switchbox

Not included with standard unit

Not possible as option Possible as option

Obligatory # ##

Not obligatory * **

Terminal unit: Digital Inputs

X1 (ID1-GND).........ﬂowswitch

X1 (ID2-GND).........remote cooling/heating selection

X1 (ID3-GND).........high pressure switch + discharge protector +

overcurrent

X1 (ID4-GND).........low pressure switch

X1 (ID5-GND).........remote On/Off

Terminal unit: Digital outputs (relays)

X2 (C1/2-NO1) .......compressor M1C on

X2 (C1/2-NO2) .......compressor M2C on

X2 (C3/4-NO3) .......voltage free contact for pump

X2 (C3/4-NO4) .......voltage free contact for reversing valve

X2 (C5-NO5) ..........alarm voltage free contact

Terminal unit: Analog inputs

X1 (B1-GND)..........evaporator inlet water temperature

X1 (B2-GND)..........evaporator outlet water temperature (Freeze up

sensor)

X1 (B3-GND)..........condenser inlet water temperature

Operation manual

EWWP045~065KAW1M + ECB2+3MUAW

Packaged water-cooled water chillers

4PW61664-1A - 2012.04

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