Page 1
OPERATION MANUAL
Packaged water-cooled water chillers
EWWP045KAW1M
EWWP055KAW1M
EWWP065KAW1M
ECB2MUAW
ECB3MUAW
Page 2
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
1
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 3
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)
4x
JT212DA-YE
2x
JT212DA-YE +
2x JT300DA-YE
4x
JT300DA-YE
2x
JT300DA-YE +
2x JT335DA-YE
4x
JT335DA-YE
4x
JT212DA-YE
+ 2x
JT300DA-YE
2x
JT212DA-YE
+ 4x
JT300DA-YE
6x
JT300DA-YE
2900 2900
4x
JT300DA-YE
+ 2x
JT335DA-YE
2x
JT300DA-YE
+ 4x
JT335DA-YE
6x
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)
(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)
(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)
(A)
(A)
(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
2
Page 4
DESCRIPTION
32~48 Hp
52~72 Hp
17
26 11
23
14
20
27
18
12
24
15
21
27
19
13
25 16
22
27
10
5
2
3
8
6
1
1
9
7
4
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
3
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 5
Function of the main components
Water
inlet
Water
outlet
Condenser
S1HP
S2HP
Filter
Filter
Compressor
Q1D
Compressor
Q2D
M1C
HP
LP
M2C
HP
LP
S4LP
S5LP
Evaporator
R4TR5T
Water
outlet
R3T
Water
inlet
32~48 Hp
52~72 Hp
S1HP
S2HP
S1HP
S2HP
M1C
Q1D
HP
LP
M2C
Q2D
HP
LP
M1C
Q1D
HP
LP
M2C
Q2D
HP
LP
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
4
Page 6
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
X1
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
5
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 7
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:
1 Field 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.
2 Additional interlock contact
An additional interlock contact S11L should be provided (e.g.
flow switch, contact of pump motor contactor). Make sure that it
has been installed between the appropriate terminals (refer to
the wiring diagram supplied with the unit). S11L should be a
normal open contact.
3 Fuses 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.
4 Earth wiring
Make sure that the earth wires have been connected properly
and that the earth terminals are tightened.
5 Internal wiring
Visually check the switch box on loose connections or damaged
electrical components.
6 Fixation
Check that the unit is properly fixed, to avoid abnormal noises
and vibrations when starting up the unit.
7 Damaged equipment
Check the inside of the unit on damaged components or
squeezed pipes.
8 Refrigerant leak
Check the inside of the unit on refrigerant leakage. If there is a
refrigerant leak, call your local dealer.
9 Oil leak
Check the compressor on oil leakage. If there is an oil leak, call
your local dealer.
10 Power supply voltage
Check the power supply voltage on the local supply panel. The
voltage should correspond to the voltage on the identification
label of the unit.
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 flow switch.
General recommendations
Before switching on the unit, read following recommendations:
1 When the complete installation and all necessary settings have
been carried out, close all front panels of the unit.
2 The service panels of the switch boxes may only be opened by a
licensed electrician for maintenance purposes.
OPERATION 32~72 HP
The 32~72 Hp units are equipped with a built-in 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 two or three modules in the
system. The models 32~48 Hp only have two modules, whereas the
models 52~72 Hp consist of three modules. These modules are
generally named M1, M2 and M3 in the following descriptions. All
information about module 3 (M3) is not applicable for 32~48 Hp
models.
Digital controller
User interface
The digital controller consists of an alphanumeric display, labelled
keys which you can press and a number of LEDs.
Figure -
Digital controller
f key, to enter the main menu
o key, to start up or to shut down the unit.
p key, to enter the safeties menu or to reset an alarm.
keys, to scroll up or down through the screens of a menu
g
(only in case W, X or C appears) or to raise, respectively
h
lower a setting.
q key, to confirm a selection or a setting.
NOTE
Working with the 32~72 Hp units
This chapter deals with the everyday usage of the unit. Here, you will
find how to perform routine tasks, such as:
■ "Setting the language" on page 7
■ "Switching the unit on" on page 7 and "Switching the unit off" on
■ "Consulting actual operational information" on page 7
■ "Selecting cooling or heating operation" on page 8
■ "Adjusting the temperature setpoint" on page 8
■ "Resetting the unit" on page 8
Temperature readout tolerance: ±1°C.
Legibility of the alphanumeric display may decrease in
direct sunlight.
page 7
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Operation manual
6
Page 8
Setting the language
Consulting actual operational information
If desired, the operating language can be changed to any of the
following languages: English, German, French, Spanish or Italian.
1 Enter the usersettings menu. Refer to chapter "Main menu" on
page 9
2 Go to the appropriate screen of the usersettings menu using the
g and h keys.
3 Select the appropriate field (LANGUAGE) using the q key.
4 Press the g and h keys to adjust the language setting.
5 Press q to confirm the adjusted language setting.
When the setting has been confirmed, the cursor switches to the next
setting.
Switching the unit on
1 Press the J key on the controller.
Depending on whether or not the remote ON/OFF switch is
configured (refer to the service manual), the following conditions
may occur.
When no remote ON/OFF switch is configured, the LED inside
the J key lights up and an initialization cycle is started. Once all
the timers have reached zero, the unit starts up.
When a remote ON/OFF switch is configured, the following table
applies:
Local key Remote switch Unit o LED
ON ON ON ON
ON OFF OFF Flashing
OFF ON OFF OFF
OFF OFF OFF OFF
2 When the unit is started up for the first time, or when the unit has
been out of operation for a longer period, it is recommended to
check the following.
Abnormal noise and vibrations
Make sure that the unit does not produce abnormal noises or
vibrations: check the fixation, stop valves and piping. If the
compressor makes abnormal noises, this may also be caused by
an overcharge of refrigerant.
3 If the water chiller does not start after a few minutes, refer to
"Troubleshooting" on page 14.
Switching the unit off
If the remote on/off control parameter is set to NO:
Press the o key on the controller.
The LED inside the o key goes out.
If the remote on/off control parameter is set to YES:
Press the o key on the controller or switch the unit off using the
remote on/off switch.
The LED inside the o key goes out in the first case and starts
blinking in the second case.
1 Enter the readout menu through the main menu. (Refer to the
chapter "Main menu" on page 9.)
The controller automatically shows the first screen of the
readout menu which provides the following information:
• MANUAL MODE or INLSETP1/2: manual/automatic control mode
operation. If the automatic control mode is selected, the
controller will indicate the active temperature setpoint.
Depending on the status of the remote contact, setpoint one
or setpoint two is active.
• INL WATER E/C: actual inlet water temperature.
• THERMOSTAT STEP: actual thermostat step. The maximum
number of thermostat steps are as listed:
32 Hp 4 48 Hp 4 64 Hp 6
36 Hp 4 52 Hp 6 68 Hp 6
40 Hp 4 56 Hp 6 72 Hp 6
44 Hp 4 60 Hp 6
2 Press the h key to enter the next screen of the readout menu.
This screen of the readout menu provides the following
information on the evaporator:
• M1: OUTLWATER: actual outlet water temperature of module 1.
• M2: OUTLWATER: actual outlet water temperature of module 2.
• M3: OUTLWATER: actual outlet water temperature of module 3.
3 Press the h key to enter the next screen of the readout menu.
The COMPRESSOR STATUS screen of the readout menu provides
information concerning the status of the different compressors.
• C11: actual status of compressor 1 of module 1.
• C12: actual status of compressor 2 of module 1.
• C21: actual status of compressor 1 of module 2.
• C22: actual status of compressor 2 of module 2.
• C31: actual status of compressor 1 of module 3.
• C32: actual status of compressor 2 of module 3.
When a circuit is OFF, the following status information may
appear.
• SAFETY ACTIVE: one of the circuit safety devices is activated
(refer to the chapter "Troubleshooting" on page 14).
• (LIMIT): the circuit is limited by a remote contact.
• TIMERS BUSY: the actual value of one of the software timers is
not zero (refer to the "Timers menu" on page 9).
• CAN STARTUP: the circuit is ready to start up when extra
cooling load is needed.
The preceding OFF messages are written down in order of priority. If
one of the timers is busy and one of the safeties is active, the status
information says SAFETY ACTIVE.
4 Press the h key to enter the next screen of the readout menu.
To consult actual operational information about the total running
hours of the compressors.
In case of emergency, switch off the unit by pushing the
emergency stopbutton.
NOTE
Operation manual
Also consult "Defining the schedule timer" on page 12.
7
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 9
Selecting cooling or heating operation
The "cooling/heating" menu allows the user to set the unit in cooling
or heating operation.
The COOL/HEAT menu provides information concerning the selected
operation mode.
■ COOLING (EVAP): cooling mode. The two setpoints for inlet
water temperature control of the evaporator can be used.
■ HEATING (COND): heating mode. The two setpoints for inlet
water temperature control of the condenser can be used.
To define cooling/heating operation, proceed as follows:
1 Enter the cooling/heating menu through the main menu. (Refer
to the chapter "Main menu" on page 9.)
2 Position the cursor behind MODE using the q key.
3 Select the appropriate setting using the g and h keys.
4 Press q to confirm.
The cursor returns to the upper left corner of the screen.
Adjusting the temperature setpoint
The unit provides definition and selection of four or two independent
temperature setpoints.
In cooling operation, two setpoints are reserved for inlet control of the
evaporator.
■ INLSETP 1 E: inlet water temperature of evaporator, setpoint 1,
■ INLSETP2 E: inlet water temperature of evaporator, setpoint 2.
In heating operation, two setpoints are reserved for inlet control of the
condenser.
■ INLSETP 1 C: inlet water temperature of condenser, setpoint 1,
■ INLSETP 2 C: inlet water temperature of condenser, setpoint 2.
In double thermostat operation, two setpoints are reserved for inlet
control of the evaporator and two others are reserved for inlet control
of the condenser.
■ INLSETP 1 E: inlet water temperature of evaporator, setpoint 1,
■ INLSETP2 E: inlet water temperature of evaporator, setpoint 2.
■ INLSETP 1 C: inlet water temperature of condenser, setpoint 1,
■ INLSETP 2 C: inlet water temperature of condenser, setpoint 2.
The selection between setpoint 1 and 2 is done by a remote dual
setpoint switch (to be installed by the customer). The actual active
setpoint can be consulted in the readout menu.
If the manual control mode is selected (refer to "User settings menu"
on page 9), none of the above-mentioned setpoints will be active.
To adjust a setpoint, proceed as follows:
1 Enter the setpoints menu through the main menu. (Refer to the
chapter "Main menu" on page 9).
If the user password is disabled for setpoint modifications (refer
to the "User settings menu" on page 9), the controller will
immediately enter the setpoints menu.
If the user password is enabled for setpoint modifications, enter
the correct code using the g and h keys. (Refer to the "User
password menu" on page 10). Press q to confirm the password
and to enter the setpoints menu.
2 Select the setpoint to be adjusted using the q key.
A setpoint is selected when the cursor is blinking behind the
setpoint's name.
The ">" sign indicates the actual active temperature setpoint.
3 Press the g and h keys to adjust the temperature setting.
The default, limit and step values for the cooling (evaporator)
and heating (condenser) temperature setpoints are:
EE
default value 12°C 30°C
limit values
(a) For glycol units the lower limit of the cooling temperature setpoint can be
(a)
step value 0.1°C 0.1°C
adapted in the factory. The following values apply:
INLSETP IN E/C: 5°C, 3°C, –2°C, –7°C
IIIINNNNLLLLSSSSEEEETTTTPPPP IIIINNNN EE
8 --> 23°C 15--> 50°C
IIIINNNNLLLLSSSSEEEETTTTPPPP IIIINNNN CC
CC
4 Press q to save the adjusted temperature setpoint.
When the setting has been confirmed, the cursor switches to the
next setpoint.
5 To adjust other setpoints, repeat from instruction 2 onwards.
NOTE
Also consult "Defining the schedule timer" on page 12.
Resetting the unit
The units are equipped with three kinds of safety devices: unit
safeties, module safeties and network safeties.
When a unit safety occurs, all compressors are shut down. The
safeties menu will indicate which safety is activated. The COMPRESSOR
STATUS screen of the readout menu will indicate OFF - SAFETY ACTIVE
for all circuits. The red LED inside the p key lights up and the buzzer
inside the controller is activated.
When a module safety occurs, the compressors of the corresponding
module are shut down. The COMPRESSOR STATUS screen of the
readout menu will indicate OFF - SAFETY ACTIVE for the module
concerned. The red LED inside the p key lights up and the buzzer
inside the controller is activated.
If the unit has been shut down due to a power failure, it will carry out
an autoreset and restart automatically when the electrical power is
restored.
To reset the unit, proceed as follows:
1 Press the p key to acknowledge the alarm.
The buzzer is deactivated.
The controller automatically switches to the corresponding
screen of the safeties menu: unit safety or module safety.
2 Find the cause of shutdown and correct.
Refer to "Listing activated safeties and checking the unit status"
on page 12 and the chapter "Troubleshooting" on page 14.
When a safety can be reset, the LED under the p key starts
blinking.
3 Press the p key to reset the safeties that are no longer active.
Once all safety devices are disactivated and reset, the LED
under the p key goes out. If one of the safeties is still active, the
LED under the p key goes on again. In this case, return to
instruction 2.
4 If a unit safety occurred or if all modules were shut down due to
module safeties, switch on the unit using the o key.
If the user shuts down the power supply in order to repair a
safety, the safety will automatically be reset after power-up.
NOTE
The history information, i.e. the number of times a unit
safety or a circuit safety occurred and the unit status at
the moment of shutdown, can be checked by means of
the history menu.
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
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Operation manual
8
Page 10
Advanced features of the digital controller
This chapter gives an overview and a brief functional description of
the screens provided by the different menus. In the following chapter,
you will find how you can set up and configure the unit using the
various menu functions.
The down arrow X on the display indicates that you can go to the next
screen of the current menu using the h key. The up arrow W on the
display indicates that you can go to the previous screen of the current
menu using the g key. If C is displayed, this indicates that you can
either return to the previous screen or can go to the next screen by
using the g and h keys.
Main menu
Scroll through the main menu using the g and h keys to move the >
mark in front of the menu of your choice. Push the q key to enter the
selected menu.
>READOUT MENU
SETPOINTS MENU
USERSETTINGS MENU
TIMERS MENU
HISTORY MENU
INFO MENU
I/O STATUS MENU
USERPASSWORD MENU
COOL/HEAT MENU
User settings menu
The "user settings" menu, protected by the user password, allows a
full customization of the units.
BC CONTROL SETTINGS
MODE :MANUAL CONTROL
C11 : OFF 12 ; OFF
C21 : OFF 22 ; OFF
BC THERMOST.SETTINGS
STEPS : 6 STPL.: 1.5°C
STEPDIFFERENCE: 0.5°C
LOADUP: 180s-DWN: 30s
C LEAD-LAG SETTINGS
LEAD-LAG MODE : AUTO
LEAD-LAG HOURS: 1000h
BC CAP. LIM. SETTINGS
MODE : REMOTE DIG INP.
L1M1 : OFF 2: OFF 3: OFF
L2M1 : OFF 2: OFF 3: OFF
BC CAP. LIM. SETTINGS
L3M1 : OFF 2: OFF 3: OFF
L4M1 : OFF 2: OFF 3: OFF
To define the manual settings and to
select the control mode.
To define the thermostat settings.
To define the lead-lag mode of the
modules.
To define capacity limitation.
(first screen)
To define capacity limitation.
(second screen)
Readout menu
BX MANUAL MODE
INL WATER E: 12.0°C
INL WATER C: 30.0 °C
THERMOSTAT STEP :2/6
BC EVAPORATOR
M1 : OUTLWATER: 07.0 °C
M2: OUTLWATER: 07.0 °C
M3: OUTLWATER:-03.0 °C
BC COMPRESSOR STATUS
C11 : OFF-CAN STARTUP
C12: OFF-CAN STARTUP
C21: OFF-CAN STARTUP
BC COMPRESSOR STATUS
C22: OFF-CAN STARTUP
C31 : OFF- SAFETY ACT.
C32: OFF- LIMIT
BW RUNNING HOURS
C11 : 00010h 12 ; 00010h
C21 : 00010h 22 ; 00010h
C31 : 00010h 32 ; 00010h
To consult actual operational information about the control mode, the
inlet water temperature of the
evaporator/condenser and the
thermostat step.
To consult information about the
outlet water temperature of the
modules 1, 2 and 3 (only for
52~72 Hp).
To consult information about the
compressor status (first screen).
To consult information about the
compressor status (second screen).
To consult actual operational
information about the total running
hours of the compressors.
Setpoints menu
Depending upon the settings in the user settings menu and on the
selected cooling/heating operation mode, the "setpoints" menu can
either be entered directly or by means of the user password.
B>INLSETP1 E : 12.0°C
INLSETP2 E : 12.0°C
INLSETP1 C : 30.0°C
INLSETP2 C : 30.0°C
To define the temperature setpoints.
BC PUMPCONTROL
PUMPLEADTIME : 020s
PUMPLAGTIME : 000s
DAILY ON : Y AT : 00h00
BC SCHEDULE TIMER
ENABLE TIMER : N
ENABLE HOLIDAY PER : N
BC HOLIDAY : 01 TO 03
1 : 00h00 2: 00h00 3: 00h00 -
BC DUAL EVAP. PUMP
MODE : AUTOM. ROTATION
OFFSET ON RH : 0048h
BC DISPLAY SETTINGS
LANGUAGE : ENGLISH
TIME : 00h00
DATE : 00/01/2001
BC SETPOINT PASSWORD
PASSWORD NEEDED TO
CHANGE SETPOINTS : Y
BC ENTER SERVICE
PASSWORD : 0000
Timers menu
BX GENERAL TIMERS
LOADUP : 000s - DWN : 000s
PUMPLEAD : 000s
FLOWSTOP : 00s
To define the pump control settings.
To define the schedule timer.
To define the dual evaporator pump.
To define the display settings.
To define whether or not a password
is needed to enter the setpoints
menu.
To enter the service menu. (Only a
qualified installer is allowed to
access this menu.)
To check the actual value of the
general software timers (first screen).
Operation manual
9
BC COMPRESSOR TIMERS
COMPR. STARTED : 00s
BC COMPRESSOR TIMERS
C11 GRD : 000s AR : 000s
C12 GRD : 000s AR : 000s
C21 GRD : 000s AR : 000s
To check the actual value of the
general software timers (second
screen).
To check the actual value of the
compressor timers (first screen).
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Packaged water-cooled water chillers
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Page 11
BW COMPRESSOR TIMERS
C22 GRD : 000s AR : 000s
C31 GRD : 000s AR : 000s
C32 GRD : 000s AR : 000s
Safeties menu
To check the actual value of the
compressor timers (second screen).
Info menu
BX TIME INFORMATION
TIME : 00h00
DATE : 00/01/2001
To consult time and date information.
The "safeties" menu provides useful information for trouble shooting
purposes. The following screens contain basic information.
BX UNIT SAFETY
0C9 : INL E SENSOR ERR
BX MODULE 1 SAFETY
1CA : OUT E SENSOR ERR
BX MODULE 2 SAFETY
2CA : OUT E SENSOR ERR
BX MODULE 3 SAFETY
3CA : OUT E SENSOR ERR
To consult which unit safety caused
the shutdown.
To consult which module 1 safety
caused the shutdown.
To consult which module 2 safety
caused the shutdown.
To consult which module 3 safety
caused the shutdown.
Along with the basic information, more detailed information screens
can be consulted while the safety menu is active. Press the q key.
Screens similar to the following will appear.
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
00h00 - 12/01/2001
MANUAL MODE
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
INL.E : 12.0°C STEP:
INL.C : 30.0°C 0
To check the time and control mode
at the moment of the unit shutdown.
To check which were the common
evaporator and condenser inlet water
temperature.
BC UNIT INFORMATION
UNITTYPE : WW-HP-32
MANUFACT. NR.: 0000000
REFRIGERANT : R134a
To consult additional information
about the unit such as the unit type,
the refrigerant used and the manufacturing number.
BC UNIT INFORMATION
SW : V1.0M6 (01/11/01)
SW CODE : FLDKNMCH0A
BW PCB INFORMATION
BOOT : V2.02-02/08/00
BIOS : V2.32-31/07/01
To consult information about the controller's software version.
To consult information about the
PCB.
Input/output menu
The "input/output" menu gives the status of all the digital inputs and
the relay outputs of the unit.
BX DIGITAL INPUTS
M1 SAFETY OK
M2 SAFETY OK
M3 SAFETY NOK
BC DIGITAL INPUTS
FLOWSWITCH : FLOW OK
REV.PHASE PR. : OK
BC CHANG. DIG. INPUTS
DI1 DUAL SETP : SETP.1
DI2 REM. ON/OFF : OFF
DI3 REM. C/H : COOL
To check whether any module
safeties are active.
To check the reverse phase protector
and if there's any waterflow to the
evaporator.
To check the status of the changeable digital inputs.
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
OUTE1 : 07.0°C OUTE3 :
OUTE2 : 07.0°C 07.0°C
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
C11 : ON C21 :
C12 : ON ON
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
C22 : ON
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
RH11 : 00000h RH21:
RH12 : 00000h 00000h
To check which were the evaporator
outlet water temperature of all
modules at the moment of shutdown.
To check which was the status of the
compressors at the moment of
shutdown (first screen).
To check which was the status of the
compressors at the moment of
shutdown (second screen).
To check which were the total
amount of running hours of the compressors at the moment of shutdown
(first screen).
BC UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
RH22 : 00000h
To check which were the total
amount of running hours of the compressors at the moment of shutdown
(second screen).
History menu
The "history" menu contains all the information concerning the latest
shutdowns. The structure of those menus is identical to the structure
of the safeties menu. Whenever a failure is solved and the operator
performs a reset, the concerning data from the safeties menu is
copied into the history menu. Warnings are also recorded.
Additionally the number of safeties that already occurred, can be
consulted on the first line of the history screens.
BC RELAY OUTPUTS
C11 : ON C12 : ON
C21 : ON C22 : ON
C31 : ON C32 : OFF
BC RELAY OUTPUTS
LPBYPASS1 : CLOSED
LPBYPASS2 : CLOSED
LPBYPASS3 : OPEN
BC RELAY OUTPUTS
GEN. ALARM : CLOSED
PUMP/GEN OPER : CLOSED
BW CHANG. REL OUTPUTS
DO1 REV.VALVE(C/H) : O
User password menu
B CHANGE PASSWORD
NEW PASSWORD : 0000
CONFIRM : 0000
Cooling/heating menu
B COOLING/HEATING
MODE : COOLING (EVAP)
To check the status of the compressor relay outputs.
To check the status of the modules
low pressure bypass.
To check the status of the alarm
voltage free contact and the pump/
general operation contact.
To check the status of the changeable relay output.
To change the user password.
To select cooling or heating mode.
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
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Operation manual
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Page 12
Tasks of the user settings menu
Entering the user settings menu
The user settings menu is protected by the user password, a 4-digit
number between 0000 and 9999.
1 Enter the USERSETTINGS MENU through the main menu. (Refer to
the chapter "Main menu" on page 9).
The controller will request the password.
2 Enter the correct password using the g and h keys.
3 Press q to confirm the password and to enter the user settings
menu.
The controller automatically enters the first screen of the user
settings menu.
To define settings of a certain function:
1 Go to the appropriate screen of the usersettings menu using the
g and h keys.
2 Position the cursor behind the parameter to be modified using
the q key.
3 Select the appropriate setting using the g and h keys.
4 Press q to confirm the selection.
When the selection has been confirmed, the cursor switches to
the next parameter which can now be modified.
5 Repeat from instruction 2 onwards to modify the other
parameters.
Defining and activating the control mode
The unit is equipped with a thermostat which controls the cooling
capacity of the unit. Two different control modes exist:
■ manual control mode: the operator controls the capacity himself
- MANUAL CONTROL
■ inlet control mode: uses the evaporator and/or condenser
entering water temperature to control the capacity of the unit -
INLET WATER
When the operator wants to control the capacity himself, he can
activate manual control mode using the CONTROL SETTINGS screen of
the user settings menu. In this case, he has to define the following
parameters:
■ MODE (present mode): manual control.
■ C11, C12, C21, C22, C31, C32 (compressor status of module 1, 2
and 3 in manual mode or capacity limitation value in case the
"capacity limitation remote contact" is enabled): ON or OFF.
NOTE
To activate manual control mode, select MANUAL as
present mode. To deactivate the manual control mode,
select INLET WATER as present mode.
Defining the thermostat settings
When automatic control mode is selected, the unit uses a thermostat
to control the cooling or heating capacity. The maximum number of
thermostat steps are as listed:
32 Hp 4 48 Hp 4 64 Hp 6
36 Hp 4 52 Hp 6 68 Hp 6
40 Hp 4 56 Hp 6 72 Hp 6
44 Hp 4 60 Hp 6
However, the thermostat parameters are not fixed and can be
modified via the THERMOST. SETTINGS screen of the user settings menu.
The default, limit and step values for the thermostat parameters are:
STPL (°C) 0.4 2.0 0.1 1.5
STEPDIFFERENCE (°C) 0.2 0.8 0.1 0.5
LOADUP (sec) 15 300 1 180
LOADDOWN (sec) 15 300 1 20
NOTE
A functional diagram showing the thermostat parame-
Lower limit Upper limit Step Default
ters can be found in "Annex I" on page 16.
Defining the lead-lag mode
The lead/lag mode determines which module starts up first in case of
a capacity demand.
The lead-lag parameters are:
■ LEAD-LAG MODE
Automatic: the controller decides whether module 1, module 2,
or module 3 starts up first.
The modules follow the entered order of starting up (see table
below).
3 modules 2 modules
first > next > last first > last
123 12
231 21
312
NOTE
■ LEAD-LAG HOURS: In the automatic mode, the number of hours
If a module is de-activated due to a failure, the next
module will start up instead.
indicated on the display is the maximum difference between the
running hours of the modules. This value is important for maintenance purposes. It should be set high enough so that the
modules do not require maintenance at the same time and that
at least one module can remain constantly active.
The lower and upper limits are 100 and 1000 hours respectively.
The default value is 1000 hours.
Operation manual
11
Defining the pump control settings
The PUMPCONTROL screen of the user settings menu allows the user to
define the pump-leadtime and pump-lagtime.
■ PUMPLEADTIME: used to define the time that the pump must run
before the unit can start up.
■ PUMPLAGTIME: used to define the time that the pump keeps
running after the unit has been stopped.
Defining the display settings
The DISPLAY SETTINGS screen of the user settings menu allows the
user to define the choice of language, time and date.
■ LANGUAGE: used to define the language of the displayed
information of the controller.
■ TIME: used to define the present time.
■ DATE: used to define the present date.
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Packaged water-cooled water chillers
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Page 13
Defining dual evaporator pump control
The DUAL EVAP. PUMP screen of the user settings menu allows the
user to define the steering of two evaporator pumps (for this to be
possible a changeable digital output has to be configured for a
second evaporator pump in the service menu).
■ MODE: used to define which kind of control will be used for the
two evaporator pumps. When automatic rotation is chosen the
offset on running hours also has to be entered.
■ OFFSET ON RH: used to define the offset in running hours between
the two pumps. Used to switch over between pumps when they
work in automatic rotation mode.
Defining the schedule timer
The SCHEDULE TIMER screen of the user settings menu allows the user
to define the schedule timer settings.
■ MON, TUE, WED, THU, FRI, SAT and SUN: used to define to which
group each day of the week belongs (-/G1/G2/G3/G4).
■ For each of the four groups up to nine actions can be set, each
with their respective timing. Actions include: putting the unit on/
off, setting a setpoint, setting cooling/heating and setting
capacity limitation.
■ Beside these four groups there is also a holiday period group
which is set the same way as the other groups. Up to 12 holiday
periods can be entered in the HD PERIOD screen. During these
periods the schedule timer will follow the settings of the holiday
period group.
NOTE
A functional diagram showing the schedule timer
working can be found in "Annex II" on page 17.
NOTE
The unit always works with "last command". This
means that the last command given, whether manually
by the user or by the schedule timer, is always
executed.
Examples of command that can be given are switching
the unit on/off or changing a setpoint.
Activating or deactivating the setpoints password
The SETPOINT PASSWORD screen of the user settings menu allows the
user to activate or deactivate the user password needed to change
the temperature setpoint. When deactivated, the user does not have
to enter the password each time he wants to change the setpoint.
Tasks of the timers menu
Checking the actual value of the software timers
To check the actual value of the software timers, proceed as follows:
1 Enter the TIMERS MENU through the main menu. (Refer to the
chapter "Main menu" on page 9.)
The controller displays the actual value of the GENERAL TIMERS:
the loadup timer, the loaddown timer, the flowstart timer, the
flowstop timer (when the unit is on and the flowstart timer has
reached zero), the pumplead timer and the pumplag timer.
2 Press the h key to check the compressor timers (first screen).
The controller shows the actual value of the COMPRESSOR TIMERS:
the guard timers (one per compressor) and the antirecycling
timers (one per compressor).
3 Press the h key to check the compressor timers (second
screen).
The controller shows the actual value of the COMPRESSOR TIMERS:
the guard timers (one per compressor) and the antirecycling
timers (one per compressor).
Tasks of the safeties menu
Listing activated safeties and checking the unit status
If the alarm buzzer is activated and the user presses the p key, the
controller automatically enters the safeties menu.
■ The controller will enter the UNIT SAFETY screen of the safeties
menu when a unit safety was the cause of shutdown. This
screen provides the following information:
• the activated safety: emergency stop, flow switch, sensor
error or reverse phase
• the unit status at the moment of shutdown
inlet water temperature setpoint of the evaporator,
inlet water temperature setpoint of the condenser,
time and date at the moment of shutdown.
■ The controller will enter the MODULE 1, MODULE 2 or MODULE 3
SAFETY screen of the safeties menu when a safety of module 1,
respectively module 2 or module 3 was activated. These
screens provide information about the module status at the
moment of shutdown.
• the activated safety: freeze-up, general safety or sensor error
• the unit status at the moment of shutdown
inlet water temperature setpoint of the evaporator,
inlet water temperature setpoint of the condenser,
time and date at the moment of shutdown.
1 Press the p key when the alarm buzzer is activated.
The appropriate safety screen with the basic information
appears. Press the q key to see the detailed information.
2 If more than one kind of safety is active (indicated by means of
W, X or C), use the g and h keys to consult them.
As a protective measure and to ensure correct operation, the
controller's software features several countdown timers:
■ LOADUP (LOADUP – refer to the thermostat parameters): starts
counting when a thermostat step change has occurred. During
the countdown, the unit is not able to enter a higher thermostat
step.
■ LOADDOWN (DWN – refer to the thermostat parameters): starts
counting when a thermostat step change has occurred. During
the countdown, the unit will not be able to enter a lower thermostat step.
■ FLOWSTOP (FLOWSTOP – 5 sec): starts counting when the water
flow through the evaporator stops after the flowstart timer has
reached zero. If the water flow has not restarted during the
countdown, the unit will shut down.
■ PUMPLEAD (PUMPLEAD – refer to the pump control settings):
starts counting whenever the unit is switched on. During the
countdown, the unit cannot start up.
■ PUMPLAG (PUMPLAG – refer to the pump control settings): starts
counting whenever the unit is switched off. During the countdown, the pump keeps running.
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
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Operation manual
12
Page 14
Tasks of the history menu
Checking the safety info and the unit status after a reset
The information available in the safeties menu is also stored in the
history menu, where it is stored after resetting the unit or the module.
In this way, the history menu provides a means of checking the unit
status at the moment of the latest 10 shutdowns.
To check the safety info and the unit status, proceed as follows:
1 Enter the HISTORY MENU through the main menu. (Refer to the
chapter "Main menu" on page 9.)
The controller enters the UNIT HISTORY screen which contains the
following information: the number of shutdowns, the unit safety
which caused the most recent shutdown and the basic
information at the moment of this shutdown.
2 Press the g and h keys to consult the M1, M2 or M3 HISTORY
screens.
3 Press the q key to see the detailed information.
Tasks of the info menu
Consulting additional unit information
1 Enter the INFO MENU through the main menu. (Refer to the
chapter "Main menu" on page 9).
The controller enters the UNIT INFORMATION screen which contains
the following information: the unit name, the refrigerant used and
the manufacturing (serial) number.
2 Press h to consult the next UNIT INFORMATION screen.
This screen contains information about the controller's software
version.
Tasks of the input/output menu
Checking the status of the inputs and outputs
The input/output menu provides a means of checking the status of
the digital inputs and the status of the relay outputs.
The locked digital inputs are:
■ M1, M2 or M3 SAFETY: indicates the status of the general module
safeties.
■ FLOWSWITCH: indicates the status of the flowswitch, activated or
deactivated.
■ REVERSE PHASE PROTECTOR: indicates the status of this safety.
The changeable digital inputs are:
■ REM. C/H: indicates the status of the remote cooling/heating
switch.
■ DUAL SETPOINT: indicates the status of the remote dual setpoint
switch, setpoint 1 or setpoint 2.
■ REM. ON/OFF: indicates the status of the remote on/off switch.
■ CAP LIM1/2/3: indicates the status of the enable/disable capacity
limitation switch(es).
The locked relay outputs are:
■ LPBYPASS 1/2/3: indicates whether the low pressure of the
module is in bypass mode or not.
■ C11, C12, C21, C22, C31, C32: indicates whether the compressor is
running or not.
■ PUMP/GEN OPER: indicates the status of this voltage free contact.
It is activated if the pump should be ON, which also indicates
general operation.
The changeable relay outputs are:
■ REV. VALVE (C/H): indicates whether the unit is running in cooling
or in heating.
■ 2ND EVAP PUMP: indicates the status of the second evaporator
pump.
■ CONDENSER PUMP: indicates the status of the condenser pump.
■ 100% CAPACITY: indicates when the unit is working at 100%.
To check the inputs and outputs, proceed as follows:
1 Enter the I/O STATUS MENU through the main menu. (Refer to the
chapter "Main menu" on page 9.)
The controller enters the first DIGITAL INPUTS screen.
2 Consult the other screens of the input/ouput menu using the g
and h keys.
Tasks of the user password menu
Changing the user password
Access to the user settings menu and the setpoints menu is
protected by the user password (a 4-digit number between 0000 and
9999).
To change the user password, proceed as follows:
1 Enter the USERPASSWORD MENU through the main menu. (Refer to
the chapter "Main menu" on page 9).
The controller will request the password.
2 Enter the correct password using the g and h keys.
3 Press q to confirm the password and to enter the password
menu.
The controller requests the new password.
4 Press q to start the modification.
The cursor is positioned behind NEW PASSWORD.
5 Enter the new password using the g and h keys.
6 Press q to confirm the new password.
When the new password has been confirmed, the controller will
ask to enter the new password a second time (for safety
reasons). The cursor is positioned behind CONFIRM.
7 Enter the new password again using the g and h keys.
8 Press q to confirm the new password.
NOTE
The actual password will only be changed when the
new password and the confirmed password have the
same value.
Operation manual
13
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 15
TROUBLESHOOTING
This section provides useful information for diagnosing and correcting
certain troubles which may occur in the unit.
Before starting the trouble shooting procedure, carry out a thorough
visual inspection of the unit and look for obvious defects such as
loose connections or defective wiring.
Before contacting your local dealer, read this chapter carefully, it will
save you time and money.
When carrying out an inspection on the supply panel or on
the switch box of the unit, always make sure that the circuit
breaker of the unit is switched off.
When a safety device was activated, stop the unit and find out why
the safety device was activated before resetting it. Under no circumstances safety devices may be bridged or changed to a value other
than the factory setting. If the cause of the problem cannot be found,
call your local dealer.
Symptom 1: The unit does not start, but the ON LED lights up
POSSIBLE CAUSES CORRECTIVE ACTION
The temperature setting is not
correct.
The flowstart timer is still running. The unit will star t after approx. 15
Neither one of the circuits can start
up.
Unit is in manual mode (all
compressors at 0%).
Power supply failure. Check the voltage on the supply
Blown fuse or interrupted protection
device.
Loose connections. Inspect connections of the field
Shorted or broken wires. Test circuits using a tester and repair
Symptom 2: The unit does not start, but the ON LED is flashing
POSSIBLE CAUSES CORRECTIVE ACTION
The remote ON/OFF input is
enabled and the remote switch is off.
Symptom 3: The unit does not start and the ON LED does not light up
POSSIBLE CAUSES CORRECTIVE ACTION
All circuits are in failure mode. Refer to Symptom 5: One of the
One of the following safety devices is
activated:
• Flow switch (S8L,S9L)
• Emergency stop
The ON LED is broken. Contact your local dealer.
The unit is in bypass mode. Check the bypass remote contact.
Check the controller setpoint.
seconds. Make sure that water is
flowing through the evaporator.
Refer to Symptom 4: One of the
circuits does not start up.
Check on the controller.
panel.
Inspect fuses and protection
devices. Replace by fuses of the
same size and type (refer to
"Electrical specifications" on
page 2).
wiring and the internal wiring of the
unit. Tighten all loose connections.
if necessary.
Put the remote switch on or disable
the remote ON/OFF input.
following safety devices is activated.
Refer to Symptom 5: One of the
following safety devices is activated.
Symptom 4: One of the circuits does not start up
POSSIBLE CAUSES CORRECTIVE ACTION
One of the following safety devices is
activated:
• Compressor thermal protector (Q*M)
• Overcurrent relay (K*S)
• Discharge thermal protector (S*T)
• Low pressure switch
• High pressure switch (S*HP)
• Reverse phase protector (R*P)
• Freeze-up
The anti-recycling timer is still active. The circuit can only start up after
The guard timer is still active. The circuit can only start up after
The circuit is limited to 0%. Check the "enable/disable capacity
Symptom 5: One of the following safety devices is activated
Symptom 5.1: Overcurrent relay of compressor
POSSIBLE CAUSES CORRECTIVE ACTION
Failure of one of the phases. Check fuses on the supply panel or
Voltage too low. Measure the supply voltage.
Overload of motor. Reset. If the failure persists, call your
Check on the controller and refer to
Symptom 5: One of the following
safety devices is activated.
approximately 10 minutes.
approximately 1 minute.
limitation" remote contact.
measure the supply voltage.
local dealer.
RESET
Push the blue button on the overcurrent relay inside the switch box
and reset the controller.
Symptom 5.2: Low pressure switch
POSSIBLE CAUSES CORRECTIVE ACTION
Water flow to water heat exchanger
too low.
Shortage of refrigerant. Check for leaks and refill refrigerant,
Unit is working out of its operation
range.
Inlet temperature to the water heat
exchanger is too low.
Flow switch is not working or no
water flow.
Increase the water flow.
if necessary.
Check the operation conditions of
the unit.
Increase the inlet water temperature.
Check the flow switch and the water
pump.
RESET
After pressure rise, this safety resets
automatically, but the controller still
needs to be reset.
Symptom 5.3: High-pressure switch
POSSIBLE CAUSES CORRECTIVE ACTION
Water flow to condenser is too low. Increase the water flow and/or check
the strainer for clogging.
RESET
After finding the cause, push the
button on the high-pressure switch
housing and reset the controller.
Symptom 5.4: Reverse phase protector is activated
POSSIBLE CAUSES CORRECTIVE ACTION
Two phases of the power supply are
connected in the wrong phase
position.
One phase is not connected
properly.
Invert two phases of the power
supply (by licensed electrician).
Check the connection of all phases.
RESET
After inverting two phases or fixing
the power supply cables properly,
the protector is reset automatically,
but the controller still needs to be
reset.
Symptom 5.5: Discharge thermal protector is activated
POSSIBLE CAUSES CORRECTIVE ACTION
Unit is working outside the operation
range.
Check the operation condition of the
unit.
RESET
After temperature decrease, the
thermal protector resets
automatically but the controller still
needs to be reset.
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Operation manual
14
Page 16
Symptom 5.6: Flow switch is activated
POSSIBLE CAUSES CORRECTIVE ACTION
No water flow. Check the water pump.
RESET
After finding the cause, the flow
switch is reset automatically, but the
controller still needs to be reset.
Symptom 5.7: Freeze-up protection is activated
POSSIBLE CAUSES CORRECTIVE ACTION
Water flow too low. Increase the water flow.
Inlet temperature to the evaporator is
too low.
Flow switch is not working or no
water flow.
Symptom 5.8: Compressor thermal protector is activated
POSSIBLE CAUSES CORRECTIVE ACTION
Compressor motor coil temperature
too high.
Symptom 6: Unit stops soon after operation
POSSIBLE CAUSES CORRECTIVE ACTION
The schedule timer is activated and
is in off mode.
One of the safety devices is
activated.
Voltage is too low. Test the voltage in the supply panel
Symptom 7: Unit runs continuously and the water temperature remains
higher than the temperature set on the controller
POSSIBLE CAUSES CORRECTIVE ACTION
The temperature setting on the
controller is too low.
The heat production in the water
circuit is too high.
Water flow is too high. Recalculate the water flow.
The circuit is limited. Check the "enable/disable capacity
Symptom 8: Excessive noises and vibrations of the unit
POSSIBLE CAUSES CORRECTIVE ACTION
Unit has not been fixed properly. Fix the unit as described in the
Increase the inlet water temperature.
Check the flow switch and the water
pump.
RESET
After temperature increase the
freeze-up is reset automatically, but
the circuit controller needs to be
reset.
Compressor is not cooled sufficiently
by the refrigerant medium.
RESET
After temperature decrease the
thermal protector is reset
automatically, but the circuit
controller needs to be reset.
If the protector is activated
frequently, call your local dealer.
Work according to the settings in the
schedule timer or disable the
schedule timer.
Check safety devices (refer to
Symptom 5: One of the following
safety devices is activated).
and, if necessary, in the electrical
compartment of the unit (voltage
drop due to supply cables is too
high).
Check and adjust the temperature
setting.
The cooling capacity of the unit is too
low. Call your local dealer.
limitation" remote contact.
installation manual.
Before carrying out any maintenance or repair activity,
always switch off the circuit breaker on the supply panel,
remove the fuses or open the protection devices of the
unit.
Do never clean the unit with water under pressure.
Important information regarding the refrigerant used
This product contains fluorinated greenhouse gases covered by the
Kyoto Protocol.
Refrigerant type: R407C
(1)
GWP
value: 1652.5
(1)
GWP = global warming potential
Periodical inspections for refrigerant leaks may be required
depending on European or local legislation. Please contact your local
dealer for more information.
Maintenance activities
The wiring and power supply must be checked by a
licensed electrician.
■ Field wiring and power supply
• Check the power supply voltage on the local supply panel.
The voltage should correspond to the voltage marked on the
identification label of the unit.
• Check the connections and make sure they are properly
fixed.
• Check the proper operation of the circuit breaker and the
earth leak detector provided on the local supply panel.
■ Internal wiring of the unit
Visually check the switch boxes on loose connections (terminals
and components). Make sure that the electrical components are
not damaged or loose.
■ Earth connection
Make sure that the earth wires are still connected properly and
that the earth terminals are tightened.
■ Refrigerant circuit
• Check for leaks inside the unit. In case a leak is detected, call
your local dealer.
• Check the working pressure of the unit. Refer to paragraph
"Switching the unit on" on page 7.
■ Compressor
• Check on oil leaks. If there is an oil leak, call your local
dealer.
• Check for abnormal noises and vibrations. If the compressor
is damaged, call your local dealer.
■ Water supply
• Check if the water connection is still well fixed.
• Check the water quality (refer to the installation manual of the
unit for specifications of the water quality).
■ Water filters
• Check if the mesh width is 1 mm maximum.
MAINTENANCE
In order to ensure optimal availability of the unit, a number of checks
and inspections on the unit and the field wiring have to be carried out
at regular intervals.
If the unit is used for air conditioning application, the described
checks should be executed at least once a year. In case the unit is
used for other applications, the checks should be executed every
4 months.
Operation manual
15
Disposal requirements
Dismantling of the unit, treatment of the refrigerant, oil and any other
parts, should be done in accordance with the relevant local and
national regulations.
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 17
ANNEX I
0
1
6
5
4
3
2
ab
Stepnumber
Setpoint
Temperature
Thermostat parameters
Cooling: Inlet water temperature control of evaporator Heating: Inlet water temperature control of condenser
The figures below show the thermostat diagram in case of inlet water temperature control.
■ 2 step thermostat control
Stepnumber
■ 2 step thermostat control
Stepnumber
52~72 Hp
ab
0
1
2
Setpoint
Temperature
0
1
2
ab
Temperature
Setpoint
■ 4 step thermostat control (default 32~48 Hp) ■ 4 step thermostat control (default 32~48 Hp)
32~48 Hp
Stepnumber
0
1
2
3
4
Setpoint
ab
Temperature
52~72 Hp
32~48 Hp
Stepnumber
0
1
2
3
4
ab
Temperature
Setpoint
■ 6 step thermostat control (default 52~72 Hp) ■ 6 step thermostat control (default 52~72 Hp)
Stepnumber
ab
0
1
2
3
4
5
6
Setpoint
Temperature
The default value and the upper and lower limits of the thermostat parameters are listed in the table below.
INLET CONTROL Default value Lower limit Upper limit
Steplength - a
Step difference - b
Load-up time
Load-down time
Setpoint Cooling
Setpoint Heating
NOTE
The thermostat parameters mentioned above only apply to standard units.
(sec)
(sec)
(°C)
(°C)
(K)
(K)
1.5 0.4 2.0
0.5 0.2 0.8
180 15 300
20 15 300
12.0 8.0 23.0
30.0 15.0 50.0
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Operation manual
16
Page 18
ANNEX II
14.0°C
Schedule timer example
MARCH
MON TUE WED THU FRI SAT SUN
1 G1 2 G1 3 G2 4 G1 5 G1 6 G3 7 G3
8 G1 9 G1 10 G2 11 G1 12 G1 13 G3 14 G3
15 G1 16 G1 17 G2 18 G1 19 G1 20 G3 21 G3
22 G1
29 H 30 G1 31 G2
To come to the schedule above following settings have to be made:
All days assigned to the same group will work according to the
settings of this group.
In this example setting:
■ all Mondays, Tuesdays, Thursdays and Fridays will work accord-
■ all Wednesdays will work according to the settings in group 2
■ all Saturdays and Sundays will work according to the group 3
■ all holiday days will work according to the settings in the holiday
All group settings of groups G1, G2, G3, G4 and H work similar as
following example (settings for group 1):
23 H 24 H 25 H 26 H 27 H 28 H
BX SCHEDULE TIMER
MON : G1 THU : G1 SAT : G3
TUE : G1 FRI : G1 SUN : G3
WED : G2
BX HD PERIOD : 01 TO 03
01 : 23/03 TO 29/03
02 : 00/00 TO 00/00
03 : 00/00 TO 00/00
ing to the settings in group 1 (G1),
(G2),
(G3),
group (H).
Cooling inlet setpoint 1
Heating inlet setpoint 1
Cooling
Heating
14.0°C
12.0°C
On
Off
6 8 12 13 15 18 20
35.0°C
30.0°C
time (h)
BX GROUP1 : 01 TO 03
1 : 06h00 ISP1 E : 12.0
2 : 06h00 ON COOL
3 : 08h00 ISP1 E : 14.0
BX GROUP1 : 04 TO 06
4 : 12h00 OFF
5 : 13h00 ISP1 C : 30.0
6 : 13h00 ON HEAT
BX GROUP1 : 07 TO 09
7 : 15h00 ISP1 C : 35.0
8 : 20h00 OFF
9 : 00h00 - -
Operation manual
17
Screen 1
Screen 2
Screen 3
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Page 19
ANNEX III - SOFTWARE STRUCTURE
Actual screens can be different than the shown example (52~72 Hp).
f
>READOUT MENU
SETPOINTS MENU
USERSETTINGS MENU
TIMERS MENU
HISTORY MENU
INFO MENU
I/O STATUS MENU
USERPASSWORD MENU
COOL/HEAT MENU
q
BX MANUAL MODE
INL WATER E: 12.0°C
INL WATER C: 30.0 °C
THERMOSTAT STEP :2/6
ENTER PASSWORD
PASSWORD : 0000
ENTER PASSWORD
PASSWORD : 0000
g
$e SCHEDULE TIMER
ENABLE TIMER : N
ENABLE HOLIDAY PER : N
g
$e HOLIDAY : 01 TO 03
1 : 00h00 2: 00h00 3: 00h00 -
BX GENERAL TIMERS
LOADUP:000s-DWN:000s
PUMPLEAD : 000s
FLOWSTOP : 00s
p
BX UNIT SAFETY
0C9 : INL E SENSOR ERR
q
$z UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
00h00 - 12/01/2001
MANUAL MODE
h
$e EVAPORATOR
M1 : OUTLWATER: 07.0 °C
M2: OUTLWATER: 07.0 °C
h
M3: OUTLWATER:-03.0 °C
$>INLSETP1 E : 12.0°C
INLSETP2 E : 12.0°C
INLSETP1 C : 30.0°C
q
INLSETP2 C : 30.0°C
$e CONTROL SETTINGS
MODE :MANUAL CONTROL
C11 : OFF 12 ; OFF 31 ; OFF
q
C21 : OFF 22; OFF 32 ; OFF
$e SCHEDULE TIMER
g
MON : G1 THU : G2 SAT : TUE : G1 FRI : G2 SUN : -
h
WED : -
$e DUAL EVAP. PUMP
h
MODE : AUTOM. ROTATION
OFFSET ON RH : 0048h
g
$e COMPRESSOR TIMERS
COMPR. STARTED : 00s
h
$e UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
INL.E : 12.0°C STEP :
qqqqqq
INL.C : 30.0°C 0
$e COMPRESSOR STATUS
g
C11 : OFF-CAN STARTUP
C12: OFF-CAN STARTUP
h
C21: OFF-CAN STARTUP
$e THERMOST.SETTINGS
STEPS : 6 STPL.: 1.5°C
STEPDIFFERENCE: 0.5°C
h
LOADUP: 180s-DWN: 30s
$e GROUP1 : 01 TO 03
g
1 : 00h00 - - 2 : 00h00 - - -
h
3 : 00h00 - - -
$e DISPLAY SETTINGS
g
LANGUAGE : ENGLISH
TIME : 00h00
h
DATE : 00/01/2001
$e COMPRESSOR TIMERS
g
C11 GRD : 000s AR : 000s
C12 GRD : 000s AR : 000s
h
C21 GRD : 000s AR : 000s
$e UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
OUTE1 : 07.0°C OUTE3 :
OUTE2: 07.0°C 07.0°C
$e COMPRESSOR STATUS
g
C22: OFF- CAN STARTUP
C31 : OFF- SAFETY ACT.
h
C32: OFF- LIMIT
$e LEAD-LAG SETTINGS
g
LEAD-LAG MODE : AUTO
LEAD-LAG HOURS: 1000h
h
$e GROUP2 : 01 TO 03
g
1 : 00h00 - - 2 : 00h00 - - -
h
3 : 00h00 - - -
$e SETPOINT PASSWORD
g
PASSWORD NEEDED TO
CHANGE SETPOINTS : Y
h
$a COMPRESSOR TIMERS
g
C22 GRD : 000s AR : 000s
C31 GRD : 000s AR : 000s
h
C32 GRD : 000s AR : 000s
$e UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
C11 : ON C21:
C12: ON ON
$a RUNNING HOURS
g
C11 : 00010h 12 ; 00010h
C21 : 00010h 22 ; 00010h
h
C31 : 00010h 32 ; 00010h
$e CAP. LIM. SETTINGS
g
MODE : REMOTE DIG INP.
L1M1 : OFF 2: OFF 3: OFF
h
L2M1 : OFF 2: OFF 3: OFF
$e GROUP3 : 01 TO 03
g
1 : 00h00 - - 2 : 00h00 - - -
h
3 : 00h00 - - -
$e ENTER SERVICE
g
PASSWORD : 0000
h
g
$e UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
C22 : ON C32 :
C31 : OFF OFF
g
$e CAP. LIM. SETTINGS
g
L3M1 : OFF 2: OFF 3: OFF
L4M1 : OFF 2: OFF 3: OFF
h
$e GROUP4 : 01 TO 03
g
1 : 00h00 - - 2 : 00h00 - - 3 : 00h00 - - -
h
g
$e UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
RH11 : 00000h RH21:
RH12 : 00000h 00000h
$e PUMPCONTROL
g
PUMPLEADTIME : 020s
PUMPLAGTIME : 000s
h
DAILY ON : Y AT : 00h00
$e HD PERIOD: 01 TO 03
g
01 : 01/09 TO 04/09
02 : 00/00 TO 00/00
h
03 : 00/00 TO 00/00
$a UNIT HISTORY : 004
0C9 : INL E SENSOR ERR
RH22: 00000h RH32:
RH31: 00000h 00000h
h
h
q
$z UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
00h00 - 01/01/2001
INLSETP2 E : 30.0°C
gh
$z MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
00h00 - 01/01/2001
INLSETP1 E : 30.0°C
gh
$z MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
00h00 - 12/01/2001
INLSETP1 C : 07.0°C
g
$z TIME INFORMATION
TIME : 00h00
DATE : 00/01/2001
$z DIGITAL INPUTS
M1 SAFETY OK
M2 SAFETY OK
M3 SAFETY NOK
ENTER PASSWORD
PASSWORD : 0000
$ COOLING/HEATING
MODE : COOLING (EVAP)
$e UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
INL.E : 12.0°C STEP :
INL.C : 30.0°C 2
$e MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
INL.E : 12.0°C STEP :
qqqqqq
INL.C : 30.0°C 2
$e MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
INL.E : 12.0°C STEP :
INL.C : 30.0°C 2
$e UNIT INFORMATION
UNITTYPE : WW-HP-32
MANUFACT. NR.: 0000000
h
REFRIGERANT : R134a
$e DIGITAL INPUTS
FLOWSWITCH : FLOW OK
REV.PHASE PR. : OK
h
$ CHANGE PASSWORD
NEW PASSWORD : 0000
q
CONFIRM : 0000
$e UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
OUTE1 : 07.0°C OUTE3:
OUTE2: 07.0°C 07.0°C
$e MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
OUTE1 : 07.0°C OUTE3:
OUTE2: 07.0°C 07.0°C
$e MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
OUTE1 : 07.0°C OUTE3:
OUTE2: 07.0°C 07.0°C
$e UNIT INFORMATION
g
SW : V1.0M6 (01/11/01)
SW CODE : FLDKNMCH0A
h
$e CHANG. DIG. INPUTS
g
DI1 DUAL SETP : SETP.1
DI2 REM. ON/OFF : OFF
h
DI3 REM. C/H : COOL
$e UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
C11 : OFF - SAF C21:
C12: OFF - SAF OFF - SAF
$e MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
C11 : OFF C21:
C12: OFF OFF
$e MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
C11 : OFF - F D C21:
C12: OFF - F D OFF - F D
$a PCB INFORMATION
g
BOOT : V2.02-02/08/00
BIOS : V2.32-31/07/01
h
$e RELAY OUTPUTS
g
C11 : ON C12 : ON
C21 : ON C22 : ON
h
C31 : OFF C32 : OFF
$e UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
C22: OFF - SAF C32:
C31 : OFF OFF
$e MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
C22: OFF C32:
C31 : ON ON
$e MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
C22: OFF - F D C32:
C31 : OFF - SAF OFF - SAF
g
$e RELAY OUTPUTS
g
LPBYPASS1 : CLOSED
LPBYPASS2 : CLOSED
h
LPBYPASS3 : OPEN
$e UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
RH11 : 00000h RH21:
RH12 : 00000h 00000h
$e MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
RH11 : 00000h RH21:
RH12 : 00000h 00000h
$e MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
RH11 : 00000h RH21:
RH12 : 00000h 00000h
$e RELAY OUTPUTS
g
GEN. ALARM: CLOSED
PUMP/GEN OPER: CLOSED
h
$a UNIT HISTORY : 003
0AE : FLOW HAS STOPPED
RH22: 00000h RH32:
RH31 : 00000h 00000h
qqqqqq
$a MOD 1 HISTORY : 002
1EO : GENERAL SAFETY
RH22: 00000h RH32:
RH31 : 00000h 0000h
$a MOD 3 HISTORY : 001
3EO : GENERAL SAFETY
RH22: 00000h RH32:
qqqqqq
RH31 : 00000h 00000h
$a CHANG. REL OUTPUTS
g
DO1 REV.VALVE(C/H) : O
h
q
q
q
only for
52~72 Hp
g
EWWP045~065KAW1M + ECB2+3MUAW
Packaged water-cooled water chillers
4PW61664-1A - 2012.04
Operation manual
18
Page 20
4PW61664-1A 2012.04
Copyright 2010 Daikin
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