Daikin EWYD-AJYNN Operation manuals
Installation, Operation and Maintenance Manual
D – 504 C – 07/05 A – EN
Air/water heat pumps
h single-screw compressor
wit
EWYD 260-380 AJYNN
50Hz – Refrigerant: R-134a
Index
General information ..........................................................................................................................................................4
Receiving the machine ...................................................................................................................................................4
Checks ...........................................................................................................................................................................4
Purpose of this manual................................................................................................................................................... 4
Nomenclature................................................................................................................................................................. 5
Specifications.................................................................................................................................................................... 6
Operating limits............................................................................................................................................................... 11
Storage......................................................................................................................................................................... 11
Operation...................................................................................................................................................................... 11
Mechanical installation................................................................................................................................................... 13
Shipping ....................................................................................................................................................................... 13
Responsibility ............................................................................................................................................................... 13
Safety ........................................................................................................................................................................... 13
Moving and lifting .........................................................................................................................................................13
Positioning and assembly............................................................................................................................................. 14
Minimum space requirements ...................................................................................................................................... 15
Sound protection .......................................................................................................................................................... 16
Water piping ................................................................................................................................................................. 16
Water treatment............................................................................................................................................................ 18
Evaporator and recovery exchangers anti-freeze protection ........................................................................................ 18
Installing the flow switch............................................................................................................................................... 18
Hydronic kit (optional)................................................................................................................................................... 19
Refrigerating circuit safety valves................................................................................................................................. 22
Electrical installation ...................................................................................................................................................... 24
General specifications .................................................................................................................................................. 24
Electrical components .................................................................................................................................................. 26
Electrical wiring ............................................................................................................................................................26
Electrical resistances.................................................................................................................................................... 26
Electrical power supply to the pumps ........................................................................................................................... 26
Water pump control ...................................................................................................................................................... 26
Alarm relays – Electrical wiring..................................................................................................................................... 26
Unit On/ Off remote control – Electrical wiring.............................................................................................................. 26
Double Setpoint – Electrical wiring ............................................................................................................................... 26
External water Setpoint reset – Electrical wiring (Optional).......................................................................................... 27
Unit limitation – Electrical wiring (Optional) .................................................................................................................. 27
Operation ......................................................................................................................................................................... 29
Operator’s responsibilities ............................................................................................................................................ 29
Description of the machine........................................................................................................................................... 29
Description of the refrigeration cycle ............................................................................................................................ 29
Description of the refrigeration cycle with partial heat recovery.................................................................................... 31
Controlling the partial recovery circuit and installation recommendations .................................................................... 31
Compressor.................................................................................................................................................................. 33
Compression process................................................................................................................................................... 33
Cooling capacity control ............................................................................................................................................... 35
VFD and related problems............................................................................................................................................37
Operating principle of the VFD ..................................................................................................................................... 38
The problem with harmonics ........................................................................................................................................ 39
Pre-startup checks.......................................................................................................................................................... 41
General......................................................................................................................................................................... 41
Units with an external water pump ............................................................................................................................... 42
Units with a built-in water pump....................................................................................................................................42
Electrical power supply................................................................................................................................................. 42
Unbalance in power supply voltage.............................................................................................................................. 43
Electrical resistances power supply.............................................................................................................................. 43
Startup procedure ...........................................................................................................................................................43
Turning on the machine................................................................................................................................................ 43
Selecting an operating mode........................................................................................................................................ 44
Shutdown for a long time.............................................................................................................................................. 44
Starting up after seasonal shutdown ............................................................................................................................ 45
System maintenance.......................................................................................................................................................45
General......................................................................................................................................................................... 45
Compressor maintenance ............................................................................................................................................ 46
Lubrication.................................................................................................................................................................... 46
Routine maintenance.................................................................................................................................................... 47
Replacement of filter dryer ........................................................................................................................................... 47
D – 504 C – 07/05 A – EN pag 2/56
Procedure to replace the filter dryer cartridge .............................................................................................................. 48
Replacement of the oil filter.......................................................................................................................................... 48
Procedure to replace oil filter........................................................................................................................................ 49
Refrigerant charge........................................................................................................................................................ 51
Procedure to replenish refrigerant ................................................................................................................................ 52
Standard checks .............................................................................................................................................................53
Temperature and pressure sensors.............................................................................................................................. 53
Test sheet ........................................................................................................................................................................ 54
Water side measurements............................................................................................................................................54
Refrigerant side measurements ................................................................................................................................... 54
Electrical measurements .............................................................................................................................................. 55
Service and limited warranty..........................................................................................................................................55
Important information regarding the refrigerant used................................................................................................. 55
Index of tables
Table 1 - Sound levels EWYD-AJYNN in cooling and heating .......................................................................................... 10
Table 2 - Sound levels EWYD-AJYNN+OPLN in cooling .................................................................................................. 10
Table 3 - Sound levels EWYD-AJYNN+OPLN in heating.................................................................................................. 10
Table 4 - Acceptable water quality limits ........................................................................................................................... 18
Table 5 - Electrical data..................................................................................................................................................... 25
Table 6 - Typical working conditions with compressors at 100% ...................................................................................... 44
Table 7 - Routine maintenance programme ...................................................................................................................... 47
Table 8 - Pressure/ Temperature ...................................................................................................................................... 52
Index of figures
Figure 1 - Operating limits in cooling - EWYD-AJYNN/AJYNN+OPLN.............................................................................. 12
Figure 2 - Operating limits in heating - EWYD-AJYNN/AJYNN+OPLN ............................................................................. 12
Figure 3 - Lifting the unit.................................................................................................................................................... 14
Figure 4 - Minimum clearance requirements for machine maintenance............................................................................ 15
Figure 5 - Minimum recommended installation clearances ............................................................................................... 16
Figure 6 - Water piping connection for heat recovery exchangers .................................................................................... 17
Figure 7 - Adjusting the safety flow switch ........................................................................................................................ 19
Figure 8 - Single- and twin-pump hydronic kit ................................................................................................................... 19
Figure 9 - Low lift water pumps kit (option on request) - Lift diagrams .............................................................................. 20
Figure 10 - High lift water pumps kit (option on request) - Lift diagrams ........................................................................... 21
Figure 11 - Evaporator pressure drop ............................................................................................................................... 22
Figure 12 - Partial heat recovery pressure drop ................................................................................................................ 23
Figure 13 - User connection to the interface M3 terminal boards...................................................................................... 28
Figure 14 - Refrigeration cycle .......................................................................................................................................... 30
Figure 15 - Refrigeration cycle with partial heat recovery ................................................................................................. 32
Figure 16 - Picture of Fr3100 compressor......................................................................................................................... 33
Figure 17 - Compression process ..................................................................................................................................... 34
Figure 18 - Capacity control mechanism for Fr3100 compressor...................................................................................... 35
Figure 19 - Continuously variable capacity control for Fr3100 compressor....................................................................... 36
Figure 20 - Nominal power of the compressor depending on the load .............................................................................. 37
Figure 21 - Typical diagram of a VFD ............................................................................................................................... 38
Figure 22 - Harmonics on the grid..................................................................................................................................... 39
Figure 23 - Harmonic content with and without line inductance ........................................................................................ 40
Figure 24 - Installation of control devices for Fr3100 compressor..................................................................................... 46
Figure 25 – Front and back views for Fr3100.................................................................................................................... 50
D – 504 C – 07/05 A – EN pag 3/56
General information
WARNING
The units described in the present manual represent a valuable investment. Maximum care should be taken to
ensure correct installation and appropriate working conditions of the units. Installation and maintenance are to be
performed by qualified personnel only.
A maintenance contract with a Daikin authorized service centre is highly recommended.
WARNING
This manual provides information about the features and standard procedures for the complete series.
All the units are delivered from factory as complete sets which include wiring diagrams, inverter manuals, and
dimensional drawings with size and weight of each model.
WIRING DIAGRAMS, INVERTER MANUALS AND DIMENSIONAL DRAWINGS MUST BE CONSIDERED
ESSENTIAL DOCUMENTS OF THIS MANUAL
In case of any discrepancy between this manual and the equipment’s document please refer to the wiring diagram
and dimensional drawings.
Receiving the machine
The machine must be inspected for any possible damage immediately upon reaching its final place of installation. All
components described in the delivery note must be carefully inspected and checked; any damage must be reported to
the carrier. Before connecting the machine to earth, check that the model and power supply voltage shown on the
nameplate are correct. Responsibility for any damage after acceptance of the machine cannot be attributed to the
manufacturer.
Checks
To prevent the possibility of incomplete delivery (missing parts) or transportation damage, please perform the following
checks upon receipt of the machine:
a) Before accepting the machine, please verify every single component in the consignment. Check for any damage.
b) In the event that the machine has been damaged, do not remove the damaged material. A set of photographs are
helpful in ascertaining responsibility.
c) Immediately report the extent of the damage to the transportation company and request that they inspect the
machine.
d) Immediately report the extent of the damage to the manufacturer representative, so that arrangements can be
made for the required repairs. In no case must the damage be repaired before the machine has been inspected
by the representative of the transportation company.
Purpose of this manual
The purpose of this manual is to allow the installer and the qualified operator to carry out all required operations in order
to ensure proper installation and maintenance of the machine, without any risk to people, animals and/or objects.
This manual is an important supporting document for qualified personnel but it is not intended to replace such personnel.
All activities must be carried out in compliance with local laws and regulations.
D – 504 C – 07/05 A – EN pag 4/56
Nomenclature
Machine type
ERA: Air-cooled condensing unit
EWW: Water-cooled packaged water chiller
EWL: Remote condenser water chiller
EWA: Air-cooled chiller, cooling only
EWY: Air-cooled chiller, heat pump
EWC: Air-cooled chiller, cooling only with centrifugal fan
EWT: Air-cooled chiller, cooling only with heat recovery
Refrigerant
D: R-134a
P: R-407C
Q: R-410A
Capacity class in kW (cooling)
Always 3-digit code
Cap < 50 kW: not rounded: example: 37 kW => 037
50 < Cap < 999 kW: rounded 0/5: 536 kW => 535
Cap > 999 kW use C-symbol (C=100): example: 2578 kW => C26
Model series
first character : letter A, B,…: major modification
second character : letter A,B,... : minor modification DENV
Voltage
V1: ~ / 220 - 240 V / 50 Hz
V3: 1~ / 230 V / 50 Hz
T1: 3~ / 230 V / 50 Hz
W1: 3N~ / 400 V / 50 Hz
Y1: 3~ / 380-415 V / 50 Hz
YN: 3~ / 400 V / 50 Hz
Hydraulic module (see option code 12)
N: No Hydraulic components
P: Pump
B: Buffer tank + pump
Option code
****: 4 digits
Option regarding efficiency version, sound version
/H: High ambient version
/A: High efficiency version
/Q: Standard efficiency and Extra low noise version
/Z: High efficiency and Extra low noise version
EWY D 320 AJ YN N **** EE
D – 504 C – 07/05 A – EN pag 5/56
Specifications
TECHNICAL SPECIFICATIONS EWYD-AJYNN 260 280 300 320
Capacity
Capacity control
Unit power input
EER 2,84 2,77 2,76 2,77
COP 3,06 3,09 3,06 2,91
ESEER 4,12 4,08 3,99 3,98
Casing
Dimensions Unit
Weight
Water heat exchanger
Air heat exchanger Type Louvred fins – Grooved tubes
Fan
Compressor
Sound level
Refrigerant circuit
Piping connections Evaporator water inlet/outlet 5” 5” 5” 5”
Safety devices High pressure (pressure switch)
Safety devices Low pressure (pressure switch)
Safety devices Condensation fan magneto-thermal
Safety devices High discharge temperature on the compressor
Safety devices Phase monitor
Safety devices Low pressure ratio
Safety devices High oil pressure drop
Safety devices Low oil pressure
Notes
Cooling kW 255 275 298 321
Heating kW 274 306 330 341
Type Stepless
Minimum capacity % 15,5 15,5 15,5 15,5
Cooling kW 89,8 99,3 108 116
Heating kW 89,5 99,1 108 117
Colour RAL7032
Material Galvanized and painted steel sheet
Height mm 2335 2335 2335 2335
Width mm 2254 2254 2254 2254
Depth mm 3547 3547 3547 4783
Unit kg 3370 3370 3370 4020
Operating weight kg 3500 3500 3500 4150
Type Shell and tube
Water volume l 138 138 138 133
Nominal water flow
rate
Nominal water
pressure drop
Insulation material Closed cell foam elastomer
Type Axial
Drive Direct drive
Diameter mm 800 800 800 800
Nominal air flow m³/min 1932 1914 1908 2580
Model
Type Semi-hermetic single-screw compressor
Oil charge l 26 26 26 26
Quantity 2 2 2 2
Sound power
Sound pressure
Sound pressure +
OPLN
Refrigerant type R-134a R-134a R-134a R-134a
Refrigerant charge kg 76 76 84 96
N. of circuits 2 2 2 2
Cooling capacity, unit power input in cooling and EER are based on the following conditions: evaporator
12°C/7°C; ambient 35°C.
Heating capacity, unit power input in heating and COP are based on the following conditions: condenser
40°C/45°C; ambient 7°CDB/6°CWB.
Cooling l/min 731 788 854 920
Heating l/min 785 877 946 978
Cooling kPa 60 65 74 50
Heating kPa 69 79 90 56
Quantity 6 6 6 8
Speed in cooling rpm 890 890 890 890
Motor output in cooling W 1730 1730 1730 1730
Speed in heating rpm 890 890 890 890
Motor output in heating W 1730 1730 1730 1730
Cooling dBA 99,5 99,5 99,5 100,4
Heating dBA 99,5 99,5 99,5 100,4
Cooling dBA 80,0 80,0 80,0 80,3
Heating dBA 80,0 80,0 80,0 80,3
Cooling dBA 73,7 73,7 73,7 74,1
Heating dBA 76,1 76,1 76,1 76,3
D – 504 C – 07/05 A – EN pag 6/56
ELECTRICAL SPECIFICATIONS EWYD-AJYNN 260 280 300 320
Phase 3~ 3~ 3~ 3~
Frequency Hz 50 50 50 50
Power Supply
Unit
Fans
Compressor
Notes
Voltage V 400 400 400 400
Voltage tolerance
Maximum starting current A 173 174 174 207
Nominal running current cooling A 142 156 169 183
Nominal running current heating A 142 155 168 186
Maximum running current A 208 208 208 246
Maximum current for wires sizing A 229 229 229 270
Nominal running current in cooling A 19,8 19,8 19,8 26,4
Nominal running current in heating A 19,8 19,8 19,8 26,4
Phase 3~ 3~ 3~ 3~
Voltage V 400 400 400 400
Voltage tolerance
Maximum running current A 188 188 188 219
Starting method Inverter
Allowed voltage tolerance ± 10%. Voltage unbalance between phases must be within ± 3%.
Nominal current in cooling mode is referred to installation with 25kA short circuit current and is based on
the following conditions: evaporator 12°C/7°C; ambient 35°C.
Nominal current in heating mode is referred to installation with 25kA short circuit current and is based on
the following conditions: condenser 40°C/45°C; ambient 7°CDB/6°CWB.
Maximum starting current: starting current of biggest compressor + 75% of maximum current of the other
compressor + fans current for the circuit at 75%.
Maximum current for wires sizing: (compressors full load ampere + fans current) x 1,1.
Minimum % -10% -10% -10% -10%
Maximum % +10% +10% +10% +10%
Minimum % -10% -10% -10% -10%
Maximum % +10% +10% +10% +10%
D – 504 C – 07/05 A – EN pag 7/56
TECHNICAL SPECIFICATIONS
Capacity
Capacity control
Unit power input
EER 2,79 2,79 2,71
COP 2,93 3,03 2,96
ESEER 4,00 4,08 3,81
Casing
Dimensions Unit
Weight
Water heat exchanger
Air heat exchanger Type Louvred fins – Grooved tubes
Fan
Compressor
Sound level
Refrigerant circuit
Piping connections Evaporator water inlet/outlet 5” 5” 5”
Safety devices High pressure (pressure switch)
Safety devices Low pressure (pressure switch)
Safety devices Condensation fan magneto-thermal
Safety devices High discharge temperature on the compressor
Safety devices Phase monitor
Safety devices Low pressure ratio
Safety devices High oil pressure drop
Safety devices Low oil pressure
Notes
Cooling kW 343 368 385
Heating kW 361 397 412
Type Stepless
Minimum capacity % 15,5 15,5 15,5
Cooling kW 123 132 142
Heating kW 123 131 139
Colour RAL7032
Material Galvanized and painted steel sheet
Height mm 2335 2335 2335
Width mm 2254 2254 2254
Depth mm 4783 4783 4783
Unit kg 4020 4020 4020
Operating weight kg 4150 4150 4150
Type Shell and tube
Water volume l 133 128 128
Nominal water flow
rate
Nominal water
pressure drop
Insulation material Closed cell foam elastomer
Type Axial
Drive Direct drive
Diameter mm 800 800 800
Nominal air flow m³/min 2580 2568 2544
Model
Type Semi-hermetic single-screw compressor
Oil charge l 26 26 26
Quantity 2 2 2
Sound power
Sound pressure
Sound pressure +
OPLN
Refrigerant type R-134a R-134a R-134a
Refrigerant charge kg 104 104 104
N. of circuits 2 2 2
Cooling capacity, unit power input in cooling and EER are based on the following conditions:
evaporator 12°C/7°C; ambient 35°C.
Heating capacity, unit power input in heating and COP are based on the following conditions:
condenser 40°C/45°C; ambient 7°CDB/6°CWB.
Cooling l/min 983 1055 1104
Heating l/min 1035 1138 1181
Cooling kPa 53 60 65
Heating kPa 58 69 74
Quantity 8 8 8
Speed in cooling rpm 890 890 890
Motor output in cooling W 1730 1730 1730
Speed in heating rpm 890 890 890
Motor output in heating W 1730 1730 1730
Cooling dBA 100,4 100,4 100,4
Heating dBA 100,4 100,4 100,4
Cooling dBA 80,3 80,3 80,3
Heating dBA 80,3 80,3 80,3
Cooling dBA 74,1 74,1 74,1
Heating dBA 76,3 76,3 76,3
EWYD-AJYNN
340 360 380
D – 504 C – 07/05 A – EN pag 8/56
ELECTRICAL SPECIFICATIONS EWYD-AJYNN
Phase 3~ 3~ 3~
Frequency Hz 50 50 50
Power Supply
Unit
Fans
Compressor
Notes
Voltage V 400 400 400
Voltage tolerance
Maximum starting current A 230 231 231
Nominal running current cooling A 193 209 220
Nominal running current heating A 192 205 219
Maximum running current A 276 276 276
Maximum current for wires sizing A 304 304 304
Nominal running current in cooling A 26,4 26,4 26,4
Nominal running current in heating A 26,4 26,4 26,4
Phase 3~ 3~ 3~
Voltage V 400 400 400
Voltage tolerance
Maximum running current A 250 250 250
Starting method Inverter
Allowed voltage tolerance ± 10%. Voltage unbalance between phases must be within ± 3%.
Nominal current in cooling mode is referred to installation with 25kA short circuit current and is based on
the following conditions: evaporator 12°C/7°C; ambient 35°C.
Nominal current in heating mode is referred to installation with 25kA short circuit current and is based
on the following conditions: condenser 40°C/45°C; ambient 7°CDB/6°CWB.
Maximum starting current: starting current of biggest compressor + 75% of maximum current of the
other compressor + fans current for the circuit at 75%.
Maximum current for wires sizing: (compressors full load ampere + fans current) x 1,1.
Minimum % -10% -10% -10%
Maximum % +10% +10% +10%
Minimum % -10% -10% -10%
Maximum % +10% +10% +10%
340 360 380
D – 504 C – 07/05 A – EN pag 9/56
Table 1 - Sound levels EWYD-AJYNN in cooling and heating
Unit
size
260
280
300
320
340
360
380
Note: The values are according to ISO 3744 and refer to units without pumps kit.
Sound pressure level at 1 m distance from the unit in semi-spherical free field
(ref. factor 2 x 10-5 Pa)
63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz dB(A) dB(A)
74,9 73,5 73,7 72,8 79,0 67,2 58,6 49,8
74,9 73,5 73,7 72,8 79,0 67,2 58,6 49,8
74,9 73,5 73,7 72,8 79,0 67,2 58,6 49,8
75,2 73,8 74,0 73,1 79,3 67,5 58,9 50,1
75,2 73,8 74,0 73,1 79,3 67,5 58,9 50,1
75,2 73,8 74,0 73,1 79,3 67,5 58,9 50,1
75,2 73,8 74,0 73,1 79,3 67,5 58,9 50,1
Table 2 - Sound levels EWYD-AJYNN+OPLN in cooling
Unit
size
260
280
300
320
340
360
380
Note: The values are according to ISO 3744 and refer to units without pumps kit.
Sound pressure level at 1 m distance from the unit in semi-spherical free field
(ref. factor 2 x 10-5 Pa)
63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz dB(A) dB(A)
74,2 70,5 69,0 67,7 72,3 62,0 53,6 44,4
74,2 70,5 69,0 67,7 72,3 62,0 53,6 44,4
74,2 70,5 69,0 67,7 72,3 62,0 53,6 44,4
74,6 70,9 69,4 68,1 72,7 62,4 54,0 44,8
74,6 70,9 69,4 68,1 72,7 62,4 54,0 44,8
74,6 70,9 69,4 68,1 72,7 62,4 54,0 44,8
74,6 70,9 69,4 68,1 72,7 62,4 54,0 44,8
Power
80,0 99,5
80,0 99,5
80,0 99,5
80,3 100,4
80,3 100,4
80,3 100,4
80,3 100,4
Power
73,7 93,2
73,7 93,2
73,7 93,2
74,1 94,2
74,1 94,2
74,1 94,2
74,1 94,2
Table 3 - Sound levels EWYD-AJYNN+OPLN in heating
Unit
size
260
280
300
320
340
360
380
Note: The values are according to ISO 3744 and refer to units without pumps kit.
Sound pressure level at 1 m distance from the unit in semi-spherical free field
(ref. factor 2 x 10-5 Pa)
63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz dB(A) dB(A)
77,8 73,8 72,0 70,5 74,5 64,8 56,5 47,2
77,8 73,8 72,0 70,5 74,5 64,8 56,5 47,2
77,8 73,8 72,0 70,5 74,5 64,8 56,5 47,2
77,9 73,9 72,1 70,6 74,7 65,0 56,6 47,4
77,9 73,9 72,1 70,6 74,7 65,0 56,6 47,4
77,9 73,9 72,1 70,6 74,7 65,0 56,6 47,4
77,9 73,9 72,1 70,6 74,7 65,0 56,6 47,4
Power
76,1 95,6
76,1 95,6
76,1 95,6
76,3 96,4
76,3 96,4
76,3 96,4
76,3 96,4
D – 504 C – 07/05 A – EN pag 10/56
Operating limits
Storage
The environmental conditions must be within the following limits:
Minimum ambient temperature : -20°C
Maximum ambient temperature : 57°C
Maximum R.H. : 95% not condensing
WARNING
Storing below the minimum temperature mentioned above may cause damage to components such as the electronic
controller and its LCD display.
WARNING
Storing above the maximum temperature may cause opening of the safety valves on the compressors’ suction line.
WARNING
Storing in condensing atmosphere may damage the electronic components.
Operation
Operation is allowed within the limits mentioned in the following diagrams.
WARNING
Operation out of the mentioned limits may damage the unit.
For any doubts contact the factory.
WARNING
The maximum operating altitude is 2,000 m above sea level.
Please contact the factory if the equipment is to be operated at altitudes of between 1,000 and 2,000 m above sea
level.
Outside ambient temperature (°C) Outside ambient temperature (°C)
Leaving water temperature (°C) Leaving water temperature (°C)
Glycol Glycol
OPFS required OPFS required
D – 504 C – 07/05 A – EN pag 11/56
Figure 1 - Operating limits in cooling - EWYD-AJYNN/AJYNN+OPLN
Glycol
Envelope for cooling - McEnergy HPI ST/LN
50
40
30
20
10
0
-10
OPFS required
Outside Ambient Temperature (°C)
-20
-10 -5 0 5 10 15 20
Leaving water temperature (°C)
Figure 2 - Operating limits in heating - EWYD-AJYNN/AJYNN+OPLN
25
20
15
10
5
0
-5
-10
Outside Ambient Temperature (°C)
-15
Envelope for heating - McEnergy HPI ST/LN
30 35 40 45 50 55 60
Leaving water temperature (°C)
D – 504 C – 07/05 A – EN pag 12/56
Mechanical installation
Shipping
The stability of the machine during shipping must be ensured. If the machine is shipped with a wooden cross-plank on its
base, this cross-plank must only be removed after the final destination has been reached.
Responsibility
The manufacturer declines all present and future responsibility for any damage to persons, animals or things caused by
negligence of operators failing to follow the installation and maintenance instructions in this manual.
All safety equipment must be regularly and periodically checked in accordance with this manual and with local laws and
regulations regarding safety and environment protection.
Safety
The machine must be firmly secured to the ground.
It is essential to observe the following instructions:
- The machine can only be lifted using the hoist points marked in yellow that are fixed to its base. These are the only
points that can support the entire weight of the unit.
- Do not allow unauthorised and/or unqualified personnel to access the machine.
- It is forbidden to access the electrical components without having opened the machine’s main switch and switched off
the power supply.
- It is forbidden to access the electrical components without using an insulating platform. Do not access the electrical
components if water and/or moisture are present.
- All operations on the refrigerant circuit and on components under pressure must be carried out by qualified personnel
only.
- Replacement of a compressor or addition of lubricating oil must be carried out by qualified personnel only.
- Sharp edges and the surface of the condenser section could cause injury. Avoid direct contact.
- Switch off the machine’s power supply, by opening the main switch, before servicing the cooling fans and/or
compressors. Failure to observe this rule could result in serious personal injury.
- Avoid introducing solid objects into the water pipes while the machine is connected to the system.
- A mechanical filter must be installed on the water pipe connected to the heat exchanger inlet.
- The machine is supplied with safety valves, that are installed both on the high-pressure and on the low-pressure
sides of the refrigerant circuit.
WARNING
Before carrying out any operation on the machine, please read carefully the instruction and operating manual.
Installation and maintenance must be carried out solely by qualified personnel that is familiar with provisions of the
law and local regulations and has been trained properly or has experience with this type of equipment.
WARNING
Avoid installing the chiller in areas that could be dangerous during maintenance operations, such as platforms
without parapets or railings or areas not complying with the clearance requirements around the chiller.
Moving and lifting
Avoid bumping and/or jolting during unloading from the lorry and moving the machine. Do not push or pull the machine
from any part other than the base frame. Secure the machine inside the lorry to prevent it from moving and causing
damage to the panels and to the base frame. Do not allow any part of the machine to fall during transportation or
unloading, as this could cause serious damage.
D – 504 C – 07/05 A – EN pag 13/56
All units of the series are supplied with lifting points marked in yellow. Only these points may be used for lifting the unit,
as shown in the following figure.
Procedure for extracting the machine from the container.
Container Kit Optional
Figure 3 - Lifting the unit
ATTENTION
Both the lifting ropes and the spacing bar and/or scales must be strong enough to support the machine safely. Please
check the unit’s weight on the machine’s nameplate.
The weights shown in the “Technical specifications” tables in the “Specifications” chapter refer to standard units.
Some specific machines might have accessories that increase their overall weight (pumps, heat recovery, copper
condenser coils, etc.).
ATTENTION
The machine must be lifted with the utmost attention and care. Avoid jolting when lifting and lift machine very slowly,
keeping it perfectly level.
Positioning and assembly
All units are designed for installation outdoors, either on balconies or on the ground, provided that the installation area is
free of obstacles that could reduce air flow to the condensers bank.
The machine must be installed on a robust and perfectly level foundation; should the machine be installed on balconies
or roofs, it might be necessary to use weight distribution beams.
For installation on the ground, a strong cement base that is at least 250 mm wider and longer than the machine must be
provided. Also, this base must be able to support the weight of the machine as stated in the technical specifications.
If the machine is installed in places that are easily accessible to people and animals, it is advisable to install protection
gratings for the condenser and compressor sections.
To ensure the best possible performance on the installation site, the following precautions and instructions must be
followed:
• Avoid air flow recirculation.
• Make sure that there are no obstacles to hamper air flow.
• Air must circulate freely to ensure proper flow in and flow out.
• Make sure to provide a strong and solid foundation to reduce noise and vibrations as much as possible.
D – 504 C – 07/05 A – EN pag 14/56
• Avoid installation in particularly dusty environments, in order to reduce soiling of condensers bank.
• The water in the system must be particularly clean and all traces of oil and rust must be removed. A mechanical
water filter must be installed on the machine’s inlet piping.
Minimum space requirements
It is fundamental to respect minimum distances on all units in order to ensure optimum ventilation to the condenser
banks. Limited installation space could reduce the normal air flow, thus significantly reducing the machine’s performance
and considerably increasing consumption of electrical energy.
When deciding where to position the machine and to ensure a proper air flow, the following factors must be taken into
consideration: avoid any warm air recirculation and insufficient air supply to the air-cooled condenser.
Both these conditions can cause an increase of condensing pressure, which leads to a reduction in energy efficiency and
refrigerating capacity. Thanks to the geometry of their air-cooled condensers, the units are less affected by poor air
circulation conditions.
Also, the software has particularly the ability to compute the machine’s operating conditions to optimise the load under
abnormal operating circumstances.
Every side of the machine must be accessible for post-installation maintenance operations. Figure 3 shows the minimum
space required.
Vertical air discharge must not be obstructed as this would significantly reduce capacity and efficiency.
If the machine is surrounded by walls or obstacles of the same height as the machine, it must be installed at a distance
of at least 2500 mm. If these obstacles are higher, the machine must be installed at a distance of at least 3000 mm.
Should the machine be installed without observing the recommended minimum distances from walls and/or vertical
obstacles, there could be a combination of warm air recirculation and/or insufficient supply to the air-cooled condenser
which could cause a reduction of capacity and efficiency.
Figure 4 - Minimum clearance requirements for machine maintenance
D – 504 C – 07/05 A – EN pag 15/56
In any case, the microprocessor will allow the machine to adapt itself to new operating conditions and deliver the
maximum capacity available under any given circumstances, even if the lateral distance is lower than recommended.
When two or more machines are positioned side by side, a distance of at least 3600 mm between the respective
condenser banks is recommended.
For further solutions, please consult Daikin technicians.
Figure 5 - Minimum recommended installation clearances
Sound protection
When sound levels require special control, great care must be exercised to isolate the machine from its base by
appropriately applying anti-vibration elements (supplied as an option). Flexible joints must be installed on the water
connections, as well.
Water piping
Piping must be designed with the lowest number of elbows and the lowest number of vertical changes of direction. In this
way, installation costs are reduced considerably and system performance is improved.
The water system should have:
1. Anti-vibration mountings in order to reduce transmission of vibrations to the underlying structure.
2. Isolating valves to isolate the machine from the water system during service.
3. Manual or automatic air venting device at the system’s highest point.; drain device at the system’s lowest point.
Neither the evaporator nor the heat recovery device must be positioned at the system’s highest point.
4. A suitable device that can maintain the water system under pressure (expansion tank, etc.).
5. Water temperature and pressure indicators on the machine to assist the operator during service and
maintenance.
6. A filter or device that can remove foreign particles from the water before it enters the pump (in order to prevent
cavitation, please consult the pump manufacturer for the recommended type of filter). The use of a filter prolongs
the life of the pump and helps keep the water system in a better condition.
7. Another filter must be installed on the machine inlet water pipe, near the evaporator and heat recovery (if
installed). The filter prevents solid particles from entering the heat exchanger, as they could damage it or reduce
its heat exchanging capacity.
D – 504 C – 07/05 A – EN pag 16/56
8. The shell and tube heat exchanger has an electrical resistance with a thermostat that ensures protection against
water freezing at ambient temperatures as low as –25°C. All the other water piping outside the machine must
therefore be protected against freezing.
9. The heat recovery device must be emptied of water during the winter season, unless an ethylene glycol mixture in
appropriate percentage is added to the water circuit.
10. If the machine is intended to replace another, the entire water system must be emptied and cleaned before the
new unit is installed. Regular tests and proper chemical treatment of water are recommended before starting up
the new machine.
11. In the event that glycol is added to the water system as anti-freeze protection, pay attention to the fact that suction
pressure will be lower, the machine’s performance will be lower and water pressure drops will be greater. All
machine-protection systems, such as anti-freeze, and low-pressure protection will need to be readjusted.
Before insulating water piping, check that there are no leaks.
Figure 6 - Water piping connection for heat recovery exchangers
Gauge Gauge
Flexible connector Flexible connector
Flow switch Flow switch
Thermometer Thermometer
Isolating valve Isolating valve
Pump Pump
Filter Filter
D – 504 C – 07/05 A – EN pag 17/56
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