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Daikin EWAD TZ User manual

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D–EIMAC00907–16EN - 1/20
Inverter
Installation, Operation and Maintenance Manual
Air cooled chiller with inverter
driven screw compressor
EWAD~TZ
Refrigerant: R-134a
Original Instructions
Installation, Operation and Maintenance Manual
D–EIMAC00907-16EN
D–EIMAC00907–16EN - 2/20
A
Typical refrigerant circuit - Water inlet and outlet are indicative. Please refer to the machine dimensional diagrams for exact water connections.
D-EIMAC00907-16EN - 3/20
B
Typical refrigerant circuit with heat recovery - Water inlet and outlet are indicative. Please refer to the machine dimensional diagrams for exact water connections.
D-EIMAC00907-16EN - 4/20
Legend
1
Compressor
2
Evaporator
3
Condenser coil & Axial fan
4
Electronic expansion valve
5
Economizer
6
Dehydration filter
7
Liquid and humidity indicator
8
Sution valve
9
Economizer electronic expansion
valve
10
Low-pressure safety valve
11
High-pressure safety valve
12
Heat exchanger (VFD cooling)
13
Heat exchanger (VFD cooling)
solenoid valve
14
Discharge shut off valve
15
Liquid line isolating valve
16
¼” SAE Flare valve
17
Evaporator water inlet connection
18
Evaporator water outlet connection
19
2 Way charging valve
20
Heat Recovery (Optional)
21
Heat Recovery water outlet
connection
22
Heat Recovery water inlet
connection
F13-F13A
High pressure switch
DT
Discharge temperature sensor
CPT
Condenser pressure transducer
EPT
Evaporator pressure transducer
ST
Suction temperature sensor
PTeco
Economizer pressure transducer
TTeco
Economizer temperature
transducer
TTvfd
VFD Temperature transducer
EEWT
Evaporator Entering Water
Temperature probe
ELWT
Evaporator Leaving Water
Temperature probe
D–EIMAC00907–16EN - 5/20
This manual is an important supporting document for qualified personnel but it is not intended to replace such personnel.
Thank you for purchasing this chiller
READ THIS MANUAL CAREFULLY BEFORE
INSTALLING AND STARTING UP THE UNIT.
IMPROPER INSTALLATION COULD RESULT IN
ELECTRIC SHOCK, SHORT-CIRCUIT, LEAKS, FIRE
OR OTHER DAMAGE TO THE EQUIPMENT OR
INJURE TO PEOPLE.
THE UNIT MUST BE INSTALLED BY A
PROFESSIONAL OPERATOR/TECHNICIAN
UNIT STARTUP HAS TO BE PERFORMED BY
AUTHORIZED AND TRAINED PROFESSIONAL
ALL ACTIVITIES HAVE TO BE PERFORMED
ACCORDING TO LOCAL LAWS AND REGULATION.
UNIT INSTALLATION AND START UP IS
ABOSOLUTELY FORBIDDEN IF ALL INSTRUCTION
CONTAINED IN THIS MANUAL ARE NOT CLEAR.
IF CASE OF DOUBT CONTACT THE
MANUFACTURER REPRESENTATIVE FOR ADVICE
AND INFORMATION.
Description
The unit you bought is an “air cooled chiller”, a machine aimed
to cool water (or water-glycol mixture) within the limits
described in the following. The unit operation is based on
vapour compression, condensation and evaporation according
to reverse Carnot cycle. The main components are:
- Screw compressor to rise the refrigerant vapour pressure
from evaporation pressure to condensation pressure
- Evaporator, where the low pressure liquid refrigerant
evaporates to cool the water
- Condenser, where high pressure vapour condensate
rejecting heat removed from the chilled water in the
atmosphere thanks to an air cooled heat exchanger.
- Expansion valve allowing to reduced the pressure of
condensed liquid from condensation pressure to
evaporation pressure.
General Information
All units are delivered with wiring diagrams, certified
drawings, nameplate; and DOC (Declaration Of
Conformity); these documents show all technical data
for the unit you have bought and they MUST BE
CONSIDERED ESSENTIAL DOCUMENTS OF THIS
MANUAL
In case of any discrepancy between this manual and the
equipment’s documents please refer to on board documents.
In case of any doubt contact the manufacturer representative.
The purpose of this manual is to allow the installer and the
qualified operator to ensure proper installation, commissioning
and maintenance of the unit, without any risk to people,
animals and/or objects.
Receiving the unit
The unit must be inspected for any possible damage
immediately upon reaching final place of installation. All
components described in the delivery note must be inspected
and checked.
Should the unit be damaged, do not remove the damaged
material and immediately report the damage to the
transportation company and request they inspect the unit..
Immediately report the damage to the manufacturer
representative, a set of photographs are helpful in recognizing
responsibility
Damage must not be repaired before the inspection of the
transportation company representative.
Before installing the unit, check that the model and power
supply voltage shown on the nameplate are correct.
Responsibility for any damage after acceptance of the unit
cannot be attributed to the manufacturer.
Operating limits
Storing Storage
Environmental conditions must be within the following limits:
Minimum ambient temperature : -20°C
Maximum ambient temperature : 57°C
Maximum R.H. : 95% not condensing
Storing below the minimum temperature may cause damage to
components. Storing above the maximum temperature causes
opening of safety valves. Storing in condensing atmosphere
may damage electronic components.
Operation
Operation is allowed within the following limits:
Evaporator Leaving Water Temperature: 4…18°C (Cool
Mode), -8…18°C (Cool with glycol, Ice Mode)
Outside Ambient Temperature @ full load:
Silver Efficiency Version: 10…47°C
Gold Efficiency Version: -18…50°C
Platinum Efficiency Version: -18…52°C
Operational envelope can be extended through selection of
specific options (such as high ambient kit, brine version, etc)
which allow the unit to operate down to -8°C evaporator
leaving temperature and/or up to 52°C ambient temperature at
full load.
The above mentioned values represent a guideline, please
refer to the chiller selection software for real operating limits for
the specific model.
As a general rule, The unit should be operated with an
evaporator water flow rate between 50% and 140% of nominal
flow rate (at standard operating conditions), however check
with the chiller selection software the correct minimum and
maximum allowed values for the specific model.
Operation out of the mentioned limits may damage the unit.
In case of doubts contact manufacturer representative.
D-EIMAC00907-16EN - 6/20
Figure 1 - Description of the labels applied to the electrical panel
Single circuit unit
Double circuits unit
Label Identification
1–Manufacturer’s logo
5–Cable tightening warning
2–Gas type
6–Non flammable gas symbol
3–Hazardous Voltage warning
7–Unit nameplate data
4–Electrical hazard symbol
8–Lifting instruction
D–EIMAC00907–16EN - 7/20
Safety
The unit must be firmly secured to the soil.
It is essential to observe the following instructions:
The unit can only be lifted using the lifting points marked
in yellow fixed to its base.
It is forbidden to access the electrical components without
having opened the unit 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.
Sharp edges and the surface of the condenser section
could cause injury. Avoid direct contact and use adeguate
protection device
Switch off 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.
Do not introduce solid objects into the water pipes while
the unit is connected to the system.
A mechanical filter must be installed on the water pipe
connected to the heat exchanger inlet.
The unit is supplied with safety valves, that are installed
both on the high-pressure and on the low-pressure sides
of the refrigerant circuit.
It is absolutely forbidden to remove all protections of
moving parts.
In case of sudden stop of the unit, follow the instructions on the
Control Panel Operating Manual which is part of the on-
board documentation delivered to the end user.
It is strongly recommended to perform installation and
maintenance with other people. In case of accidental injury or
unease, it is necessary to:
-keep calm
-press the alarm button if present in the installation site
-move the injured person in a warm place far from the unit
and in rest position
-contact immediately emergency rescue personnel of the
building or the Health Emergency Service
-wait without leaving the injured person alone until the
rescue operators come
-give all necessary information to the rescue operators
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.
Noise
The unit is a source of noise mainly due to rotation of
compressors and fans.
The noise level for each model size is listed in sales
documentation.
If the unit is correctly installed, operated and manteined the
noise emission level do not require any special protection
device to operate continuosly close to the unit without any risk.
In case of installation with special noise requirements it could
be necessary to install additional sound attenuation devices.
Moving and lifting
Avoid bumping and/or jolting during loading/unloading unit
from the truck and moving it. Do not push or pull the unit from
any part other than the base frame. Secure the unit inside the
truck to prevent it from moving and causing damages. Do not
allow any part of the unit to fall during transportation or
loading/unloading.
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.
Use spacing bars to prevent damage to the condensation
bank. Position these above the fan grills at a distance of at
least 2.5 metres.
Both the lifting ropes and the spacing bars must be
strong enough to support the unit safely. Please check
the unit’s weight on the unit nameplate.
The unit must be lifted with the utmost attention and care
following lifting label instructions; lift unit 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 coil.
The unit must be installed on a robust and perfectly level
foundation; should the unit be installed on balconies or roofs, it
might be necessary to use weight distribution beams.
Figure 2 - Lifting
Unit with 4 lifting points
(The drawing shows only the 6 fans version. For the 4 fans version the lifting mode is the same)
D-EIMAC00907-16EN - 8/20
Unit with 6 lifting points
(The drawing shows only the 12 fans version. The lifting mode is the same for the different number of fans)
Figure 3 –Unit Levelling
For installation on the ground, a strong concrete base, at least
250 mm thickness and wider than the unit must be provided.
This base must be able to support the weight of the unit.
The unit must be installed above antivibrating mounts (AVM),
rubber or spring types. The unit frame must be perfectly
levelled above the AVM.
Installation such as in the figure above must always be
avoided. In case the AVM’s are not adjustable (spring type are
normally not adjustable) the flatness of the unit frame must be
guaranteed by using metal plate spacers.
Before unit commissioning, the flatness must be verified by
using a laser levelling device or other similar devices. The
flatness shall not be over 5 mm for units within 7 m length and
10 mm for units over 7 m.
If the unit is installed in places that are easily accessible to
people and animals, it is advisable to install protection grids for
the condenser and compressor sections.
To ensure best 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.
D-EIMAC00907-16EN - 9/20
Make sure to provide a strong and solid foundation to
reduce noise and vibrations.
Avoid installation in particularly dusty environments, in
order to reduce soiling of condensers coils.
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 unit’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 coils.
When deciding where to position the unit and to ensure a
proper air flow, the following factors must be taken into
consideration:
avoid any warm air recirculation
avoid 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.
Any side of the unit must be accessible for post-installation
maintenance operations. Figure 3 shows the minimum space
required.
Vertical air discharge must not be obstructed.
If the unit is surrounded by walls or obstacles of the same
height as the unit, this must be installed at a distance no lower
than 3000 mm.
In case of two chillers installed in free field, minimum
recommended distance between them is 3600 mm; in case of
two chillers in a row, minimum distance is 1500 mm. The
pictures below show example of recommended installations.
Should the unit 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.
In any case, the microprocessor will allow the unit to adapt
itself to new operating conditions and deliver the maximum
available capacity under any given circumstances, even if the
lateral distance is lower than recommended, unless the
operating conditions should affect personel safety or unit
reliability.
Figure 4 –Minimum clearance requirements
D-EIMAC00907-16EN - 10/20
The minimum distances, reported above, ensure functionality
of the chiller in most applications. However, there are specific
situations which include multiple chiller installations: in this
case the following recommendations are to be followed:
Multiple chiller installed side by side in a free field with
dominant wind.
Considering an installation in areas with a dominant wind from
a specific direction (as shown in the Fig.5):
Chiller N°1: is performing normally without any
ambient over-temperature
Chiller N° 2: is working in a warmed ambient. The
first circuit (from the left) is working with air
recirculating from Chiller 1 and the second circuit to
the recirculating air from the chiller N°1 and
recirculation from itself.
Chiller N° 3: circuit on the left is working in a over-
temperature ambient due to the recirculating air from
the other two chillers, circuit on the right is working
quite normally.
In order to avoid the hot air recirculation due to dominant
winds, the installation where all chillers are aligned to the
dominant wind is preferred (see figure below):
Multiple chiller installed side by side in a compound.
In case of compounds with walls of the same height of the
chillers or higher, the installation is not recommended. Chiller 2
and chiller 3 work with sensible higher temperature due to the
enhanced recirculation. In this case special precautions must
be taken in to account according to the specific installation (eg:
louvered walls, install the unit on base frame in order to
increase the height, ducts on the discharge of the fans, high lift
fans, etc).
All the above cases are even more sensitive in case of design
conditions close to the limits of the unit operating envelope.
NOTE: Daikin cannot be considered responsible in case of
malfunctions generated by hot air recirculation or insufficient
airflow as result of improper installation if the above
recommendations are ignored.
Figure 5 –Multiple Chiller Installation