Daikin EWAP800AJYNN User manual

D – 508 C – 07/02 D – EN pag. 1/36
Air-cooled screw chillers
EWAP 800-C18AJYNN
EWAP 850-C18AJYNN/A
50Hz – Refrigerant: R-407C
Installation, Operation and Maintenance Manual
D – 508 C – 07/02 D – EN

D – 508 C – 07/02 D – EN pag. 2/36

D – 508 C – 07/02 D – EN pag. 3/36
Introduction
General description
Each unit is completely assembled, wired, evacuated, charged, tested, and ready for installation. The main
components are air-cooled condensers with integral sub-cooler sections, accessible semi-hermetic single-screw
compressors, shell-and-tube evaporators, shell-and-tube water heat recovery condensers (optional), oil
separators, complete refrigerant piping and electrical panel (including control and power sections). Liquid line
components are shut-off valves, charging valves, filter-dryers, sight-glass/moisture indicators, electronic expansion
valves, liquid receivers (only with total heat recovery option). Other features are compressor heaters, evaporator
heater for low ambient water freeze protection, automatic pump-down during circuit shutdown and fully integrated
microprocessor control system.
The chiller uses R407C refrigerant and operates at positive pressures.
Purpose of the manual
The manual allows the installer and the operator to perform correctly all the required operations for unit installation
and maintenance without causing any damage to the chiller or injuries to qualified personnel.
Nomenclature
EWA P 600 AJ YN N **** /A
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, heatpump
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
letter J-W… : minor modification New Series
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/Heat recovery version/
Pump & electrical options (Consult Selection software)
N: No Hydraulic components
M: Modular
A-V: Combination of specific options
Option code (Consult Selection software)
****: 4 digits
Option regarding efficiency version, sound version
/H: High ambient version
/A: High efficiency version
/Q: Extra low noise version
/Z: High efficiency and Extra low noise version

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WARNING
This manual provides information about the features and standard procedure for the complete series.
All units are delivered from the factory complete with wiring diagrams and dimensional drawings including size and
weight for each model.
WIRING DIAGRAMS AND DIMENSIONAL DRAWING S 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.
Installation
Receiving and handling
The unit should be inspected immediately after receipt for possible damage.
All items on the bill of lading should be carefully checked to ensure a complete shipment. The unit should be
carefully checked and shipping damages should be reported to the carrier. The unit serial plate should be checked
before unloading the unit to ensure that it agrees with the power supply available. Physical damage to the unit
after acceptance is not DAIKIN’s responsibility.
Responsibilities
DAIKIN declines all present and future responsibilities referred to injuries to people and damages to things and to
the unit, caused by operator's negligence, failure to respect installation/maintenance data from this manual, failure
to respect the current regulations regarding the safety of both the equipment and qualified personnel in charge of
the installation and the maintenance.
Servicing and maintenance personnel
Experienced personnel with specific training in refrigeration must carry out servicing and maintenance of the unit.
Regular checking of safety devices should be carried out, but routine maintenance should be carried out in line
with the recommendation list in the main section.
The simple design of the refrigeration circuit minimises potential problems during normal unit operation.
Safety
The unit must be suitably clamped to the ground.
It is necessary to follow these cautions and warnings.
- Lift the unit only using the proper tools that are able to support the weight of the unit fixed in the base frame on
the yellow holes.
- No admittance to unauthorised or unqualified personnel should be allowed.
- No operation on the electrical components is allowed without having switched off the power supply.
- No operation on the electrical components is allowed without using insulated platforms; no water or moisture
should be present.
- All operations on the refrigerant circuit and pressurised components are to be performed by qualified personnel
only.
- Replacing the compressor or adding oil may only be performed by qualified personnel.
- Sharp edges and coil surface are potential injury hazards. Avoid contact with them.
- Disconnect all electrical power supply to the unit while servicing the condenser fan motors. Failure to observe this
rule may cause bodily injuries.
- Avoid contamination with foreign bodies in the water piping when connecting the unit to the water system.
-Fit a mechanical filter to the piping connected to the evaporator inlet.
-The unit is equipped with safety relief valves installed on both high and low pressure side of the refrigerant
circuit.

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Warning
Check the instructions for use before operating the unit.
Installation and maintenance must be performed only by qualified personnel with the required knowledge about
chillers, local codes and regulations. Unit installation must be avoided in areas that could be considered
dangerous for maintenance operations.
Transport
For transport in containers, the optional container kit is available on request, for preventing damage and to
facilitate the sliding of the chiller into the container during push-in and pull-out operations.
The kit includes:
- base frame bracing plus two lifting rings fixed on it;
- wood planks fixed below the unit base frame.
The additional lifting rings are on the same side of the control panel, therefore the chiller has to be loaded into the
container with the control panel on the container doors’ side.
Handling and lifting
Care should be taken to avoid rough handling or shocks due to the unit being dropped. Do not push or pull the unit
from anything else than the base, and block the pushing vehicle away from the unit to prevent damage to the
sheet metal cabinet and end frame.
Never allow any part of the unit to fall during unloading or moving as this may result in serious damage.
To lift the unit, suitable holes are provided in the unit base, and spreader bars and cables should be used to
prevent damage to the condenser coils or to the cabinet.
Use spreader bars to avoid
damage to the
unit
Suggested lifting arrangement for units with 2 compressors
Suggested lifting arrangement for units with 3 compressors

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Location
These units are produced for outdoor installation on roof floors or below ground level on the condition that the the
condenser air flow is not obstructed. The unit should be positioned on a solid foundation and perfectly leveled; in
case of installation on roofs or floors, it may be advisable to arrange the use of suitable weight distribution beams.
When the unit is installed on the ground, a concrete base, at least 250 mm wider and longer than the unit’s
footprint, should be laid. Furthermore, this base should withstand the unit weight mentioned in the technical data
table. When the unit is positioned in an area that is easily accessible by persons or animals, it is advisable to fit
guards for the condenser coil and, when necessary, guards for the evaporator area.
To obtain the best performance in the installation location, make sure the following requirements are met:
−Avoid a short airflow re-circulation.
−Ensure that obstacles do not obstruct proper airflow.
−To reduce noise and vibration, a stiff floor is required.
−Avoid a dusty environment in order to keep the condenser clean.
−Chiller water must be quite clean; oil traces and rust particles must be removed. Fit a water filter on the water
inlet pipes.
Space requirements
Since these units are air-cooled, it is important to ensure sufficient airflow across the condenser coils.
Two conditions must be avoided to achieve best performance: warm air re-circulation and coil starvation.
Both these conditions cause an increase in the condensing pressure, which reduces unit efficiency and capacity.
Each side of the unit must be accessible after installation for periodic service. Figure 3 shows the minimum
clearance requirements.
Vertical condenser air discharge must be unobstructed, because otherwise the unit efficiency and capacity would
be significantly reduced.
If the unit is positioned in a location surrounded by walls or obstacles of the same height as the unit, the unit
should be at least 2500 mm from any obstacle (figure 4). If the obstacles are higher than the unit, the unit should
be at least 3000 mm from the obstacles (figure 5). Units installed closer than the minimum recommended distance
to walls or other vertical risers may experience a combination of coil starvation and warm air re-circulation, thus
causing reduced unit capacity and efficiency.
When two or more units are positioned side by side it is recommended that the condenser coils of each unit be at
least at 3600 mm apart (figure 6).
For different installation solutions, consult DAIKIN technicians.
Figure 4
Figure 3
Figure 6
Figure 5

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Acoustic protection
When the noise level must meet special requirements, it will be necessary to pay the maximum attention to ensure
perfect insulation of the unit from the support base by applying appropriate vibration-dampening devices, applying
vibration-dampening mounts on the water pipes and on the electrical connections.
Water piping
Due to the variety of piping practices, it is advisable to follow the recommendations of local authorities. They can
supply the installer with the proper building and safety codes required for a safe and proper installation.
Basically, the piping should be designed with a minimum number of bends and changes in elevation to keep
system cost down and performance up. It should contain:
1. Vibration eliminators to reduce vibration and noise transmission to the building.
2. Shutoff valves to isolate the unit from the piping system during unit servicing.
3. Manual or automatic air vent valves at the higher points of the system. Drains at the lower points of the
system. The evaporator and heat recovery condensers should not be the highest point in the piping system.
4. Devices to maintain adequate system water pressure (e.g. expansion tank or regulating valve).
5. Water temperature and pressure indicators located at the unit to aid in unit servicing.
6. A strainer or devices to remove foreign matter from the water before it enters the pump. The strainer should
be placed far enough upstream to prevent cavitations at the pump inlet (consult pump manufacturer for
recommendations). The use of a strainer will prolong pump life and help maintain high system performance
levels.
7. A strainer should be placed in the supply water line just prior to the inlet of the evaporator and heat recovery
condensers. This will aid in preventing foreign material from entering and decreasing the performance of the
heat exchangers.
8. The shell-and-tube evaporator has a thermostat and an electric heater to prevent freeze-up down to -28°C.
Any water piping to the unit must be protected to prevent freezing.
9. The shell-and-tube heat recovery condensers must be empty of water during the winter season, unless you fill
the water circuit with ethylene glycol.
10. If the unit is used as a replacement chiller on a previously existing piping system, the system should be
thoroughly flushed prior to unit installation and then regular chilled water analysis and chemical water
treatment is recommended immediately at equipment start-up.
11. In the event glycol is added to the water system, as an afterthought for freeze protection, recognize that the
refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop greater.
System safety devices such as freeze protection and low pressure protection must be reset.
Prior to insulating the piping and filling the system, a preliminary leak check should be made.
Evaporator/Heat Recovery condenser freeze protection
All evaporators are equipped with a thermostatically controlled electric heater that provides freeze protection down
to -28°C. However, this should not be the only method of freeze protection. Unless the evaporator and heat
recovery condensers are flushed and drained as is described below in note 4, two or more of the remaining three
recommendations must be followed as part of the system design:
1. Continuous circulation of water through the piping and the heat exchanger.
2. Filling of glycol solution in the chilled water circuit.
3. Additional insulation and heating of the exposed piping.
4. Draining and flushing the chiller vessel with air during winter season.
It is the responsibility of the installing contractor and/or on-site maintenance personnel to ensure that this
additional protection is provided. Routine checks should be made to ensure adequate freeze protection is
maintained.
Failure to do so may result in damage to unit components. Freeze damage is not considered a warranty failure.

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Flow switch
A water flow switch must be mounted in either the entering or leaving water line to insure adequate water flow
through the evaporator before starting the unit. This will safeguard against slugging the compressors on start-up. It
serves to shut down the unit in the event that water flow is interrupted to protect against evaporator freeze-up.
Whenever the unit is equipped with the heat recovery condensers a water flow switch must be mounted in either
the entering or leaving water line to ensure adequate water flow before switching the unit in “Heat recovery mode”.
It prevents the unit from shutting down due to high condensing pressure.
A flow switch is available from DAIKIN; this is a "paddle" type switch which may be adapted to any pipe size from
5" (127 mm) to 8" (203 mm) nominal.
Certain minimum flow rates are required to close the switch (Table 1).
NOMINAL PIPE
SIZE INCHES (MM) MINIMUM REQUIRED FLOW TO ACTIVATE SWITCH –
LITERS PER SECONDS
5 (127) 3.7
6 (152) 5.0
8 (203) 8.8
Table 2 – Operating limits – EWAP-AJYNN
Unit version Standard OPRN-OPLN
Max ambient temperature (1) °C 42 38
Min ambient temperature °C +10 (2) +10 (2)
Max leaving evaporator water temperature °C +10 +10
Min leaving evap. water temp. (without glycol) °C +4 +4
Min leaving evap. water temp. (with glycol) °C -8 -8
Max evaporator ΔT °C 6 6
Min evaporator ΔT °C 4 4
Note:
(1) Max ambient temperatures are referred to units working at full load. With higher temperatures the chillers will
unload.
(2) When the air temperature is lower than +10°C you need the fan speed control device (OPFS). It allows the unit to
operate with air temperature down to –10°C. Low ambient operation (OPLA) allows to reach –18°C.
Table 3 – Operating limits – EWAP-AJYNN/A
Unit version Standard OPRN-OPLN
Max ambient temperature (1) °C 46 42
Min ambient temperature °C +10 (2) +10 (2)
Max leaving evaporator water temperature °C +10 +10
Min leaving evap. water temp. (without glycol) °C +4 +4
Min leaving evap. water temp. (with glycol) °C -8 -8
Max evaporator ΔT °C 6 6
Min evaporator ΔT °C 4 4
Note:
(1) Max ambient temperatures are referred to units working at full load. With higher temperatures the chillers will
unload.
(2) When the air temperature is lower than +10°C you need the fan speed control device (OPFS). It allows the unit to
operate with air temperature down to –10°C. Low ambient operation (OPLA) allows to reach –18°C.
Flow direction marked on switch
NPT flow switch conne
ction
Tee
Table 1

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Physical data EWAP-AJYNN R-407C
Unit size
800 900 950 C10 C11 C12
Cooling capacity (1) kW
790,4 875,0 943,6 1026,1 1091,9 1158,0
Power input (1) kW
317,0 348,2 376,9 412,4 444,8 471,2
COP
2,49 2,51 2,50 2,49 2,45 2,46
Single-screw compressors N°
2 2 2 2 2 3
Refrigerant circuits N°
2 2 2 2 2 3
Refrigerant charge kg
120 130 140 150 160 180
Oil charge kg
40 40 40 40 40 60
Min % of capacity reduction %
12,5 12,5 12,5 12,5 12,5 8,3
Condenser fans
N°of fans / Nominal power fan kW
12/2 13/2 14/2 15/2 16/2 18/2
Fan speed rpm
860 860 860 860 860 860
Diameter mm
800 800 800 800 800 800
Total air flow m
3
/s
66,3 71,9 77,4 82,9 88,4 99,5
Evaporator
Evaporator / Water volume N°/l
1 / 278 1 / 271 1 / 271 1 / 256 1 / 256 1 / 263
Max operating pressure bar
10,5 10,5 10,5 10,5 10,5 10,5
Water connections diameter mm
219 219 219 219 219 219
Condenser coil
Coil type
Lanced fins – Internally spiral wound tubes
Weight and dimension
Standard unit shipping weight kg
5165 5425 5555 5795 5905 7990
Standard unit operating weight kg
5430 5710 5840 6070 6180 8270
Unit length mm
6210 7110 7110 8010 8010 9170
Unit width mm
2230 2230 2230 2230 2230 2230
Unit height mm
2520 2520 2520 2520 2520 2520
Unit size
C13 C14 C15 C16 C17 C18
Cooling capacity (1) kW
1284,2 1353,5 1426,3 1516,3 1583,0 1649,8
Power input (1) kW
509,1 537,9 564,5 604,3 636,8 669,4
COP
2,52 2,52 2,53 2,51 2,49 2,46
Single-screw compressors N°
3 3 3 3 3 3
Refrigerant circuits N°
3 3 3 3 3 3
Refrigerant charge kg
190 200 220 220 230 245
Oil charge kg
60 60 60 60 60 60
Min % of capacity reduction %
8,3 8,3 8,3 8,3 8,3 8,3
Condenser fans
N°of fans / Nominal power fan kW
19/2 20/2 22/2 22/2 23/2 24/2
Fan speed rpm
860 860 860 860 860 860
Diameter mm
800 800 800 800 800 800
Total air flow m
3
/s
105 110,6 124 121,6 127,2 132,7
Evaporator
Evaporator / Water volume N°/l
1 / 432 1 / 432 1 / 432 1 / 419 1 / 419 1 / 419
Max operating pressure bar
10,5 10,5 10,5 10,5 10,5 10,5
Water connections diameter mm
273 273 273 273 273 273
Condenser coil
Coil type
Lanced fins – Internally spiral wound tubes
Weight and dimension
Standard unit shipping weight kg
8305 8435 8890 8905 9155 9265
Standard unit operating weight kg
8775 8905 9360 9350 9600 9710
Unit length mm
10070 10070 10970 10970 11870 11870
Unit width mm
2230 2230 2230 2230 2230 2230
Unit height mm
2520 2520 2520 2520 2520 2520
Note: (1) Nominal cooling capacity and power input are based on: 12/7°C entering / leaving evaporator water temperature;
35°C ambient temperature. The power input is for compressor only .

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Electrical data EWAD-AJYNN R-407C
Unit size
800 900 950 C10 C11 C12
Standard voltage (1)
400 V – 3f – 50 Hz
Nominal unit current (2) A
517 561 673 729 780 796
Max compressor current (3) A
599 651 711 773 832 891
Fans current A
48 52 56 60 64 72
Max unit current (3) A
647 703 767 833 896 963
Max unit inrush current (4) A
1050 1054 1116 1120 1165 1265
Max unit current for wires sizing (5) A
668 728 788 848 908 1002
Unit size
C13 C14 C15 C16 C17 C18
Standard voltage (1)
400 V – 3f – 50 Hz
Nominal unit current (2) A
823 864 1012 1070 1122 1173
Max compressor current (3) A
950 1002 1064 1134 1193 1251
Fans current A
76 80 88 88 92 96
Max unit current (3) A
1026 1082 1152 1222 1285 1347
Max unit inrush current (4) A
1248 1344 1402 1405 1489 1491
Max unit current for wires sizing (5) A
1062 1122 1186 1242 1302 1362
Notes: (1) Allowed voltage tolerance ± 10%. Voltage unbalance between phases must be within ± 3%.
(2) Nominal current is based on: 12/7 °C entering/leaving evaporator water temperature and 35°C ambient temp.
(3) Maximum current is based on: 14/9 °C entering/leaving evaporator water temperature and 42°C ambient temp.
(4) Inrush current of biggest compressor + 75 % of nominal absorbed current of the other compressor + fans current.
(5) Compressor FLA + fans current.