Daikin EWWD 340 C18 I-SS Series User manual

Water-cooled screw chillers
EWWD 340 ÷ C18 I-SS
EWWD 360 ÷ C12 I-XS
EWLD 320 ÷ C17 I-SS
50Hz –Refrigerant: R-134a
Original Instructions
Installation, Operation and Maintenance Manual
D–EIMWC00408-16EN
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D–EIMWC00408-16EN - 2/60
Contents
Contents.............................................................................................................................................................................2
General information..........................................................................................................................................................6
Warnings for the operator.................................................................................................................................................6
Assistance........................................................................................................................................................................6
Spare parts.......................................................................................................................................................................6
Receiving the machine.....................................................................................................................................................6
Checks .............................................................................................................................................................................7
Purpose of this manual.....................................................................................................................................................7
Important information on the refrigerant used...................................................................................................................7
Operating limits.................................................................................................................................................................8
Storage.............................................................................................................................................................................8
Operation..........................................................................................................................................................................8
Mechanical Installation.....................................................................................................................................................9
Shipping ...........................................................................................................................................................................9
Responsibility...................................................................................................................................................................9
Safety...............................................................................................................................................................................9
Handling and lifting...........................................................................................................................................................9
Positioning and assembly...............................................................................................................................................10
Minimum space requirements ........................................................................................................................................11
Ventilation.......................................................................................................................................................................11
Sound protection............................................................................................................................................................11
Water piping...................................................................................................................................................................11
Water treatment..............................................................................................................................................................13
Evaporator and exchangers anti-freeze protection.........................................................................................................13
Installing the flow switch.................................................................................................................................................13
General specifications....................................................................................................................................................14
Electrical components ....................................................................................................................................................16
Electrical wiring ..............................................................................................................................................................16
Oil Heaters .....................................................................................................................................................................16
Water pump control........................................................................................................................................................16
Unit On/Off remote control –Electrical wiring.................................................................................................................16
Double Setpoint –Electrical wiring.................................................................................................................................16
External water Setpoint reset –Electrical wiring (Optional)............................................................................................16
Unit limitation –Electrical wiring (Optional) ....................................................................................................................17
Guidelines for remote condenser application ..............................................................................................................18
Refrigerant piping design................................................................................................................................................18
Determining Equivalent Line Length...............................................................................................................................19
Liquid Line Sizing...........................................................................................................................................................20
Discharge (Hot Gas) Line Sizing....................................................................................................................................20
Oil Charge......................................................................................................................................................................21
Operation.........................................................................................................................................................................22
Operator’s responsibilities ..............................................................................................................................................22
Description of the machine.............................................................................................................................................22
Description of the refrigeration cycle ..............................................................................................................................22
Description of the refrigeration cycle with partial heat recovery......................................................................................22
Controlling the partial recovery circuit and installation recommendations ......................................................................23
Compression process.....................................................................................................................................................38
Pre-startup checks..........................................................................................................................................................41
General...........................................................................................................................................................................41
Units with external water pump ......................................................................................................................................42
Electrical power supply...................................................................................................................................................42
Unbalance in power supply voltage................................................................................................................................42
Oil Heaters power supply ...............................................................................................................................................42
Emergency Stop.............................................................................................................................................................42
Startup procedure...........................................................................................................................................................43
Turning on the machine..................................................................................................................................................43
Seasonal shutdown........................................................................................................................................................44
Starting up after seasonal shutdown ..............................................................................................................................44
System maintenance.......................................................................................................................................................45
General...........................................................................................................................................................................45
Compressor maintenance ..............................................................................................................................................45
Lubrication......................................................................................................................................................................45
Routine maintenance .....................................................................................................................................................47
Replacement of filter dryer .............................................................................................................................................47
Procedure to replace the filter dryer cartridge ................................................................................................................47
Replacement of the oil filter............................................................................................................................................48
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Fr4200 compressor ........................................................................................................................................................49
Oil filter replacement procedure .....................................................................................................................................49
Procedure to replace oil filter..........................................................................................................................................49
Refrigerant charge..........................................................................................................................................................50
Refrigerant filling procedure ...........................................................................................................................................50
Standard Checks.............................................................................................................................................................51
Temperature and pressure sensors ...............................................................................................................................51
Test sheet ........................................................................................................................................................................52
Water side measurements..............................................................................................................................................52
Refrigerant side measurements .....................................................................................................................................52
Electrical measurements................................................................................................................................................52
Service and limited warranty..........................................................................................................................................54
Obligatory routine checks and starting up apparatuses under pressure..................................................................55
84
List of tables
Table 1 - Acceptable water quality limits ......................................................................................................................13
Table 2 - Equivalent Lengths (in meters) ......................................................................................................................20
Table 3 - Liquid line sizes...............................................................................................................................................20
Table 4 - Discharge line sizes ........................................................................................................................................21
Table 5 –Typical operating conditions with compressors at 100% ...........................................................................43
Table 6 –Routine maintenance programme (Note 2)...................................................................................................47
List of Figures
Fig. 1 - Lifting the unit........................................................................................................................................................10
Fig. 2 - Minimum clearance requirements for machine maintenance................................................................................11
Fig. 3 - Water piping connection for evaporator ................................................................................................................12
Fig. 4 - Water piping connection for condenser and heat recovery...................................................................................12
Fig. 5 - Adjusting the safety flow switch.............................................................................................................................14
Fig. 6 - User connection to the interface terminal board....................................................................................................17
Fig. 7 - Condenser Located with No Elevation Difference.................................................................................................18
Fig. 8 - Condenser Located above Chiller Unit..................................................................................................................19
Fig. 9 - Condenser Located below Chiller Unit..................................................................................................................19
Fig. 10 - Refrigeration cycle of the EWWD I-SS Single Circuit..........................................................................................24
Fig. 11 - Refrigeration cycle of the EWLD I-SS Single Circuit...........................................................................................25
Fig. 12 - Refrigeration cycle of the EWLD I-SS + Liquid Receiver Single Circuit ..............................................................26
Fig. 13 - Refrigeration cycle of the EWWD Single Circuit –Total heat recovery ...............................................................27
Fig. 14 - Refrigeration cycle of the EWWD I-XS Single Circuit..........................................................................................28
Fig. 15 - Refrigeration cycle of the EWWD I-SS Double Circuits.......................................................................................29
Fig. 16 - Refrigeration cycle of the EWLD I-SS Double Circuits........................................................................................30
Fig. 17 - Refrigeration cycle of the EWLD I-SS + Liquid Receiver Double Circuits...........................................................31
Fig. 18 - Refrigeration cycle of the EWWD Double Circuits –Total heat recovery............................................................32
Fig. 19 - Refrigeration cycle of the EWWD I-XS Double Circuits.......................................................................................33
Fig. 20 - Refrigeration cycle of the EWWD I-SS Trial Circuits...........................................................................................34
Fig. 21 - Refrigeration cycle of the EWLD I-SS Trial Circuits ............................................................................................35
Fig. 22 - Refrigeration cycle of the EWLD I-SS + Liquid Receiver Trial Circuits................................................................36
Fig. 23 - Refrigeration cycle of the EWWD Trial Circuits –Total heat recovery ................................................................37
Fig. 24 - Picture of Fr4100 compressor.............................................................................................................................38
Fig. 25 - Compression process .........................................................................................................................................39
Fig. 26 - Refrigeration capacity control mechanism of compressor Fr4 ............................................................................40
Fig. 27 - Installation of control devices for Fr4 compressor...............................................................................................46
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IMPORTANT
The present Installation and Maintenance Manual is drawn up for information only and does not constitute an offer
binding upon Daikin
Specifications are subject to change without prior notice. Refer to the data communicated at the time of the order as
per the “Documents Certified” such as “Dimensional Drawings”, “Wiring diagrams” and “Nameplate”. Daikin explicitly
reject any liability for any direct or indirect damage, in the broadest sense, arising from or related to the use and/or
interpretation of this Installation and Maintenance Manual.
WARNING
Before starting the installation of the unit, please read this manual carefully. Starting up the unit is absolutely
forbidden if all instructions contained in this manual are not clear.
Key to symbols
Important note: failure to respect the instruction can damage the unit or compromise functioning
Note regarding safety in general or respect of laws and regulations
Note concerning electrical safety
Description of the labels applied to the electrical panel
Single compressor Unit
1–Lifting instructions
6–Gas type
2–Unit nameplate data
7–Hazardous Voltage warning
3–Non flammable gas symbol
8–Cable tightening warning
4–Manufacturer’s logo
9–Water circuit filling warning
5–Emergency stop
10 –Electrical hazard symbol
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Two Compressors Unit
1 –Unit nameplate data
6–Non flammable gas symbol
2–Lifting instructions
7–Manufacturer’s logo
3–Hazardous Voltage warning
8–Gas type
4–Cable tightening warning
9–Electrical hazard symbol
5–Water circuit filling warning
10 –Emergency stop
Three Compressors Unit
1 –Unit nameplate data
6–Hazardous Voltage warning
2–Lifting instructions
7–Manufacturer’s logo
3–Cable tightening warning
8–Gas type
4–Non flammable gas symbol
9–Electrical hazard symbol
5 –Water circuit filling warning
10 –Emergency stop
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General information
IMPORTANT
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.
A maintenance contract with a authorized service centre is highly recommended.
CAUTION
This manual provides information about the features and procedures for the complete series.
All units are delivered from factory as complete sets which include wiring diagrams and dimensional drawings with
size, weight and features of each model.
WIRING DIAGRAMS AND DIMENSIONAL DRAWINGS MUST BE CONSIDERED ESSENTIAL DOCUMENTS OF
THIS MANUAL
In case of any discrepancy between this manual and the two aforesaid documents, please refer to the wiring diagram
and dimensional drawings.
IMPORTANT
The present Installation and Maintenance Manual is drawn up for information only and does not constitute an offer
binding upon Daikin
Specifications are subject to change without prior notice. Refer to the data communicated at the time of the order as
per the “Documents Certified” such as “Dimensional Drawings”, “Wiring diagrams” and “Nameplate”. Daikin explicitly
reject any liability for any direct or indirect damage, in the broadest sense, arising from or related to the use and/or
interpretation of this Installation and Maintenance Manual.
Key to symbols
Important note: failure to respect the instruction can damage the unit or compromise functioning
Note regarding safety in general or respect of laws and regulations
Note concerning electrical safety
Safe use and maintenance of the unit, as explained in this manual, is fundamental to prevent accidents during operation
and maintenance and repair work.
Therefore, it is highly recommended that this document be read carefully, complied with and stored safely.
Warnings for the operator
The operator must read this manual before using the unit.
The operator must be trained and instructed on how to use the unit.
The operator must strictly follow local safety regulation and laws.
The operator must strictly follow all instruction and limitation given for the unit
Assistance
Should additional maintenance be required, it is advisable to consult authorised staff before carrying out any repair work.
Spare parts
Spare parts to be used for maintenance of the unit must be original. Therefore, always consult the manufacturer.
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.
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D–EIMWC00408-16EN - 7/60
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.
Important information on the refrigerant used
This product contains fluorate gases which have a greenhouse effect and which are covered by the Kyoto protocol. Do
not release such gases into the atmosphere.
Type of refrigerant: R134A
GWP value(1) = 1430
The quantity of refrigerant used is indicated on the identity plate with the name of the unit.
Routine inspections may be necessary pursuant to local and/or European laws, to check on possible refrigerant leakage.
For more detailed information, contact your local dealer.
(1) GWP=Global warming potential
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Operating limits
Storage
The units can be stored under the following environmental conditions:
Minimum ambient temperature : -20°C
Maximum ambient temperature : 53°C
Maximum relative humidity : 95% non-condensing
ATTENTION
Storage at a lower temperature than the minimum indicated can cause damage to certain parts including the
electronic control unit and its LCD display.
ATTENTION
Storage at a higher temperature than that indicated will cause the safety valves on the suction valves of the
compressors to open.
ATTENTION
Storage in a condensed atmosphere can damage the electronic components.
Storage at ambient temperature near or below 0°C, with water loops filled with water require to protect against water
freezing. See anti-freeze protection in Mechanical installation paragraph.
Operation
The unit must operate within the limits indicated in the following diagram.
ATTENTION
Operating outside the limits indicated may trigger the protection devices and interrupt functioning of the unit and, in
extreme cases, may damage the unit.
For any doubts, consult the manufacturer.
The operating limits refer to a fully load operating unit. For partial load operation limits please contact the factory
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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, the cross-plank must be removed only after the final destination has been reached.
Responsibility
The manufacturer declines all responsibility, present and future, for any damage to persons, animals or property 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 lifting points on the base of the machine itself. 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 general disconnecting 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 can cause wounds. Avoid direct contact.
- Avoid introducing solid bodies 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 on both the high and the low pressure sides of the
refrigerant circuit.
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 with this manual.
It is 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 if the Health Emergency Service
-wait without leaving the injured person alone until the rescue operators come
-give all necessary information to the the rescue operators
WARNING
Before carrying out any operation on the machine, please read this instruction and operating manual carefully.
Installation and maintenance must be carried out only by qualified personnel that is familiar with the provisions of law
and local regulations and has been trained properly or has experience with this type of equipment.
C
WARNING
Avoid installing the machine in a place that could be dangerous during maintenance operations, such as (but not
only) platforms without parapets or railings or areas not complying with the clearance requirements.
Handling 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 and/or
unloading, as this could cause serious damage.
All units of the series are supplied with four lifting points. Only these points may be used for lifting the unit, as shown in
figure 1.
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Fig. 1 - Lifting the unit
WARNING
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 data" tables in the "General Information" chapter refer to standard units.
Some specific machines might have accessories that increase their overall weight (heat recovery, etc.)
WARNING
The machine must be lifted with the utmost attention and care. Avoid jolting when lifting and lift the machine very
slowly, keeping it perfectly level.
Positioning and assembly
All units are designed for installation indoors. 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, prepare a strong cement base that is at least 250 mm wider and longer than the machine.
Also, this base must be strong enough 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 compressor section.
To ensure the best possible performance on the installation site, the following precautions and instructions must be
followed:
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Make sure to provide a strong and solid foundation to reduce noise and vibration as much as possible.The water in
the system must be particularly clean and all traces of oil or rust must be removed. A mechanical water filter must be
installed on the machine’s inlet piping.
Minimum space requirements
Every side of the machine must be accessible for all post-installation maintenance activities. Figure 2 shows the
minimum space necessary.
Fig. 2 –Lifting the unit
Ventilation
The temperature of the room where the unit is placed should be always maintained between 0°C and 40°C.
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 must 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 which can remove debris 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.
8. If the machine is intended to replace of 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.
9. 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.
10. No system is installed on the unit to prevent water freezing in case the ambient temperature goes down below
0°C (thermal insulation is not enough to assure freezing prevent). Machine and water pipes must be protected
against freezing
Before insulating water piping, check that there are no leaks.
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Fig. 3 - Minimum clearance requirements for machine maintenance
Fig. 4 - Water piping connection for condenser and heat recovery
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D–EIMWC00408-16EN - 13/60
ATTENTION
Install a mechanical filter on the inlet to each heat exchanger. Failure to install a mechanical filter allows solid
particles and/or welding slag to enter the exchanger. Installation of a filter with a mesh size not exceeding 0.5 –1
mm in diameter is advised.
The manufacturer cannot be held responsible for any damage to exchangers ensuing from the lack of a mechanical
filter.
Water treatment
Before putting the machine into operation, clean the water circuit. Dirt, scaling, corrosion residue and other foreign
material can accumulate inside the heat exchanger and reduce its heat exchanging capacity. Pressure drops can
increase as well, thus reducing water flow. Proper water treatment therefore reduces the risk of corrosion, erosion,
scaling, etc. The most appropriate water treatment must be determined locally, according to the type of system and local
characteristics of the process water.
The manufacturer is not responsible for damage to or malfunctioning of equipment caused by failure to treat water or by
improperly treated water. Table 1 - Acceptable water quality limits
PH (25°C)
6.88.0
Total hardness (mg CaCO3/ l)
200
Electricity conductivity S/cm (25°C)
800
Iron (mg Fe / l)
1.0
Chloride ion (mg Cl - / l)
200
Sulphide ion (mg S2 - / l)
None
Sulphate ion (mg SO24- / l)
200
Ammonium ion (mg NH4+/ l)
1.0
Alkalinity (mg CaCO3 / l)
100
Silica (mg SiO2/ l)
50
Evaporator and exchangers anti-freeze protection
Two or more of below protection methods should be considered when designing the system as a whole:
1. Continuous water flow circulation inside piping and exchangers.
2. Addition of an appropriate amount of glycol inside the water circuit.
3. Additional heat insulation and heating of exposed piping.
4. Emptying and cleaning of the heat exchanger during the winter season.
It is the responsibility of the installer and/or local maintenance personnel to ensure that two or more of the described anti-
freeze methods are used. Make sure that appropriate anti-freeze protection is maintained at all times. Failure to follow
the instructions above could result in damage to some of the machine’s components. Damage caused by freezing is not
covered by the warranty.
Installing the flow switch
To ensure sufficient water flow through the evaporator, it is essential that a flow switch be installed on the water circuit.
The flow switch can be installed either on the inlet or outlet water piping. The purpose of the flow switch is to stop the
machine in the event of interrupted water flow, thus protecting the evaporator from freezing.
A flow switch specifically gauged for this purpose, with identification code 131035072, is available as an option.
This paddle-type flow switch is suitable for heavy-duty outdoor applications (IP67) for pipe diameters in the range of 1" to
6".
The flow switch is provided with a clean contact which must be electrically connected to the terminals of the terminal
board (check the machine’s wiring diagram for further information).
For further information regarding device installation and settings, please read the instruction leaflet in the device box.
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Fig. 5 - Adjusting the safety flow switch
Refrigerating circuit safety valves
Each system comes with safety valves that are installed on each circuit, both on the evaporator and on the condenser.
The purpose of the valves is to release the refrigerant inside the refrigerant circuit in the event of certain malfunctions.
WARNING
The unit is designed for indoor installation.
Damage may be caused by inhaling the refrigerant gas. Avoid the release of the refrigerant into the atmosphere.
The safety valves must be connected to the outdoor environment. The installer is responsible for connecting the
safety valves to the drainage pipes and for their correct dimensioning.
Check for adequate air circulation around the machine.
General specifications
CAUTION
All electrical connections to the machine must be carried out in compliance with applicable laws and regulations.
All installation, operating and maintenance activities must be carried out by qualified personnel.
Please refer to the specific wiring diagram for the machine that you have purchased and which was sent with the unit.
Should the wiring diagram not appear on the machine or should it have been lost, please contact your dealer who will
provide for a copy to be forwarded.
3” 83 mm
4” 107 mm
5” 134 mm
6” 162 mm
5 mm
For 3” - 6” piping
Use paddle b = 29 mm
Adjusting the flow switch’s
trigger sensitivity
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CAUTION
Use copper conductors only. Use of conductors in any material other than copper could cause overheating or
corrosion at the connection points and damage the unit.
To avoid interference, all control wires must be installed separately from the power cables. Use separate electrical
conduits for this purpose.
CAUTION
Before servicing the machine in any way, open the main disconnecting switch on the machine’s main power supply.
When the machine is off but the disconnector switch is in the closed position, unused circuits are live, as well.
CAUTION
Concurrence of single-phase and three-phase charges and unbalance between phases can cause leakages towards
ground of up to 150 mA during the normal operation of the units of the series.
If the unit includes devices that cause superior harmonics (such as VFD and phase cut), the leakage towards ground
could increase to very high values (about 2 Ampere).
The protections for the power supply system must be designed in accordance with the above mentioned values.
The area where unit is installed has to be restricted accessible by authorized personnel only.
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Electrical components
All power and interface electrical connections are specified in the wiring diagram that is shipped with the machine.
The installer must supply the following components:
-Power supply wires (dedicated conduit)
-Interconnection and interface wires (dedicated conduit)
-Thermal-magnetic circuit breaker of suitable size (please see electrical data).
Electrical wiring
Power circuit:
Connect the electrical power supply cables to the terminals of the general circuit breaker on the machine’s
terminal board. The access panel must have a hole of appropriate diameter for the cable used and its cable
gland. A flexible conduit can also be used, containing the three power phases plus earth.
In any case, absolute protection against any water penetrating through the connection point must be ensured.
Control circuit:
Every machine of the series is supplied with an auxiliary 400/115V control circuit transformer. No additional
cable for the control system power supply is thus required.
Only if the optional separate accumulation tank is requested, the electrical anti-freeze resistance must have a
separate power supply.
Oil Heaters
Each circuit has an electrical resistance installed in the compressor, whose purpose is to keep the oil warm thus
preventing the presence of liquid refrigerant mixed with the oil in the compressor. Obviously, the operation of the
electrical resistance is guaranteed only if there is a constant power supply. If it is not possible to keep the machine
powered when inactive during winter, apply at least two of the procedures described in the “Mechanical Installation”
section under the “Anti-freeze protection of evaporator and exchangers”.
If the plant uses pumps outside the machine (not supplied with the unit), the power line of each pump must be provided
with a magnetothermic switch and a control switch.
Water pump control
Connect the control contactor coil power supply to terminals 27 and 28 (pump #1) and 401 and 402 (pump 2) located on
terminal board M3, and install the contactor on a power supply having the same voltage as the pump contactor coil. The
terminals are connected to a clean microprocessor contact.
The microprocessor contact has the following commutation capacity:
Maximum voltage: 250 Vac
Maximum current: 2 A Resistive - 2 A Inductive
Reference standard: EN 60730-1
The wiring described above allows the microprocessor to manage the water pump automatically. It is good practice to
install a clean status contact pump’s thermal-magnetic circuit breaker and to connect it in series with the flow switch.
Alarm relays –Electrical wiring
The machine has a clean-contact digital output that changes state whenever an alarm occurs in one of the refrigerant
circuits. Connect this signal to an external visual, sound alarm or to the BMS in order to monitor its operation. See the
machine’s wiring diagram for wiring.
Unit On/Off remote control –Electrical wiring
The machine has a digital input that allows remote control. A startup timer, a circuit breaker or a BMS can be connected
to this input. Once the contact has been closed, the microprocessor launches the startup sequence by first turning on the
water pump and then the compressors. When the contact is opened the microprocessor launches the machine shutdown
sequence. The contact must be clean.
Double Setpoint –Electrical wiring
The Double Setpoint function allows to change over the unit setpoint between two predefined values in the unit controller.
An example of an application is ice production during the night and standard operation during the day. Connect a circuit
breaker or timer between terminals 5 and 21 of terminal board M3. The contact must be clean.
External water Setpoint reset –Electrical wiring (Optional)
The machine’s local setpoint can be modified by means of an external analogue 4-20 mA signal. Once this function has
been enabled, the microprocessor allows to modify the setpoint from the set local value up to a differential of 3°C. 4 mA
corresponds to a 0°C differential, 20 mA corresponds to the setpoint plus the maximum differential.
The signal cable must be directly connected to terminals 35 and 36 of the M3 terminal board.
The signal cable must be of the shielded type and must not be laid in the vicinity of the power cables, so as not to induce
interference with the electronic controller.
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Unit limitation –Electrical wiring (Optional)
The machine’s microprocessor allows to limit the capacity by means of two separate criteria:
- >Load limitation: The load can be varied by means of a 4-20 mA external signal from a BMS.
The signal cable must be directly connected to terminals 36 and 37 of the M3 terminal board.
The signal cable must be of the shielded type and must not be laid in the vicinity of the power cables, so as not
to induce interference with the electronic controller.
-Current limitation: The machine’s load can be varied by means of a 4-20 mA external signal from an external
device. In this case, current control limits must be set on the microprocessor so that the microprocessor
transmits the value of the measured current and limits it.
The signal cable must be directly connected to terminals 36 and 37 of the M3 terminal board.
The signal cable must be of the shielded type and must not be laid in the vicinity of the power cables, so as not
to induce interference with the electronic controller.
A digital input allows to enable the current limitation at the desired time. Connect the enabling switch or the
timer (clean contact) to terminals 5 and 9.
Attention: the two options cannot be enabled simultaneously. Setting one function excludes the other.
Fig. 6 - User connection to the interface terminal board
LEGEND
1S Compressor Status 1 PS Power Supply
2S Compressor Status 2 Q10 Main Switch
Al Analog Inputs S.O. Setpoint Override
AO Analog Output TW1 Tower 1 Fan Step
C-3W Condenser 3-Way Valve TW2 Tower 2 Fan Step
C.L. Current Limit TW3 Tower 3 Fan Step
CFS Condensator Flow Switch TW4 Tower 4 Fan Step
CLE Current Limit Enable
CP-VFD Condenser Pump VFD
D.L. Demand Limit
DI Digital Inputs
DO Digital Outputs
DPS Double Set Point
EF Esternal Fault
EFS Evaporator Flow Switch
EFS-1 Evaporator Flow Switch 1
EFS-2 Evaporator Flow Switch 2
GA General Alarm
KPC Condensator Water Pump
KPE-1 Evaporator Water Pump 1
KPE-2 Evaporator Water Pump 2
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Guidelines for remote condenser application
Design of remote condenser application, and, in particular, sizing of piping and piping path, is a responsibility of plant
designer. This paragraph is only focused to give suggestion to plant designer, this suggestions have to be weighted with
references to application peculiarities.
For remote condenser application, such as air-cooled or evaporative condensers, the chillers are shipped with holding
Nitrogen charge. It is important that the unit be kept tightly closed until the remote condenser is installed and piped to the
unit.
Chillers are supplied with filter drier, moisture indicator and expansion valve factory mounted as standard.
It is the contractor’s responsibility to install the interconnection piping, leak test it and the entire system, evacuate the
system and supply the refrigerant charge.
All piping must be conform to the applicable local and state codes.
Use refrigerant grade copper tubing only and isolate the refrigeration lines from building structures to prevent transfer of
vibration.
It is important that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant
and oil from draining into the compressors; looping the discharge line also provide greater flexibility.
Do not use a saw to remove end caps. This might allow copper chips to contaminate the system. Use a tube cutter or
heat to remove caps. When sweating copper joints it is important to flow dry nitrogen through the system prior to
charging with refrigerant. This prevents scale formation and the possible formation of an explosive mixture of HFC-134a
and air. This will also prevent the formation of toxic phosgene gas, which occurs when HFC-134a is exposed to open
flame.
Soft solders are not to be used. For copper-to-copper joints use a phos-copper solder with 6% to 8% silver content. A
high silver content brazing rod must be used for copper-to-brass or copper-to-steel joints. Only use oxy-acetylene
brazing.
After the equipment is correctly installed, leak tested and evacuated , it can be charged with R134a refrigerant and
started under the supervision of Daikin authorized technician.
Charge will be added until the liquid line sight glass is clear, with no bubbles flowing into the expansion valve. Total
refrigerant charge will depend on the used remote condenser and volume of refrigerant piping
Refrigerant piping design
The system can be configured in any of the main arrangements as shown in Figures 7, 8 and 9. The configuration and its
associated elevation, along with the total distance between the chiller and the air-cooled condenser are important factors
in determining the liquid line and discharge line sizes. This will also affect the field refrigerant charges. Consequently,
there are physical limits that must not be violated if the system is to operate as designed.
1. The total distance between the chiller and the air-cooled condenser should not exceed 60 equivalent meters
2. Liquid line risers must not exceed 5 meters in height from the condenser liquid line connection.
3. Discharge line risers cannot exceed an elevation difference greater than 30 actual meters.
Fig. 7 - Condenser Located with No Elevation Difference
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Fig. 8 - Condenser Located above Chiller Unit
Fig. 9 - Condenser Located below Chiller Unit
Determining Equivalent Line Length
To determine the appropriate size for field installed liquid and discharge lines, it is first necessary to establish the
equivalent length of pipe for each line. The equivalent length is the actual friction loss from the linear run of pipe plus the
added friction loss of elbows, valves, etc. Table 2 shows the equivalent length of pipe for various nonferrous valves and
fittings. Follow these steps when calculating line size:
1. Start with an initial approximation of equivalent length by assuming that the equivalent length of pipe is 1.5
times the actual pipe length.
2. Refer to Tables 2 and 3 for a first approximation of line size.
3. Check the line size by calculating the actual equivalent length.
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Note: When calculating the equivalent length, do not include piping of the chiller unit. Only field piping must be
considered.
Table 2 - Equivalent Lengths (in meters)
Line Size
OD (inches)
Angle
Valve
Short
Radius
EL
Long
Radius EL
1/4
5.8
0.8
0.6
3/8
7.3
1.2
0.9
1/2
7.3
1.4
1.0
5/8
7.6
1.7
1.2
3/4
7.6
2.0
1.4
7/8
8.5
2.4
1.6
1-1/8
8.8
0.8
0.6
1-3/8
10.1
1.0
0.7
1-5/8
10.4
1.2
0.8
2-1/8
11.9
1.6
1.0
2-5/8
13.4
2.0
1.3
3-1/8
14.3
2.4
1.6
Liquid Line Sizing
In designing liquid lines it is important that the liquid reaches the expansion valve without flash gas, since this gas will
reduce the valve capacity. Because flashing gas can be caused by pressure drop in the line, the pressure losses due to
friction and changes in static head should be kept at minimum.
A check valve must be installed in the liquid line where the ambient temperature can drop below the equipment room
temperature to prevent liquid migration to the condenser and to maintain liquid refrigerant in the line for unit startup (if
thermostatic expansion valve is used, the check valve also help to keep liquid pressure high enough to keep the valve
closed with compressor off).
A relief valve should be installed between the check valve and the expansion avlve.
The liquid line diameter should be as small as possible while maintaining acceptable pressure drop. This is necessary to
minimize refrigerant charge. The total length between the chiller unit and the air-cooled condenser must not exceed 60
equivalent meters.
Liquid line risers in the system will require an additional 11.5 kPa pressure drop per meter of vertical rise. When it is
necessary to have a liquid line riser, make the vertical run immediately after the condenser before any additional
restrictions. The liquid line risers must not exceed 3 meters in height from the condenser liquid line connection (see
Figure 22). The liquid line does not have to be pitched.
Liquid lines are not typically insulated. However, if the lines are exposed to solar heat gain or temperatures exceeding
43°C, sub-cooling may be effected. In these situations, insulate the liquid lines.
Reference for liquid line sizing is shown in Table 3. It has to be used for reference only, for circuit working with
condensing temperature equal to 55°C and 5°C subcooling at the condenser outlet. Line dimensioning is responsibility of
plant designer, use ASHRAE Refrigeration Handbook or other suitable design guide.
Table 3 - Liquid line sizes
Circuit
Capacity
kW
Total Equivalent Length (meters)
5
10
15
20
25
30
40
50
60
300
1-1/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-5/8
1-5/8
350
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-5/8
1-5/8
1-5/8
400
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-5/8
1-5/8
1-5/8
1-5/8
450
1-1/8
1-3/8
1-3/8
1-3/8
1-5/8
1-5/8
1-5/8
2-1/8
2-1/8
Discharge (Hot Gas) Line Sizing
Discharge line size is based on the velocity needed for proper chiller operation handling oil properly and protecting
compressor from damage that can result from condensing liquid refrigerant during shutdown.
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