Daikin ZUWCM/DM Manual

Single Screw Chillers
This manual is applicable to following models and their derived and
modified models.
ZUWCM/DM ZUW.C-B ZUWY ZUWV ZUW-HCA
Thanks for purchasing DAIKIN chiller.
The Manual specifies safety, installation and maintenance precautions.
Please read through the manual before installation and use.
For future reference, please be sure to keep it safe.
Engineered for Flexibility and performance
IMM Chiller universal part
Category: Single Screw Chiller
Date: Mar. 2019
New Part No.: Z8100180-09
Prior Part No.: Z8100180-08
Engineering Data
(Installation, Maintenance Manual)

Safety Matters
Single screw chiller can serve safely and reliably under design conditions. Good judgment and
safety precaution measures shall be available for operating the chiller to avoid losses of
equipment and property or personal in-juries.
Operators must understand and abide by the operation procedures and safety precaution
measures in the installation operation and maintenance manual.
Warning
Installation works shall be entrusted to professional installers, otherwise, any improper installation
will lead to accidents, such as leakage, electric shock and fire, etc.
Please refer to the Safety Requirement for Cooling and Heating Supply Mechanical Refrigeration
System of GB 9237 Standard: Do not place the safety discharge hole of refrigerant in buildings.
Refrigerant emissions from the safety valve must be vented to the outdoors, the refrigerant
accumulated in an enclosed space can cause suffocation.
Please provide adequate ventilation especially in the closed space with a lower story height
according to the GB 9237 Standard. It’s harmful to inhale various refrigerant vapors with extra
heavy concentration. The refrigerant vapor is higher than the air, so it will reduce the oxygen
content in the air, but also cause eye and skin irritation, its decomposition products of thermal
decomposition or photodecomposition is also dangerous.
The chiller cannot be installed in the area with potential leakage of combustible gas, otherwise the
leaking gas around the chiller may cause fire.
It is prohibited to exceed the specific test pressure and the allowable test pressure shall be
confirmed by checking the design pressure in the instructions and on the equipment name plate.
Do not close any valve of the safety devices and please confirm all safety valves shall be installed
correctly and operated normally before the operation of chiller.
Beware of any electrical shock. Please disconnect the power supply before touching the motor
terminal or connection.
The leakage protector is needed, and the Installation of leakage protector shall be complied with
the provisions of a Electrical Equipment Technical Standards and Internal Line Practice.
Non-installation or incorrect installation may cause electrical shock accidents.
Each compressor shall have the circuit breaker respectively, and it may cause accidents of
electrical shock or fire if one master breaker controls more than 2 chillers.
Processing and welding on the chiller directly are prohibited and it may cause the leakage of chiller
and hypoxia of machine room environment.
Only qualified electricians are allowed to work on the electrical equipment.
Do not work on the electric components including control box, switches, and starter cabinet or oil
heater before all power supplies have been disconnected and no residual voltage is released from
the capacitors or solid state components. Lock the open circuit and mark the circuit during the
maintenance. Confirm all the circuits are open before restarting the work if the work is interrupted.
The wrong categories refrigerant or refrigeration oil are prohibited to use, or it may cause the
chiller run improperly; the chiller is easy to cause accidents such as fire or explosion when its
performance fails to meet the design requirements.
Do not attempt to unload connector, cover plate, etc., when the chiller is under pressures or
operating normally. Confirming the pressure is 0kPa before loosening any connector.
Please be careful when assembling the spring to prevent personal injury resulting in sudden
release of spring;

Notes:
It’s forbidden to clean the pipe or pressure chiller with oxygen and compressed air.
Only refrigerant or dry nitrogen other than air is allowed to use for leakage test.
Walking on the chiller pipeline is prohibited in order to prevent pipeline damage and personal
injury caused by refrigerant leakage.
Please use Safety goggles to prevent the refrigerant liquid from splashing into eyes. Please clean
the skin with soapy water after it splashes on the skin. Please flush with water immediately and
consult a doctor if the refrigerant liquid splashes into eyes.
Inspect safety devices like safety valve carefully at least once a year. Inspect these devices more
frequently if the installation environment of chiller is corrosive. Replace safety valve if corrosion or
rust or grease stain is detected inside and outside of the valve body.
Do not allow an open flame or steam used for refrigerant cylinders, will lead to dangerous
overpressure or it will lead to overpressure hazards.
Do not use the obsolete steel cylinder or attempt to re-charge.

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 1
Contents
■1. NOMENCLATURE.................................................................................................................... 3
●1.1 WATER COOLED SINGLE SCREW CHILLER (FLOODED) .................................................................... 3
●1.2 WATER COOLED SINGLE SCREW CHILLER (FALLING-FILM) .............................................................. 3
●1.3 WATER COOLED SINGLE SCREW CHILLER (NEW PLATFORM FOR ZUW-HCA).................................. 3
■2. MAJOR COMPONENT LOCATIONS....................................................................................... 4
■3. WORKING PRINCIPLES.......................................................................................................... 8
■4. SAFETY (PLEASE FOLLOW THE FOLLOWING CONTENT STRICTLY)........................... 10
●4.1 PRECAUTIONS DURING INSTALLATION........................................................................................... 10
●4.3 PRECAUTIONS DURING RELOCATION AND REPAIR ......................................................................... 14
●4.4 NOTES FOR RELIEF VALVE........................................................................................................... 15
■5. CHILLER TRANSIT ................................................................................................................ 17
●5.1 CHECKING ITEMS AFTER CHILLER ARRIVAL .................................................................................... 17
●5.2 CHILLER LIFTING......................................................................................................................... 17
●5.3 LIFTING REQUIREMENTS OF CHILLER ........................................................................................... 17
●5.4 HORIZONTAL TRANSITING ............................................................................................................ 18
■6. INSTALLATION ...................................................................................................................... 19
●6.1 CHILLER LOCATION AND FOUNDATION ........................................................................................... 19
●6.2 KNOCKDOWN OF CHILLER ........................................................................................................... 21
●6.3 PIPING OF THE CHILLERS ............................................................................................................. 22
●6.4 ELECTRIC WORKS ...................................................................................................................... 24
■7. MATTERS TO BE CONFIRMED BEFORE TEST RUN......................................................... 26
●7.1 INSPECT THE POWER CIRCUIT (PLEASE CONFIRM BEFORE IT BEING POWERED UP)........................... 26
●7.2 ACKNOWLEDGEMENT OF CABLES (BEFORE BEING POWERED UP).................................................... 26
●7.3 POWER SUPPLY CHECK ............................................................................................................... 26
●7.4 WATER SYSTEM CHECK ............................................................................................................... 27
●7.5 CHECK CHILLER .......................................................................................................................... 27
●7.6 PANEL SETTING CHECK................................................................................................................ 28
■8. FUNCTIONS OF CHILLER .................................................................................................... 29
●8.1 AUTOMATIC CONTROL OF WATER-TEMPERATURE FOR THE CHILLERS............................................... 29
●8.2 CHILLER CAPACITY CONTROL UNDER LOW COOLING LOAD.............................................................. 29
●8.3 LIMITS OF START/STOP ............................................................................................................... 30
■9. MAINTENANCE...................................................................................................................... 31
●9.1 REGULAR MAINTENANCE OF PROTECTIVE DEVICE,ETC. ............................................................... 31
●9.2 PRE-MAINTENANCE ..................................................................................................................... 31
●9.3 REGULAR MAINTENANCE............................................................................................................. 31
●9.4 MAINTENANCE CONTRACT........................................................................................................... 31
●9.5 ABOUT REFRIGERANT AND REFRIGERATION OIL ............................................................................ 31
●9.6 ROUTINE MAINTENANCE.............................................................................................................. 32
■10. PRECAUTIONS FOR LONG-TIME STOP ........................................................................... 33
■11. OPERATING RANGE ........................................................................................................... 34
●11.1 STANDARD OPERATING ENVIRONMENT....................................................................................... 34
●11.2 MINIMUM RETAINING WATER CAPACITY OF SYSTEM .................................................................... 34

SINGLE SCREW CHILLERS IMM
2Engineered for Flexibility and Performance
●11.3 WATER QUALITY FOR CHILLER ................................................................................................... 34
■APPENDIX A............................................................................................................................... 36
■APPENDIX B .............................................................................................................................. 37
■APPENDIX C .............................................................................................................................. 43
●1. DIMENSION OF FLOW SWITCHES.................................................................................................... 43
●2. OPERATING CONDITIONS OF FLOW SWITCHES................................................................................ 43
●3. FLOWING DIRECTION SHEET .......................................................................................................... 44
●4. INSTALLATION REQUIREMENTS....................................................................................................... 44
●5. SWITCH ADJUSTMENT ................................................................................................................... 46
●6. CHECK PROCEDURES ................................................................................................................... 46
●7. FAULT ELIMINATION ....................................................................................................................... 47
■APPENDIX D .............................................................................................................................. 48

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 3
1. Nomenclature
1.1 Water Cooled Single Screw Chiller (Flooded)
1.2 Water Cooled Single Screw Chiller (Falling-film)
Compressor Code Condenser Code
Evaporator Code
Power Supply:
F:380V/50Hz
Water Cooled Single Screw Chiller
Application Code
Starting Method:
Y:Star-detla V:Variable frequency
Condenser Pass:2-pass
Condenser Tube Type Code
Evaporator Pass：3-pass
Evaporator Tube Type Code
1.3 Water Cooled Single Screw Chiller (New Platform for ZUW-HCA)
Compressor code
Refrigerant circuits
Economizer Code:
H:Vertical N:None
Water Cooled Single Screw Chiller
Power Supply:
F:380V/50Hz
G:400V/50Hz
K:415V/50Hz
Design Code
Refrigerant Code:
C:R134a A:R410A
Running Frequency Code:
A:60Hz B:55Hz C:50Hz D:45Hz
ZUWY:Null value
Application Code:
N:Normal B:Hot gas bypass
Evaporator Type:
F:Falling film E:Flooded
Number of Evaporator tubes
Evaporator Tube Type
Evaporator Pass Code
Starting method:
Y:Star-delta V:Variable frequency
Evaporator Code:
Diameter:30 inch,Length:9 feet
Condenser Type:
C:Shell&tube
N:Shell&tube with built-in oil
separator
Condenser Code:
Diameter:22 inch,Length:9 feet
Condenser Tube Type
Number of Condenser tubes
Condenser Pass Code

SINGLE SCREW CHILLERS IMM
4Engineered for Flexibility and Performance
2. Major Component Locations
Single screw chillers are classified into the single-compressor, double-compressor chillers
according to the quantity of compressors, taking the double-compressor chiller(as shown in
Fig.2-2),ZUWY6Q2OFLHE3LDL2N falling-film chiller(as shown in Fig.2-3) and
ZUWY6Q2OSF-HCA Falling-film chiller with Flash-tank Economizer (as shown in Fig.2-4) as
examples to introduce each component of chiller.
All the structures of single screw chillers are similar and different types varies in the aspects of
specifications and types; the specific one is subject to the delivery of chiller and the direction of
water pipe is in line with the order requirements.
A View
Fig.2-1
A

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 5
A View
Fig.2-2
A

SINGLE SCREW CHILLERS IMM
6Engineered for Flexibility and Performance
A
A View
Fig.2-3

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 7
compressor
starter cabinet
Evaporator
condenser
Flash-tank Economizer
A View
condenser inlet
condenser outlet evaporator inlet
evaporator outlet
control cabinet
screen
Fig.2-4

SINGLE SCREW CHILLERS IMM
8Engineered for Flexibility and Performance
3. Working Principles
3.1 Working principles of single screw chiller without Flash-tank Economizer
1. Low temp/pressure refrigerant gas enters the compressor. After compression, the gas will be
discharged into oil separator in high temp/pressure;
2. Oil is separated from refrigerant in oil separator. The former goes back to compressor and the
later goes to condenser;
3. Refrigerant gas is condensed to high pressure liquid and then goes through expansion valve to
the evaporator with low pressure and temperature;
4. Refrigerant liquid absorbs heat from AHUs in evaporator so that the chiller can provide lower
temperature water;
5. Refrigerant gas goes back to compressor for the next circulation.
Fig.3-1

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 9
3.2 Working principles of single screw chiller with Flash-tank Economizer
1. Low temp/pressure refrigerant gas enters the compressor. After compression, the gas will be
discharged into oil separator in high temp/pressure;
2. Oil is separated from refrigerant in oil separator. The former goes back to compressor and the
later goes to condenser;
3. Refrigerant gas is condensed to high pressure liquid and then goes through expansion valve to
the Flash-tank Economizer. Gas and liquid will be separated in the economizer and the former
goes back to compressor and the later goes to evaporator with low pressure and temperature;
4. Refrigerant liquid absorbs heat from AHUs in evaporator so that the chiller can provide lower
temperature water;
5. Refrigerant gas goes back to compressor for the next circulation.
Fig.3-2

SINGLE SCREW CHILLERS IMM
10 Engineered for Flexibility and Performance
4. Safety (Please follow the following content strictly)
Precautions in this section include:
Warning: a faulty operation that may cause death or serious injuries.
Caution: a faulty operation that may cause injuries or equipment failure. It may lead to even more
serious consequences according to severity.
Above two precautions are essential for safety, please keep it accessible to each chiller operator
after reading the manual, Be sure to hand over the Manual to the next person on duty.
4.1 Precautions during Installation
Make sure chiller is installed as per below requirements, otherwise rectifying measures must be
taken.
Warning:
A) Chiller installation must be carried out by qualified person.
Inappropriate installation might cause refrigerant leakage, electrical shock, fire accident etc.
B) Prevent refrigerant leakage
In case of refrigerant leakage, certain measure shall be taken to prevent suffocation caused
by high concentration refrigerant in air.
C) Strictly follow this manual during installation
Inappropriate installation might cause refrigerant leakage, electrical shock, fire accident etc.
D) Electrical cable shall be wired or connected by qualified and professional electrical engineers.
Please size the cable according to local electrical standard (refer to the Engineering Data,
EDUA14-04-2). Undersize cable might cause electrical shock or fire, etc.
E) Chiller foundation shall be capable to carry chiller weight
Chiller shall be installed in horizontal foundation and fixed by the anchor bolts. Chiller may
overturn if the foundation is not strong enough.
F) Check the unit alignment
This step operation must be done for Falling-film Chiller. As follows: Check the longitudinal
alignment by placing a level on the top center of the evaporator shell. Check the transverse
alignment by placing a level on the top of shell end sheets at each end of the unit. The unit
should be level within 6.5 mm longitudinally and 6.5mm transversely. When the unit is in place,
check that the chiller is level. If the unit is not level within the amount specified, lift it and place
as many shims as needed between the isolation pad and the end sheets. As shown in
Fig.4-1:

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 11
△
horizontal line
△
horizontal line
Fig.4-1
G) Chiller shall be installed in indoor space
If chiller is installed in rainy or water dropping place, electric leakage \ shock might happen.
H) Use specified cable and ensure the connections are firm
Ensure the connections of cables are firm. Otherwise it may cause fire accident.
I) Constant pressure leakage test
In case of leakage when unit in constant pressure leakage testing, emptying lubricating oil (if
has) and nitrogen and then repair and test again. In case repair is conducted without
emptying lubricating oil, it might cause explosion.
Attention:
A) It is forbidden to install the chiller in flammable gas leakage condition
Fire accident or even explosion will happen when flammable gas concentration achieves
certain level.
B) Chiller shell shall be grounded
Ground cable shall avoid gas pipe\water pipe\lightning rod or telecom cable, wrong grounding
might cause shock.
C) Ground protector shall be equipped for the chiller
Leakage protector shall be installed as per local electrical standard. No leakage protector or
improper installation may cause electrical shock.
D) Each chiller shall be equipped with dedicated circuit breaker.
If only one main breaker is equipped for multiple chiller plant, it may cause shock or fire
accident.
E) Draining system shall be smooth at chiller installation location
A wrong draining system may cause draining failure which in turn may harm chiller electric
parts.
F) It is prohibited to lay the power cables between chillers, otherwise it may cause fire accident.
G) Chiller plant floor shall go through water proof treatment
Water proof floor will protect chiller from moisture.

SINGLE SCREW CHILLERS IMM
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H) It is prohibited to locate chiller in severe environment
Hot well, coast area, etc. will cause chiller corrosion which might cause shock or fire accident.
I) The water (cooling water\chilled water) in chiller system shall follow the criteria of local water
quality standard.
Bad water quality will cause leakage and reduced chiller efficiency.
J) Follow the local regulations or rules while handling waste brine, cleaning agent, refrigerant,
etc.
Illegally discharged waste liquid or gas will harm health and environment.
K) It is forbidden to close the AC contactor to start the compressor.
It may cause electric shock or fire accident.
L) It is forbidden to weld on the chiller
Welding on chiller may cause refrigerant leakage. And too high concentration of refrigerant in
air will cause suffocation.
M) It is forbidden to charge other kinds of refrigerant or lubricant oil in chiller.
It may cause chiller instability, chiller efficiency decrease, or even fire accident.
N) Ensure sufficient space for chiller service and maintenance
Insufficient space will threaten operator or service people’s safety.

SINGLE SCREW CHILLERS IMM
Engineered for Flexibility and Performance 13
4.2 Precautions during Use
Warning:
A) If chiller running abnormally (e.g. smell of burning), please cut off the power and contact local
Daikin office or distributors.
Running the chiller after abnormity happen might damage the chiller or shock and fire
accidents.
B) It is prohibited to start or stop the chiller by main breaker or switch during normal working
condition.
It may cause shock or fire accident.
C) It is prohibited to use other category coolant; otherwise it will cause fire accident or explosion.
D) Prevent leakage of refrigerant
If refrigerant leakage happens, certain measure shall be taken to prevent suffocation caused
by high concentration of gas refrigerant in air.
Attention:
A) Chiller shall not be used for other condition which goes beyond its designed working scope.
It may cause tubes damage, refrigerant leakage or even explosion. Chilled water and heating
water can’t be used for preserving animals, plants, precision devices, artworks, etc. otherwise
it will degrade their quality.
B) Do not operate the chiller with wet hands.
This is one of the causes of electrical shock.
C) It is prohibited to use oversized fuse.
An oversized fuse will cause protection failed. And it might damage the chiller or cause fire
accident.
D) It is prohibited to localize the chiller in flammable gas circumstance.
It might cause fire accident.
E) It is prohibited to operate contactor to start the chiller manually.
It may cause fire accident or electrical shock.
F) It is prohibited to bypass chiller protection device to start the chiller.
It may cause fire accident or explosion.
G) It is prohibited to start the chiller when open the starter cabinet door.
It may cause electrical shock or fire accident.
H) Ensure the power supply is correct.
Using the power supply other than the rated one specified on chiller name plant might cause
electrical shock or fire accident.
I) It is prohibited to change the protection set point.
It may cause fire or explosion.
J) It is prohibited to put or hang any object upon the chiller.
Dropping of the object might damage the chiller.

SINGLE SCREW CHILLERS IMM
14 Engineered for Flexibility and Performance
K) It is prohibited to put any container which contains water on the chiller.
If water seeps in control cabinet, the insulation may become worse or even cause electrical
shock.
L) Check the foundation after chiller operates for certain period.
Unstable foundation may cause chiller distortion or even accident.
M) Stop the chiller and cut off the power supply when cleaning the chiller.
Otherwise it may cause accident.
N) It is prohibited to flush the chiller.
It will cause electrical shock.
O) It is prohibited to drink chilled water or cooling water
It’s not healthy to drink cooling or chilled water.
P) Water quality must be ensured.
Bad water quality might cause chiller capacity reduce or water leakage.
Q) Do not feed other category of refrigerant or oil in chiller
This might cause chiller operating abnormal or efficiency reducing. And it is also a cause of
fire or explosion.
R) Do not touch the compressor and discharge pipes.
It will cause scald.
S) Drain the water in chiller unit if chiller will stop for a long time.
Before long period stop, drain the water or add anti-freeze in chiller, or it might cause chiller
water side leakage or refrigerant side leakage.
T) Treat the chilled water\cleaning agent\wasted refrigerant according to local rules
Illegally dump the waste will break the law and harm environment.
4.3 Precautions during Relocation and Repair
Warning:
A) Chiller transit and service shall be done by vender
Inappropriate installation will cause electrical shock or fire accident.
B) Chiller relocation shall be done by chiller vender.
Inappropriate relocation will cause electrical shock or fire accident.
C) It is prohibited to modify the chiller without Daikin authorization.
Unauthorized chiller alteration will cause electrical shock or fire accident.
Attention:
A) Client shall follow the local regulations or rules when handling the wasted chilled water,
cleaning agent and refrigerant.
It is harmful to the environment and health.
B) Do not mix with other categories of refrigerant or oil in chiller.
It may cause fire accident or explosion.

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Engineered for Flexibility and Performance 15
C) It is prohibited to change the set point of protection device.
It may cause fire accident.
D) It is prohibited to bypass the protection device when starting the chiller
It will cause fire accident.
E) Ventilation is required during chiller servicing.
Refrigerant leakage will reduce the concentration of oxygen. So it may cause suffocation
when ventilation is insufficient.
4.4 Notes for Relief Valve
Each system will be equipped with a relief valve on the top of the evaporator and oil separator (No
relief valve on the condenser because it connects the oil separator) in order to release the
pressure of vessel when it is too high.
The relief valve installation for double valve design, adjust the tee globe valve stem so that when a
valve is under repair, the other valve can still work. the specific structure is shown as below.
Note: When the tee globe valve stem is the shortest,1# relief valve is open, When the stem is the
longest,2# relief valve is open.
Fig.4-2
If local regulations required, so in the safety valve to connect one emptying pipe to the outdoor
(Daikin advices that customers installation emptying pipe). Refer to below; the connected pipe of
relief valve must use flexible connectors.

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16 Engineered for Flexibility and Performance
Fig.4-3
Note: Before connect the pipe, Need to remove the plastic plug in the valve (if any), According to
the local regulations.
When the emptying pipe is installed to the relief valve, the dimension of emptying pipe is based on
the size of one relief valve. Then it is connected to two valves.
The connected type of relief valve is FPT1 (internal thread NPT1). There are two relief valves
installed on the oil separator, If one is damaged, adjust the cut off valve to isolate it, and the other
relief valve can protect the system, at the same time, the damaged valve could be changed.
To set the pressure of relief valve, please refer to the Engineering Data, EDUA14-04-2.
Note: 1 inch pipe is too smaller for the valve; the reducing tube must be connected on the valve
outlet.
The equivalent lengths of reducing connectors are shown below:
Equivalent length
(m)
＜0.67
0.67~5.6
5.6~32.2
32.2~90.4
90.4~296.8
296.8~1255
Reducing
connector(NPT)
1 1/4
1 1/2
2
2 1/2
3
4
When from more than one line into the public joint, the public joint's area cannot be less than the
total area, the following equations can be calculated:
D1, D2, Dn: the area of each branch line.