Air-Cooled Screw Chillers: Installation, Operation and Maintenance Manual
Air-Cooled Screw Chillers: Installation, Operation and Maintenance Manual
Air-Cooled Screw Chillers: Installation, Operation and Maintenance Manual
D – 510 C – 07/02 E – EN
Nomenclature
EWA D 600 BJ YN N **** /Z
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
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
All units are delivered from the factory complete with wiring diagrams and dimensional drawings including size and
weight for each model.
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.
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.
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.
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.
Picture 3 Picture 4
Picture 5 Picture 6
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.
Tee
Oil Heater
The oil separator is equipped with an immersion electric heater that is installed in a tube and can be
removed without disturbing the oil or opening the refrigerant circuit.
Leaving Connections
520.4
U
495.4
T
392.3
Q
J
273.2
R
426.4
S
355.4 - 460.4
312.3-327.3-344.3-358.3
M-N-O-P
258.2
H
241.2
G
240.3
F
260.3 - 279.3
I - -K296.3
-L
178.2 -B196.2
-C
212.2 -D229.2
-E
163.2
A
Pressure drop (kPa)
(kPa)
drop(l/s)
Pressuredrop
Pressure
46587:9EABD@ ?
279.3K
46587:9EA=P@ ?
260.3J
46587:9EAAD@ AJIF46587:9EAHK;H@ AJIF46587<9GALCF@ AJI4M587<9GAB?@ ANI4M587OAKP@ ?
229.2 – 241.2 – 258.2 E -– F 273.2 - G–-240.3
H-I
46587:9EA;-AF@ A
212.2D
46587:9<;>D=@ A
196.2C
46587:9<;>BC@ A
178.2B
46587:9<;>=?@ A
163.2A
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Water
Portata
flow
acqua
rate (l/s)
(l/s)
}-x
|-x
(kPa)
drop (kPa)
{x
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z-x
Pressure
Perdita
y-x
v0x
sutwv0x y-x z-x {x |-x~}-x-x)s-xt-xWv0x-x y-x-x
Portata
Water acqua
flow
rate (l/s)
(l/s)
Chilled water
Piping complete
Water system filled and vented
Pump installed, (rotation checked), strainers cleaned
Controls (3-way valves, face and bypass dampers, by-pass valves, etc.) operative
Water system operated and flow adjusted to meet unit design requirements
Electrical
Power leads connected to starter
All interlock wiring to the control panel complete and in accordance with specification
Pump starter and interlock wired
Wiring complies with local codes
Miscellaneous
Thermometer wells, thermometers, gauges, control wells, controls, etc., installed
A minimum 60% of system capacity is available for tests and control adjustments
Note: This check list must be completed and sent to the local DAIKIN service center two weeks prior to start-up.
Operation
Operator Responsibilities
It is important that the operator become familiar with the equipment and the system before attempting to operate the
chiller. In addition to reading this manual, the operator should study the operating manual for the control panel (latest
edition) and the electrical wiring diagram furnished with the unit before starting, operating, or shutting it down.
During the initial start up of the chiller, the DAIKIN technician will be available to answer any questions and advise
procedures for a correct operation.
It is recommended that the operator maintain a separate operation log for each chiller unit. In addition, a separate
maintenance log, specific for periodic maintenance and service activities, should be kept in place.
If the operator encounters abnormal or unusual operating conditions, it is recommended that a DAIKIN service technician
be consulted.
Refrigeration Cycle
The low-pressure refrigerant gas from the evaporator enters the screw compressor through the motor, thus cooling motor
windings. The compressor compresses the refrigerant from low to high pressure and during this process oil is injected
into the screw chamber for cooling, lubrication and sealing purposes. As a result of the injection of oil, a mixture of oil and
refrigerant reaches the high efficiency oil separator where both elements are separated by the combined action of
centrifugal force and low velocity,
As the gas leaves from the top of the oil separator, the oil flows down the receiver walls and is forced, by the effect of the
differential pressure between suction and discharge sides, back into the compressor injection port.
After leaving the oil separator, the high pressure and hot gas goes through the “four-way valve” and, depending on the
unit operation mode, enters either the air-cooled coil condenser (cooling mode) or the heat recovery water condenser
(heat recovery mode).
Refrigerant circuit
EWAD-BJYNN - EWAD-BJYNN/Q
EWAD-BJYNN/A - EWAD-BJYNN/Z
ST1 WL1
Y6
EVAPORATOR
ST2 WL2
Y6
Regulation type
Proportional + integral + derivative regulation with feed-back input taken from the temperature sensor at the
evaporator water outlet.
Condensation
The condensation control can be based on temperature or on pressure. The fans can be managed according
to ON/OFF mode or with a 0/10 V modulating signal.
Controller terminal
The controller terminal has following features:
• 4-line by 20-character backlit liquid crystal display
• Key-pad consisting of 15 keys using a “clear language presentation”
• Memory to protect the data
• General faults alarm LED
• 4-level password access to modify settings
• Service report displaying all running hours and general conditions
• Memorized alarm history to facilitate fault analysis.
Remote control
Compatibility with supervisory systems is becoming increasingly important in the HVAC industry. The unit
controller allows easy interfacing with BMS (Building Management Systems), the external world that may be:
HEAT RECOVERY
OPERATION
Key Pad
Chiller Operation Switch Selector “Q7”
“0” Cooling Mode
“1” Heat Recovery
Mode
Heat Recovery
Microprocessor
Control
Carel type “ IR32”
Both models are equipped with NTC PT100 temperature sensors to control the inlet water temperature of the
heat recovery condenser and to measure the hot outlet water temperature.
The temperature sensors are supplied electrically connected to the microprocessor but not fitted in the pipe
well pockets; the installation must be done locally by the installer.
Standard controls
High pressure control
The high pressure switch will shut-down the compressor when the discharge pressure exceeds the setting point
value.
Phase/voltage monitor
The phase/voltage monitor is a device which provides protection against three-phase electrical motor fault
conditions such as power failure, phase failure, and phase reversal. Whenever any of these conditions occur, an
open contact signal is sent to the microprocessor which then de-energizes all inputs. Once power is restored,
contacts close and the microprocessor enables compressors for operation. When three-phase power has been
applied, the output relay should close and the "run light" should turn on. If the output relay does not close, perform
the following tests:
1. Check the voltages between L1-L2, L1-L3 and L2-L3 (L1, L2, L3 are the three phases). These voltages should
be even and within + 10% of the rated three-phase line-to-line voltage.
2. If these voltages are extremely low or widely unbalanced check the power system to determine the cause of the
problem.
3. If the voltages are good, using a phase tester, verify that phases are in A, B, C sequence for L1, L2 and L3.
Correct rotation is required for compressor operation. If it is necessary to correct the phase sequence, turn off the
power supply and interchange any two of the supply power leads wired to the main disconnect switch. This may be
necessary as the phase voltage monitor is sensitive to phase reversal. Turn on the power. The output relay should
now close after the appropriate delay.
System Maintenance
General
To ensure proper operation at peak capacity and to avoid damage to system components, a periodic inspections
program should be set up and followed. The information given below is intended as a guide to be used during
inspection and must be combined with observation of compressor sound and good electrical practices to ensure
trouble-free performance. The sight-glass indicator in the liquid line of every circuit must be checked to verify the
glass is full and clear. If the indicator shows a wet condition and/or there are bubbles in the sight-glass, even when
the system has a full refrigerant charge, the filter-dryer element must be changed.
Compressor maintenance
The screw compressor does not required frequent maintenance. However, a vibration test is an excellent check for
proper mechanical operation. Compressor vibration indicates that maintenance is required as it adversely affects
the performance and efficiency of the unit. It is recommended that the compressor be checked with a vibration
analyser at or shortly after start-up and again on an annual basis. When performing the test, the load should be
maintained as close to the rated load as possible. The vibration analysis provides a fingerprint of the compressor
Electrical control
Warning: Electric shock hazard. Turn off all electrical power supplies before attempting electrical service as
described below.
Caution: It is necessary to de-energize the complete electrical panel, including crankcase heater, before doing
any servicing inside.
Prior to attempting any service on the control panel, it is advisable to study the wiring diagram and understand the
operation system of the water chiller. Electrical components do not require any special maintenance other than a
monthly tightening of cable connections.
Warning: The warranty becomes void if the wiring connection to the unit is not in accordance with the
specification. A blown fuse or tripped protector indicates that a short, ground or overload condition exists.
Before replacing the fuse or restarting the compressor, the cause of the problem must be found and corrected. It is
important to have a qualified electrician service this panel. Unqualified tampering with the controls may cause
serious damage to the equipment and makes the warranty void.
Refrigerant sight-glass
The refrigerant sight-glasses should be observed periodically (a weekly observation should be adequate). A clear
liquid sight-glass indicates that the system is charged with the correct amount of refrigerant to ensure proper feed
through the expansion valve. Bubbling refrigerant in the sight-glass, during stable running conditions, indicates that
the system may be short of refrigerant charge. Refrigerant gas flashing in the sight-glass might also indicate an
excessive pressure drop in the liquid line, possibly due to a clogged filter-dryer or a restriction elsewhere in the
liquid line. If sub-cooling is low add refrigerant to make the sight-glass clear. If sub-cooling is normal and flashing
is visible in the sight-glass, replace the filter-dryer. The moisture condition of the refrigerant is indicated by the
changing color of the element inside the sight-glass. If the sight-glass does not indicate a dry condition after about
3 hours of operation, the unit should be pumped down and the filter-dryers changed.
The following table is a guide to determinate the dry or wet condition of the system:
COLOUR MEANS
Green (Sky Blue) Dry
Yellow (Pink) Wet
Filter-dryers
A replacement of the filter-dryer is recommended during scheduled service maintenance of the unit when, even if
sub-cooling temperature is normal, bubbles can be seen in the sight-glass. The filter-dryer should also be changed
if the colour of the moisture indicator in the sight-glass shows excessive humidity content. During the first few
months of operation, it might be necessary to replace the filter dryer if bubbles appear in the liquid line as
explained before. Any residual particles from the unit working process, compressor and miscellaneous
components are carried over by the refrigerant into the liquid line and retained by the filter-drier.
To change the filter drier, close the manual liquid line shutoff valve and pump the unit down by opening the
switches Q1, Q2 (ON/OFF switches of compressors) in “off” position.
Move the ON/OFF unit switch Q0 to the “off” position.
Close the suction line valve. Remove and replace the filter-drier. Evacuate the liquid line through the manual
shutoff valve to remove non-condensable that may have entered during filter replacement.
Open the suction line valve; open the liquid line manual shutoff valve. A leak check is recommended before putting
the unit in operation.
Lubricating oils
In addition to lubricating the bearing and other moving parts, the oil has the equally important task of sealing the
clearances between the rotors and other potential leakage paths, thus improving pumping efficiency; the oil also
helps dissipate the heat of compression. The amount of oil injected is therefore well in excess of that required for
lubrication alone. To reduce the oil circulation in the refrigerant circuit, the oil separator is installed on the
compressor discharge line
Lubricating oil approved by DAIKIN is mentioned on the compressor label.
The oil pressure transducer monitors the oil injection pressure in the compressor. If the oil pressure value is below
the setpoint for microprocessor control, the compressor stops.
The oil pressure is generated by the discharge pressure; therefore this must maintain a minimum value, which will
increase as the suction pressure increases, so that the required pressure difference is maintained.
Warning: Make sure that the heaters have been energized at least 12 hours prior to the start-up.
Refrigerant
Refrigerant charging
These air-cooled screw chillers have been factory-charged with a full operating charge of refrigerant; however,
there might be times when the unit must be recharged at the jobsite. Follow these recommendations when
charging in the field. Refer to the unit operating charge found in the table of physical data, pages 9 through 15,
according to the version of the unit, either chiller or heat recovery . The optimum charge is the charge that allows
the unit to run with no flashing in the liquid line at any operating conditions. When the liquid line temperature does
not drop with the addition of 2,0-4,0 kg of charge and the discharge pressure goes up by 20-35 kPa then the sub-
cooler is nearly full and proper charge has been reached. Unit can be charged at any steady load condition, at any
outdoor ambient temperature. Unit must be allowed to run for 5 minutes or longer so that the condenser fan
Note: Do not discharge the refrigerant into the atmosphere. To recover it, use empty, clean and dry bottles. The
liquid refrigerant recovery can be made through the valve provided on the condenser coil sub-cooler outlet. To
facilitate the recovery of refrigerant, put the bottle inside a container full of ice; avoid excessive filling of the bottle
(70÷80% max).
Start-up
− Verify that all shut-off valves are open.
− Prior to starting the unit, open the water circulation pump(s) and regulate the flow through the evaporator
and through the heat recovery condensers (if supplied) in accordance with the working conditions of the
unit. If no flow meter is available in the water system, it is recommended to adjust the water flow, as a first
step, by establishing the corresponding differential pressure drop across the heat exchangers as specified
in the pressure drop diagram. The final set up will be done, when the unit is running, by adjusting the
water flow to reach the water "∆Τ” at full load.
− Verify that both evaporator inlet and outlet water temperature sensors indicate the same temperature as
the local thermometers, or the discrepancy does not exceed 0,1°C.
− Verify that the inlet water temperature sensor of the heat recovery condenser (if supplied) has been
installed in a well pocket on the common pipe and indicates the same temperature as the local
thermometer, or the discrepancy does not exceed 0,1°C.
− Verify that the flow switch(es) is(are) connected to the electrical panel at the terminal blocks M3.8 – M3.23
for the evaporator and M3.426 – M3.427 for heat recovery condensers (if supplied).
− Check the electrical power connection to the electrical panel and put all the switches in “OFF” position.
Switch “ON” the main switch isolator “Q10” and the selector “Q12”. In this way the electric heaters of the
compressors and the oil separators are energized.
− Check if the software installed on the microprocessor corresponds to the unit type and make sure that the
setpoints are correct. See the controller operating manual for instructions
− Turn the selector switch Q0 to ”Local” position. For normal unit operation, if the unit is controlled remotely,
switch Q0 to “remote” position.
− Push the “on/off” button on the keypad and wait for the green light.
− Before turning the Q1 selector to ON position, check that the Q10 and Q12 have been switched ON at
least 12 hours before. The controller, if there is a cooling load demand, will start the corresponding
compressor. Repeat the sequence for Q2, Q3, Q4 selectors depending on the number of compressors
installed.
Operational Shut-down
− Push the “On/Off” button on the keypad, or use remote switch, to de-energize the unit. The green light will
turn off and all the compressors will carry out their pump-down cycle and then stop.
− Switch off the water pumps
Seasonal Shut-down
− Turn the Q1 selector to Off position. The compressor will carry out its pump-down cycle and then stop.
− Repeat the sequence for all the selectors Q2, (Q3 and Q4) to stop all the other compressors.
− Switch the “Q0” selector from “Local” to off position.
D – 510 C – 07/02 E – EN pag. 44/48
− Push the “On/Off” button on the keypad to de-energize the unit, green light becomes off.
− Open the circuit breaker Q12 to stop the auxiliary circuit.
− Open the main switch Q10 to disconnect the power supply to the unit. In this condition the oil electric
heater is off. When you restart the unit, before switching on the compressors, wait for at least 12 hours to
warm up the oil.
− Close the shut-off valves of the refrigerant circuits.
− Switch off the water pumps
− Empty the water heat exchangers or fill them with glycol for freeze protection.
Maintenance Shut-down
− Turn the Q1 selector to Off position. The compressor will carry out its pump-down cycle and then stop.
− Repeat the sequence for all the selectors Q2, (Q3 and Q4) to stop all the other compressors.
− Switch the “Q0” selector from “Local” to off position.
− Push the “On/Off” button on the keypad to de-energize the unit, green light become off.
− Open the circuit breaker Q12 to stop the auxiliary circuit.
− Open the main switch Q10 to disconnect the power supply to the unit. In this condition the oil electric
heater is off. When you restart the unit, before switching on the compressors, wait for at least 12 hours to
warm up the oil.
− Close the shut-off valves of the refrigerant circuits.
− Switch off the water pumps
− Service the unit in accordance with the program
Zandvoordestraat 300
B-8400 Ostend – Belgium
www.daikineurope.com