Daikin EWAD620-C17C-SS Service Manual Download

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ESIE10-01

General Outline

1–123

1.36.19 Expansion Control Compressor 1

Summary of Contents for EWAD620-C17C-SS

Page 1: ...ESIE10 01 Service Manual EWAD620 C17C SS SL SR EWAD740 C19C XS XL XR EWAD810 C14C PS PL PR Air cooled chiller EWAD CJ...

Page 2: ......

Page 3: ...Specifications EWAD C SL 1 43 1 16 Electrical Specifications EWAD C SR 1 44 1 17 Electrical Specifications EWAD C XS 1 45 1 18 Electrical Specifications EWAD C XL 1 47 1 19 Electrical Specifications...

Page 4: ...Events 3 14 1 4 Circuit Stop Alarms 3 18 1 5 Circuit Events 3 45 1 6 Alarm Logging 3 52 1 7 Event Logging 3 53 2 Controller Inputs and Outputs 2 1 What is in This Chapter 3 55 2 2 Main Board Controlle...

Page 5: ...e to Clear the Refrigerant Circuit in Case of Frozen Evaporators 5 1 What Is in This Chapter 3 73 5 2 Procedure to Clean the Refrigerant Circuit in Case of Frozen Evaporators 3 74 6 Troubleshooting Ch...

Page 6: ...ESIE10 01 iv Table of Contents 3 1 4 5 Part 5 Maintenance 1 Maintenance 1 1 What Is in This Chapter 5 3 1 2 System Maintenance 5 4 1 3 Standard Checks 5 10...

Page 7: ...3 4 5 1 Part 1 System Outline Introduction This part contains an outline of all the relevant elements in the EWAD CJ air cooled units What is in this part This part contains the following chapters Ch...

Page 8: ...ESIE10 01 1 2 Part 1 System Outline 3 1 1 5...

Page 9: ...24 1 9 Technical Specifications EWAD C XL 1 28 1 10 Technical Specifications EWAD C XR 1 32 1 11 Technical Specifications EWAD C PS 1 36 1 12 Technical Specifications EWAD C PL 1 38 1 13 Technical Sp...

Page 10: ...78 1 28 Heat Recovery Ratings 1 79 1 29 Evaporator Pressure Drops 1 80 1 30 Condensor Pressure Drops 1 83 1 31 Operation Range 1 84 1 32 Mechanical Installation 1 85 1 33 Dimensional Drawing 1 90 1 34...

Page 11: ...rol logic and are full factory run tested to optimized trouble free operation Infinite capacity control Cooling capacity control is infinitely variable by means of a single screw asymmetric compressor...

Page 12: ...with an EER up to 3 29 and an ESEER up to 4 23 data referred to Standard Noise Q PR Premium Efficiency 7 sizes to cover a range from 821 up to 1390 kW with an EER up to 3 64 and an ESEER up to 4 53 da...

Page 13: ...ESIE10 01 General Outline Part 1 System Outline 1 7 3 1 4 5 Q XN Extra Low Noise Condenser fan rotating at 710 rpm rubber antivibration on compressor compressor sound enclo sure...

Page 14: ...d chiller heat pump EWC Air cooled chiller cooling only with centrifugal fan EWR Air cooled chiller cooling only with heat recovery Efficiency level X High efficiency S Standard efficiency P Premium e...

Page 15: ...r water outlet connections are provided with Victaulic Kit as standard Condenser coils The condenser is manufactured with internally enhanced seamless copper tubes arranged in a staggered row pattern...

Page 16: ...an contactors and control circuit transformer MicroTech III controller MicroTech III controller is installed as standard it can be used to modify unit set points and check control parameters A built i...

Page 17: ...mpressors load Q Fan management according to condensing pressure Q Re start in case of power failure automatic manual Q Soft Load optimized management of the compressors load during the start up Q Sta...

Page 18: ...remote control MicroTech III is able to communicate to BMS Building Management System based on the most common protocols as Q ModbusRTU Q LonWorks now also based on the international 8040 Standard Ch...

Page 19: ...essor motor overloading This device together with internal motor protection standard guarantee the best safety system for compressor motor Under Over Voltage This device controls the voltage value of...

Page 20: ...ump are protected from freezing with an additional electrical heater Hydronic Kit twin water pumps available only on chiller with 2 compressors Hydronic kit consists of twin direct driven centrifugal...

Page 21: ...sure drop Cooling kPa 73 59 52 61 68 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter...

Page 22: ...n material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 74822 85510 10688...

Page 23: ...es 1 Cooling capacity unit power input in cooling and EER are based on the following conditions evaporator 12 7 C ambient 35 C unit at full load operation 2 The values are according to ISO 3744 and ar...

Page 24: ...ressure drop Cooling kPa 73 59 52 61 68 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diame...

Page 25: ...ion material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 74822 85510 106...

Page 26: ...tes 1 Cooling capacity unit power input in cooling and EER are based on the following conditions evaporator 12 7 C ambient 35 C unit at full load operation 2 The values are according to ISO 3744 and a...

Page 27: ...essure drop Cooling kPa 67 55 47 57 62 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diamet...

Page 28: ...sulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 57408 6561...

Page 29: ...es 1 Cooling capacity unit power input in cooling and EER are based on the following conditions evaporator 12 7 C ambient 35 C unit at full load operation 2 The values are according to ISO 3744 and ar...

Page 30: ...op Cooling kPa 80 56 64 61 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 No...

Page 31: ...Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 85510 106888 106888 106888 1...

Page 32: ...terial Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 128266 128266 138954...

Page 33: ...es 1 Cooling capacity unit power input in cooling and EER are based on the following conditions evaporator 12 7 C ambient 35 C unit at full load operation 2 The values are according to ISO 3744 and ar...

Page 34: ...drop Cooling kPa 80 56 64 61 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800...

Page 35: ...al Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 85510 106888 106888 10688...

Page 36: ...terial Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 128266 128266 138954...

Page 37: ...es 1 Cooling capacity unit power input in cooling and EER are based on the following conditions evaporator 12 7 C ambient 35 C unit at full load operation 2 The values are according to ISO 3744 and ar...

Page 38: ...ater pres sure drop Cooling kPa 76 54 61 58 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL D...

Page 39: ...74 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 65610...

Page 40: ...61 35 Insulation material Closed cell Air heat exchanger Type High efficiency fin and tube type with integral subcooler Fan Type Direct propeller type Drive DOL Diameter mm 800 Nominal air flow l s 9...

Page 41: ...es 1 Cooling capacity unit power input in cooling and EER are based on the following conditions evaporator 12 7 C ambient 35 C unit at full load operation 2 The values are according to ISO 3744 and ar...

Page 42: ...Water heat exchanger Type Single Pass Shell Tube Water volume l 599 599 1043 1027 1027 995 979 Nominal water flow rate Cooling l s 39 22 42 53 46 6 51 3 55 31 61 12 66 41 Nominal Water pressure drop C...

Page 43: ...3744 and are referred to evaporator 12 7 C ambient 35 C full load operation Safety devices High discharge pressure pressure switch High discharge pressure pressure transducer Low suction pressure pre...

Page 44: ...10 Water heat exchanger Type Single Pass Shell Tube Water volume l 599 599 1043 1027 1027 995 979 Nominal water flow rate Cooling l s 39 22 42 53 46 6 51 3 55 31 61 12 66 41 Nominal Water pressure dro...

Page 45: ...3744 and are referred to evaporator 12 7 C ambient 35 C full load operation Safety devices High discharge pressure pressure switch High discharge pressure pressure transducer Low suction pressure pre...

Page 46: ...10 Water heat exchanger Type Single Pass Shell Tube Water volume l 599 599 1043 1027 1027 995 979 Nominal water flow rate Cooling l s 38 65 41 81 45 69 50 3 54 11 59 76 64 95 Nominal Water pressure dr...

Page 47: ...3744 and are referred to evaporator 12 7 C ambient 35 C full load operation Safety devices High discharge pressure pressure switch High discharge pressure pressure transducer Low suction pressure pre...

Page 48: ...Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 223 223 223 269 269 269 269 326 326 326 Starting Method Wye Delta type Y Model EWAD C SS C11 C12 C14 C15 C16...

Page 49: ...Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 223 223 223 269 269 269 269 326 326 326 Starting Method Wye Delta type Y Model EWAD C SL C11 C12 C14 C15 C16...

Page 50: ...e No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 223 223 223 269 269 269 269 326 326 326 Starting Method Wye Delta type Y Model EWAD C SR C10 C11 C13 C14 C15 C16...

Page 51: ...6 64 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 223 223 223 269 269 269 269 326 Starting Method Wye Delta type Y Model EWAD C XS C10 C11 C12...

Page 52: ...317 8 1377 1385 Nominal running current cooling A 787 834 885 934 985 Maximum running current A 1017 1074 1146 1218 1290 Maximum current for wires sizing A 1119 1181 1261 1340 1419 Fans Nominal runnin...

Page 53: ...56 64 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 223 223 223 269 269 269 269 326 Starting Method Wye Delta type Y Model EWAD C XL C10 C11 C1...

Page 54: ...317 8 1377 1385 Nominal running current cooling A 787 834 885 934 985 Maximum running current A 1017 1074 1146 1218 1290 Maximum current for wires sizing A 1119 1181 1261 1340 1419 Fans Nominal runnin...

Page 55: ...36 42 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 223 223 223 269 269 269 269 326 Starting Method Wye Delta type Y Model EWAD C XR C10 C11 C1...

Page 56: ...281 4 1337 8 1343 Nominal running current cooling A 799 851 901 950 1001 Maximum running current A 983 1040 1110 1179 1248 Maximum current for wires sizing A 1082 1144 1221 1297 1373 Fans Nominal runn...

Page 57: ...um 10 Unit Maximum starting current A 660 4 697 2 697 2 936 2 981 8 1041 1049 Nominal running current cooling A 384 420 461 506 551 609 665 Maximum running current A 518 564 610 675 732 804 876 Maximu...

Page 58: ...mum 10 Unit Maximum starting current A 660 4 697 2 697 2 936 2 981 8 1041 1049 Nominal running current cooling A 384 420 461 506 551 609 665 Maximum running current A 518 564 610 675 732 804 876 Maxim...

Page 59: ...um 10 Unit Maximum starting current A 635 2 672 672 908 2 953 8 1010 2 1015 4 Nominal running current cooling A 376 416 461 505 554 614 671 Maximum running current A 493 539 585 647 704 773 842 Maximu...

Page 60: ...8 751 237 726 258 692 281 676 291 659 302 615 300 7 792 222 771 241 744 262 710 285 693 295 673 305 624 301 8 812 225 790 245 763 266 728 289 711 300 682 305 633 301 9 833 228 810 248 782 270 746 294...

Page 61: ...362 941 394 918 408 894 423 842 426 5 1 077 310 1 048 337 1 012 367 965 400 942 414 917 429 853 426 6 1 105 314 1 075 342 1 038 373 990 406 966 420 938 434 867 427 7 1 133 319 1 103 347 1 064 378 1 0...

Page 62: ...6 574 1 861 623 1 732 662 1 612 647 1 468 620 1 305 580 C16 4 1 598 468 1 554 509 1 501 554 1 431 604 1 397 625 1 359 648 1 275 650 5 1 641 475 1 596 517 1 541 562 1 469 613 1 434 635 1 395 658 1 292...

Page 63: ...5 221 711 241 681 263 658 278 641 288 605 299 496 268 6 754 225 730 245 698 268 674 283 655 292 615 300 499 266 7 773 229 748 250 715 272 691 287 665 293 625 300 502 263 8 793 233 766 254 732 277 707...

Page 64: ...2 343 949 375 917 396 892 411 842 427 689 382 5 1 052 320 1 018 349 973 382 939 403 912 416 856 428 693 379 6 1 079 326 1 043 355 996 388 962 409 923 417 870 428 697 375 7 1 106 331 1 069 361 1 02 395...

Page 65: ...714 638 1 566 622 1 429 590 1 346 568 1 043 490 C15 4 1 562 481 1 511 525 1 444 573 1 395 605 1 358 627 1 286 657 1 071 590 5 1 604 489 1 550 534 1 481 583 1 430 615 1 392 638 1 300 651 1 088 590 6 1...

Page 66: ...84 247 756 267 710 295 691 305 671 315 6 853 212 831 231 807 250 778 271 731 299 712 309 691 319 7 877 214 855 234 830 253 800 274 752 303 732 313 711 323 8 900 217 879 237 854 257 823 278 773 307 753...

Page 67: ...4 1 160 295 1 130 322 1 097 349 1 057 378 991 417 964 431 934 446 5 1 194 299 1 163 326 1 130 354 1 088 384 1 021 423 994 437 963 452 6 1 228 303 1 197 331 1 163 359 1 120 389 1 051 429 1 023 443 992...

Page 68: ...446 1 720 484 1 660 525 1 567 579 1 509 591 1 415 587 C15 4 1 484 385 1 446 419 1 403 455 1 349 493 1 262 544 1 226 563 1 186 583 5 1 526 390 1 488 425 1 443 461 1 388 500 1 299 552 1 262 571 1 221 5...

Page 69: ...531 1 863 576 1 793 625 1 681 691 1 636 715 1 566 732 10 2 018 494 1 969 538 1 912 584 1 839 634 1 725 700 1 679 724 1 591 734 11 2 070 500 2 020 545 1 961 592 1 886 642 1 769 709 1 722 734 1 592 728...

Page 70: ...75 256 944 278 905 303 773 305 675 284 585 263 14 1 024 238 999 260 966 282 926 307 774 302 680 282 585 259 15 1 046 241 1 020 263 989 287 947 312 778 300 682 279 586 256 870 4 849 226 826 246 798 268...

Page 71: ...365 449 1 109 427 969 396 840 367 C12 4 1 224 325 1 190 354 1 148 385 1 095 420 1 008 466 921 454 798 415 5 1 259 330 1 224 360 1 181 392 1 125 426 1 036 473 927 448 801 407 6 1 294 335 1 258 366 1 21...

Page 72: ...07 544 1 721 591 1 316 526 1 155 489 993 448 C16 4 1 527 411 1 483 448 1 430 488 1 360 532 1 249 591 1 088 558 933 520 5 1 570 418 1 525 456 1 469 496 1 398 540 1 259 589 1 093 553 933 512 6 1 612 425...

Page 73: ...2 122 582 2 045 633 1 948 688 1 519 633 1 332 587 1 152 541 15 2 237 543 2 172 591 2 093 643 1 993 699 1 520 625 1 338 581 1 157 534 C19 4 1 778 478 1 731 522 1 674 569 1 600 620 1 479 690 1 372 691 1...

Page 74: ...3 833 328 14 1141 230 1113 251 1083 272 1049 294 996 322 963 338 841 327 15 1171 232 1143 254 1112 276 1077 298 1023 326 989 342 843 325 980 4 942 223 916 243 889 263 858 285 810 312 779 328 743 344 5...

Page 75: ...368 1 269 398 1 194 437 1 146 459 980 445 9 1 436 316 1 398 345 1 357 374 1 307 404 1 229 444 1 181 465 983 441 10 1 478 321 1 439 350 1 397 379 1 345 410 1 265 450 1 216 472 990 438 11 1 521 325 1 48...

Page 76: ...19 839 314 666 281 14 1 123 228 1 094 250 1 062 271 1 023 294 962 324 855 316 667 278 15 1 152 232 1 123 253 1 090 275 1 049 298 980 326 856 313 670 275 960 4 927 219 902 239 873 260 839 282 783 312 7...

Page 77: ...370 1 232 401 1 144 443 997 431 773 381 9 1 411 317 1 371 346 1 325 376 1 267 408 1 177 450 1 000 427 779 378 10 1 451 323 1 410 352 1 362 382 1 303 414 1 211 457 1 002 423 783 374 11 1 493 328 1 450...

Page 78: ...at working conditions evaporator leaving water temperature 7 C Fouling factors m2 C kW Cooling capacity correction factor Power input correction factor EER correction factor 0 0176 1 000 1 000 1 000 0...

Page 79: ...for water and glycol mixture on page 1 73 Ethylene Glycol 10 20 30 40 50 Ethylene Glycol Cooling Capacity 0 991 0 982 0 972 0 961 0 946 Compressor Power Input 0 996 0 992 0 986 0 976 0 966 Flow Rate...

Page 80: ...ge 1 72 and table Correction factors for water and glycol mixture on page 1 73 Starting from this new value of Cooling Capacity calculate the Flow Rate l s and the Evapo rator Pressure Drop kPa Now mu...

Page 81: ...1 045 Reduction of Max CIAT C 1 000 0 3 0 5 0 7 1 0 1 1 1 3 1 6 1 8 2 1 2 4 Type EWAD C SR EWAD C XR EWAD C PR External Static Pressure Pa 0 10 20 30 40 50 60 70 Cooling Capacity kW Correction factor...

Page 82: ...ow 0 3 Below 0 3 Below 0 3 Below 0 3 Free carbide mgCO2 l Below 4 0 Below 4 0 Below 4 0 Below 4 0 Below 4 0 Stability index 6 0 7 0 Items 1 5 Heated water 2 Tendency if out of criteria Low temperature...

Page 83: ...more than 40 C corrosion is generally noticeable Especially when the iron materials is in direct contact with water without any protection shields it is desirable to give the valid measure for corrosi...

Page 84: ...of one hour there will be no more than 6 starts of the compressor The plant side should therefore ensure that the overall water content allows a more constant functioning of the unit and consequently...

Page 85: ...0 X X X X X 990 X X X X X X X C10 X X X X X X X C11 X X X X X X C12 X X X X X X C13 X X X X X X EWAD C PS EWAD C PL EWAD C PR 820 X X X X X 890 X X X X X 980 X X X X X X X C11 X X X X X X X C12 X X X...

Page 86: ...39 74 43 60 46 21 50 85 55 04 67 78 73 5 77 51 81 89 Pressure Drops kPa 73 59 52 61 68 63 72 47 59 65 73 650 740 830 910 970 C11 C12 C14 C15 C16 C17 Cooling Capacity kW 619 715 789 876 922 1020 1112 1...

Page 87: ...rking at the following conditions Evaporator water in out 11 6 C Condenser air inlet 46 C Q The cooling capacity at these working conditions is 536 kW Q The water flow at these working conditions is 2...

Page 88: ...4 5 The pressure drop at the selected working condition will be Notes If the calculated evaporator water pressure drop is below 10 kPa or above 100 kPa please contact the factory for dedicated evapora...

Page 89: ...glycol please contact the factory as above specification can change Notes Q The above curves are referred to the discharge head of the pump only Q When selecting the pump you have to consider the ins...

Page 90: ...maximum water t Standard Efficiency Evaporator Leaving Water Temp C High Efficiency Premium Efficiency Condenser Inlet Air Temp C Operation with Glycol below 4 C Evap LWT Fan Speed Regulation required...

Page 91: ...the entire weight of the unit and only if used according to the lifting diagram described in this manual Q The machine can only be used safely once it has been firmly secured to the ground or to an e...

Page 92: ...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 Moving and lifting The m...

Page 93: ...re there are no obstacles obstructing air flow to the banks guaranteeing correct suction and expulsion Q Guarantee a strong solid foundation to reduce noise and vibration as much as possible Q Do not...

Page 94: ...s For further solutions please consult authorised technicians In any case the microprocessor will allow the machine to adapt to the new condition producing maximum capacity available even at side dist...

Page 95: ...overy device must be positioned at the system s highest point 5 A suitable device that can maintain the water system under pressure expansion tank etc and offset temperature changes 6 Water temperatur...

Page 96: ...0 SR 2285 6185 2540 450 2412 435 810 Nr 12 C11 SS SL C10 SR 2285 7085 2540 1350 2412 435 810 Nr 14 C12 SS SL C11 SR 2285 7985 2540 2250 2412 435 810 Nr 16 760 XS XL 740 XR 2285 6185 2540 470 2412 435...

Page 97: ...sor 8 7 5 4 1 B E D A G F C 2 3 9 6 EWAD C Dimensions Size Size A B C D E F G Fans C14 C15 SS SL C13 C14 SR 2285 10185 2540 4440 2360 540 285 Nr 20 C16 C17 SS SL C15 C16 SR 2285 11085 2540 5340 2360 5...

Page 98: ...ound about 2 A The protection for the power supply system must be designed in accordance with the above mentioned values Q The short circuit current that can be withstood by the electrical board in ac...

Page 99: ...esistive 2 A Inductive Q 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...

Page 100: ...als 37 39 on the terminal board M5 Once the digital input is closed the microprocessor will limit the current absorbed by the machine according to the command set point set The enabling of this contro...

Page 101: ...e high efficiency strip fin Q Fan Axial high efficiency type Allows for quiet system operation even during adjustment Q Expansion valve As standard the machine is fitted with an electronic expansion v...

Page 102: ...ystem Outline 3 1 1 4 5 Legend CONDENSER COIL CONDENSER COIL EVAPORATOR EVAPORATOR HEATER WATER OUTLET WATER INLET No Name 1 Compressor 2 2 way discharge valve 3 High pressure transducer 4 Schrader va...

Page 103: ...es through the subcooling section where it loses even more heat increasing cycle efficiency The subcooled fluid then passes through the high efficiency filter dryer It subsequently passes through the...

Page 104: ...the heat recovery piping The water joints of the exchangers are not designed to support the weight 6 Should heat recovery water temperature be lower than ambient temperature it is advised to switch o...

Page 105: ...Legend CONDENSER COIL CONDENSER COIL EVAPORATOR EVAPORATOR HEATER WATER OUTLET WATER INLET WATER OUTLET WATER INLET WATER OUTLET WATER INLET No Name 1 Compressor 2 2 way discharge valve 3 High pressu...

Page 106: ...ng movement The basic components are therefore only the main rotor and the two satellites that carry out the compression process meshing perfectly together The F3B and F4A compressors are fitted with...

Page 107: ...ite teeth that gear onto the screw thereby reducing the volume available to the gas mixture This entails compression mixture to its maximum value Q STAGE 4 5 DISCHARGE As the satellite tooth approache...

Page 108: ...by the spring action At the same time the gasses contained on the right hand side of the slide discharge in suction through the free vent pipes Non modulating on off box The non modulating slide oper...

Page 109: ...Board 1 116 1 36 13 Digital Outputs Board 1 117 1 36 14 Digital Outputs Board 1 118 1 36 15 Extension Control Fans 1 2 1 119 1 36 16 Extension Control Fans 3 1 120 1 36 17 Extension Control Fans 4 1...

Page 110: ...1 1 4 5 Symbols The following symbols are used on the wiring diagrams Optional equipments Equipment installed Electrical equipment installed on compressor terminals box Field wiring connections Remove...

Page 111: ...ESIE10 01 General Outline Part 1 System Outline 1 105 3 1 4 5 1 36 1 Power Compressor 1 2...

Page 112: ...General Outline ESIE10 01 1 106 Part 1 System Outline 3 1 1 4 5 1 36 2 Power Compressor 3...

Page 113: ...ESIE10 01 General Outline Part 1 System Outline 1 107 3 1 4 5 1 36 3 Kit Pumps...

Page 114: ...General Outline ESIE10 01 1 108 Part 1 System Outline 3 1 1 4 5 1 36 4 Circuit Fan Power Supply 1...

Page 115: ...ESIE10 01 General Outline Part 1 System Outline 1 109 3 1 4 5 1 36 5 Circuit Fan Power Supply 1...

Page 116: ...General Outline ESIE10 01 1 110 Part 1 System Outline 3 1 1 4 5 1 36 6 Circuit Fan Power Supply 2...

Page 117: ...ESIE10 01 General Outline Part 1 System Outline 1 111 3 1 4 5 1 36 7 Circuit Fan Power Supply 2...

Page 118: ...General Outline ESIE10 01 1 112 Part 1 System Outline 3 1 1 4 5 1 36 8 Circuit Fan Power Supply 3...

Page 119: ...ESIE10 01 General Outline Part 1 System Outline 1 113 3 1 4 5 1 36 9 Circuit Fan Power Supply 3...

Page 120: ...General Outline ESIE10 01 1 114 Part 1 System Outline 3 1 1 4 5 1 36 10 Unit Control Circuit Power Supply...

Page 121: ...ESIE10 01 General Outline Part 1 System Outline 1 115 3 1 4 5 1 36 11 Analog Inputs Output Board...

Page 122: ...General Outline ESIE10 01 1 116 Part 1 System Outline 3 1 1 4 5 1 36 12 Digital Inputs Board...

Page 123: ...ESIE10 01 General Outline Part 1 System Outline 1 117 3 1 4 5 1 36 13 Digital Outputs Board...

Page 124: ...General Outline ESIE10 01 1 118 Part 1 System Outline 3 1 1 4 5 1 36 14 Digital Outputs Board...

Page 125: ...ESIE10 01 General Outline Part 1 System Outline 1 119 3 1 4 5 1 36 15 Extension Control Fans 1 2...

Page 126: ...General Outline ESIE10 01 1 120 Part 1 System Outline 3 1 1 4 5 1 36 16 Extension Control Fans 3...

Page 127: ...ESIE10 01 General Outline Part 1 System Outline 1 121 3 1 4 5 1 36 17 Extension Control Fans 4...

Page 128: ...General Outline ESIE10 01 1 122 Part 1 System Outline 3 1 1 4 5 1 36 18 Expansion Input Output Unit Alarm Limiting...

Page 129: ...ESIE10 01 General Outline Part 1 System Outline 1 123 3 1 4 5 1 36 19 Expansion Control Compressor 1...

Page 130: ...General Outline ESIE10 01 1 124 Part 1 System Outline 3 1 1 4 5 1 36 20 Expansion Control Compressor 1...

Page 131: ...ESIE10 01 General Outline Part 1 System Outline 1 125 3 1 4 5 1 36 21 EEXV Compressor 1...

Page 132: ...General Outline ESIE10 01 1 126 Part 1 System Outline 3 1 1 4 5 1 36 22 Expansion Control Compressor 2...

Page 133: ...ESIE10 01 General Outline Part 1 System Outline 1 127 3 1 4 5 1 36 23 Expansion Control Compressor 2...

Page 134: ...General Outline ESIE10 01 1 128 Part 1 System Outline 3 1 1 4 5 1 36 24 EEXV Compressor 2...

Page 135: ...ESIE10 01 General Outline Part 1 System Outline 1 129 3 1 4 5 1 36 25 Expansion Control Compressor 3...

Page 136: ...General Outline ESIE10 01 1 130 Part 1 System Outline 3 1 1 4 5 1 36 26 Expansion Control Compressor 3...

Page 137: ...ESIE10 01 General Outline Part 1 System Outline 1 131 3 1 4 5 1 36 27 EEXV Compressor 3...

Page 138: ...General Outline ESIE10 01 1 132 Part 1 System Outline 3 1 1 4 5 1 36 28 Pumps Control...

Page 139: ...ESIE10 01 General Outline Part 1 System Outline 1 133 3 1 4 5 1 36 29 Terminals M1 M2...

Page 140: ...General Outline ESIE10 01 1 134 Part 1 System Outline 3 1 1 4 5 1 36 30 Terminals M3...

Page 141: ...ESIE10 01 General Outline Part 1 System Outline 1 135 3 1 4 5 1 36 31 Terminals M5 MQ...

Page 142: ...Expansion Compressor 1 ELWT Evaporator Leaving Water Temperature EP 1 Evaporator Pressure Transducer Cir 1 EP 2 Evaporator Pressure Transducer Cir 2 EP 3 Evaporator Pressure Transducer Cir 2 ESV 1 Eco...

Page 143: ...iary Relay K2B 3 Auxiliary Relay KM10 Power Factor Correction Contactors KM20 Power Factor Correction Contactors KM30 Power Factor Correction Contactors KM90 Pump Contactor KM90A Pump Contactor KM1 1...

Page 144: ...n Motor M205 Fan Motor M206 Fan Motor M207 Fan Motor M208 Fan Motor M209 Fan Motor M210 Fan Motor M301 Fan Motor M302 Fan Motor M303 Fan Motor M304 Fan Motor M305 Fan Motor M306 Fan Motor M307 Fan Mot...

Page 145: ...oice Switch R1 Compressor Crankcase Heater Circ 1 R2 Compressor Crankcase Heater Circ 2 R3 Compressor Crankcase Heater Circ 2 R5 Evaporator Heater SPN11 Thermal Relay SPN11 Thermal Relay SPN11 Thermal...

Page 146: ...Unloader Sol Valve Cir 1 YJ 1 Oil By Pass Solenoid Valve Circ 1 YJ 2 Oil By Pass Solenoid Valve Circ 1 YJ 3 Oil By Pass Solenoid Valve Circ 1 YT 1 Oil By Pass Solenoid Valve Circ 1 YT 2 Oil By Pass So...

Page 147: ...l power supply 24VAC to 230VAC External power supply 24VAC to 230VAC External power supply 24VAC to 230VAC External power supply 24VAC to 230VAC Pump 2 contact Maximum load 2A 230VAC Unit Alarm NO def...

Page 148: ...General Outline ESIE10 01 1 142 Part 1 System Outline 3 1 1 4 5...

Page 149: ...nformation is used as background information for troubleshooting An extensive overview of the functioning of the controller is also given in this part Knowledge of the controller is essential to gathe...

Page 150: ...ESIE10 01 2 2 Part 2 Functional Description 3 1 2 5...

Page 151: ...is chapter gives more detailed information about the controller and the software Understanding these functions is vital when diagnosing a malfunction which is related to system architecture or softwar...

Page 152: ...All modules are connected with a BUS system throughout the unit Microtech III Main Controller Peripheral Bus BAS Interface Bacnet Lon Modbus I O Extension Alarm Limiting I O Extension Fans Circuit 1...

Page 153: ...igital Controller Part 2 Functional Description 2 5 3 2 4 5 1 Configuration of chiller BACnet MSTP BACnet IP Communication MicroTech III Unit Controller Remote Operator Interface Extension I O Modules...

Page 154: ...01 2 6 Part 2 Functional Description 3 1 2 4 5 1 3 Customer Interfaces Overview This chapter contains the following topics Topic See page 1 3 1 Control Panel 2 7 1 3 2 Addresses Used In System 2 8 1...

Page 155: ...ESIE10 01 The Digital Controller Part 2 Functional Description 2 7 3 2 4 5 1 1 3 1 Control Panel General description Layout of controller Back button Menu button Display Alarm button Navigation wheel...

Page 156: ...age Unit PolyCool Controller 687 70 MCQ UC n a Used on all configurations Comp 1 Ext IO 965 00 CC1 2 Used on all configurations EEXV 1 Ext ECV EEXV1 3 Comp 2 Ext IO 965 00 CC2 4 EEXV 2 Ext ECV EEXV2 5...

Page 157: ...y of the following modules can be connected directly to the left side of the main controller to allow a BMS interface to function Module Siemens Description of Expansion Boards Usage BacNet IP POL908...

Page 158: ...l Controller ESIE10 01 2 10 Part 2 Functional Description 3 1 2 4 5 1 4 Display and Keypad Overview This chapter contains the following topics Topic See page 1 4 1 General Description 2 11 1 4 2 Set P...

Page 159: ...t 2 Functional Description 2 11 3 2 4 5 1 1 4 1 General Description Layout of screen Menu title A parameter setpoint value Link to further menu arrow on right side Status Settings View Set Unit 3 b Se...

Page 160: ...Current R Menu Password Softload Limit Value R Network Limit Value R Demand Limit Value R View Set Circuit Unit Mode R Control Source R W Status Settings Current Limit Setpoint R W Compressor Time Un...

Page 161: ...estart Stage Down DT R Compressor 1 Cycle Time R Max Pulldown Rate R Compressor 2 Cycle Time R Stage Up Delay R Compressor 3 Cycle Time R Chiller Status After Power R Compressor 4 Cycle Time R Ice Cyc...

Page 162: ...ompressor 2 Cycle Time R Apply Changes R W Compressor 3 Cycle Time R Name R W Compressor 4 Cycle Time R Dev Instance R W UDP Port R W Scheduled Maintenance DHCP R W Next Maintenance Month Year R W Act...

Page 163: ...w set Status Settings Password Disable R W Compressor Status Settings view set Time Until Restart Status Circuit 1 Compressor 1 Cycle Time R Circuit Status R Compressor 2 Cycle Time R Circuit Mode R W...

Page 164: ...Status after Power Failure OFF OFF ON Control source Local Local Network Available Modes Cool COOL COOL w GLYCOL COOL ICE w GLYCOL ICE TEST Cool LWT 1 7 C See auto adjusted settings Cool LWT 2 7 C Se...

Page 165: ...ne None BACnet LonWorks Modbus Ident number 1 Baud Rate 19200 1200 2400 4800 9600 19200 Evap LWT sensor offset 0 C 5 0 to 5 0 C Evap EWT sensor offset 0 C 5 0 to 5 0 C OAT sensor offset 0 C 5 0 to 5 0...

Page 166: ...120 sec 10 to 180 sec High Discharge Temperat 110 C 65 to 110 C High Lift Pressure Delay 5 sec 0 to 30 sec Low Pressure Ratio Delay 90 sec 30 300 sec Start Time Limit 60 sec 20 to 180 sec Evaporator W...

Page 167: ...nable On Off On Number of fans 5 5 to 12 Saturated Condenser Temp Target Min 32 C 26 0 to 43 0 C Saturated Condenser Temp Target Max 43 C 32 0 to 50 C Fan Stage Up Deadband 0 2 5 C 1 10 C Fan Stage Up...

Page 168: ...porator Pressure Unload Low Ambient Lockout Available Mode Selection Range SI Without Glycol 4 to 15 C With Glycol 4 to 15 C Available Mode Selection Range SI Without Glycol 2 to 6 C With Glycol 18 to...

Page 169: ...d C C Fan Stage Up Deadband 1 2 5 Fan Stage Up Deadband 0 4 Fan Stage Up Deadband 2 4 Fan Stage Up Deadband 1 5 Fan Stage Up Deadband 3 5 Fan Stage Up Deadband 2 5 5 Fan Stage Up Deadband 4 4 Fan Stag...

Page 170: ...The Digital Controller ESIE10 01 2 22 Part 2 Functional Description 3 1 2 4 5...

Page 171: ...troduction This chapter will give more detailed information about the functions used to control the system Understanding these functions is vital when diagnosing a malfunction which is related to func...

Page 172: ...e following topics Topic See page 2 2 1 Unit Enable 2 25 2 2 2 Unit Mode Selection 2 26 2 2 3 Unit Control States 2 27 2 2 4 Unit Status 2 28 2 2 5 Ice Mode Start Delay 2 29 2 2 6 Evaporator Pump Cont...

Page 173: ...e additional requirement that the BMS request must be on Unit is enabled according to the following table Note An x indicates that the value is ignored All these normal methods for disabling the chill...

Page 174: ...e control source is set to network The Available Modes Set Point should only be changeable when the unit switch is off This is to avoid changing modes of operation inadvertently while the chiller is r...

Page 175: ...t start even after any cycle timers have expired The unit mode is ice all circuits are off and the ice mode delay is active The unit should be in the Auto state if any of the following are true Unit e...

Page 176: ...it State Off and Remote Switch is open 8 Off BMS Disable Unit State Off Control Source Network and BMS Enable false 9 Off Unit Switch Unit State Off and Unit Switch Disable 10 Off Test Mode Unit State...

Page 177: ...when the first compressor starts while the unit is in ice mode While this timer is active the chiller cannot restart in Ice mode The time delay is user adjustable The ice delay timer may be manually...

Page 178: ...ntrol set point This setting allows the following configurations 1 only Pump 1 will always be used 2 only Pump 2 will always be used Auto The primary pump is the one with the least run hours the other...

Page 179: ...set point the unit mode is cool and the unit controller clock time is between the Noise Reduction start time and end time When Noise Reduction is in effect the Maximum Reset is applied to the cool LWT...

Page 180: ...d every 5 minutes and a proportional cor rection is made to the leaving chilled water setpoint The corrected leaving water setpoint is never set to a value greater than the return water setpoint and i...

Page 181: ...le of the oper ation of 4 20 reset in Cool mode is shown below Reset Type OAT The Active Leaving Water variable is reset based on the outdoor ambient temperature Parame ters used 1 Cool LWT set point...

Page 182: ...Functional Control ESIE10 01 2 34 Part 2 Functional Description 3 1 2 4 5 Cool LWT Max Reset 54 60 75 Max Reset 10 Active LWT F OAT F OAT Reset Cool LWT Set Point 44...

Page 183: ...ls on an alarm another compressor may start without this minimum time passing For units in Ice mode a fixed stage up delay of one minute between compressor starts should be used in this mode When at l...

Page 184: ...equal it must be the lowest numbered compressor Compressor capacity control in cool mode In Cool mode evaporator LWT is controlled to within 0 2 C of the target under constant flow conditions by contr...

Page 185: ...al it must have the most starts If starts are equal it must be the highest numbered compressor Next To Unload The next compressor to unload must meet the following requirements Highest capacity of the...

Page 186: ...meet this limit except that the last running compressor cannot be turned off to meet a limit lower than the minimum unit capacity Network limit The maximum unit capacity can be limited by a network s...

Page 187: ...mited to a maximum of 75 Compressors shall unload to 75 or less if running at greater than 75 load when the LWT exceeds the limit This feature is to keep the circuit running within the capacity of the...

Page 188: ...it Functions Overview This chapter contains the following topics Topic See page 2 3 1 Circuit Control Logic 2 41 2 3 2 Circuit Status 2 43 2 3 3 Compressor Control 2 44 2 3 4 Condenser Fan Control 2 4...

Page 189: ...sure alarm logic should be ignored When the compressor has been running at least 20 seconds and the evaporator pressure rises above the low evaporator pressure unload set point the startup is complete...

Page 190: ...State is Pumpdown A pumpdown alarm occurs on the circuit Circuit switch is open Circuit Mode set point is set to Disable BMS Circuit Mode set point is set to Off The normal shutdown is complete when a...

Page 191: ...f Circuit Switch Circuit is off and circuit switch is off 5 Off Refr In Oil Sump Circuit is off and Discharge Temperature Oil Saturated Tempera ture at gas pressure 5 C 6 Off Alarm Circuit is off and...

Page 192: ...control The capacity of the compressor may be controlled manually Manual capacity control is to be ena bled via a set point with choices of auto or manual Another set point should allow setting the c...

Page 193: ...llowed to increase in capacity until the Low Evaporator Pressure Hold event has cleared High Condenser Pressure If the High Condenser Pressure Hold event is triggered the compressor will not be allowe...

Page 194: ...dead bands Stages six through twelve should all use the sixth stage up dead band When the saturated condenser temperature is above the Target the active deadband a Stage Up error is accumulated Stage...

Page 195: ...rget less the active stage down deadband VFD Condenser pressure trim control is accomplished using an optional VFD on the first fan This VFD control should vary the fan speed to drive the saturated co...

Page 196: ...normal operation the EXV should control suction superheat to a target that can vary from 4 C to 8 5 C The EXV should control the suction superheat within 0 8 C during stable operating conditions stabl...

Page 197: ...is forced to auto When EXV control is set to manual the EXV position is equal to the manual EXV position setting If set to manual when the circuit state transitions from run to another state the cont...

Page 198: ...5 2 3 6 Economizer Control The economizer shall be activated when the circuit is in a run state and the capacity exceeds 95 It shall turn back off when either the load drops below 60 or the circuit i...

Page 199: ...be activated when the circuit is in a run state and the discharge temperature rises above the Liquid Injection Activation set point Liquid injection should be turned off when the discharge temperatur...

Page 200: ...Functional Control ESIE10 01 2 52 Part 2 Functional Description 3 1 2 4 5...

Page 201: ...ical circuit repair are explained Remark Not all repair procedures are described Some procedures are considered common practice What is in this part This part contains the following chapters Chapter S...

Page 202: ...ESIE10 01 3 2 Part 3 Troubleshooting 3 1 3 5...

Page 203: ...use a normal stop or a rapid stop Most alarms require manual reset but some reset automatically when the alarm condition is corrected Other conditions can trigger what is known as an event which may o...

Page 204: ...view This chapter contains the following topics Topic See page 1 2 1 Phase Volts Loss GFP Fault 3 5 1 2 2 Evaporator Flow Loss 3 6 1 2 3 Evaporator Water Freeze Protect 3 7 1 2 4 Evaporator Water Temp...

Page 205: ...oss GFP Fault Alarm description as shown on screen Unit PVM GFP Fault Trigger PVM set point is set to Single Point and PVM GFP input is low Action Taken Rapid stop all circuits Reset Auto reset when P...

Page 206: ...via trigger condition 1 When the alarm occurs due to this trigger it can auto reset the first two times each day with the third occurrence being manual reset For the auto reset occurrences the alarm w...

Page 207: ...or either LWT or EWT then that sensor value cannot trigger the alarm Action Taken Rapid stop all circuits Reset This alarm can be cleared manually via the keypad or via the BMS clear alarm signal but...

Page 208: ...ed Alarm description as shown on screen Evap Water Inverted Trigger Evap EWT Evap LWT 1 deg C AND at least one circuit is running AND EWT sensor fault not active AND LWT sensor fault not active for 30...

Page 209: ...Leaving Evaporator Water Temperature Sensor Fault Alarm description as shown on screen Evap LWT Sens Fault Trigger Sensor shorted or open Action Taken Rapid stop all circuits Reset This alarm can be c...

Page 210: ...iption as shown on screen AC Comm Fail Trigger Communication with the I O extension module has failed Action Taken Rapid stop of all running circuits Reset This alarm can be cleared manually via the k...

Page 211: ...nsor Fault Alarm description as shown on screen OAT Sensor Fault Trigger Sensor shorted or open and Low Ambient Lockout is enabled Action Taken Normal shutdown of all circuits Reset This alarm can be...

Page 212: ...External Alarm Alarm description as shown on screen External Alarm Trigger External Alarm Event input is open for at least 5 seconds and external fault input is configured as an alarm Action Taken Ra...

Page 213: ...1 1 2 9 Emergency Stop Alarm Alarm description as shown on screen Emergency Stop Switch Trigger Emergency Stop input is open Action Taken Rapid stop of all circuits Reset This alarm can be cleared man...

Page 214: ...Unit Events The following unit events are logged in the event log with a time stamp Overview This chapter contains the following topics Topic See page 1 3 1 Entering Evaporator Water Temperature Senso...

Page 215: ...3 15 3 3 4 5 1 1 3 1 Entering Evaporator Water Temperature Sensor Fault Event description as shown on screen EWT Sensor Fail Trigger Sensor shorted or open Action Taken Return water reset cannot be u...

Page 216: ...1 3 4 5 1 3 2 External Event Alarm description as shown on screen External Event Trigger External Alarm Event input is open for at least 5 seconds and external fault is configured as an event Action...

Page 217: ...igger The OAT drops below the low ambient lockout set point and low ambient lockout is enabled Action Taken Normal shutdown of all running circuits Reset The lockout should clear when OAT rises to the...

Page 218: ...echanical Low Pressure Switch 3 22 1 4 5 High Condenser Pressure 3 23 1 4 6 Low Pressure Ratio 3 24 1 4 7 Mechanical High Pressure Switch 3 25 1 4 8 High Discharge Temperature 3 26 1 4 9 High Oil Pres...

Page 219: ...hase Volts Loss GFP Fault Alarm description as shown on screen PVM GFP Fault N Trigger PVM input is low and PVM set point Multi Point Action Taken Rapid stop circuits Reset Auto reset when PVM input i...

Page 220: ...or Low Evaporator Pressure Unload Evaporator Pressure Freeze time 70 6 25 x freeze error limited to a range of 20 70 seconds When the evaporator pressure goes below the Low Evaporator Pressure Unload...

Page 221: ...ow Pressure Start Fail Alarm description as shown on screen LowPressStartFail N Trigger Circuit state is in the start status for time greater than Startup Time set point Action Taken Rapid stop circui...

Page 222: ...hanical Low Pressure Switch Alarm description as shown on screen Mech Low Pressure Sw N Trigger Mechanical Low Pressure switch input is low Action Taken Rapid stop circuit Reset This alarm can be clea...

Page 223: ...Pressure High N Trigger Condenser Saturated Temperature is higher than the Max Saturated Condenser Value for time longer than High Cond Delay set point Action Taken Rapid stop circuit Reset This alar...

Page 224: ...mit for a time longer than Low Pressure Ratio Delay set point after circuit startup has completed The calculated limit will vary from 1 4 to 1 8 as the compressor s capacity varies from 25 to 100 Acti...

Page 225: ...shown on screen Mech High Pressure Sw N Trigger Mechanical High Pressure switch input is low AND Emergency Stop Alarm is not active Opening emergency stop switch kills power to MHP switches Action Tak...

Page 226: ...ription as shown on screen Disc Temp High N Trigger Discharge Temperature High Discharge Temperature set point AND compressor is running Alarm cannot trigger if discharge temperature sensor fault is a...

Page 227: ...re Differential measured over the oil filter is bigger then the High Oil Pressure Differential set point for a time greater than Oil Pressure Differential Delay the unit will trip on high oil pressure...

Page 228: ...screen Starter Fault N Trigger If PVM set point None SSS any time starter fault input is open If PVM set point Single Point or Multi Point compressor has been running for at least 14 seconds and star...

Page 229: ...dings of the compressor a temperature sensitive resistor is installed If the value for the resistor is 4500 ohms or higher the unit will trip on high motor temperature alarm Action Taken Rapid stop ci...

Page 230: ...3 1 3 4 5 1 4 12 Low OAT Restart Fault Alarm description as shown on screen LowOATRestart Fail N Trigger Circuit has failed three low OAT start attempts Action Taken Rapid stop circuit Reset This alar...

Page 231: ...m description as shown on screen NoPressChgAtStrt N Trigger After start of compressor at least a 1 psi drop in evaporator pressure OR 5 psi increase in condenser pressure has not occurred after 15 sec...

Page 232: ...Startup Alarm description as shown on screen No Press At Start N Trigger Evap Pressure 5 psi OR Cond Pressure 5 psi AND Compressor start requested AND circuit does not have a fan VFD Action Taken Rap...

Page 233: ...scription as shown on screen CC Comm Fail N Trigger Communication with the I O extension module has failed Action Taken Rapid stop of affected circuit Reset This alarm can be cleared manually via the...

Page 234: ...m Fail Cir 1 2 Trigger Circuit 1 or Circuit 2 have more than 6 fans OR PVM Config Multi Point and communication with the I O extension module has failed Action Taken Rapid stop of circuit 1 and 2 Rese...

Page 235: ...n screen FC Comm Fail Cir 3 Trigger Number of Circuits set point is greater than 2 and communication with the I O extension module has failed Action Taken Rapid stop of circuit 3 Reset This alarm can...

Page 236: ...n screen FC Comm Fail Cir 4 Trigger Number of Circuits set point is greater than 3 and communication with the I O extension module has failed Action Taken Rapid stop of circuit 4 Reset This alarm can...

Page 237: ...screen FC Comm Fail Cir 3 4 Trigger Circuit 3 or circuit 4 have more than 6 fans and communication with the I O extension module has failed Action Taken Rapid stop of circuit 3 and 4 Reset This alarm...

Page 238: ...ith the I O extension module has failed Alarm on Circuit 3 will be enabled if Number of Circuits set point 2 alarm on Circuit 4 will be enabled if Number of Circuits set point 3 Action Taken Rapid sto...

Page 239: ...5 1 1 4 21 Evaporator Pressure Sensor Fault Alarm description as shown on screen EvapPressSensFault N Trigger Sensor shorted or open Action Taken Rapid stop circuit Reset This alarm can be cleared ma...

Page 240: ...4 5 1 4 22 Condenser Pressure Sensor Fault Alarm description as shown on screen CondPressSensFault N Trigger Sensor shorted or open Action Taken Rapid stop circuit Reset This alarm can be cleared man...

Page 241: ...5 1 1 4 23 Oil Pressure Sensor Fault Alarm description as shown on screen OilPressSensFault N Trigger Sensor shorted or open Action Taken Normal shutdown of circuit Reset This alarm can be cleared ma...

Page 242: ...1 4 24 Suction Temperature Sensor Fault Alarm description as shown on screen SuctTempSensFault N Trigger Sensor shorted or open Action Taken Normal shutdown of circuit Reset This alarm can be cleared...

Page 243: ...1 4 25 Discharge Temperature Sensor Fault Alarm description as shown on screen DiscTempSensFault N Trigger Sensor shorted or open Action Taken Normal shutdown of circuit Reset This alarm can be cleare...

Page 244: ...3 4 5 1 4 26 Motor Temperature Sensor Fault Alarm description as shown on screen MotorTempSensFault N Trigger Sensor shorted or open Action Taken Rapid stop circuit Reset This alarm can be cleared man...

Page 245: ...it event only affects the circuit on which it occurred Circuit events are logged in the event log on the unit controller Overview This chapter contains the following topics Topic See page 1 5 1 Low Ev...

Page 246: ...g if evaporator pressure Low Evaporator Pressure Hold set point the event is triggered The event is not to be triggered for 90 seconds following the capacity change of the compressor from 50 to 60 Act...

Page 247: ...lowing the capacity change of the compressor from 50 to 60 Action Taken Unload the compressor by decreasing the capacity by one step every 5 seconds until the evaporator pressure rises above the Low E...

Page 248: ...mode is Cool if saturated condenser temperature is higher or equal to the High Saturated Condenser Hold Value the event is triggered Action Taken Inhibit loading Reset While still running the event wi...

Page 249: ...Taken Unload the compressor by decreasing the capacity by one step every 5 seconds until the evaporator pressure rises above the High Condensing Pressure Unload set point Reset While still running the...

Page 250: ...ooting 3 1 3 4 5 1 5 5 Failed Pumpdown Event description as shown on screen Pumpdown Fail Cir N Trigger If the circuit state is pumpdown for a time longer then the pumpdown time setpoint the alarm is...

Page 251: ...Troubleshooting 3 51 3 3 4 5 1 1 5 6 Power Loss While Running Event description as shown on screen Run Power Loss Cir N Trigger Circuit controller is powered up after losing power while compressor was...

Page 252: ...ng the Edit key when the end of the list has been reached by scrolling A separate alarm log stores the last 25 alarms to occur When an alarm occurs it is put into the first slot in the alarm log and a...

Page 253: ...ur When an event occurs it is put into the first slot in the event log and all other entries are moved down one dropping the last event Each entry in the event log includes an event description as wel...

Page 254: ...Alarms and Events ESIE10 01 3 54 Part 3 Troubleshooting 3 1 3 4 5...

Page 255: ...ollowing topics Topic See page 2 2 Main Board Controller POL687 70 MCQ 3 56 2 3 Expansion I O Compressor 1 to 4 POL965 00 MCQ 3 58 2 4 Expansion I O EXV Circuit 1 to 4 POL94U 00 MCQ 3 60 2 5 Expansion...

Page 256: ...C Thermister 10K 25 C 50 C 120 C X2 Outside Ambient Temperature NTC Thermister 10K 25 C 50 C 120 C X4 LWT Reset 4 20 mA Current 1 to 23 mA Description Output Signal Range X5 Fan VFD 1 0 10VDC 0 to 100...

Page 257: ...Alarm Alarm not Active Alarm Active Flashing circuit alarm DO3 Circuit 1 Fan Step 1 Fan Off Fan On DO4 Circuit 1 Fan Step 2 Fan Off Fan On DO5 Circuit 1 Fan Step 3 Fan Off Fan On DO6 Circuit 1 Fan Ste...

Page 258: ...t for this Analog outputs Digital inputs Description Signal Source Expected Range X1 Discharge Temperature NTC Thermister 10K 25 C 50 C 120 C X2 Evaporator Pressure Ratiometric 0 5 4 5 Vdc 0 to 5 Vdc...

Page 259: ...Open DO5 Modulating Slide Load Solenoid Closed Solenoid Open DO6 Modulating Slide Unload Solenoid Closed Solenoid Open X5 Modulating Slide Turbo Solenoid Closed Solenoid Open Description Output Off Ou...

Page 260: ...utputs Stepper motor output Description Signal Source Expected Range X2 Suction Temperature NTC Thermister 10K 25 C 50 C 120 C Description Output Signal Range Not Needed Description Signal Off Signal...

Page 261: ...Digital inputs Digital outputs Description Output Off Output On DI1 PVM GFP Circuit 1 Fault No fault DI2 PVM GFP Circuit 2 Fault No fault Description Output Off Output On DO1 Circuit 1 Fan Step 5 Fan...

Page 262: ...it 3 POL945 00 MCQ Digital inputs Digital outputs Description Output Off Output On DI1 PVM GFP Circuit 3 Fault No fault Description Output Off Output On DO1 Circuit 3 Fan Step 1 Fan Off Fan On DO2 Cir...

Page 263: ...it 4 POL945 00 MCQ Digital inputs Digital outputs Description Output Off Output On DI1 PVM GFP Circuit 4 Fault No fault Description Output Off Output On DO1 Circuit 4 Fan Step 1 Fan Off Fan On DO2 Cir...

Page 264: ...3 4 5 2 8 Expansion I O Fan Module Circuit 3 4 POL945 00 MCQ Digital outputs Description Output Off Output On DO1 Circuit 3 Fan Step 5 Fan Off Fan On DO2 Circuit 3 Fan Step 6 Fan Off Fan On DO3 Circu...

Page 265: ...ription Signal Off Signal On X1 External Alarm Event External Device Failure External Device OK X2 Current Limit Enable No Limiting Limiting X5 Circuit Switch 1 Circuit Off Circuit On X6 Circuit Switc...

Page 266: ...Controller Inputs and Outputs ESIE10 01 3 66 Part 3 Troubleshooting 3 1 3 4 5...

Page 267: ...Programming Part 3 Troubleshooting 3 67 3 3 4 5 1 Part 3 3 Procedure for Software Programming 3 1 What is in This Chapter Overview This chapter contains the following topics Topic See page 3 2 Softwa...

Page 268: ...3 Troubleshooting 3 1 3 4 5 3 2 Software Programming with SD Card Controllers are programmed with a SD card You ll need following things SD card with software not new fast SD card Pin Controller Put...

Page 269: ...ESIE10 01 Procedure for Software Programming Part 3 Troubleshooting 3 69 3 3 4 5 1 Put the pin in the small hole in the controller and push Switch on power...

Page 270: ...3 70 Part 3 Troubleshooting 3 1 3 4 5 Remove pin when LED becomes orange Then LED will start to blink red green Programming complete when LED is orange again 1 Pin till orange 2 Remove pin 3 Blinking...

Page 271: ...art 3 Troubleshooting 3 71 3 3 4 5 1 Part 3 4 Procedure to Protect Compressor in Case of Frozen Evaporator 4 1 What is in This Chapter Overview This chapter contains the following topics Topic See pag...

Page 272: ...o close the suction of the compressor 3 Open the oilplugs to drain the oil and the water out of the compressor 4 Blow dry nitrogen through the compressor using the service ports on the HP and LP side...

Page 273: ...Troubleshooting 3 73 3 3 4 5 1 Part 3 5 Procedure to Clear the Refrigerant Circuit in Case of Frozen Evaporators 5 1 What Is in This Chapter Overview This chapter contains the following topics Topic S...

Page 274: ...e drilled holes Draw the rags through the suction and liquid line Blow dry N2 through all the pipes Drain compressor oil Vacuum the whole installation Check on a regular basis the condition of the oil...

Page 275: ...ubleshooting Chart Part 3 Troubleshooting 3 75 3 3 4 5 1 Part 3 6 Troubleshooting Chart 6 1 What is in This Chapter Overview This chapter contains the following topics Topic See page 6 2 Troubleshooti...

Page 276: ...rts or grounds Investigate for possible overloading Check for loose or corroded connections Reset breakers or replace fuses after fault is corrected 7 Unit phase voltage monitor is not satisfied 7 Che...

Page 277: ...pacity control section 2 The unloader mechanism is defective 2 Replace 3 The control solenoids are defective 3 Replace High discharge pressure 1 Discharge shut off valve is partially closed 1 Open the...

Page 278: ...is clogged 3 Replace 4 The expansion valve is malfunctioning 4 Check the expansion valve superheat and valve opening positions Replace only the valve that is not working 5 The water flow to the evapor...

Page 279: ...t run are well known practices in service engineering This part contains a systematic approach on test run checks and test values which guarantees a high quality installation and operation of the unit...

Page 280: ...ESIE10 01 4 2 Part 4 Commissioning and Test Run 3 1 4 5...

Page 281: ...est Run Checks 1 1 What Is in This Chapter Introduction This chapter contains checks you have to carry out before every test run Overview This chapter contains the following topics Topic See page 1 2...

Page 282: ...lves cooling towers bypass valves etc opera tional Water volume checked and according to specs Water flow checked and according to specs Water quality checked and according to specs Electrical YES NO...

Page 283: ...ally with a deviation of maximum 1 4 Anti vibration pads are required 5 Check for remaining metal dust of burrs Metal dust or burrs from grinding or drilling in the metal parts during construction fac...

Page 284: ...imits 3 There is adequate water flow 4 The water quality meets the standards 5 The water piping is properly insulated 6 Measurement points for temperature and pressure are available on the water circu...

Page 285: ...ESIE10 01 Pre Test Run Checks Part 4 Commissioning and Test Run 4 7 3 4 5 1 The water pressure should not exceed the maximum working pressure of 10 bar Evaporator Condenser...

Page 286: ...Pre Test Run Checks ESIE10 01 4 8 Part 4 Commissioning and Test Run 3 1 4 5...

Page 287: ...ing and Test Run 4 9 3 4 5 1 Part 4 2 Running Data 2 1 What Is in This Chapter Introduction This chapter contains the typical operating data Overview This chapter contains the following topics Topic S...

Page 288: ...d Sub Cooling 4 6 C 4 6 C Suction Superheat 4 6 C 4 6 C Discharge Superheat 20 25 C 20 25 C Operating Value Standard Noise Low Noise Condensing Temperature 50 52 C 53 55 C Evaporating Temperature 2 4...

Page 289: ...ESIE10 01 Running Data Part 4 Commissioning and Test Run 4 11 3 4 5 1...

Page 290: ...Running Data ESIE10 01 4 12 Part 4 Commissioning and Test Run 3 1 4 5...

Page 291: ...nce should be set up for operation at maximum capacity or to avoid damage The following chapter explain how to or when to maintain the units It is also applicable on other types of Daikin chillers Wha...

Page 292: ...ESIE10 01 5 2 Part 5 Maintenance 3 1 5...

Page 293: ...loss of refrigerant or lead to system contamination Avoid high gas concentrations While the heavy concentration of the refrigerant gas will remain on the floor level good ventilation is a must Avoid a...

Page 294: ...within the range of operating parameters A recommended ordinary maintenance programme is given at the end of this chapter whilst an operating data collection card is at the end of the manual We recom...

Page 295: ...ly Note 2 General Collection of operating data Note 3 X Visual inspection of machine for any damage and or loosening X Checking of thermal insulation integrity X Clean and paint where necessary X Wate...

Page 296: ...y recommended that the filter dryer cartridges be replaced in the event of a considerable pressure drop across the filter or if bubbles are observed through the liquid sight glass while the subcooling...

Page 297: ...to 230 Pa 16 Close the vacuum pump valve 17 Recharge the filter with the refrigerant recovered during emptying 18 Open the liquid line valve 19 Open the suction valve if any 20 Start up the compresso...

Page 298: ...nnecting switch 19 Close the general disconnecting switch Q10 to supply power to the machine 20 Start the machine by following the start up procedure described above Refrigerant charge Important The u...

Page 299: ...find small leaks 2 Add refrigerant to the system through the service valve on the evaporator inlet pipe 3 The refrigerant can be added under any load condition between 25 and 100 of the circuit Suc ti...

Page 300: ...mpressor This is installed on every compressor and allows to monitor the discharge pressure and to control the fans Should the condensation pressure increase the microprocessor will control the compre...

Page 301: ...ion I O Fan Module Circuit 3 4 k 3 64 Expansion I O Fan Module Circuit 4 k 3 63 Expansion I O Unit Alarm Limiting k 3 65 Main Board Controller k 3 56 Controller Inputs And Outputs k 3 55 Cooling Capac...

Page 302: ...ternal Event k 3 16 F Failed Pumpdown k 3 50 FC Comm Failure Circuit 1 2 k 3 34 FC Comm Failure Circuit 3 k 3 35 FC Comm Failure Circuit 3 4 k 3 37 FC Comm Failure Circuit 4 k 3 36 Features k 1 5 G Ge...

Page 303: ...door Air Temperature Sensor Fault k 3 11 P Phase Volts Loss GFP Fault k 3 5 3 19 Power Loss While Running k 3 51 Procedure To Clean The Refrigerant Circuit In Case Of Frozen Evaporators k 3 74 Procedu...

Page 304: ...ESIE10 01 iv Index 3 1 4 5 W Water Charge Flow And Quality k 1 76 Water Content In Cooling Circuits k 1 78 Wiring Diagrams k 1 103...

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Daikin EWAD620-C17C-SS, Service Manual

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