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Water-cooled screw chillers

EWWD 340 ÷ C18 I-SS
EWWD 360 ÷ C12 I-XS
EWLD 320 ÷ C17 I-SS

50Hz

– Refrigerant: R-134a

Original Instructions

Installation, Operation and Maintenance Manual

–EIMWC00408-16EN

Содержание EWWD 340

Страница 1: ...Water cooled screw chillers EWWD 340 C18 I SS EWWD 360 C12 I XS EWLD 320 C17 I SS 50Hz Refrigerant R 134a Original Instructions Installation Operation and Maintenance Manual D EIMWC00408 16EN ...

Страница 2: ...l 16 Unit limitation Electrical wiring Optional 17 Guidelines for remote condenser application 18 Refrigerant piping design 18 Determining Equivalent Line Length 19 Liquid Line Sizing 20 Discharge Hot Gas Line Sizing 20 Oil Charge 21 Operation 22 Operator s responsibilities 22 Description of the machine 22 Description of the refrigeration cycle 22 Description of the refrigeration cycle with partia...

Страница 3: ...fference 18 Fig 8 Condenser Located above Chiller Unit 19 Fig 9 Condenser Located below Chiller Unit 19 Fig 10 Refrigeration cycle of the EWWD I SS Single Circuit 24 Fig 11 Refrigeration cycle of the EWLD I SS Single Circuit 25 Fig 12 Refrigeration cycle of the EWLD I SS Liquid Receiver Single Circuit 26 Fig 13 Refrigeration cycle of the EWWD Single Circuit Total heat recovery 27 Fig 14 Refrigerat...

Страница 4: ... and Maintenance Manual WARNING Before starting the installation of the unit please read this manual carefully Starting up the unit is absolutely forbidden if all instructions contained in this manual are not clear Key to symbols Important note failure to respect the instruction can damage the unit or compromise functioning Note regarding safety in general or respect of laws and regulations Note c...

Страница 5: ...as type 4 Cable tightening warning 9 Electrical hazard symbol 5 Water circuit filling warning 10 Emergency stop Three Compressors Unit 1 Unit nameplate data 6 Hazardous Voltage warning 2 Lifting instructions 7 Manufacturer s logo 3 Cable tightening warning 8 Gas type 4 Non flammable gas symbol 9 Electrical hazard symbol 5 Water circuit filling warning 10 Emergency stop ...

Страница 6: ...aintenance Manual Key to symbols Important note failure to respect the instruction can damage the unit or compromise functioning Note regarding safety in general or respect of laws and regulations Note concerning electrical safety Safe use and maintenance of the unit as explained in this manual is fundamental to prevent accidents during operation and maintenance and repair work Therefore it is hig...

Страница 7: ...n company Purpose of this manual The purpose of this manual is to allow the installer and the qualified operator to carry out all required operations in order to ensure proper installation and maintenance of the machine without any risk to people animals and or objects This manual is an important supporting document for qualified personnel but it is not intended to replace such personnel All activ...

Страница 8: ...f the compressors to open ATTENTION Storage in a condensed atmosphere can damage the electronic components Storage at ambient temperature near or below 0 C with water loops filled with water require to protect against water freezing See anti freeze protection in Mechanical installation paragraph Operation The unit must operate within the limits indicated in the following diagram ATTENTION Operatin...

Страница 9: ...e connected to the heat exchanger inlet The machine is supplied with safety valves that are installed on both the high and the low pressure sides of the refrigerant circuit In case of sudden stop of the unit follow the instructions on the Control Panel Operating Manual which is part of the on board documentation delivered to the end user with this manual It is recommended to perform installation a...

Страница 10: ...level Positioning and assembly All units are designed for installation indoors The machine must be installed on a robust and perfectly level foundation should the machine be installed on balconies or roofs it might be necessary to use weight distribution beams For installation on the ground prepare a strong cement base that is at least 250 mm wider and longer than the machine Also this base must b...

Страница 11: ...be positioned at the system s highest point 4 A suitable device that can maintain the water system under pressure expansion tank etc 5 Water temperature and pressure indicators on the machine to assist the operator during service and maintenance 6 A filter or device which can remove debris from the water before it enters the pump in order to prevent cavitation please consult the pump manufacturer ...

Страница 12: ...D EIMWC00408 16EN 12 60 Fig 3 Minimum clearance requirements for machine maintenance Fig 4 Water piping connection for condenser and heat recovery ...

Страница 13: ...tection methods should be considered when designing the system as a whole 1 Continuous water flow circulation inside piping and exchangers 2 Addition of an appropriate amount of glycol inside the water circuit 3 Additional heat insulation and heating of exposed piping 4 Emptying and cleaning of the heat exchanger during the winter season It is the responsibility of the installer and or local maint...

Страница 14: ...esponsible for connecting the safety valves to the drainage pipes and for their correct dimensioning Check for adequate air circulation around the machine General specifications CAUTION All electrical connections to the machine must be carried out in compliance with applicable laws and regulations All installation operating and maintenance activities must be carried out by qualified personnel Plea...

Страница 15: ...e machine is off but the disconnector switch is in the closed position unused circuits are live as well CAUTION Concurrence of single phase and three phase charges and unbalance between phases can cause leakages towards ground of up to 150 mA during the normal operation of the units of the series If the unit includes devices that cause superior harmonics such as VFD and phase cut the leakage towar...

Страница 16: ... as the pump contactor coil The terminals are connected to a clean microprocessor contact The microprocessor contact has the following commutation capacity Maximum voltage 250 Vac Maximum current 2 A Resistive 2 A Inductive Reference standard EN 60730 1 The wiring described above allows the microprocessor to manage the water pump automatically It is good practice to install a clean status contact ...

Страница 17: ...st be of the shielded type and must not be laid in the vicinity of the power cables so as not to induce interference with the electronic controller A digital input allows to enable the current limitation at the desired time Connect the enabling switch or the timer clean contact to terminals 5 and 9 Attention the two options cannot be enabled simultaneously Setting one function excludes the other F...

Страница 18: ...stem prior to charging with refrigerant This prevents scale formation and the possible formation of an explosive mixture of HFC 134a and air This will also prevent the formation of toxic phosgene gas which occurs when HFC 134a is exposed to open flame Soft solders are not to be used For copper to copper joints use a phos copper solder with 6 to 8 silver content A high silver content brazing rod mu...

Страница 19: ...t length is the actual friction loss from the linear run of pipe plus the added friction loss of elbows valves etc Table 2 shows the equivalent length of pipe for various nonferrous valves and fittings Follow these steps when calculating line size 1 Start with an initial approximation of equivalent length by assuming that the equivalent length of pipe is 1 5 times the actual pipe length 2 Refer to...

Страница 20: ...e total length between the chiller unit and the air cooled condenser must not exceed 60 equivalent meters Liquid line risers in the system will require an additional 11 5 kPa pressure drop per meter of vertical rise When it is necessary to have a liquid line riser make the vertical run immediately after the condenser before any additional restrictions The liquid line risers must not exceed 3 meter...

Страница 21: ...f valve should be installed on the discharge line Reference for discharge line sizing is shown in Table 9 It has to be used for reference only for circuit working with evaporator leaving temperature equal to 7 C and condensing temperature equal to 55 C Line dimensioning is responsibility of plant designer use ASHRAE Refrigeration Handbook or other suitable design guide Table 4 Discharge line sizes...

Страница 22: ...ant It is subsequently compressed and during this process the refrigerant mixes with the oil from the oil separator The high pressure oil refrigerant mixture is introduced into the centrifuge type high efficiency oil separator where the oil is separated from the refrigerant The oil accumulated on the bottom of the separator is forced by the pressure difference back into the compressor while the oi...

Страница 23: ...mperature until complete evaporation followed by superheating Once it has reached the superheated vapour state the refrigerant leaves the evaporator and is once again taken into the compressor to repeat the cycle Controlling the partial recovery circuit and installation recommendations The partial heat recovery system is not managed and or controlled by the machine The installer should follow the ...

Страница 24: ...S CHARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 PARTIAL HEAT RECOVERY OPTIONAL IN OUT WATER PARTIAL RECOVERY 2...

Страница 25: ...S 2 WAY ANGLE VALVE WITH GAS CHARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 DISHARGE LINE CONNECTION LIQUID LIN...

Страница 26: ...LASS 2 WAY ANGLE VALVE WITH GAS CHARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 24 5 BAR DISHARGE LINE CONNECTIO...

Страница 27: ... FLARE VALVE SIGHT GLASS 2 WAY ANGLE VALVE WITH GAS CHARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 23 5 bar 23 ...

Страница 28: ...ALVE WITH GAS CHARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 PARTIAL HEAT RECOVERY OPTIONAL IN OUT WATER PARTIA...

Страница 29: ...GH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 PARTIAL HEAT RECOVERY OPTIONAL IN OUT WATER PARTIAL RECOVERY PARTIAL HEAT RECOVERY OPTIONAL IN OUT...

Страница 30: ...LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 DISHARGE LINE CONNECTION LIQUID LINE CONNECTION DISHARGE LINE CONNECTION LIQ...

Страница 31: ...T LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 DISHARGE LINE CONNECTION LIQUID LINE CONNECTION DISHARGE LINE CONNECTION 1...

Страница 32: ...ARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 DISHARGE LINE CONNECTION LIQUID LINE CONNECTION DISHARGE LINE CONN...

Страница 33: ...GH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 PARTIAL HEAT RECOVERY OPTIONAL IN OUT WATER PARTIAL RECOVERY PARTIAL HEAT RECOVERY OPTIONAL IN OUT...

Страница 34: ...E TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 IN OUT WATER PARTIAL RECOVERY PARTIAL HEAT RECOVERY OPTIONAL IN OUT WATER PARTIAL RECOVERY WL1 ST1 15 5 BAR WO1 PARTIAL HEAT RECOVERY OPTIONAL...

Страница 35: ...E TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 IN OUT WATER PARTIAL RECOVERY PARTIAL HEAT RECOVERY OPTIONAL IN OUT WATER PARTIAL RECOVERY WL1 ST1 15 5 BAR WO1 PARTIAL HEAT RECOVERY OPTIONAL...

Страница 36: ...SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 WL1 ST1 15 5 BAR DISHARGE LINE CONNECTION DISHARGE LINE CONNECTION 23 5 bar 23 5 bar 23 5...

Страница 37: ... GAS CHARGE PORT LOW PRESSURE SWITCH HIGH PRESSURE SWITCH F12 LP F13 HP LOW PRESSURE TRANSDUCER 0 5 7 bar HIGH PRESSURE TRANSDUCER 0 30 bar LEAVING WATER TEMPERATURE ENTERING WATER TEMPERATURE WH1 WOE WL1 WIE OIL TEMPERATURE WD1 ST1 SUCTION TEMPERATURE LIQUID INJECTION SOL VALVE Y5 OIL PRESSURE TRANDUCER WO1 COMPRESSOR CRANKCASE HEATER R1 WL1 ST1 15 5 BAR WO1 15 5 bar 15 5 bar 15 5 bar 23 5 bar 23...

Страница 38: ...er Compression sealing is done thanks to a suitably shaped special composite material that is interposed between the main screw and the satellite The main shaft on which the main rotor is splined is supported by 2 ball bearings The system made up in this way is both statically and dynamically balanced before assembly Fig 24 Picture of Fr4100 compressor Compression process With the single screw com...

Страница 39: ...rotor Once the flute volume is closed off from the suction chamber the suction stage of the compression cycle is complete 1 2 3 Compression As the main rotor turns the volume of gas trapped within the flute is reduced as the length of the flute shortens and compression occurs 3 4 Discharge As the satellite tooth approaches the end of a flute the pressure of the trapped vapour reaches a maximum val...

Страница 40: ...D EIMWC00408 16EN 40 60 Fig 26 Refrigeration capacity control mechanism of compressor Fr4 Load Unload ...

Страница 41: ...or block disconnector switch terminals The power supply voltage must be the same as that on the nameplate Maximum allowed tolerance 10 Voltage unbalance between the three phases must not exceed 3 The unit comes with a factory supplied phase monitor that prevents compressors from starting if the phase sequence is incorrect Properly connect the electrical terminals to the disconnector switch so as t...

Страница 42: ...respectively the average is 383 386 392 387 Volts 3 thus the unbalance percentage is 29 1 100 387 387 392 x below the maximum allowed 3 Oil Heaters power supply Each compressor comes with an electrical resistance located in the compressor s lower area Its purpose is to warm the lubricating oil and thus avoid the mixing of refrigerant fluid within It is therefore necessary to ensure that the resist...

Страница 43: ... valve inlet pipe is completely fully without bubbles and that the humidity indicator shows Dry Any bubbles inside the liquid sight glass might indicate a low refrigerant level or an excessive pressure drop through the filter dryer or an expansion valve that is blocked at the full open position 14 In addition to checking the liquid sight glass check circuit operating parameters by verifying a Supe...

Страница 44: ...is to remain inactive during the winter season One must remember that once the machine s power supply has been cut off the anti freeze electrical resistance cannot function Do not leave the evaporator and piping exposed to the atmosphere during the entire period of inactivity Starting up after seasonal shutdown 1 With the general disconnecting switch open make sure that all the electrical connecti...

Страница 45: ... a complete check on the unit and on the state of the pressurised refrigeration circuits carried out after ten years of use in compliance with Italian law Lgs Decree 93 2000 for all groups belonging to categories I and IV containing fluids of group 2 The manufacturer also recommends that all users analyse compressor vibrations annually and make routine inspections to check on possible refrigerant ...

Страница 46: ...D EIMWC00408 16EN 46 60 Fig 27 Installation of control devices for Fr4 compressor ...

Страница 47: ... 19 Replace anti acid filters and re check after 1000 running hours Continue to replace filters until the TAN is lower than 0 10 0 19 Change oil replace oil filter and filter dryer Verify at regular intervals 7 Safety valves Check that the lid and seal have not been tampered with Check that the discharge socket of the safety valves is not obstructed by any objects rust or ice Check the manufacturi...

Страница 48: ...this purpose POE 11 Close the filter cover 12 Connect the vacuum pump to the filter and pull vacuum to 230 Pa 13 Close the vacuum pump valve 14 Recharge the filter with the refrigerant recovered during emptying 15 Open the liquid line valve 16 Open the suction valve if any 17 Start the compressor by turning switch Q1 or Q2 Replacement of the oil filter ATTENTION The lubrication system has been des...

Страница 49: ... filter replacement procedure Procedure to replace oil filter 1 Shut down both compressors by turning the Q1 and Q2 switches to the Off position 2 Turn the Q0 switch to Off wait for the circulation pump to turn off and open the general disconnecting switch Q10 to cut off the machine s electrical power supply 3 Place a label on the handle of the general disconnecting switch in order to prevent acci...

Страница 50: ...subcooling should not come below 2 C under any condition Also the subcooling value can change slightly as the water temperature and the suction superheating vary As the suction superheating value decreases there is a corresponding decrease in subcooling One of the two following scenarios can arise in a machine without refrigerant 1 If the refrigerant level is slightly low flow of bubbles can be se...

Страница 51: ...ion pressure increase the microprocessor will control the compressor load in order to allow it to function even if the compressor flow gas must be reduced It also contributes to the oil control logic Oil pressure transducer This is installed on every compressor and allows to monitor the oil pressure The microprocessor uses this sensor to inform the operator on the conditions of the oil filter and ...

Страница 52: ...ion saturated temperature _____ bar Suction gas temperature _____ C Suction superheating _____ C Condensation saturated temperature _____ C Discharge superheating _____ C Liquid temperature _____ C Subcooling _____ C _____ C Circuit 2 Compressor load _____ N of expansion valve cycles electronic only _____ Evaporation pressure _____ Refrigerant Oil pressure Condensation pressure _____ bar Oil press...

Страница 53: ... voltage unbalance Phases RS ST RT _____ V _____ V _____ V Unbalance _____ 100 max x Vaverage Vaverage V Compressors current Phases R S T Compressor 1 _____ A _____ A _____ A Compressor 2 _____ A _____ A _____ A Compressor 3 _____ A _____ A _____ A ...

Страница 54: ...g the machine in an inappropriate manner beyond its operating limits or not performing proper maintenance according to this manual can void the warranty Observe the following points in particular in order to conform to warranty limits 1 The machine cannot function beyond the specified limits 2 The electrical power supply must be within the voltage limits and without voltage harmonics or sudden cha...

Страница 55: ...y an authorized agency Please check with your local requirements Important information regarding the refrigerant used This product contains fluorinated greenhouse gases Do not vent gases into the atmosphere Refrigerant type R134a GWP 1 value 1430 1 GWP Global Warming Potential The refrigerant quantity is indicated on the unit name plate Periodical inspections for refrigerant leaks may be required ...

Страница 56: ...igerant charge Factory Field h Greenhouse gas emission of the total refrigerant charge expressed as tonnes of CO2 equivalent m Refrigerant type n GWP Global Warming Potential p Unit serial number 2 The filled out label must be adhered inside the electrical panel Periodical inspections for refrigerant leaks may be required depending on European or local legislation Please contact your local dealer ...

Страница 57: ...frigerant charge Factory Field h Greenhouse gas emission of the total refrigerant charge expressed as tonnes of CO2 equivalent m Refrigerant type n GWP Global Warming Potential p Unit serial number 2 The filled out label must be adhered inside the electrical panel Periodical inspections for refrigerant leaks may be required depending on European or local legislation Please contact your local deale...

Страница 58: ...posal The unit is made of metal and plastic parts All these parts must be disposed of in accordance with the local regulations in terms of disposal Lead batteries must be collected and taken to specific refuse collection centres ...

Страница 59: ...D EIMWC00408 16EN 59 60 ...

Страница 60: ... of its content and the products and services presented therein Specification are subject to change without prior notice Refer to the data communicated at the time of the order Daikin Applied Europe S p A explicitly rejects any liability for any direct or indirect damage in the broadest sense arising from or related to the use and or interpretation of this publication All content is copyrighted by...

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