Daikin EWAD620-C17C-SL Service Manual Download

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ESIE10-01

Maintenance

Part 5 – Maintenance

5–5

Ordinary
maintenance

The following table shows the ordinary maintenance schedule:

Solenoid load valve

Solenoid disc

High-pressure pressure switch

High-pressure transducer

Oil filter

Oil and delivery
temperature
transducer

Oil load/discharge
valve position

Position of electric
resistance for oil
heating

Maximum oil level

Minimum oil level

Installation of F4AL compressor control devices

List of activities

Weekly

Monthly

(Note 1)

Yearly

(Note 2)

General:

Collection of operating data (Note 3)

Visual inspection of machine for any damage and/or loosening

Checking of thermal insulation integrity

Clean and paint where necessary

Water analysis (6)

Electrical:

Checking of correct function of on-board machine instruments

Check contactor wear - Replace if necessary

Check fastening of all electrical terminals - Tighten if neces-
sary

Clean the inside of the electrical control board

Visual inspection of components for any signs of overheating

Check operation of compressor and electrical resistance

Measure compressor motor insulation using the Megger

Refrigeration circuit:

Check for any refrigerant leakage

Summary of Contents for EWAD620-C17C-SL

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: ...l 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 EWAD C XR 1 49 1 20 Electrical Specifications EWAD C PS 1 51 1 21 Electrical Specifications EWAD C PL 1 52 1 22 Electrical Specifications EWAD C PR 1 53 1 23 Cooling Capacity Tables 1 54 1 24 Capacit...

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 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 I O Fan Module Circuit 1 2 POL945 00 MCQ 3 61 2 6 Exp...

Page 5: ...re 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 Chart 6 1 What is in This Chapter 3 75 6 2 Troubleshooting Chart 3 76 Part 4 Commissioning and Test Run 1 Pre Test Run Checks 1 1 What Is in This Chapter 4 3 1 2 Pre Start Commissioning Check List 4 4 ...

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: ...4 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 Chapter See page 1 General Outline 1 3 ...

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

Page 9: ...1 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 Specifications EWAD C PR 1 40 1 14 Electrical Specifications EWAD C SS 1 42 1 15 Electrical Specifications EWAD C SL 1 43 1 16 Electrical Specifications EWAD C SR 1 44 1 17 Electrical Specifications EW...

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 Electrical Installation 1 92 1 35 Operation 1 95 1 36 Wiring Diagrams EWAD CJYNN 1 103 Topic See page ...

Page 11: ...trol 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 controlled by microprocessor system Each unit has infinitely variable capacity control from 100 down to 12 two compressor unit down to 7 three compressors units This modulation allows the 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 data referred to Standard Noise The EER Energy Efficiency Ratio is the ratio of the Cooling Capacity to the Power Input of the unit The Power Input includes the power input for operation of the compres...

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: ...ed 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 efficiency H High ambient Capacity class in kW Cooling Approximation of cooling capacity Model series Letter A B major modification Refrigerant D R 134a P R 407c Q R 410A Inverter Non inverter Z Inver...

Page 15: ...or 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 and mechanically expanded into lanced and rippled aluminium condenser fins with full fin collars An integral sub cooler circuit provides sub cooling to effectively eliminate liquid flashing and incre...

Page 16: ...fan 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 in display shows chiller operating status plus temperatures and pressures of water refrigerant and air programmable values set points A sophisticated software with predictive logic selects the most en...

Page 17: ...ompressors 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 Start at high evaporator water temperature Q Return Reset Set Point Reset based on return water temperature Q OAT Outside Ambient temperature Reset Q Set point Reset optional Q Application and system up...

Page 18: ...I 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 Chiller Profile and LonMark Technology Q BacNet BTP certified over IP and MS TP class 4 Native Q Ethernet TCP IP Standard accessories supplied on basic unit Wye Delta Compressors starter Y D For low in...

Page 19: ...pressor 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 power supply and stops the chiller if the value exceeds the allowed operating limits Ampere Volt meter Device installed inside the control box showing ampere and volt values Capacitors for power fac...

Page 20: ...pump 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 pumps water filling system with pressure gauge safety valve drain valve The motor pump is protected by a circuit breaker installed in control panel The kit is assembled and wired to the control panel...

Page 21: ...ssure 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 mm 800 Nominal air flow l s 53444 53444 53444 64133 64133 Model Quantity No 10 10 10 12 12 Speed rpm 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single s...

Page 22: ...on 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 106888 106888 117577 117577 Model Quantity No 14 16 20 20 22 22 Speed rpm 920 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil char...

Page 23: ...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 are referred to evaporator 12 7 C ambient 35 C full load operation ...

Page 24: ...pressure 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 mm 800 Nominal air flow l s 53444 53444 53444 64133 64133 Model Quantity No 10 10 10 12 12 Speed rpm 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic singl...

Page 25: ...tion 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 106888 106888 117577 117577 Model Quantity No 14 16 20 20 22 22 Speed rpm 920 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil ch...

Page 26: ...otes 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 are referred to evaporator 12 7 C ambient 35 C full load operation ...

Page 27: ...ressure 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 Diameter mm 800 Nominal air flow l s 41006 41006 41006 49207 49207 Model Quantity No 10 10 10 12 12 Speed rpm 715 715 715 715 715 Motor input W 0 78 0 78 0 78 0 78 0 78 Compressor Type Semi hermetic single...

Page 28: ...nsulation 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 65610 82012 82012 90213 90213 Model Quantity No 14 16 20 20 22 22 Speed rpm 715 715 715 715 715 715 Motor input W 0 78 0 78 0 78 0 78 0 78 0 78 Compressor Type Semi hermetic single screw compressor Oil c...

Page 29: ...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 are referred to evaporator 12 7 C ambient 35 C full load operation ...

Page 30: ...rop 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 Nominal air flow l s 64133 74822 74822 85510 Model Quantity No 12 14 14 16 Speed rpm 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil charge l...

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 128266 Model Quantity No 16 20 20 20 24 Speed rpm 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil charge l 50 50 50 50 63 Quantity ...

Page 32: ...aterial 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 149643 160332 Model Quantity No 24 24 26 28 30 Speed rpm 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil charge l 69 75 75 75 75 Q...

Page 33: ...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 are referred to evaporator 12 7 C ambient 35 C full load operation ...

Page 34: ...e 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 Nominal air flow l s 64133 74822 74822 85510 Model Quantity No 12 14 14 16 Speed rpm 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil charg...

Page 35: ...ial 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 128266 Model Quantity No 16 20 20 20 24 Speed rpm 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil charge l 50 50 50 50 63 Quanti...

Page 36: ...aterial 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 149643 160332 Model Quantity No 24 24 26 28 30 Speed rpm 920 920 920 920 920 Motor input W 1 75 1 75 1 75 1 75 1 75 Compressor Type Semi hermetic single screw compressor Oil charge l 69 75 75 75 75 Q...

Page 37: ...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 are referred to evaporator 12 7 C ambient 35 C full load operation ...

Page 38: ...Water 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 Diameter mm 800 Nominal air flow l s 49207 57408 57408 65610 Model Quantity No 12 14 14 16 Speed rpm 715 Motor input W 0 78 Compressor Type Semi hermetic single screw compressor Oil charge l 38 38 38 ...

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 82012 82012 82012 98414 Model Quantity No 16 20 20 20 24 Speed rpm 715 Motor input W 0 78 Compressor Type Semi hermetic single screw compressor Oil charge l 50 50 50 50 63 Quantity No 2 2 2 2 3 Soun...

Page 40: ...5 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 98414 98414 106616 114817 123018 Model Quantity No 24 24 26 28 30 Speed rpm 715 Motor input W 0 78 Compressor Type Semi hermetic single screw compressor Oil charge l 69 75 75 75 75 Quantity No 3 2 2 2...

Page 41: ...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 are referred to evaporator 12 7 C ambient 35 C full load operation ...

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 Cooling kPa 57 65 30 61 69 60 73 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 ...

Page 43: ...O 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 pressure transducer Compressor motor protection High discharge temperature Low oil pressure Low pressure ratio High oil filter pressure drop Phase monitor Emergency stop button Water freeze protection c...

Page 44: ...010 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 Cooling kPa 57 65 30 61 69 60 73 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 45: ...O 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 pressure transducer Compressor motor protection High discharge temperature Low oil pressure Low pressure ratio High oil filter pressure drop Phase monitor Emergency stop button Water freeze protection c...

Page 46: ...010 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 drop Cooling kPa 56 63 29 59 66 58 70 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 47: ...O 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 pressure transducer Compressor motor protection High discharge temperature Low oil pressure Low pressure ratio High oil filter pressure drop Phase monitor Emergency stop button Water freeze protection c...

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 Δ Model EWAD C SS C11 C12 C14 C15 C16 C17 Power Supply Phase 3 Frequency Hz 50 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Unit Maximum starting current A 1009 1017 1242 6 1293 8 1353 1353 Nominal running current cooling A 624...

Page 49: ...hase 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 Δ Model EWAD C SL C11 C12 C14 C15 C16 C17 Power Supply Phase 3 Frequency Hz 50 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Unit Maximum starting current A 1009 1017 1242 6 1293 8 1353 1353 Nominal running current cooling A 624 ...

Page 50: ... 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 Δ Model EWAD C SR C10 C11 C13 C14 C15 C16 Power Supply Phase 3 Frequency Hz 50 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Unit Maximum starting current A 989 4 994 6 1214 6 1265 8 1322 2 1322 2 Nominal running current cooling A 65...

Page 51: ... 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 Δ Model EWAD C XS C10 C11 C12 C13 C14 Power Supply Phase 3 Frequency Hz 50 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Unit Maximum starting current A 965 8 1033 1033 1033 1167 4 Nominal running current cooling A 559 60...

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 running current in cooling A 96 96 104 112 120 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 390 390 326 390 390 390 326 326 390 390 390 326 390 390 3...

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 Δ Model EWAD C XL C10 C11 C12 C13 C14 Power Supply Phase 3 Frequency Hz 50 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Unit Maximum starting current A 965 8 1033 1033 1033 1167 4 Nominal running current cooling A 559 ...

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 running current in cooling A 96 96 104 112 120 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 326 326 269 326 326 326 326 326 390 390 390 326 390 390 3...

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 Δ Model EWAD C XR C10 C11 C12 C13 C14 Power Supply Phase 3 Frequency Hz 50 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Unit Maximum starting current A 943 4 1005 1005 1005 1133 8 Nominal running current cooling A 570 ...

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 running current in cooling A 62 62 68 73 78 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Maximum running current A 326 326 269 326 326 326 326 326 390 390 390 326 390 390 39...

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 Maximum current for wires siz ing A 570 620 671 743 805 884 964 Fans Nominal running current in cool ing A 72 72 72 80 80 88 96 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Ma...

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 Maximum current for wires siz ing A 570 620 671 743 805 884 964 Fans Nominal running current in cool ing A 72 72 72 80 80 88 96 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 M...

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 Maximum current for wires siz ing A 542 593 643 712 774 851 927 Fans Nominal running current in cool ing A 47 47 47 52 52 57 62 Compressor Phase No 3 Voltage V 400 Voltage Tolerance Minimum 10 Maximum 10 Ma...

Page 60: ...18 751 237 726 258 692 281 676 291 659 302 615 300 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 9 833 228 810 248 782 270 746 294 729 304 692 306 642 302 10 854 232 830 252 801 274 764 298 746 309 702 307 645 299 11 875 235 851 256 821 278 782 303 762 312 712 308 647 297 12 896 239 871 260 840 282 801 307 770 312 721 308 650 29...

Page 61: ...6 362 941 394 918 408 894 423 842 426 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 1 014 412 990 427 950 435 879 428 8 1 162 324 1 130 353 1 091 384 1 039 418 1 015 433 964 436 892 429 9 1 191 329 1 158 358 1 117 389 1 065 424 1 039 439 978 438 896 425 10 1 220 334 1 187 363 1 144 395...

Page 62: ...36 574 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 1 292 650 6 1 685 482 1 639 525 1 581 571 1 507 622 1 471 644 1 432 667 1 308 650 7 1 729 489 1 682 533 1 622 580 1 546 631 1 509 654 1 451 668 1 324 648 8 1 774 497 1 725 541 1 664 588 1 585 641 1 547 663...

Page 63: ...735 221 711 241 681 263 658 278 641 288 605 299 496 268 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 8 793 233 766 254 732 277 707 292 673 294 635 300 506 261 9 812 237 785 258 749 282 724 297 682 295 644 300 507 258 10 832 241 803 263 767 287 734 299 692 296 655 301 511 255 11 852 245 822 267 784 292 744 300 701 296 660 298 51...

Page 64: ...92 343 949 375 917 396 892 411 842 427 689 382 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 02 395 985 416 937 419 884 428 701 371 8 1 133 337 1 094 368 1 044 401 1 008 423 951 421 897 428 706 368 9 1 160 343 1 120 374 1 069 408 1 023 425 964 422 909 427 708 362 10 1 188 349 1 146 380 1 093 415 1...

Page 65: ...1 714 638 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 1 645 498 1 589 543 1 518 593 1 466 626 1 411 639 1 319 649 1 102 588 7 1 687 507 1 629 553 1 556 603 1 502 636 1 423 637 1 336 646 1 101 578 8 1 729 515 1 670 562 1 593 614 1 537 647 1 440 638 1 353 ...

Page 66: ... 784 247 756 267 710 295 691 305 671 315 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 8 900 217 879 237 854 257 823 278 773 307 753 317 731 328 9 923 220 902 240 877 260 845 282 795 311 774 321 751 332 10 947 223 925 243 900 264 868 286 816 315 795 325 764 333 11 971 226 948 246 923 267 891 290 838 319 817 330 777 334 12 995 22...

Page 67: ...1 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 1 023 443 992 458 7 1 263 307 1 231 335 1 196 364 1 152 394 1 082 435 1 053 449 1 021 464 8 1 298 312 1 266 340 1 229 369 1 184 400 1 113 440 1 083 455 1 051 471 9 1 333 316 1 300 344 1 263 374 1 217 405 1 144 44...

Page 68: ...9 446 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 1 221 591 6 1 569 395 1 530 431 1 485 468 1 428 507 1 336 559 1 299 579 1 257 599 7 1 612 401 1 572 437 1 526 474 1 468 514 1 374 567 1 336 587 1 293 607 8 1 655 406 1 614 443 1 567 481 1 508 521 1 412 575 ...

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 12 2 123 507 2 071 553 2 010 600 1 934 651 1 814 719 1 762 742 1 599 723 13 2 176 514 2 123 560 2 061 608 1 982 660 1 859 728 1 796 748 1 604 717 14 2 230 522 2 176 568 2 111 617 2 030 669 1 904 738 ...

Page 70: ...975 256 944 278 905 303 773 305 675 284 585 263 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 4 849 226 826 246 798 268 761 292 701 324 641 320 546 297 5 874 230 849 250 820 272 782 297 721 329 645 318 552 296 6 898 234 873 254 842 277 803 301 741 334 643 314 553 292 7 924 237 898 259 866 281 825 306 741 331 650 313 ...

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 1 214 398 1 156 433 1 059 477 932 442 810 402 7 1 329 341 1 292 372 1 247 404 1 188 440 1 066 474 936 435 810 393 8 1 364 346 1 327 378 1 280 411 1 220 447 1 065 465 939 427 817 388 9 1 400 352 1 361 384...

Page 72: ...807 544 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 1 567 463 1 510 504 1 435 549 1 258 583 1 096 547 941 508 7 1 655 432 1 609 471 1 550 513 1 474 558 1 265 579 1 098 541 949 504 8 1 698 439 1 650 478 1 591 521 1 512 567 1 271 575 1 110 538 956 499 ...

Page 73: ...4 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 1 165 641 5 1 827 485 1 779 530 1 720 578 1 644 630 1 521 701 1 371 683 1 178 638 6 1 877 493 1 827 538 1 766 586 1 687 639 1 561 711 1 379 679 1 180 629 7 1 927 501 1 876 547 1 813 595 1 731 649 1 5...

Page 74: ...33 833 328 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 5 971 226 945 246 917 267 886 288 836 317 804 332 767 349 6 1 002 229 974 250 946 271 913 292 862 321 829 337 792 353 7 1 032 232 1 004 253 975 274 941 296 888 325 855 341 810 356 8 1 064 235 1 035 25...

Page 75: ...8 368 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 1 481 355 1 437 384 1 384 415 1 302 456 1 251 478 990 433 12 1 564 330 1 523 360 1 478 390 1 423 421 1 338 462 1 273 480 993 429 13 1 607 335 1 565 365 1 519 395 1 463 427 1 376 469 1 278 478 1 001 427 ...

Page 76: ...319 839 314 666 281 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 4 927 219 902 239 873 260 839 282 783 312 749 328 632 317 5 956 222 930 243 901 264 864 286 807 316 772 333 635 314 6 986 226 958 247 928 268 891 291 832 321 796 338 637 311 7 1 016 230 988 251 956 272 918 295 857 326 820 343 638 307 8 1 046 ...

Page 77: ...88 370 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 1 450 358 1 401 388 1 339 421 1 241 462 1 007 420 787 370 12 1 534 334 1 491 364 1 439 395 1 376 428 1 247 460 1 012 416 790 365 13 1 576 339 1 532 370 1 479 401 1 413 435 1 246 456 1 015 412 792 360 14 ...

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 0440 0 978 0 986 0 992 0 0880 0 957 0 974 0 983 0 1320 0 938 0 962 0 975 Elevation above sea level m 0 300 600 900 1200 1500 1800 Barometric pressure mbar 1013 977 942 908 875 843 812 Cooling capaci...

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 Δt 1 013 1 040 1 074 1 121 1 178 Evaporator Pressure Drop 1 070 1 129 1 181 1 263 1 308 Propylene Glycol Cooling Capacity 0 985 0 964 0 932 0 889 0 846 Compressor Power Input 0 993 0 983 0 969 0 948 0 ...

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 multiply the new Flow Rate and the new Evaporator Pressure Drop by the Correction Factors of table Correction factors for water and glycol mixture on page 1 73 Example Unit Size EWAD650C SS Mixture Wate...

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 1 000 0 996 0 991 0 985 0 978 0 97 0 954 0 927 Compr Power Input kW Correction factor 1 000 1 005 1 012 1 02 1 028 1 039 1 058 1 092 Reduction of Max CIAT C 1 000 0 3 0 7 1 1 1 6 2 2 3 3 5 1 Example ...

Page 82: ...low 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 High temperature Circulating water 20 C 60 C Supply water 4 Circulating water 20 C 60 C Supply water 4 Items to be controlled pH at 25 C 7 0 8 0 7 0 8 0 7 0 8 0 7 0 8 0 Corrosion Scale Electrical co...

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 corrosion E g chemical measure 4 Supply water is considered drink water industrial water and ground water except for genuine water neutral water and soft water 5 The above mentioned items are representable ...

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 greater environmental comfort The minimum water content per unit should be calculated using this simplified formula Q For 2 compressors unit M litres 0 1595 x ΔT C 3 0825 x P kW Q For 2 compressors un...

Page 85: ...90 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 X X X C13 X X X X X X C14 X X X X X Pump Motor Power kW Pump Motor Current A Power Supply V ph Hz PN Motor Protection Insulation Class Working Temp C Single Pump SPK1 11 0 20 0 400V 3ph 50hz 16 IP55 ...

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 1367 1471 1556 1623 Water Flow l s 29 57 34 15 37 71 41 83 44 05 48 75 53 11 65 32 70 28 74 32 77 57 Pressure Drops kPa 67 55 47 57 62 58 68 44 54 60 66 760 830 890 990 C10 C11 C12 C13 C14 C15 C16 C17...

Page 87: ...orking 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 25 61 l s Q The unit EWAD650C SS at nominal working conditions has the following data Evaporator water in out 12 7 C Condenser air inlet 35 C Q The cooling capacity at these working conditions is 647 ...

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 evaporator PD2 kPa 73 kPa x PD2 kPa 52 kPa 1 8 25 61 l s 30 90 l s ...

Page 89: ...d 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 installation and evaporator pressure drops Q When using mixture of water and glycol please contact the factory as above specification can change Single Pump 2 poles Discharge Head Water Flow l s SPK 3 S...

Page 90: ...aximum water Δt 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 below 10 C Amb Temp Speedtroll required below 10 C Amb Temp Max evaporator water Δt C 8 Min evaporator water Δt C 4 ...

Page 91: ...t 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 equivalent structure Q Do not access the electrical components if the machine is not in safe conditions Q Do not access the electrical components without having opened the machine s general switch to ...

Page 92: ...a place that could be dangerous during maintenance operations such as but not only platforms without parapets or railings or areas not complying with the clearance requirements Moving and lifting The machine must be moved and lifted by using cables spacing bars and scales of appropriate dimensions to the machine weight This is stated on its identification plate The table of weights included in the...

Page 93: ...ure 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 install in particularly dusty environments as this will dirty the condensation banks Q The water in the system must be particularly clean and all traces of oil or rust must be removed A mechanical wa...

Page 94: ...ks 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 distances of less that the recommended clearance space 1800 1800 Clearance requirements for machine maintenance 1500 2000 3000 3000 3000 Minimum installation clearance of the individual machine ...

Page 95: ...covery 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 temperature and pressure indicators on the machine to assist the operator during service and maintenance 7 A filter or device which can remove foreign particles from the water before it enters the pump in orde...

Page 96: ...20 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 435 810 Nr 12 830 800 XS XL 810 870 XR 2285 7085 2540 1370 2412 435 810 Nr 14 990 C10 XS XL 970 C10 XR 2285 7985 2540 2270 2360 540 760 Nr 16 C11 C13 XS XL C11 C13 XR 2285 9785 2540 4070 2360 540 760 Nr ...

Page 97: ...ssor 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 540 285 Nr 22 C14 XS XL C14 XR 2285 11985 2540 5680 2910 540 285 Nr 24 C15 C16 XS XL C15 C16 XR 2285 11985 2540 5680 2840 540 210 Nr 24 C17 XS XL C17 XR 2285 12885 2540 6580 2840 540 210 Nr 26 C18 XS ...

Page 98: ...round 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 accordance with EN 60439 1 is 25 kA Please therefore check the short circuit current at the machine power supply line connection terminals to ensure that it is less than or equal to the machine panel h...

Page 99: ...Resistive 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 pump s thermal magnetic circuit breaker and to connect it in series with the flow switch Alarm relays Electrical wiring The unit has a clean contact digital output that changes state whenever an ala...

Page 100: ...nals 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 control needs enabling by means of a clean contact using terminals 6 9 on terminal board M5 Caution The two options cannot be enabled simultaneously Setting one function excludes the other General alarm Pu...

Page 101: ...he 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 valve controlled by an electronic control device that optimises its operation Description of the refrigeration cycle The low temperature refrigerant gas from the evaporator is drawn by the compressor ...

Page 102: ...System 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 valve 5 High pressure safety valve 6 Fans ...

Page 103: ...ses 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 lamination element which by means of a pressure drop starts the evaporation process The result at this point is a low pressure and low temperature liquid gas mixture entering the evaporator When the ...

Page 104: ...f 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 off the heat recovery water pump 3 minutes after having switched off the last compressor Important Partial heat recovery which exploits the post overheating cooling of the delivery gas is designed as ...

Page 105: ...5 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 pressure transducer 4 Schrader valve 5 High pressure safety valve ...

Page 106: ...ing 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 two satellites arranged horizontally to the screw Compression sealing is obtained thanks to a suitably shaped special composite material that is interposed between the main screw and the satellite Th...

Page 107: ...lite 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 approaches the end of the flute the pressure of the trapped vapour reaches a maximum value occurring near the triangular aperture of the discharge port Compression immediately ceases and the gas is delivered ...

Page 108: ...d 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 operating diagram is shown in the following figure The slide is only controlled by means of the opening and closing of two solenoids that always operate by opposition During the load stage the solenoid b...

Page 109: ...s 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 1 121 1 36 18 Expansion Input Output Unit Alarm Limiting 1 122 1 36 19 Expansion Control Compressor 1 1 123 1 36 20 Expansion Control Compressor 1 1 124 1 36 21 EEXV Compressor 1 1 125 1 36 22 Expansio...

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 this wire or MJ if the option is requested Manual reset ...

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 Economizer Solenoid Valve Cir 1 ESV 2 Economizer Solenoid Valve Cir 1 ESV 3 Economizer Solenoid Valve Cir 1 EXV 1 Electronic Expansion Valve EXV 2 Electronic Expansion Valve EXV 3 Electronic Expansion V...

Page 143: ...liary 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 Contactor KM1 2 Contactor KM1 3 Contactor KM101 Fan Motor Contactor KM102 Fan Motor Contactor KM103 Fan Motor Contactor KM105 Fan Motor Contactor KM107 Fan Motor Contactor KM110 Fan Motor Contactor K...

Page 144: ...an 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 Motor M308 Fan Motor M309 Fan Motor M310 Fan Motor MOV V Varistor OAT Outside Air Temperature OP 1 Oil Pressure Transducer Cir 1 OP 2 Oil Pressure Transducer Cir 2 OP 3 Oil Pressure Transducer Cir 2 OPL...

Page 145: ...hoice 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 Relay SPN95 Forced Ventilation SPN15a Variable Phase Monitor ST 1 Suction Temperature Sensor 1 ST 2 Suction Temperature Sensor 2 ST 3 Suction Temperature Sensor 2 T1 400 115 V Transformer T2 230 V 2...

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 Solenoid Valve Circ 1 YT 3 Turbo Solenoid Valve Circ 3 Item Description ...

Page 147: ...al 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 default Maximum load 2A 230VAC Comp 1 Alarm NO default Maximum load 2A 230VAC Comp 2 Alarm NO default Maximum load 2A 230VAC Comp 3 Alarm NO default Maximum load 2A 230VAC Current limit enable remove wi...

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

Page 149: ...information 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 gather information prior to servicing and troubleshooting What is in this part This part contains the following chapters Chapter See page 1 The Digital Controller 2 3 2 Functional Control 2 23 ...

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

Page 151: ...his 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 software Overview This chapter contains the following topics Topic See page 1 2 System Architecture 2 4 1 3 Customer Interfaces 2 6 1 4 Display and Keypad 2 10 ...

Page 152: ...d 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 and 2 I O Extension Fans Circuit 3 I O Extension Fans Circuit 4 I O Extension Fans Circuit 3 and 4 I O Extension Compressor 1 I O Extension EXV 1 I O Extension EXV 2 I O Extension EXV 3 I O Extension...

Page 153: ...Digital 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 MODbus LON AWC ...

Page 154: ...0 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 3 3 Communication Modules 2 9 ...

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: ...sage 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 Fans 1 2 Ext IO 945 FC12 6 Used when number of fans on cir cuit 1 is more than 6 number of fans on circuit 2 is more than 6 or unit has multipoint power Comp 3 Ext IO 965 00 CC3 7 Used when configur...

Page 157: ...ny 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 00 MCQ Optional Lon POL906 00 MCQ Optional MODBUS POL902 00 MCQ Optional BACnet MSTP POL904 00 MCQ Optional ...

Page 158: ...al 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 Point 2 16 ...

Page 159: ...rt 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 Set Up Temperature Date Time Schedule ...

Page 160: ...t 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 Until Restart Scheduled Maintenance Time Until Restart Alarms Compressor 1 Cycle Time Remaining R Compressor 2 Cycle Time Remaining R About This Chiller Compressor 3 Cycle Time Remaining R Compressor 4...

Page 161: ...Restart 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 Cycle Delay R Scheduled Maintenance Temperatures view set unit Next Maintenance Month Year R W Evap Leaving Water Temp R Service Support Reference R Evap Entering Water Temp R Evaporator Delta T R Alarm...

Page 162: ...Compressor 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 Actual IP Address R Service Support Reference R Actual Mask R Actual Gateway R Alarms Given IP Address R W Alarm Active Given Mask R W Alarm Log Given Gateway R W Unit Support R W About This Chiller NC ...

Page 163: ...ew 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 Compressor 3 Cycle Time R Circuit Capacity R Compressor 4 Cycle Time R Status Circuit 2 Status Circuit 3 Scheduled Maintenance Status Circuit 4 Next Maintenance Month Year R W Service Support Refere...

Page 164: ...t 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 See auto adjusted settings Ice LWT 4 C 8 to 4 C Startup Delta T 2 7 C 0 to 5 C Shut Down Delta T 0 7 C 0 to 1 7 C Stage Up Delta T between compressors 1 C 0 to 1 7 C Stage Down Delta T between compres ...

Page 165: ...one 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 C Compressors Global SI Start start timer 20 min 15 60 minutes Stop start timer 5 min 3 20 minutes Pumpdown Pressure 100 KPA 70 to 280 KPA Pumpdown Time Limit 120 sec 0 to 180 sec Light Load Stg Dn ...

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 Water Freeze 2 2 C See auto adjusted settings Evaporator Flow Proof 15 sec 5 to 15 sec Recirculate Timeout 3 min 1 to 10 min Low Ambient Lockout Enable Disable Disable Enable Low Ambient Lockout 12 C ...

Page 167: ...enable 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 Deadband 1 2 5 C 1 10 C Fan Stage Up Deadband 2 4 C 1 10 C Fan Stage Up Deadband 3 5 C 1 10 C Fan Stage Up Deadband 4 4 C 1 10 C Fan Stage Up Deadband 5 4 C 1 10 C Fan Stage Down Deadband 2 4 C 1 13...

Page 168: ...aporator 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 6 C Available Mode Selection Range SI Without Glycol 195 to 310 KPA With Glycol 0 to 310 KPA Available Mode Selection Range SI Without Glycol 180 to 310 KPA With Glycol 0 to 410 KPA Fan VFD Range SI...

Page 169: ...ed 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 Stage Up Deadband 3 6 Fan Stage Up Deadband 5 4 Fan Stage Up Deadband 4 6 5 Fan Stage Up Deadband 5 6 5 Fan Stage Down Deadband 2 4 Fan Stage Down Deadband 2 10 Fan Stage Down Deadband 3 3 5 Fan Stage Do...

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

Page 171: ...ntroduction 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 functional control Overview This chapter contains the following topics Topic See page 2 2 Unit Functions 2 24 2 3 Circuit Functions 2 40 ...

Page 172: ...he 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 Control 2 30 2 2 7 Noise Reduction 2 31 2 2 8 LWT Target 2 32 2 2 9 Unit Capacity Control 2 35 2 2 10 Unit Capacity Overrides 2 38 ...

Page 173: ...he 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 chiller no alarms should cause a normal shutdown discussed later on of any running circuits When the controller is powered up the Unit Enable Set Point should be initialized to off if the Unit Status Afte...

Page 174: ...he 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 running Unit Mode is set according to the following table Note An x indicates that the value is ignored Glycol Configuration If the Available Modes Set Point is set to an option w Glycol then glycol o...

Page 175: ...ot 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 enabled based on settings and switches If unit mode is ice the ice timer has expired No manual reset unit alarms are active At least one circuit is enabled and available to start Low OAT Lockout is no...

Page 176: ...nit 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 Off and Unit Mode Test 11 Auto Noise Reduction Unit State Auto and Noise Reduction is active 12 Auto Wait for load Unit State Auto no circuits running and LWT is less than the active set point start...

Page 177: ...s 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 cleared to force a restart in ice mode A set point specifically for clearing the ice mode delay is available In addition cycling the power to the controller should clear the ice delay timer Comp stat...

Page 178: ...ontrol 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 is used as a backup 1 Primary Pump 1 is used normally with pump 2 as a backup 2 Primary Pump 2 is used normally with pump 1 as a backup Primary Standby Pump Staging The pump designated as primary wi...

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 set point However if any reset type is selected that reset will continue to be used rather than the maximum reset Also the saturated condenser target for each circuit will be offset by the Noise Red...

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 is never set to a value less than the actual leaving chilled water setpoint Function description Remark When the unit is designed for a ΔT of 5 C at 100 capacity then the start ΔT and Max Reset should ...

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 2 Max Reset set point 3 OAT Reset is 0 if the outdoor ambient temperature is greater than Start Reset OAT set point From Start Reset OAT set point down to Max Reset OAT the reset varies linearly from ...

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: ...ils 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 least one compressor is running the other compressors should start as quickly as possible with respect to the stage up delay Required Load for Stage Up An additional compressor should not be started u...

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 controlling capacity of the individual compressors Compressors are loaded with a fixed step scheme The rate of capacity adjustment should be determined by the time between capacity changes The farther awa...

Page 185: ...ual 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 running compressors If capacities are equal it must have the lowest sequence number of the compressors that are running If sequence numbers are equal it must have the most run hours If run hours are...

Page 186: ...o 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 signal This function is only enabled if the unit control source is set to network The signal will be received through the BMS interface on the unit controller As the signal varies from 0 up to 100 the...

Page 187: ...imited 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 condenser coil A dead band placed below the limit set point will be used to increase function stability If the actual capacity is in the band unit loading will be inhibited ...

Page 188: ...uit 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 46 2 3 5 EXV Control 2 48 2 3 6 Economizer Control 2 50 2 3 7 Liquid Injection 2 51 ...

Page 189: ...ssure 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 If the pressure does not rise above the unload set point and the circuit has been running longer than the Startup Time set point then the circuit should be turned off and an alarm triggered If the e...

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 any of the following are true Evaporator Pressure is less than the Pumpdown Pressure set point Circuit has been pumping down for longer than the Pumpdown Time Limit set point Rapid Shutdown A rapid sh...

Page 191: ...ff 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 cannot start due to active circuit alarm 7 Off Test Mode Circuit is in test mode 8 EXV Preopen Circuit is in preopen state 9 Run Pumpdown Circuit is in pumpdown state 10 Run Normal Circuit is in run ...

Page 192: ...y 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 compressor capacity from 25 to 100 Capacity control shall revert back to automatic control if either The circuit shuts down for any reason Capacity control has been set to manual for four hours Slide ...

Page 193: ...allowed 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 allowed to increase capacity High Cond Hold Value Max Saturated Condenser Value 2 78 C If the High Condenser Pressure Unload event is triggered the compressor will begin reducing capacity High Cond Unload ...

Page 194: ...e 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 up Error Step Saturated Condenser Refrigerant temperature Target Stage Up dead band The Stage Up Error Step is added to Stage Up Accumulator once every 5 seconds only if the Saturated Condenser Refr...

Page 195: ...arget 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 condenser temperature to a target value The target value is normally the same as the saturated condenser temperature target VFD State The VFD speed signal should always be 0 when the fan stage is 0 Whe...

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 stable water loop static compressor capacity and stable condensing temperature The target value should be adjusted as needed to maintain discharge superheat within a range from 15 C to 25 C As the dischar...

Page 197: ...t 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 control setting is automatically set back to auto If EXV control is changed from manual back to auto while the circuit state remains run the EXV state should go back to the normal operations if possible ...

Page 198: ...4 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 is no longer in a run state ON 60 95 OFF Economizer Compressor Capacity ...

Page 199: ...l 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 temperature decreases below the activation set point by a differential of 10 C Liq Inj ON 75 C 85 C Liq Inj OFF del Temp Oil Temp ...

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

Page 201: ...rical 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 See page 1 Alarms and Events 3 3 2 Controller Inputs and Outputs 3 55 3 Procedure for Software Programming 3 67 4 Procedure to Protect Compressor in Case of Frozen Evaporator 3 71 5 Procedure to Clear...

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

Page 203: ...ause 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 or may not cause the chiller to respond with a specific action in response All alarms and events are logged Overview This chapter contains the following topics Topic See page 1 2 Unit Stop Alarms 3 4 ...

Page 204: ...rview 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 Temperatures Inverted 3 8 1 2 5 Leaving Evaporator Water Temperature Sensor Fault 3 9 1 2 6 AC Comm Failure 3 10 1 2 7 Outdoor Air Temperature Sensor Fault 3 11 1 2 8 External Alarm 3 12 1 2 9 Emergency ...

Page 205: ...Loss 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 PVM input is high or PVM set point does not equal single point for at least 5 seconds ...

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 will reset automatically when the evaporator state is Run again This means the alarm stays active while the unit waits for flow then it goes through the recirculation process after flow is detected On...

Page 207: ...for 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 only if the alarm trigger conditions no longer exist 4 C 3 C Freeze Prevention Setpoint possible for the compressor to upload possible to reset Anti freeze Alarm Freeze up prevention load down Anti f...

Page 208: ...ted 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 seconds Action Taken Pumpdown stop on all circuits Reset This alarm can be cleared manually via the keypad ...

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 cleared manually via the keypad but only if the sensor is back in range ...

Page 210: ...ription 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 keypad when communication between main controller and the extension module is working for 5 seconds ...

Page 211: ...ensor 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 cleared manually via the keypad if the sensor is back in range or Low Ambient Lockout is disabled ...

Page 212: ...8 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 Rapid stop of all circuits Reset Auto clear when digital input is closed ...

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 manually via the keypad but only if the emergency switch is closed ...

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 Sensor Fault 3 15 1 3 2 External Event 3 16 1 3 3 Low Ambient Lockout 3 17 ...

Page 215: ...g 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 used Reset Auto reset when sensor is back in range ...

Page 216: ...3 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 Taken None Reset Auto clear when digital input is closed ...

Page 217: ...rigger 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 lockout set point plus 2 5 C or when low ambient lockout is disabled 5 6 Setpoint reset ambient lockout and restart unit diff switch off unit Ambient ...

Page 218: ...Mechanical 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 Pressure Difference 3 27 1 4 10 Compressor Starter Fault 3 28 1 4 11 High Motor Temperature 3 29 1 4 12 Low OAT Restart Fault 3 30 1 4 13 No Pressure Change After Start 3 31 1 4 14 No Pressure At Startup...

Page 219: ...Phase 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 is high or PVM set point does not equal multi point for at least 5 seconds ...

Page 220: ...ror 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 set point a timer starts If this timer exceeds the freeze time then a freezestat trip occurs If the evaporator pressure rises to the unload set point or higher and the freeze time has not been exceed...

Page 221: ...Low 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 circuit Reset This alarm can be cleared manually via the Unit Controller keypad ...

Page 222: ...chanical 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 cleared manually via the Unit Controller keypad if the MLP switch input is high ...

Page 223: ...d 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 alarm can be cleared manually via the Unit Controller keypad Setpoint 20 5 HP Alarm If HP is below this value possible to reset 15 5 HP Time ...

Page 224: ...imit 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 Action Taken Normal shutdown of circuit Reset Alarm can be cleared manually via the Unit Controller keypad pressure ratio discharge pressure Abs suction pressure Abs 1 8 1 4 25 cap 100 cap Pressure ratio...

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 Taken Rapid stop circuit Reset This alarm can be cleared manually via the Unit Controller keypad if the MHP switch input is high ...

Page 226: ...cription 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 active Action Taken Rapid stop circuit Reset This alarm can be cleared manually via the Unit Controller keypad ...

Page 227: ...ure 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 difference Action Taken Rapid stop circuit Reset This alarm can be cleared manually via the Unit Controller keypad HP Oil Pressure sensor Oil Filter inside compressor DP HP oil pressure ...

Page 228: ...n 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 starter fault input is open Action Taken Rapid stop circuit Reset This alarm can be cleared manually via the Unit Controller keypad ...

Page 229: ...ndings 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 circuit Reset This alarm can be cleared manually via the Unit Controller keypad after input value for motor temperature has been 200 ohms or less for at least 5 minutes ...

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 alarm can be cleared manually via the Unit Controller keypad ...

Page 231: ...rm 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 seconds Action Taken Rapid stop circuit Reset This alarm can be cleared manually via the Unit Controller keypad ...

Page 232: ...t 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 Rapid stop circuit Reset This alarm can be cleared manually via the Unit Controller keypad ...

Page 233: ...escription 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 keypad when communication between main controller and the extension module is working for 5 seconds ...

Page 234: ...mm 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 Reset This alarm can be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds ...

Page 235: ...on 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 be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds ...

Page 236: ...on 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 be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds ...

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 can be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds ...

Page 238: ...with 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 stop of affected circuit Reset This alarm can be cleared manually via the keypad when communication between main controller and the extension module is working for 5 seconds ...

Page 239: ...4 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 manually via the keypad but only if the sensor is back in range ...

Page 240: ...3 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 manually via the keypad but only if the sensor is back in range ...

Page 241: ...4 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 manually via the keypad but only if the sensor is back in range ...

Page 242: ...5 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 manually via the keypad but only if the sensor is back in range ...

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 cleared manually via the keypad but only if the sensor is back in range ...

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 manually via the keypad but only if the sensor is back in range ...

Page 245: ...uit 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 Evaporator Pressure Hold 3 46 1 5 2 Low Evaporator Pressure Unload 3 47 1 5 3 High Condenser Pressure Hold 3 48 1 5 4 High Condenser Pressure Unload 3 49 1 5 5 Failed Pumpdown 3 50 1 5 6 Power Loss Whi...

Page 246: ...ng 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 Action Taken Inhibit loading Reset While still running the event will be reset if evaporator pressure gets above the Low Evaporator Pressure Hold setpoint plus a difference The event is also reset if th...

Page 247: ...llowing 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 Evaporator Pressure Unload set point Reset While still running the event will be reset if evaporator pressure gets above the Low Evaporator Pressure Hold setpoint plus a difference The event is also r...

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 will be reset if saturated condenser temperature drops below the High Saturated Condenser Hold Value 5 C The event is also reset if the unit mode is switched to Ice or the circuit is no longer in the r...

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 event will be reset if saturated condenser temperature drops below the High Saturated Condenser Unload Value 5 C The event is also reset if the unit mode is switched to Ice or the circuit is no long...

Page 250: ...hooting 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 triggered Action Taken Shutdown circuit Reset N A ...

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 running Action Taken N A Reset N A ...

Page 252: ...ing 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 all others are moved down one dropping the last alarm In the alarm log the date and time the alarm occurred are stored as well as a list of other parameters These parameters include unit state OAT LWT...

Page 253: ...cur 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 well as the time and date of the occurrence No additional parameters are logged for events The event log shall only be accessible with the Manager password ...

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

Page 255: ...following 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 I O Fan Module Circuit 1 2 POL945 00 MCQ 3 61 2 6 Expansion I O Fan Module Circuit 3 POL945 00 MCQ 3 62 2 7 Expansion I O Fan Module Circuit 4 POL945 00 MCQ 3 63 2 8 Expansion I O Fan Module Circuit...

Page 256: ...TC 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 1000 steps resolution X6 Fan VFD 2 0 10VDC 0 to 100 1000 steps resolution X7 Fan VFD 3 0 10VDC 0 to 100 1000 steps resolution X8 Fan VFD 4 0 10VDC 0 to 100 1000 steps resolution Description Signal O...

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 Step 4 Fan Off Fan On DO7 Circuit 2 Fan Step 1 Fan Off Fan On DO8 Circuit 2 Fan Step 2 Fan Off Fan On DO9 Circuit 2 Fan Step 3 Fan Off Fan On DO10 Circuit 2 Fan Step 4 Fan Off Fan On ...

Page 258: ...nt 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 X3 Oil Pressure Ratiometric 0 5 4 5 Vdc 0 to 5 Vdc X4 Condenser Pressure Ratiometric 0 5 4 5 Vdc 0 to 5 Vdc X7 Motor Protection NTC Thermister 10K 25 C n a Description Output Signal Range Not Needed ...

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 Output On DO1 Start Compressor Compressor Off Compressor On DO2 Economizer Solenoid Closed Solenoid Open DO3 Non modulating Slide Load Solenoid Closed Solenoid Open DO4 Non modulating Slide Unload Sole...

Page 260: ...outputs 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 On DI1 Low Pressure switch Fault No fault Description Output Off Output On DO1 Liquid Line Solenoid Closed Solenoid Open Description M1 EXV Stepper Coil 1 M1 M2 EXV Stepper Coil 2 M2 ...

Page 261: ...Q 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 Off Fan On DO2 Circuit 1 Fan Step 6 Fan Off Fan On DO3 Circuit 2 Fan Step 5 Fan Off Fan On DO4 Circuit 2 Fan Step 6 Fan Off Fan On ...

Page 262: ...uit 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 Circuit 3 Fan Step 2 Fan Off Fan On DO3 Circuit 3 Fan Step 3 Fan Off Fan On DO4 Circuit 3 Fan Step 4 Fan Off Fan On ...

Page 263: ...uit 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 Circuit 4 Fan Step 2 Fan Off Fan On DO3 Circuit 4 Fan Step 3 Fan Off Fan On DO4 Circuit 4 Fan Step 4 Fan Off Fan On ...

Page 264: ...1 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 Circuit 4 Fan Step 5 Fan Off Fan On DO4 Circuit 4 Fan Step 6 Fan Off Fan On ...

Page 265: ...cription 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 Switch 2 Circuit Off Circuit On X7 Circuit Switch 3 Circuit Off Circuit On X8 Circuit Switch 4 Circuit Off Circuit On Description Output Off Output On DO1 Evaporator Water Pump 2 Pump Off Pump On DO2 Open...

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

Page 267: ...e 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 Software Programming with SD Card 3 68 ...

Page 268: ...t 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 the SD card in the controller in the correct position ...

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: ...1 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 till orange 4 Power off and remove SD card ...

Page 271: ...Part 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 page 4 2 Procedure to Protect Compressor in Case of Frozen Evaporator 3 72 ...

Page 272: ...to 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 of the compressor 5 Close the drain plugs and vacuum the compressor for a few hours while the crank case heater is on 6 If the vacuum oil becomes coloured milky colour replace the vacuum oil 7 Repeat...

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 See page 5 2 Procedure to Clean the Refrigerant Circuit in Case of Frozen Evaporators 3 74 ...

Page 274: ...he 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 of the vacuum pump If the vacuum oil becomes milky it should be replaced by new vacuum oil The crankcase heater must be activated It is advisable to connect a second heater tape at the suction of th...

Page 275: ...oubleshooting 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 Troubleshooting Chart 3 76 ...

Page 276: ...orts 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 Check unit power wiring to unit for correct phasing Check voltage 8 Compressor overload is tripped 8 Overloads are manual reset Reset overload at button on overload 9 Compressor contactor or contactor c...

Page 277: ...apacity 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 shut off valve 2 Non condensable is in the system 2 Purge the non condensable from the condenser coil after shutdown 3 Fans are not running 3 Check the fan fuses and electrical circuits 4 Fan contro...

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 evaporator is insufficient 5 Check the water pressure drop across the evaporator and adjust the flow 6 The water temperature leaving the evaporator is too low 6 Adjust the water temperature to a higher val...

Page 279: ...st 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 units What is in this part This part contains the following chapters Chapter See page 1 Pre Test Run Checks 4 3 2 Running Data 4 9 ...

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

Page 281: ...Test 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 Pre Start Commissioning Check List 4 4 1 3 General Checks 4 5 1 4 Water Piping Checks 4 6 ...

Page 282: ...alves 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 N A Flowswitch fully installed and wired Power supply connected earth wiring Pump contact wired in series with the flow switch Field wiring in accordance with the local regulation Completed and check...

Page 283: ...tally 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 facilitates the rust process and shortens the lifetime of the unit 6 The operator has received the operation manual 7 The installer has received the installation manual 8 The air volume over the coil is...

Page 284: ...limits 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 circuit 7 The flow switch and pump are properly working 8 Air purge points are installed on the high parts of the water piping 9 Drain taps are installed at the low points of the water piping 10 Other par...

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: ...ning 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 See page 2 2 Typical Operating Data 4 10 ...

Page 288: ...id 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 C 2 4 C Total Liquid Sub Cooling 19 24 C 19 24 C Cond Coil 4 6 C Eco 15 18 C Suction Superheat 4 6 C 4 6 C Economiser Superheat 5 8 C 5 8 C Discharge Superheat 20 25 C 20 25 C Operating Value Standar...

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: ...ance 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 What is in this part This part contains the following chapter Chapter See page 1 Maintenance 5 3 ...

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 all contact with open fires or hot surfaces By high temperatures the refrigerant gas R 134a may decompose into irritating and poisonous gas Avoid skin and hand contact with the liquid refrigerant and ...

Page 294: ...l 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 recommend recording all machine operating parameters on a weekly basis The collection of this data will also be very useful for technicians should technical assistance be required Compressor maintenance I...

Page 295: ...rly 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 Water analysis 6 X Electrical Checking of correct function of on board machine instruments X Check contactor wear Replace if necessary X Check fastening of all electrical terminals Tighten if neces sary ...

Page 296: ...ly 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 value is within the accepted limits Replacement of the cartridges is advised when the pressure drop across the filter reaches 50 kPa with the compressor under full load The cartridges must also be r...

Page 297: ...m 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 compressor turning the Q1 or Q2 switch Oil filter replacement Important The lubrication system has been designed to keep most of the oil charge inside the compressor During operation however a small amount of...

Page 298: ...onnecting 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 units have been designed to operate with R 134a refrigerant DO NOT USE refrigerants other than R 134a Warning The addition or removal of refrigerant gas must be in accordance with current regulations ...

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 tion superheating must be between 4 and 6 C 4 Add enough refrigerant to fill the liquid sight glass entirely so that no flow of bubbles can be seen any more Add an extra 2 3 kg of refrigerant as a rese...

Page 300: ...ompressor 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 compressor load in order to allow it to function even if split It also contributes to the oil control logic Oil pressure transducer This is installed on every compressor and allows you to monitor the oil p...

Page 301: ...sion 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 Capacity Tables k 1 54 Correction Factor Altitude k 1 72 Available Fan Static Pressure k 1 75 Evaporator k 1 72 Low Evaporator Leaving Water Temperature k 1 72 Minimum Glycol For Low Air Temperature k 1 7...

Page 302: ...xternal 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 General Characteristics k 1 9 H Heat Recovery Ratings k 1 79 High Condenser Pressure Hold k 3 48 High Condenser Pressure Unload k 3 49 High Condenser Pressure k 3 23 High Discharge Temperature k 3 26 H...

Page 303: ...tdoor 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 Procedure To Protect Compressor In Case Of Frozen Evaporator k 3 72 S Software Programming With SD Card k 3 68 Standard Checks k 5 10 Suction Temperature Sensor Fault k 3 42 System Maintenance k 5 4 T Techn...

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-SL, Service Manual

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