OPERATION MANUAL. Packaged water-cooled water chillers EWWP045KAW1M EWWP055KAW1M EWWP065KAW1M ECB2MUAW ECB3MUAW

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1 OPERATION MANUAL Packaed water-cooled water cillers EWWP045KAW1M EWWP055KAW1M EWWP065KAW1M ECB2MUAW ECB3MUAW

2 EWWP045KAW1M EWWP055KAW1M EWWP065KAW1M ECB2MUAW ECB3MUAW Packaed water-cooled water cillers CONTENTS Pae INTRODUCTION Introduction... 1 Tecnical specifications... 2 Electrical specifications... 2 Description... 3 Function of te main components... 4 Safety devices... 5 Internal wirin - Parts table... 5 Before operation... 6 Cecks before initial start-up... 6 Water supply... 6 General recommendations... 6 Operation 32~72 Hp... 6 Diital controller... 6 Workin wit te 32~72 Hp units... 6 Advanced features of te diital controller... 9 Troublesootin Maintenance Important information reardin te refrierant used Maintenance activities Disposal reuirements Tis operation manual concerns packaed water-cooled water cillers of te Daikin EWWP-KA series. Tese units are provided for indoor installation and used for coolin and/or eatin applications. Te units can be combined wit Daikin fan coil units or air andlin units for air conditionin purposes. Tey can also be used for supplyin water for process coolin. Tis manual as been prepared to ensure adeuate operation and maintenance of te unit. It will tell you ow to use te unit properly and will provide elp if problems occur. Te unit is euipped wit safety devices, but tey will not necessarily prevent all problems caused by improper operation or inadeuate maintenance. In case of persistin problems contact your local dealer. Before startin up te unit for te first time, make sure tat it as been properly installed. It is terefore necessary to carefully read te installation manual supplied wit te unit and te recommendations listed in "Cecks before initial start-up" on pae 6. READ THIS MANUAL ATTENTIVELY BEFORE STARTING UP THE UNIT. DO NOT THROW THIS MANUAL AWAY. KEEP IT IN YOUR FILES FOR FUTURE REFERENCE. Read te capter "User settins menu" on pae 9 before canin te parameters. Te Enlis text is te oriinal instruction. Oter lanuaes are translations of te oriinal instructions. Tis appliance is not intended for use by persons, includin cildren, wit reduced pysical, sensory or mental capabilities, or lack of experience and knowlede, unless tey ave been iven supervision or instruction concernin use of te appliance by a person responsible for teir safety. Cildren sould be supervised to ensure tat tey do not play wit te appliance. 1 Packaed water-cooled water cillers

3 Tecnical specifications (1) General Hp Nominal coolin capacity (a) (kw) Nominal input (b) (kw) Dimensions HxWxD (mm) 1200x600x x600x1200 Macine weit (k) Connections water inlet (inc) 2x 2x FBSP 1.5" 3x 2x FBSP 1.5" water outlet (inc) 2x 2x FBSP 1.5" 3x 2x FBSP 1.5" Compressor Type Qty x model 4x JT212DA-YE 2x JT212DA-YE + 2x JT300DA-YE 4x JT300DA-YE 2x JT300DA-YE + 2x JT335DA-YE ermetically sealed scroll 4x JT335DA-YE 4x JT212DA-YE + 2x JT300DA-YE 2x JT212DA-YE + 4x JT300DA-YE 6x JT300DA-YE Speed (rpm) Oil type FVC 68D FVC 68D Oil care volume (l) 4x 2.7 6x 2.7 4x JT300DA-YE + 2x JT335DA-YE 2x JT300DA-YE + 4x JT335DA-YE 6x JT335DA-YE Evaporator Type brased plate eat excaner Qty 2 3 Nominal water flow (l/min) Water flow rane (l/min) Condenser Type brased plate eat excaner Qty 2 3 Nominal water flow (l/min) Water flow rane (l/min) (a) (b) Te nominal coolin capacity is based on: - enterin water temperature of 12 C - cilled water temperature of 7 C - condenser in/out water temperature of 30/35 C Te nominal input includes total input of te unit: compressor, control circuit and water pumps. Electrical specifications (1) General Hp Power supply Pase 3N~ 3N~ Freuency (Hz) Voltae (V) Voltae tolerance (%) ±10 ±10 Unit Nominal runnin current (A) Maximum runnin current (A) Recommended fuses accordin to IEC (A) 3x 63 3x 63 3x 80 3x 80 3x 80 3x 100 3x 100 3x 125 3x 125 3x 125 3x 125 Compressor Pase 3~ 3~ Freuency (Hz) Voltae (V) Nominal runnin current (A) / / / / / /15 15 (1) Refer to te enineerin data book for te complete list of specifications. Packaed water-cooled water cillers 2

4 DESCRIPTION 5 52~72 Hp 32~48 Hp Fiure - Main components 1 Compressor 15 Condenser water in 2 2 Evaporator 16 Condenser water in 3 3 Condenser 17 Evaporator enterin water temperature sensor 1 4 Switcbox 18 Evaporator enterin water temperature sensor 2 5 Cilled water in 1 19 Evaporator enterin water temperature sensor 3 6 Cilled water in 2 20 Freeze up sensor 1 7 Cilled water in 3 21 Freeze up sensor 2 8 Cilled water out 1 22 Freeze up sensor 3 9 Cilled water out 2 23 Condenser enterin water temperature sensor 1 10 Cilled water out 3 24 Condenser enterin water temperature sensor 2 11 Condenser water out 1 25 Condenser enterin water temperature sensor 3 12 Condenser water out 2 26 Diital display controller 32~72 Hp 13 Condenser water out 3 27 Power supply intake 14 Condenser water in 1 Reuired space around te unit for service 3 Packaed water-cooled water cillers

5 Function of te main components Filter S1HP Compressor M1C Q1D HP S4LP R5T Condenser Filter LP Evaporator R4T Water inlet S2HP Water outlet Water outlet Compressor M2C Q2D HP S5LP R3T Water inlet 32~48 Hp S1HP LP Q1D M1C HP S4LP 52~72 Hp R5T LP R4T S2HP Q2D M2C R3T HP S5LP LP S1HP Q1D M1C HP S4LP R5T LP R4T S2HP Q2D M2C R3T HP S5LP LP Fiure - Functional diaram As te refrierant circulates trou te unit, canes in its state or condition occur. Tese canes are caused by te followin main components: Compressor Te compressor (M*C) acts as a pump and circulates te refrierant in te refrieration circuit. It compresses te refrierant vapour comin from te evaporator to a pressure at wic it can easily be liuified in te condenser. Condenser Te function of te condenser is to cane te state of te refrierant from aseous to liuid. Te eat ained by te as in te evaporator is discared trou te condenser and te vapour condenses to liuid. Filter Te filter installed beind te condenser removes small particles from te refrierant to prevent blockae of te tubes. Expansion valve Te liuid refrierant comin from te condenser enters te evaporator via an expansion valve. Te expansion valve brins te liuid refrierant to a pressure at wic it can easily be evaporated in te evaporator. Evaporator Te main function of te evaporator is to take eat from te water tat flows trou it. Tis is done by turnin te liuid refrierant, comin from te condenser, into aseous refrierant. Water inlet/outlet connection Te water inlet and outlet connections allow an easy connection of te unit to te water circuit of te air andlin unit or industrial euipment. Packaed water-cooled water cillers 4

6 Safety devices Overcurrent relay Te overcurrent relay (K*S) is located in te switc box of te unit and protects te compressor motor in case of overload, pase failure or too low voltae. Te relay is factory-set and may not be adjusted. Wen activated, te overcurrent relay as to be reset in te switc box and te controller needs to be reset manually. Hi-pressure switc Te i-pressure switc (S*HP) is installed on te discare pipe of te unit and measures te condenser pressure (pressure at te outlet of te compressor). Wen te pressure is too i, te pressure switc is activated and te circuit stops. Wen activated, it resets automatically, but te controller needs to be reset manually. Low pressure switc Te low-pressure switc (S*LP) is installed on te suction pipe of te unit and measures te evaporator pressure (pressure at te inlet of te compressor). Wen te pressure is too low, te pressure switc is activated and te circuit stops. Wen activated, it resets automatically, but te controller needs to be reset manually. Reverse pase protector Te reverse pase protector (R1P) is installed in te switc box of te unit. It prevents te compressor from runnin in te wron direction. If te unit does not start, two pases of te power supply must be inverted. Discare termal protector Te discare termal protector (Q*D) is activated wen te temperature of te refrierant leavin te compressor becomes too i. Wen te temperature returns to normal, te protector resets automatically, but te controller needs to be reset manually. Freeze-up protection Te freeze-up protection prevents te water in te evaporator from freezin durin operation. Wen te outlet water temperature is too low, te controller disables te circuit. Wen te outlet water temperature returns to normal, te circuit can start up aain. Wen freeze-up protection occurs several times in a certain period, te freeze-up alarm will be activated and te circuit will be sut down. Te cause of freezin up sould be investiated and after outlet water temperature as risen enou, te alarm indicator on te controller needs to be reset manually. Additional interlock contact To avoid tat te unit could be started or run witout water circulatin trou te water eat excaner, an interlock contact (S11L) of e.. a flow switc must be installed in te startup circuit of te unit. Internal wirin - Parts table Refer to te internal wirin diaram supplied wit te unit. Te abbreviations used are listed below: A1P...PCB terminal unit A2P... **...PCB address card F1,2,3U... #...Main fuses for te unit F5B,F6B...Automatic fuse for te control circuit/secondary of TR1 F8U...Sure-proof fuse F9U... ##...Sure-proof fuse H1P... *...Indication lamp alarm H3P... *...Indication lamp operation compressor (M1C) H4P...Indication lamp operation compressor (M2C) K1A...auxiliary contactor for i pressure K1M...Compressor contactor (M1C) K1P... *...Pumpcontactor K2M...Compressor contactor (M2C) 5 K4S... Overcurrent relay (M1C) K5S... Overcurrent relay (M2C) K19T... Timer, time delay for M2C M1C,M2C... Compressor motor PE... Main eart terminal Q1D... Discare termal protector (M1C) Q2D... Discare termal protector (M2C) R1P... Reverse pase protector R3T... Evaporator inlet water temperature sensor R4T... Evaporator outlet water temperature sensor (Freeze up sensor) R5T... Condenser inlet temperature sensor S1HP,S2HP... Hi pressure switc S4LP,S5LP... Low pressure switc S7S... Caneable diital input 1 S9S...*... Caneable diital input 2 S10L...#... Flowswitc S11L...#... Contact tat closes if te pump is workin S12S...#... Main isolator switc TR1... Transfo 230 V 24 V for power supply of controllers Y1R... Reversin valve Y1S... Solenoid valve for injection line X1... Connector for diital inputs, analo inputs, analo outputs and for power supply controller (A1P) X2... Connector for diital outputs (A1P) X3... Connector for (A1P) X4,X5,X6... Interconnection connector Main Control switcbox Not included wit standard unit Not possible as option Possible as option Obliatory # ## Not obliatory * ** Terminal unit: Diital Inputs X1 (ID1-GND)... flowswitc X1 (ID2-GND)... remote coolin/eatin selection X1 (ID3-GND)... i pressure switc + discare protector + overcurrent X1 (ID4-GND)... low pressure switc X1 (ID5-GND)... remote On/Off Terminal unit: Diital outputs (relays) X2 (C1/2-NO1)... compressor M1C on X2 (C1/2-NO2)... compressor M2C on X2 (C3/4-NO3)... voltae free contact for pump X2 (C3/4-NO4)... voltae free contact for reversin valve X2 (C5-NO5)... alarm voltae free contact Terminal unit: Analo inputs X1 (B1-GND)... evaporator inlet water temperature X1 (B2-GND)... evaporator outlet water temperature (Freeze up sensor) X1 (B3-GND)... condenser inlet water temperature Packaed water-cooled water cillers

7 BEFORE OPERATION Cecks before initial start-up After te installation of te unit, ceck te followin before switcin on te circuit breaker: 1 Field wirin Make sure tat te field wirin between te local supply panel and te unit as been carried out accordin to te instructions described in te installation manual, accordin to te wirin diarams and accordin to European and national reulations. 2 Additional interlock contact An additional interlock contact S11L sould be provided (e.. flow switc, contact of pump motor contactor). Make sure tat it as been installed between te appropriate terminals (refer to te wirin diaram supplied wit te unit). S11L sould be a normal open contact. 3 Fuses or protection devices Ceck tat te fuses or te locally installed protection devices are of te size and type specified in te installation manual. Make sure tat neiter a fuse nor a protection device as been bypassed. 4 Eart wirin Make sure tat te eart wires ave been connected properly and tat te eart terminals are titened. 5 Internal wirin Visually ceck te switc box on loose connections or damaed electrical components. 6 Fixation Ceck tat te unit is properly fixed, to avoid abnormal noises and vibrations wen startin up te unit. 7 Damaed euipment Ceck te inside of te unit on damaed components or sueezed pipes. 8 Refrierant leak Ceck te inside of te unit on refrierant leakae. If tere is a refrierant leak, call your local dealer. 9 Oil leak Ceck te compressor on oil leakae. If tere is an oil leak, call your local dealer. 10 Power supply voltae Ceck te power supply voltae on te local supply panel. Te voltae sould correspond to te voltae on te identification label of te unit. Water supply Make sure tat te circuit breaker on te power supply panel of te unit is switced off. Fill te water pipin, takin into account te minimum water volume reuired by te unit. Refer to te "installation manual". Make sure tat te water is of te uality as mentioned in te installation manual. Pure te air at te i points of te system and ceck te operation of te circulation pump and te flow switc. General recommendations Before switcin on te unit, read followin recommendations: 1 Wen te complete installation and all necessary settins ave been carried out, close all front panels of te unit. 2 Te service panels of te switc boxes may only be opened by a licensed electrician for maintenance purposes. OPERATION 32~72 HP Te 32~72 Hp units are euipped wit a built-in diital controller offerin a user-friendly way to set up, use and maintain te unit. Tis part of te manual as a task-oriented, modular structure. Apart from te first section, wic ives a brief description of te controller itself, eac section or subsection deals wit a specific task you can perform wit te unit. Dependin on te model tere are two or tree modules in te system. Te models 32~48 Hp only ave two modules, wereas te models 52~72 Hp consist of tree modules. Tese modules are enerally named M1, M2 and M3 in te followin descriptions. All information about module 3 (M3) is not applicable for 32~48 Hp models. Diital controller User interface Te diital controller consists of an alpanumeric display, labelled keys wic you can press and a number of LEDs. Fiure - Diital controller f o p NOTE key, to enter te main menu key, to start up or to sut down te unit. key, to enter te safeties menu or to reset an alarm. keys, to scroll up or down trou te screens of a menu (only in case W, X or C appears) or to raise, respectively lower a settin. key, to confirm a selection or a settin. Temperature readout tolerance: ±1 C. Leibility of te alpanumeric display may decrease in direct sunlit. Workin wit te 32~72 Hp units Tis capter deals wit te everyday usae of te unit. Here, you will find ow to perform routine tasks, suc as: "Settin te lanuae" on pae 7 "Switcin te unit on" on pae 7 and "Switcin te unit off" on pae 7 "Consultin actual operational information" on pae 7 "Selectin coolin or eatin operation" on pae 8 "Adjustin te temperature setpoint" on pae 8 "Resettin te unit" on pae 8 Packaed water-cooled water cillers 6

8 Settin te lanuae If desired, te operatin lanuae can be caned to any of te followin lanuaes: Enlis, German, Frenc, Spanis or Italian. 1 Enter te usersettins menu. Refer to capter "Main menu" on pae 9 2 Go to te appropriate screen of te usersettins menu usin te and keys. 3 Select te appropriate field (LANGUAGE) usin te key. 4 Press te and keys to adjust te lanuae settin. 5 Press to confirm te adjusted lanuae settin. Wen te settin as been confirmed, te cursor switces to te next settin. Switcin te unit on 1 Press te J key on te controller. Dependin on weter or not te remote ON/OFF switc is confiured (refer to te service manual), te followin conditions may occur. Wen no remote ON/OFF switc is confiured, te LED inside te J key lits up and an initialization cycle is started. Once all te timers ave reaced zero, te unit starts up. Wen a remote ON/OFF switc is confiured, te followin table applies: Local key Remote switc Unit o LED ON ON ON ON ON OFF OFF Flasin OFF ON OFF OFF OFF OFF OFF OFF 2 Wen te unit is started up for te first time, or wen te unit as been out of operation for a loner period, it is recommended to ceck te followin. Abnormal noise and vibrations Make sure tat te unit does not produce abnormal noises or vibrations: ceck te fixation, stop valves and pipin. If te compressor makes abnormal noises, tis may also be caused by an overcare of refrierant. 3 If te water ciller does not start after a few minutes, refer to "Troublesootin" on pae 14. Switcin te unit off If te remote on/off control parameter is set to NO: Press te o key on te controller. Te LED inside te o key oes out. If te remote on/off control parameter is set to YES: Press te o key on te controller or switc te unit off usin te remote on/off switc. Te LED inside te o key oes out in te first case and starts blinkin in te second case. Consultin actual operational information 1 Enter te readout menu trou te main menu. (Refer to te capter "Main menu" on pae 9.) Te controller automatically sows te first screen of te readout menu wic provides te followin information: MANUAL MODE or INLSETP1/2: manual/automatic control mode operation. If te automatic control mode is selected, te controller will indicate te active temperature setpoint. Dependin on te status of te remote contact, setpoint one or setpoint two is active. INL WATER E/C: actual inlet water temperature. THERMOSTAT STEP: actual termostat step. Te maximum number of termostat steps are as listed: 32 Hp 4 48 Hp 4 64 Hp 6 36 Hp 4 52 Hp 6 68 Hp 6 40 Hp 4 56 Hp 6 72 Hp 6 44 Hp 4 60 Hp 6 2 Press te key to enter te next screen of te readout menu. Tis screen of te readout menu provides te followin information on te evaporator: M1: OUTLWATER: actual outlet water temperature of module 1. M2: OUTLWATER: actual outlet water temperature of module 2. M3: OUTLWATER: actual outlet water temperature of module 3. 3 Press te key to enter te next screen of te readout menu. Te COMPRESSOR STATUS screen of te readout menu provides information concernin te status of te different compressors. C11: actual status of compressor 1 of module 1. C12: actual status of compressor 2 of module 1. C21: actual status of compressor 1 of module 2. C22: actual status of compressor 2 of module 2. C31: actual status of compressor 1 of module 3. C32: actual status of compressor 2 of module 3. Wen a circuit is OFF, te followin status information may appear. SAFETY ACTIVE: one of te circuit safety devices is activated (refer to te capter "Troublesootin" on pae 14). (LIMIT): te circuit is limited by a remote contact. TIMERS BUSY: te actual value of one of te software timers is not zero (refer to te "Timers menu" on pae 9). CAN STARTUP: te circuit is ready to start up wen extra coolin load is needed. Te precedin OFF messaes are written down in order of priority. If one of te timers is busy and one of te safeties is active, te status information says SAFETY ACTIVE. 4 Press te key to enter te next screen of te readout menu. To consult actual operational information about te total runnin ours of te compressors. In case of emerency, switc off te unit by pusin te emerency stopbutton. NOTE Also consult "Definin te scedule timer" on pae Packaed water-cooled water cillers

9 Selectin coolin or eatin operation Te "coolin/eatin" menu allows te user to set te unit in coolin or eatin operation. Te COOL/HEAT menu provides information concernin te selected operation mode. COOLING (EVAP): coolin mode. Te two setpoints for inlet water temperature control of te evaporator can be used. HEATING (COND): eatin mode. Te two setpoints for inlet water temperature control of te condenser can be used. To define coolin/eatin operation, proceed as follows: 1 Enter te coolin/eatin menu trou te main menu. (Refer to te capter "Main menu" on pae 9.) 2 Position te cursor beind MODE usin te key. 3 Press te and keys to adjust te temperature settin. Te default, limit and step values for te coolin (evaporator) and eatin (condenser) temperature setpoints are: INLSETP IN E INLSETP IN C default value 12 C 30 C limit values (a) (a) 8 --> 23 C 15--> 50 C step value 0.1 C 0.1 C For lycol units te lower limit of te coolin temperature setpoint can be adapted in te factory. Te followin values apply: INLSETP IN E/C: 5 C, 3 C, 2 C, 7 C 4 Press to save te adjusted temperature setpoint. Wen te settin as been confirmed, te cursor switces to te next setpoint. 5 To adjust oter setpoints, repeat from instruction 2 onwards. NOTE Also consult "Definin te scedule timer" on pae Select te appropriate settin usin te and keys. 4 Press to confirm. Te cursor returns to te upper left corner of te screen. Adjustin te temperature setpoint Te unit provides definition and selection of four or two independent temperature setpoints. In coolin operation, two setpoints are reserved for inlet control of te evaporator. INLSETP 1 E: inlet water temperature of evaporator, setpoint 1, INLSETP2 E: inlet water temperature of evaporator, setpoint 2. In eatin operation, two setpoints are reserved for inlet control of te condenser. INLSETP 1 C: inlet water temperature of condenser, setpoint 1, INLSETP 2 C: inlet water temperature of condenser, setpoint 2. In double termostat operation, two setpoints are reserved for inlet control of te evaporator and two oters are reserved for inlet control of te condenser. INLSETP 1 E: inlet water temperature of evaporator, setpoint 1, INLSETP2 E: inlet water temperature of evaporator, setpoint 2. INLSETP 1 C: inlet water temperature of condenser, setpoint 1, INLSETP 2 C: inlet water temperature of condenser, setpoint 2. Te selection between setpoint 1 and 2 is done by a remote dual setpoint switc (to be installed by te customer). Te actual active setpoint can be consulted in te readout menu. If te manual control mode is selected (refer to "User settins menu" on pae 9), none of te above-mentioned setpoints will be active. To adjust a setpoint, proceed as follows: 1 Enter te setpoints menu trou te main menu. (Refer to te capter "Main menu" on pae 9). If te user password is disabled for setpoint modifications (refer to te "User settins menu" on pae 9), te controller will immediately enter te setpoints menu. If te user password is enabled for setpoint modifications, enter te correct code usin te and keys. (Refer to te "User password menu" on pae 10). Press to confirm te password and to enter te setpoints menu. Resettin te unit Te units are euipped wit tree kinds of safety devices: unit safeties, module safeties and network safeties. Wen a unit safety occurs, all compressors are sut down. Te safeties menu will indicate wic safety is activated. Te COMPRESSOR STATUS screen of te readout menu will indicate OFF - SAFETY ACTIVE for all circuits. Te red LED inside te p key lits up and te buzzer inside te controller is activated. Wen a module safety occurs, te compressors of te correspondin module are sut down. Te COMPRESSOR STATUS screen of te readout menu will indicate OFF - SAFETY ACTIVE for te module concerned. Te red LED inside te p key lits up and te buzzer inside te controller is activated. If te unit as been sut down due to a power failure, it will carry out an autoreset and restart automatically wen te electrical power is restored. To reset te unit, proceed as follows: 1 Press te p key to acknowlede te alarm. Te buzzer is deactivated. Te controller automatically switces to te correspondin screen of te safeties menu: unit safety or module safety. 2 Find te cause of sutdown and correct. Refer to "Listin activated safeties and ceckin te unit status" on pae 12 and te capter "Troublesootin" on pae 14. Wen a safety can be reset, te LED under te p key starts blinkin. 3 Press te p key to reset te safeties tat are no loner active. Once all safety devices are disactivated and reset, te LED under te p key oes out. If one of te safeties is still active, te LED under te p key oes on aain. In tis case, return to instruction 2. 4 If a unit safety occurred or if all modules were sut down due to module safeties, switc on te unit usin te o key. If te user suts down te power supply in order to repair a safety, te safety will automatically be reset after power-up. 2 Select te setpoint to be adjusted usin te key. A setpoint is selected wen te cursor is blinkin beind te setpoint's name. Te ">" sin indicates te actual active temperature setpoint. NOTE Te istory information, i.e. te number of times a unit safety or a circuit safety occurred and te unit status at te moment of sutdown, can be cecked by means of te istory menu. Packaed water-cooled water cillers 8

10 Advanced features of te diital controller Tis capter ives an overview and a brief functional description of te screens provided by te different menus. In te followin capter, you will find ow you can set up and confiure te unit usin te various menu functions. Te down arrow X on te display indicates tat you can o to te next screen of te current menu usin te key. Te up arrow W on te display indicates tat you can o to te previous screen of te current menu usin te key. If C is displayed, tis indicates tat you can eiter return to te previous screen or can o to te next screen by usin te and keys. Main menu Scroll trou te main menu usin te and keys to move te > mark in front of te menu of your coice. Pus te key to enter te selected menu. >READOUT MENU SETPOINTS MENU USERSETTINGS MENU TIMERS MENU HISTORY MENU INFO MENU I/O STATUS MENU USERPASSWORD MENU COOL/HEAT MENU User settins menu Te "user settins" menu, protected by te user password, allows a full customization of te units. BC CONTROL SETTINGS MODE :MANUAL CONTROL C11 : OFF 12 ; OFF C21 : OFF 22 ; OFF BC THERMOST.SETTINGS STEPS : 6 STPL.: 1.5 C STEPDIFFERENCE: 0.5 C LOADUP: 180s-DWN: 30s C LEAD-LAG SETTINGS LEAD-LAG MODE : AUTO LEAD-LAG HOURS: 1000 BC CAP. LIM. SETTINGS MODE : REMOTE DIG INP. L1M1 : OFF 2: OFF 3: OFF L2M1 : OFF 2: OFF 3: OFF BC CAP. LIM. SETTINGS L3M1 : OFF 2: OFF 3: OFF L4M1 : OFF 2: OFF 3: OFF To define te manual settins and to select te control mode. To define te termostat settins. To define te lead-la mode of te modules. To define capacity limitation. (first screen) To define capacity limitation. (second screen) Readout menu BX MANUAL MODE INL WATER E: 12.0 C INL WATER C: 30.0 C THERMOSTAT STEP :2/6 To consult actual operational information about te control mode, te inlet water temperature of te evaporator/condenser and te termostat step. BC PUMPCONTROL PUMPLEADTIME : 020s PUMPLAGTIME : 000s DAILY ON : Y AT : 0000 BC SCHEDULE TIMER ENABLE TIMER : N ENABLE HOLIDAY PER : N To define te pump control settins. To define te scedule timer. BC EVAPORATOR M1 : OUTLWATER: 07.0 C M2: OUTLWATER: 07.0 C M3: OUTLWATER:-03.0 C To consult information about te outlet water temperature of te modules 1, 2 and 3 (only for 52~72 Hp). BC HOLIDAY : 01 TO 03 1 : : : BC COMPRESSOR STATUS C11 : OFF-CAN STARTUP C12: OFF-CAN STARTUP C21: OFF-CAN STARTUP To consult information about te compressor status (first screen). BC DUAL EVAP. PUMP MODE : AUTOM. ROTATION OFFSET ON RH : 0048 To define te dual evaporator pump. BC COMPRESSOR STATUS C22: OFF-CAN STARTUP C31 : OFF- SAFETY ACT. C32: OFF- LIMIT BW RUNNING HOURS C11 : ; C21 : ; C31 : ; Setpoints menu To consult information about te compressor status (second screen). To consult actual operational information about te total runnin ours of te compressors. Dependin upon te settins in te user settins menu and on te selected coolin/eatin operation mode, te "setpoints" menu can eiter be entered directly or by means of te user password. B>INLSETP1 E : 12.0 C INLSETP2 E : 12.0 C INLSETP1 C : 30.0 C INLSETP2 C : 30.0 C To define te temperature setpoints. BC DISPLAY SETTINGS LANGUAGE : ENGLISH TIME : 0000 DATE : 00/01/2001 BC SETPOINT PASSWORD PASSWORD NEEDED TO CHANGE SETPOINTS : Y BC ENTER SERVICE Timers menu PASSWORD : 0000 BX GENERAL TIMERS LOADUP : 000s - DWN : 000s PUMPLEAD : 000s FLOWSTOP : 00s To define te display settins. To define weter or not a password is needed to enter te setpoints menu. To enter te service menu. (Only a ualified installer is allowed to access tis menu.) To ceck te actual value of te eneral software timers (first screen). BC COMPRESSOR TIMERS COMPR. STARTED : 00s To ceck te actual value of te eneral software timers (second screen). BC COMPRESSOR TIMERS C11 GRD : 000s AR : 000s C12 GRD : 000s AR : 000s C21 GRD : 000s AR : 000s To ceck te actual value of te compressor timers (first screen). 9 Packaed water-cooled water cillers

11 BW COMPRESSOR TIMERS C22 GRD : 000s AR : 000s C31 GRD : 000s AR : 000s C32 GRD : 000s AR : 000s Safeties menu To ceck te actual value of te compressor timers (second screen). Info menu BX TIME INFORMATION TIME : 0000 DATE : 00/01/2001 To consult time and date information. Te "safeties" menu provides useful information for trouble sootin purposes. Te followin screens contain basic information. BX UNIT SAFETY To consult wic unit safety caused te sutdown. BC UNIT INFORMATION UNITTYPE : WW-HP-32 MANUFACT. NR.: REFRIGERANT : R134a To consult additional information about te unit suc as te unit type, te refrierant used and te manufacturin number. BX MODULE 1 SAFETY 1CA : OUT E SENSOR ERR To consult wic module 1 safety caused te sutdown. BC UNIT INFORMATION SW : V1.0M6 (01/11/01) SW CODE : FLDKNMCH0A To consult information about te controller's software version. BX MODULE 2 SAFETY 2CA : OUT E SENSOR ERR To consult wic module 2 safety caused te sutdown. BW PCB INFORMATION BOOT : V /08/00 BIOS : V /07/01 To consult information about te PCB. Input/output menu BX MODULE 3 SAFETY 3CA : OUT E SENSOR ERR To consult wic module 3 safety caused te sutdown. Te "input/output" menu ives te status of all te diital inputs and te relay outputs of te unit. Alon wit te basic information, more detailed information screens can be consulted wile te safety menu is active. Press te key. Screens similar to te followin will appear. BC UNIT HISTORY : /01/2001 MANUAL MODE To ceck te time and control mode at te moment of te unit sutdown. BX DIGITAL INPUTS M1 SAFETY OK M2 SAFETY OK M3 SAFETY NOK BC DIGITAL INPUTS FLOWSWITCH : FLOW OK REV.PHASE PR. : OK To ceck weter any module safeties are active. To ceck te reverse pase protector and if tere's any waterflow to te evaporator. BC UNIT HISTORY : 004 INL.E : 12.0 C STEP: INL.C : 30.0 C 0 To ceck wic were te common evaporator and condenser inlet water temperature. BC CHANG. DIG. INPUTS DI1 DUAL SETP : SETP.1 DI2 REM. ON/OFF : OFF DI3 REM. C/H : COOL To ceck te status of te caneable diital inputs. BC UNIT HISTORY : 004 OUTE1 : 07.0 C OUTE3 : OUTE2 : 07.0 C 07.0 C To ceck wic were te evaporator outlet water temperature of all modules at te moment of sutdown. BC C11 : ON C21 : ON C31 : ON RELAY OUTPUTS C12 : ON C22 : ON C32 : OFF To ceck te status of te compressor relay outputs. BC UNIT HISTORY : 004 C11 : ON C21 : C12 : ON ON To ceck wic was te status of te compressors at te moment of sutdown (first screen). BC RELAY OUTPUTS LPBYPASS1 : CLOSED LPBYPASS2 : CLOSED LPBYPASS3 : OPEN To ceck te status of te modules low pressure bypass. BC UNIT HISTORY : 004 C22 : ON To ceck wic was te status of te compressors at te moment of sutdown (second screen). BC RELAY OUTPUTS GEN. ALARM : CLOSED PUMP/GEN OPER : CLOSED To ceck te status of te alarm voltae free contact and te pump/ eneral operation contact. BC UNIT HISTORY : 004 RH11 : RH21: RH12 : BC UNIT HISTORY : 004 RH22 : To ceck wic were te total amount of runnin ours of te compressors at te moment of sutdown (first screen). To ceck wic were te total amount of runnin ours of te compressors at te moment of sutdown (second screen). BW CHANG. REL OUTPUTS DO1 REV.VALVE(C/H) : O User password menu B CHANGE PASSWORD NEW PASSWORD : 0000 CONFIRM : 0000 To ceck te status of te caneable relay output. To cane te user password. History menu Coolin/eatin menu Te "istory" menu contains all te information concernin te latest sutdowns. Te structure of tose menus is identical to te structure of te safeties menu. Wenever a failure is solved and te operator performs a reset, te concernin data from te safeties menu is copied into te istory menu. Warnins are also recorded. Additionally te number of safeties tat already occurred, can be consulted on te first line of te istory screens. B COOLING/HEATING MODE : COOLING (EVAP) To select coolin or eatin mode. Packaed water-cooled water cillers 10

12 Tasks of te user settins menu Enterin te user settins menu Te user settins menu is protected by te user password, a 4-diit number between 0000 and Enter te USERSETTINGS MENU trou te main menu. (Refer to te capter "Main menu" on pae 9). Te controller will reuest te password. 2 Enter te correct password usin te and keys. 3 Press to confirm te password and to enter te user settins menu. Te controller automatically enters te first screen of te user settins menu. To define settins of a certain function: 1 Go to te appropriate screen of te usersettins menu usin te and keys. 2 Position te cursor beind te parameter to be modified usin te key. 3 Select te appropriate settin usin te and keys. 4 Press to confirm te selection. Wen te selection as been confirmed, te cursor switces to te next parameter wic can now be modified. 5 Repeat from instruction 2 onwards to modify te oter parameters. Definin and activatin te control mode Te unit is euipped wit a termostat wic controls te coolin capacity of te unit. Two different control modes exist: manual control mode: te operator controls te capacity imself - MANUAL CONTROL inlet control mode: uses te evaporator and/or condenser enterin water temperature to control te capacity of te unit - INLET WATER Wen te operator wants to control te capacity imself, e can activate manual control mode usin te CONTROL SETTINGS screen of te user settins menu. In tis case, e as to define te followin parameters: MODE (present mode): manual control. C11, C12, C21, C22, C31, C32 (compressor status of module 1, 2 and 3 in manual mode or capacity limitation value in case te "capacity limitation remote contact" is enabled): ON or OFF. NOTE To activate manual control mode, select MANUAL as present mode. To deactivate te manual control mode, select INLET WATER as present mode. Definin te termostat settins Wen automatic control mode is selected, te unit uses a termostat to control te coolin or eatin capacity. Te maximum number of termostat steps are as listed: 32 Hp 4 48 Hp 4 64 Hp 6 36 Hp 4 52 Hp 6 68 Hp 6 40 Hp 4 56 Hp 6 72 Hp 6 44 Hp 4 60 Hp 6 However, te termostat parameters are not fixed and can be modified via te THERMOST. SETTINGS screen of te user settins menu. Te default, limit and step values for te termostat parameters are: Lower limit Upper limit Step Default STPL ( C) STEPDIFFERENCE ( C) LOADUP (sec) LOADDOWN (sec) NOTE A functional diaram sowin te termostat parameters can be found in "Annex I" on pae 16. Definin te lead-la mode Te lead/la mode determines wic module starts up first in case of a capacity demand. Te lead-la parameters are: LEAD-LAG MODE Automatic: te controller decides weter module 1, module 2, or module 3 starts up first. Te modules follow te entered order of startin up (see table below). 3 modules 2 modules first > next > last first > last NOTE If a module is de-activated due to a failure, te next module will start up instead. LEAD-LAG HOURS: In te automatic mode, te number of ours indicated on te display is te maximum difference between te runnin ours of te modules. Tis value is important for maintenance purposes. It sould be set i enou so tat te modules do not reuire maintenance at te same time and tat at least one module can remain constantly active. Te lower and upper limits are 100 and 1000 ours respectively. Te default value is 1000 ours. Definin te pump control settins Te PUMPCONTROL screen of te user settins menu allows te user to define te pump-leadtime and pump-latime. PUMPLEADTIME: used to define te time tat te pump must run before te unit can start up. PUMPLAGTIME: used to define te time tat te pump keeps runnin after te unit as been stopped. Definin te display settins Te DISPLAY SETTINGS screen of te user settins menu allows te user to define te coice of lanuae, time and date. LANGUAGE: used to define te lanuae of te displayed information of te controller. TIME: used to define te present time. DATE: used to define te present date. 11 Packaed water-cooled water cillers

13 Definin dual evaporator pump control Te DUAL EVAP. PUMP screen of te user settins menu allows te user to define te steerin of two evaporator pumps (for tis to be possible a caneable diital output as to be confiured for a second evaporator pump in te service menu). MODE: used to define wic kind of control will be used for te two evaporator pumps. Wen automatic rotation is cosen te offset on runnin ours also as to be entered. OFFSET ON RH: used to define te offset in runnin ours between te two pumps. Used to switc over between pumps wen tey work in automatic rotation mode. Definin te scedule timer Te SCHEDULE TIMER screen of te user settins menu allows te user to define te scedule timer settins. MON, TUE, WED, THU, FRI, SAT and SUN: used to define to wic roup eac day of te week belons (-/G1/G2/G3/G4). For eac of te four roups up to nine actions can be set, eac wit teir respective timin. Actions include: puttin te unit on/ off, settin a setpoint, settin coolin/eatin and settin capacity limitation. Beside tese four roups tere is also a oliday period roup wic is set te same way as te oter roups. Up to 12 oliday periods can be entered in te HD PERIOD screen. Durin tese periods te scedule timer will follow te settins of te oliday period roup. NOTE NOTE A functional diaram sowin te scedule timer workin can be found in "Annex II" on pae 17. Te unit always works wit last command. Tis means tat te last command iven, weter manually by te user or by te scedule timer, is always executed. Examples of command tat can be iven are switcin te unit on/off or canin a setpoint. Activatin or deactivatin te setpoints password Te SETPOINT PASSWORD screen of te user settins menu allows te user to activate or deactivate te user password needed to cane te temperature setpoint. Wen deactivated, te user does not ave to enter te password eac time e wants to cane te setpoint. Tasks of te timers menu Ceckin te actual value of te software timers To ceck te actual value of te software timers, proceed as follows: 1 Enter te TIMERS MENU trou te main menu. (Refer to te capter "Main menu" on pae 9.) Te controller displays te actual value of te GENERAL TIMERS: te loadup timer, te loaddown timer, te flowstart timer, te flowstop timer (wen te unit is on and te flowstart timer as reaced zero), te pumplead timer and te pumpla timer. 2 Press te key to ceck te compressor timers (first screen). Te controller sows te actual value of te COMPRESSOR TIMERS: te uard timers (one per compressor) and te antirecyclin timers (one per compressor). 3 Press te key to ceck te compressor timers (second screen). Te controller sows te actual value of te COMPRESSOR TIMERS: te uard timers (one per compressor) and te antirecyclin timers (one per compressor). Tasks of te safeties menu Listin activated safeties and ceckin te unit status If te alarm buzzer is activated and te user presses te p key, te controller automatically enters te safeties menu. Te controller will enter te UNIT SAFETY screen of te safeties menu wen a unit safety was te cause of sutdown. Tis screen provides te followin information: te activated safety: emerency stop, flow switc, sensor error or reverse pase te unit status at te moment of sutdown inlet water temperature setpoint of te evaporator, inlet water temperature setpoint of te condenser, time and date at te moment of sutdown. Te controller will enter te MODULE 1, MODULE 2 or MODULE 3 SAFETY screen of te safeties menu wen a safety of module 1, respectively module 2 or module 3 was activated. Tese screens provide information about te module status at te moment of sutdown. te activated safety: freeze-up, eneral safety or sensor error te unit status at te moment of sutdown inlet water temperature setpoint of te evaporator, inlet water temperature setpoint of te condenser, time and date at te moment of sutdown. 1 Press te p key wen te alarm buzzer is activated. Te appropriate safety screen wit te basic information appears. Press te key to see te detailed information. 2 If more tan one kind of safety is active (indicated by means of W, X or C), use te and keys to consult tem. As a protective measure and to ensure correct operation, te controller's software features several countdown timers: LOADUP (LOADUP refer to te termostat parameters): starts countin wen a termostat step cane as occurred. Durin te countdown, te unit is not able to enter a ier termostat step. LOADDOWN (DWN refer to te termostat parameters): starts countin wen a termostat step cane as occurred. Durin te countdown, te unit will not be able to enter a lower termostat step. FLOWSTOP (FLOWSTOP 5 sec): starts countin wen te water flow trou te evaporator stops after te flowstart timer as reaced zero. If te water flow as not restarted durin te countdown, te unit will sut down. PUMPLEAD (PUMPLEAD refer to te pump control settins): starts countin wenever te unit is switced on. Durin te countdown, te unit cannot start up. PUMPLAG (PUMPLAG refer to te pump control settins): starts countin wenever te unit is switced off. Durin te countdown, te pump keeps runnin. Packaed water-cooled water cillers 12

14 Tasks of te istory menu Ceckin te safety info and te unit status after a reset Te information available in te safeties menu is also stored in te istory menu, were it is stored after resettin te unit or te module. In tis way, te istory menu provides a means of ceckin te unit status at te moment of te latest 10 sutdowns. To ceck te safety info and te unit status, proceed as follows: 1 Enter te HISTORY MENU trou te main menu. (Refer to te capter "Main menu" on pae 9.) Te controller enters te UNIT HISTORY screen wic contains te followin information: te number of sutdowns, te unit safety wic caused te most recent sutdown and te basic information at te moment of tis sutdown. 2 Press te and keys to consult te M1, M2 or M3 HISTORY screens. 3 Press te key to see te detailed information. Tasks of te info menu Consultin additional unit information 1 Enter te INFO MENU trou te main menu. (Refer to te capter "Main menu" on pae 9). Te controller enters te UNIT INFORMATION screen wic contains te followin information: te unit name, te refrierant used and te manufacturin (serial) number. 2 Press to consult te next UNIT INFORMATION screen. Tis screen contains information about te controller's software version. Tasks of te input/output menu Ceckin te status of te inputs and outputs Te input/output menu provides a means of ceckin te status of te diital inputs and te status of te relay outputs. Te locked diital inputs are: M1, M2 or M3 SAFETY: indicates te status of te eneral module safeties. FLOWSWITCH: indicates te status of te flowswitc, activated or deactivated. REVERSE PHASE PROTECTOR: indicates te status of tis safety. Te caneable diital inputs are: REM. C/H: indicates te status of te remote coolin/eatin switc. DUAL SETPOINT: indicates te status of te remote dual setpoint switc, setpoint 1 or setpoint 2. REM. ON/OFF: indicates te status of te remote on/off switc. CAP LIM1/2/3: indicates te status of te enable/disable capacity limitation switc(es). Te caneable relay outputs are: REV. VALVE (C/H): indicates weter te unit is runnin in coolin or in eatin. 2ND EVAP PUMP: indicates te status of te second evaporator pump. CONDENSER PUMP: indicates te status of te condenser pump. 100% CAPACITY: indicates wen te unit is workin at 100%. To ceck te inputs and outputs, proceed as follows: 1 Enter te I/O STATUS MENU trou te main menu. (Refer to te capter "Main menu" on pae 9.) Te controller enters te first DIGITAL INPUTS screen. 2 Consult te oter screens of te input/ouput menu usin te and keys. Tasks of te user password menu Canin te user password Access to te user settins menu and te setpoints menu is protected by te user password (a 4-diit number between 0000 and 9999). To cane te user password, proceed as follows: 1 Enter te USERPASSWORD MENU trou te main menu. (Refer to te capter "Main menu" on pae 9). Te controller will reuest te password. 2 Enter te correct password usin te and keys. 3 Press to confirm te password and to enter te password menu. Te controller reuests te new password. 4 Press to start te modification. Te cursor is positioned beind NEW PASSWORD. 5 Enter te new password usin te and keys. 6 Press to confirm te new password. Wen te new password as been confirmed, te controller will ask to enter te new password a second time (for safety reasons). Te cursor is positioned beind CONFIRM. 7 Enter te new password aain usin te and keys. 8 Press to confirm te new password. NOTE Te actual password will only be caned wen te new password and te confirmed password ave te same value. Te locked relay outputs are: LPBYPASS 1/2/3: indicates weter te low pressure of te module is in bypass mode or not. C11, C12, C21, C22, C31, C32: indicates weter te compressor is runnin or not. PUMP/GEN OPER: indicates te status of tis voltae free contact. It is activated if te pump sould be ON, wic also indicates eneral operation. 13 Packaed water-cooled water cillers

15 TROUBLESHOOTING Tis section provides useful information for dianosin and correctin certain troubles wic may occur in te unit. Before startin te trouble sootin procedure, carry out a torou visual inspection of te unit and look for obvious defects suc as loose connections or defective wirin. Before contactin your local dealer, read tis capter carefully, it will save you time and money. Wen carryin out an inspection on te supply panel or on te switc box of te unit, always make sure tat te circuit breaker of te unit is switced off. Wen a safety device was activated, stop te unit and find out wy te safety device was activated before resettin it. Under no circumstances safety devices may be brided or caned to a value oter tan te factory settin. If te cause of te problem cannot be found, call your local dealer. Symptom 1: Te unit does not start, but te ON LED lits up Te temperature settin is not Ceck te controller setpoint. correct. Te flowstart timer is still runnin. Te unit will start after approx. 15 seconds. Make sure tat water is flowin trou te evaporator. Neiter one of te circuits can start up. Unit is in manual mode (all compressors at 0%). Power supply failure. Blown fuse or interrupted protection device. Loose connections. Sorted or broken wires. Refer to Symptom 4: One of te circuits does not start up. Ceck on te controller. Ceck te voltae on te supply panel. Inspect fuses and protection devices. Replace by fuses of te same size and type (refer to "Electrical specifications" on pae 2). Inspect connections of te field wirin and te internal wirin of te unit. Titen all loose connections. Test circuits usin a tester and repair if necessary. Symptom 2: Te unit does not start, but te ON LED is flasin Te remote ON/OFF input is enabled and te remote switc is off. Put te remote switc on or disable te remote ON/OFF input. Symptom 3: Te unit does not start and te ON LED does not lit up All circuits are in failure mode. One of te followin safety devices is activated: Flow switc (S8L,S9L) Emerency stop Te ON LED is broken. Te unit is in bypass mode. Refer to Symptom 5: One of te followin safety devices is activated. Refer to Symptom 5: One of te followin safety devices is activated. Contact your local dealer. Ceck te bypass remote contact. Symptom 4: One of te circuits does not start up One of te followin safety devices is activated: Compressor termal protector (Q*M) Overcurrent relay (K*S) Discare termal protector (S*T) Low pressure switc Hi pressure switc (S*HP) Reverse pase protector (R*P) Freeze-up Te anti-recyclin timer is still active. Te uard timer is still active. Te circuit is limited to 0%. Ceck on te controller and refer to Symptom 5: One of te followin safety devices is activated. Te circuit can only start up after approximately 10 minutes. Te circuit can only start up after approximately 1 minute. Ceck te "enable/disable capacity limitation" remote contact. Symptom 5: One of te followin safety devices is activated Symptom 5.1: Overcurrent relay of compressor Failure of one of te pases. Voltae too low. Overload of motor. Symptom 5.2: Low pressure switc Water flow to water eat excaner too low. Sortae of refrierant. Unit is workin out of its operation rane. Inlet temperature to te water eat excaner is too low. Flow switc is not workin or no water flow. Symptom 5.3: Hi-pressure switc Water flow to condenser is too low. Symptom 5.4: Reverse pase protector is activated Two pases of te power supply are connected in te wron pase position. One pase is not connected properly. Symptom 5.5: Discare termal protector is activated Ceck fuses on te supply panel or measure te supply voltae. Measure te supply voltae. Reset. If te failure persists, call your local dealer. RESET Pus te blue button on te overcurrent relay inside te switc box and reset te controller. Increase te water flow. Ceck for leaks and refill refrierant, if necessary. Ceck te operation conditions of te unit. Increase te inlet water temperature. Ceck te flow switc and te water pump. RESET After pressure rise, tis safety resets automatically, but te controller still needs to be reset. Increase te water flow and/or ceck te strainer for cloin. RESET After findin te cause, pus te button on te i-pressure switc ousin and reset te controller. Invert two pases of te power supply (by licensed electrician). Ceck te connection of all pases. RESET After invertin two pases or fixin te power supply cables properly, te protector is reset automatically, but te controller still needs to be reset. Unit is workin outside te operation rane. Ceck te operation condition of te unit. RESET After temperature decrease, te termal protector resets automatically but te controller still needs to be reset. Packaed water-cooled water cillers 14