Daikin DWDC079, Installation, Operation And Maintenance Manual

Page 1: ...Single Dual Compressor Centrifugal Chillers Vintage B DWSC DWDC 079 087 100 113 126 Cooling Only REV 09 Date January 2020 Supersedes D EIMC00808 16_08EN Installation Operation and Maintenance Manual...

Page 2: ...s in force in the country of installation IMPORTANT READ THIS DOCUMENT IN ITS ENTIRETY BEFORE BEGINNING ANY WORK ON THE UNIT ALL FEDERAL STATE LOCAL ENVIRONMENTAL AND SAFETY REGULATIONS INCLUDING DAIK...

Page 3: ...to earth higher than 300 mA The electricity supply system protection must take the above values into account WARNING Before starting the installation of the unit please read this manual carefully Star...

Page 4: ...ve equipment and working tools Key to symbols Important note failure to respect the instruction can damage the unit or compromise functioning Note regarding safety in general or respect of laws and re...

Page 5: ...warning 4 Electrical hazard symbol Unit Control Panel 1 Non flammable gas symbol 5 Unit nameplate data 2 Electrical hazard symbol 6 Unit characteristics technical 3 Gas type 7 Emergency stop 4 Contro...

Page 6: ...D EIMWC00808 16HU 7 64 Motor Terminal Box 1 Terminal box fixing 3 Electrical hazard symbol 2 Manufacturer s logo 4 Terminal connection Label on Compressor 1 Label Device Under Pressure 1...

Page 7: ...Power Wiring 30 Multiple Chiller Setup 35 Prestart System Checklist 38 Operation 39 Operator Responsibilities 39 Standby Power 39 MicroTech II Control 39 Capacity Control System 40 Surge and Stall 43...

Page 8: ...D EIMWC00808 16HU 9 64...

Page 9: ...087 100 113 and 126 They provide a cooling capacity range from 80 tons to 2500 tons In this manual all references to the DWSC models will equally apply to other models unless specifically referenced o...

Page 10: ...aid in handling the equipment Extreme care must be used when rigging the equipment to prevent damage to the control panels or refrigerant piping See the certified dimension drawings included in the jo...

Page 11: ...e allowed at one end Doors or removable wall sections can be utilized for tube clearance Minimum clearance at all other points including the top is 3 feet 1 meter The National Electric Code NEC can re...

Page 12: ...d will identify it These numbers should be used to identify the unit for service parts or warranty questions This plate also has the unit refrigerant charge Vessel nameplates are located on the evapor...

Page 13: ...ange and stabilize without undesirable short cycling of the compressors or loss of control In air conditioning systems the potential for short cycling usually exists when the building load falls below...

Page 14: ...consumed than the expected savings in chiller power would suggest due to the excessive fan power required Cooling tower fans must continue to operate at 100 capacity at low wet bulb temperatures As c...

Page 15: ...noise and vibration It is also possible to build up a frequency beat due to the slight difference in the operating rpm of the pump motor and the Daikin centrifugal motor Daikin encourages the use of...

Page 16: ...e drops and flow rates for the various evaporators and condensers are job specific and the original job documentation can be consulted for this information Refer to the nameplate on the vessel shell f...

Page 17: ...s a 6 inch paddle loose 2 Flow rates for a 2 inch paddle trimmed to fit the pipe 3 Flow rates for a 3 inch paddle trimmed to fit the pipe 4 Flow rates for a 3 inch paddle 5 Flow rates for a 6 inch pad...

Page 18: ...commended Unless the system and chiller unit are specifically for condenser bypass or variable condenser flow is not recommended since low condenser flow rates can cause unstable operation and excessi...

Page 19: ...D EIMWC00808 16HU 20 64 Field Insulation Guide Figure 7 Insulation Requirements Cooling only Units...

Page 20: ...D EIMWC00808 16HU 21 64...

Page 21: ...238 2 E2612 X 708 321 72 273 102 9 4 3640 1651 2 E2612 X 925 418 101 381 102 9 4 4745 2150 2 E2616 X 1542 700 126 478 162 15 0 5645 2558 4 E3009 X 676 307 67 252 86 8 0 3582 1625 2 E3012 X 901 409 89...

Page 22: ...3063 4 C3612 X 2963 1344 234 884 7095 3219 4 C3616 X 3703 1725 331 1251 9575 4343 4 C3620 4628 92100 414 1567 12769 5797 4 C4212 X 3796 1722 344 1302 9984 4529 4 C4216 X 5010 2273 475 1797 12662 5743...

Page 23: ...r Data 1 DWDC dual compressor units will have twice the cooling water flow rate of the comparable DWSC chiller and the pressure drop will be the same 2 Pressure drops include valves on the unit Table...

Page 24: ...discharging it into the tower sump from a point above the highest possible water level NOTE Particular attention must be paid to chillers with variable chilled water flow through the evaporator The p...

Page 25: ...The oil sump is equipped with an immersion heater that is installed in a tube so that it can be removed without disturbing the oil Oil Reservoir Solenoid Valve Temperature Control Valve Compressor Con...

Page 26: ...ection sizes are one inch FPT and are in the quantity shown in Table 2 and Table 3 on page 22 Twin relief valves mounted on a transfer valve are used on the condenser so that one relief valve can be s...

Page 27: ...data Electrical Wiring fuse and wire size must be in accordance with the National Electric Code NEC Standard NEMA motor starters require modification to meet Daikin specifications Refer to Daikin Spec...

Page 28: ...rotation Following this verification by the Daikin technician the contractor should apply the following furnished items Materials required 1 Loctite brand safety solvent 12 oz package available as Da...

Page 29: ...sor controller and to the bias block both located in the compressor control panel Figure 13 Field Wiring for Optional Display Control Power Wiring The control circuit on the Daikin centrifugal package...

Page 30: ...er source and the unit control panel 2 Panel terminal connectors will accommodate up to number 10 AWG wire Larger conductors will require an intermediate junction box The Unit On Off switch located in...

Page 31: ...nd the control panel is required Minimum wire size for 115 Vac is 12 GA for a maximum length of 50 feet If greater than 50 feet refer to Daikin for recommended wire size minimum Wire size for 24 Vac i...

Page 32: ...f the motor rated load amperes RLA times 1 25 Wiring of free standing starter must be in accordance with the NEC and connection to the compressor motor terminals shall be made with copper wire and cop...

Page 33: ...TOWER THIRD STAGE STARTER COOLING TOWER SECONDH STAGE STARTER COOLING TOWER FIRST STAGE STARTER COOLING TOWER BYPASS VALVE COOLING TOWER VFD ALARM RELAY NOTE 4 MICROTECH COMPRESSOR CONTROL BOX TERMIN...

Page 34: ...isolation board is attached to the DIN rail adjacent to the Chiller A unit controller The isolation board has a pigtail that is plugged into J10 on the controller Most chillers will already have a uni...

Page 35: ...to four single or dual compressors can be interconnected 2 The Operator Interface Touch Screen OITS setting is not a DIP switch setting The OITS address is selected by selecting the service set screen...

Page 36: ...start first and the compressor with maximum hours will stop first and so on Units with higher numbers will stage on in sequence The Modes setpoints will do several different types of operation Normal...

Page 37: ...for connection when service engineer is on hand for start up Do not connect starter or compressor terminals All interlock wiring complete between control panel and complies with specifications Starte...

Page 38: ...al operators at its factory Training Center in Staunton Virginia several times a year These sessions are structured to provide basic classroom instruction and include hands on operating and troublesho...

Page 39: ...D EIMWC00808 16HU 40 64 Figure 17 Unit Control Panel Figure 18 Compressor Control Panel...

Page 40: ...efer to Figure 21 and Figure 22 for solenoid action Note that both solenoids cannot be energized simultaneously Vane Speed Metering Valves The speed at which the capacity control vanes are opened or c...

Page 41: ...Pressure To Oil Pump Sump Section SB De energized Section SA De energized From Oil Pump Discharge Adjustable Needle Valves Integral With Four Way Solenoid Valve HOLDING NOTE 4 way solenoid valve and v...

Page 42: ...r capacity control DWDC dual compressor chillers have completely independent lubrication systems for each compressor Only the recommended lubricant as shown in Table 13 can be used for proper operatio...

Page 43: ...Approved Polyolester Oils For R 134a Units Compressor Models CE050 126 Lubricant Designation Mobil Artic EAL 46 ICI Emkarate RL32H 2 Daikin Part Number 55 Gal Drum 5 Gal Drum 1 Gal Can 735030432 Rev 4...

Page 44: ...recovery units The factory setpoint for bringing on hot gas bypass is 40 of RLA Condenser Water Temperature When the ambient wet bulb temperature is lower than design the entering condenser water tem...

Page 45: ...115 9 136 216 6 18 17 1 58 54 9 98 120 0 138 222 8 20 18 4 60 57 4 100 124 1 140 229 2 22 19 9 62 60 0 102 128 4 142 235 6 24 21 3 64 62 7 104 132 7 144 242 2 26 22 9 66 65 4 106 137 2 146 249 0 28 24...

Page 46: ...personnel should attempt this service For qualified assistance contact your local Daikin service location After the system is once placed into operation no other additional oil is required except in...

Page 47: ...se the oil discharge line service valve at the oil pump at the filter on CE126 Remove the filter cover some foaming can occur but the check valve should limit leakage from other compressor cavities Re...

Page 48: ...D EIMWC00808 16HU 49 64 The superheat will increase linearly to 55 degrees F 30 degrees C at 10 load The MicroTech II interface panel can display all superheat and subcooling temperatures...

Page 49: ...D EIMWC00808 16HU 50 64 Figure 25 Typical Refrigerant Flow Diagram Connections are not necessarily in correct relative location...

Page 50: ...r a motor while in a vacuum Severe motor damage can result 6 The centrifugal compressor must rotate in the direction indicated by the arrow on the rear motor cover plate near the rotation sight glass...

Page 51: ...labor spent in the cleanup of a system after a motor burnout 1 The control circuit must be energized at all times except during service If the control circuit has been off and oil is cool energize oil...

Page 52: ...described in the following section Evacuation After it has been determined that there are no refrigerant leaks the system must be evacuated using a vacuum pump with a capacity that will reduce the vac...

Page 53: ...y on centrifugal compressors technicians need to be aware that there is a potential risk of the low speed seal trapping pressure in the motor housing Refrigerant in the motor housing must be recovered...

Page 54: ...ndividual bolts Always loosen each bolt slightly and in turn sequentially until the flange is clear of the connection This will retain most of the bolt safety integrity as the flange is removed If pre...

Page 55: ...tory of the equipment A single oil sample is not sufficient to estimate the condition of the chiller Oil analysis is only useful if employed to establish wear trends over time Changing lubricating oil...

Page 56: ...ich should be of concern is the TAN Total Acid Number A TAN below 0 09 requires no immediate action TANs above 0 09 require certain actions In the absence of a high TAN reading and a regular loss of r...

Page 57: ...val If content increases 25 or more inspect compressor 2 Re sample after 500 hours of unit operation If content increases less than 10 change filter drier and re sample at normal interval If content i...

Page 58: ...Clean Oil Cooler Strainer water X Oil Cooler Solenoid Operation O Oil Appearance clear color quantity O Oil Filter Pressure Drop O Oil Analysis Note 5 X Oil change if indicated by oil analysis X III...

Page 59: ...e a low reading In handling electrical components only fully qualified technicians must attempt service 2 Approach temperature the difference between the leaving water temperature and the saturated re...

Page 60: ...D EIMWC00808 16HU 61 64...

Page 61: ...n should be made after 3 to 4 weeks of normal operation on a new installation and on a regular basis thereafter Daikin offers a variety of maintenance services through the local Daikin service office...

Page 62: ...rginia The school duration is three and one half days and includes instruction on basic refrigeration MicroTech controllers enhancing chiller efficiency and reliability MicroTech troubleshooting syste...

Page 63: ...any 3M Scotchfil and Scotchkote from the 3M Company Victaulic from Victaulic Company Megger from Megger Group Limited Distinction Series MicroTech II and Protocol Selectability from Daikin Obligatory...

Page 64: ...t vent gases into the atmosphere Refrigerant type R134a R513A GWP 1 value 1430 631 1 GWP Global Warming Potential The refrigerant quantity is indicated on the unit name plate Periodical inspections fo...

Page 65: ...es b Circuit number c Factory charge d Field charge e Refrigerant charge for each circuit according to the number of circuits f Total refrigerant charge g Total refrigerant charge Factory Field h Gree...

Page 66: ...f metal plastic and electronic parts All of these components must be disposed of in accordance with local disposal laws and if in scope with the national laws implementing the Directive 2012 19 EU RAE...

Page 67: ...nt and the products and services presented therein Specification are subject to change without prior notice Refer to the data communicated at the time of the order Daikin Applied Europe S p A explicit...