Daikin WCT, Installation, Operation And Maintenance Manual

Page 1: ...with Two Stage Compressors 2200 to 3250 TONS 7750 to 11400 kW Series Counter Flow with Two Stage Compressors 4500 to 6400 TONS 15830 to 22500 kW HFC 134a Original Instructions Installation Operation and Maintenance Manual D EIMWC01308 16EN ...

Page 2: ...ion and Mounting 10 System Water Volume 11 Low Condenser Water Temperature Operation Needs to be updated 11 Water Piping 12 Thermal Insulation 14 Weights and Dimensions 17 Relief Valves 25 Electrical 28 Control Power Wiring 29 Field Wiring Diagram 31 Prestart System Checklist 33 Important information regarding the refrigerant used 34 ...

Page 3: ...the best of its knowledge The content cannot be held as explicitly or implicitly guaranteed as complete precise or reliable All data and specifications contained herein may be modified without notice The data communicated at the moment of the order shall hold firm Daikin shall assume no liability whatsoever for any direct or indirect damage in the widest sense of the term ensuing from or connected...

Page 4: ... this manual and any other referenced material must be carefully read and understood Cautions and Warnings At several points in the manual items of special interest or significant impact are highlighted by one of the following notices DANGER Dangers indicate a hazardous situation which will result in death or serious injury if not avoided WARNING Warnings indicate potentially hazardous situations ...

Page 5: ...t Control Panel 1 Non flammable gas symbol 6 Unit characteristics technical 2 Electrical hazard symbol 5 Unit nameplate data 3 Gas type 7 Emergency stop 4 Control panel code Motor Terminal Box 1 Terminal box fixing 3 Electrical hazard symbol 2 Manufacturer s logo 4 Terminal connection ...

Page 6: ...porator Each condenser and evaporator has two separate refrigerant circuits WCT chiller is suitably designed for series counter flow which two WCT unit is connecting in series and work as one chiller The driveline of the WCT is made up of two two stage compressors each with a gear set and a 2 pole induction semi hermetic motor The controls are pre wired adjusted and tested Only normal field connec...

Page 7: ...r Rating kW Z Voltage V and Frequency Hz EVAPORATOR E5426 Evaporator Diameter in and Length ft B Tube Count G Tube Type 1 Number of Passes L Water Inlet Nozzle Location R Right Inlet L Left Inlet L Nozzle Configuration CONDENSER C5426 Condenser Diameter in and Length ft B Tube Count R Tube Type 1 Number of Passes L Water Inlet Nozzle Location R Right Inlet L Left Inlet L Nozzle Configuration REFRI...

Page 8: ...d loose Check that these items have been delivered with the unit If so equipped leave the shipping skid in place until the unit is in its final position This will aid in handling the equipment Figure 1 WCT Major Component Locations Note Evaporator nozzles may be side by side or over and under depending on model NOTE Chilled water and condenser connection location can vary Check markings on unit an...

Page 9: ...ng all 6 lifting locations see Figure 3 and the lifting be done with the load at all six locations being vertically up and not at an angle to prevent possible damage to the control panel piping motor terminal box and tubesheets Lift only using locations shown in Figure 2 Recommended type of shackle is 50 Ton B S 3032 by Van Beest or equal If optional shipping skids are used remove them before lowe...

Page 10: ...with the sides and outside edge of the foot supports affixed to the chiller tube sheets Mounting Make sure that the floor or structural support is adequate to support the full operating weight of the complete unit The pads should be located in accordance with the unit dimensional drawing After the pads have been placed into position on the floor lower the unit onto the pads which are to be centere...

Page 11: ...the designer should consider when looking at water volume are the minimum cooling load the minimum chiller plant capacity during the low load period and the desired cycle time for the compressors Assuming that there are no sudden load changes and that the chiller plant has reasonable turndown a rule of thumb of gallons of water volume equal to two to three times the chilled water gpm flow rate is ...

Page 12: ...ter flow control such as tower bypass is recommended and is required if fan control alone will not maintain minimum water temperatures For cold weather operation the bypass valve and piping is required and should be inside the building Water Piping Water Pumps Avoid the use of two pole pump motors It is not uncommon to find that these pumps operate with objectionable noise and vibration It is also...

Page 13: ...the MicroTech unit controller can occur Water pressure gauge connection taps and gauges must be provided in the field piping at the inlet and outlet connections of both vessels for measuring the water pressure drops The pressure 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 unit...

Page 14: ...ary to allow a larger fouling factor for the chiller provided and or specific construction materials for the job site Thermal Insulation Insulation of cold surfaces is required to prevent condensation These surfaces include the evaporator economizer evaporator water heads and nozzles suction piping motor housing oil cooler refrigerant supply and return economizer gas line expansion valve piping be...

Page 15: ...e components require insulation ISOMETRIC VIEW CONDENSER Circuit 2 CONDENSER Circuit 1 002 001 002 00 001 003 3 00 003 3 00 EVAPORATOR Circuit 1 EVAPORATOR Circuit 2 005 005 006 006 008 008 009 00 009 00 010 33 00 010 33 00 011 33 00 012 00 012 00 004 00 007 007 BACK VIEW 013 00 013 00 ...

Page 16: ...AD TO HEAD AND NOZZLES 0 75 59 77 o F 15 25 o C 006 ECONOMIZER GAS LINE 0 75 59 77 o F 15 25 o C 007 EXPANSION VALVE TO ECONOMIZER 0 75 59 77 o F 15 25 o C 008 ALL PIPING LEAVING ECONOMIZER TO EVAPORATOR 0 75 36 45 o F 2 7 o C 009 SUCTION LINE COMPRESSOR TO EVAPORATOR 0 75 36 45 o F 2 7 o C 010 EVAPORATOR END TUBESHEETS 0 75 36 45 o F 2 7 o C 011 BOTH SIDES OF BRACKETS TO BOTTOM OF WIREWAY 0 75 36...

Page 17: ...ll Dimensions Figure 7 Unit Mounting Feet Top Sectional View Position of Center of Gravity relative to 0 0 0 changes depending on Unit Size A B Y Z X Y C CENTER OF GRAVITY 0 0 0 ORIGIN OF COORDINATES Bottom left corner of evaporator feet opposite to compressor suction ...

Page 18: ... 1 190 580 1 010 371 125 124 142 62 52 36 800 48 600 3 000 1 790 4 570 2 220 3 880 9 436 3 167 3 148 3 610 1 580 1 326 C4224 B E4824 D 81 100 106 800 6 850 470 1 190 580 960 371 125 124 142 62 52 36 700 48 300 3 100 1 790 4 570 2 220 3 700 9 436 3 167 3 148 3 610 1 585 1 329 C4224 C E4824 B 81 500 107 900 6 250 470 1 120 580 1 060 371 125 124 142 62 52 36 900 48 800 2 900 1 790 4 290 2 220 4 060 9...

Page 19: ... 3 167 3 148 4 018 1 540 1 326 C4226 C E4826 B 93 300 108 900 6 650 470 1 170 580 1 100 396 125 124 158 60 52 42 200 49 200 3 100 1 790 4 500 2 220 4 220 10 058 3 167 3 148 4 018 1 516 1 324 C4226 C E4826 C 92 500 108 300 6 950 470 1 170 580 1 050 396 125 124 158 60 52 41 800 49 000 3 200 1 790 4 500 2 220 4 020 10 058 3 167 3 148 4 018 1 522 1 325 C4226 C E4826 D 91 100 107 800 7 300 470 1 170 58...

Page 20: ...C E4824 D 89 900 107 400 7 050 570 1 400 580 960 371 125 130 142 68 53 40 700 48 600 3 200 2 200 5 380 2 220 3 700 9 436 3 167 3 300 3 601 1 722 1 341 C4824 D E4824 B 89 900 106 900 6 500 570 1 310 580 1 060 371 125 130 142 68 52 40 600 48 400 3 000 2 200 5 020 2 220 4 060 9 436 3 167 3 300 3 602 1 730 1 321 C4824 D E4824 C 89 500 106 400 6 750 570 1 310 580 1 010 371 125 130 142 68 52 40 500 48 1...

Page 21: ...0 49 700 3 300 2 200 5 260 2 220 4 020 10 058 3 167 3 300 4 018 1 621 1 331 C4826 D E4826 D 91 300 109 300 7 550 570 1 370 580 1 000 396 125 130 158 64 53 41 300 49 400 3 400 2 200 5 260 2 220 3 820 10 058 3 167 3 300 4 018 1 628 1 340 C4824 B E5424 B 95 400 125 000 7 200 570 1 400 730 1 380 371 132 130 142 66 53 43 100 56 500 3 300 2 200 5 380 2 780 5 310 9 436 3 362 3 300 3 611 1 668 1 357 C4824...

Page 22: ...E5426 C 97 300 128 300 8 100 570 1 570 730 1 370 396 132 130 158 63 53 44 000 58 000 3 700 2 200 6 030 2 780 5 250 10 058 3 362 3 300 4 018 1 593 1 350 C4826 B E5426 D 96 800 127 500 8 550 570 1 570 730 1 300 396 132 130 158 63 53 43 800 57 700 3 900 2 200 6 030 2 780 4 970 10 058 3 362 3 300 4 018 1 601 1 354 C4826 C E5426 B 97 000 127 400 7 700 570 1 470 730 1 440 396 132 130 158 62 53 43 900 57...

Page 23: ...0 59 300 3 400 2 750 5 930 2 780 5 310 9 436 3 362 3 300 3 604 1 708 1 394 C5424 C E5424 C 99 300 130 400 7 900 720 1 550 730 1 320 371 132 130 142 68 55 44 900 59 000 3 600 2 750 5 930 2 780 5 060 9 436 3 362 3 300 3 607 1 716 1 398 C5424 C E5424 D 98 800 129 700 8 300 720 1 550 730 1 250 371 132 130 142 68 55 44 700 58 600 3 800 2 750 5 930 2 780 4 800 9 436 3 362 3 300 3 601 1 725 1 402 C5424 D...

Page 24: ...058 3 362 3 300 4 019 1 604 1 474 C5426 D E5426 B 102 900 135 500 8 050 720 1 770 730 1 440 396 132 130 158 62 58 46 500 61 300 3 700 2 750 6 780 2 780 5 520 10 058 3 362 3 300 4 019 1 573 1 471 C5426 D E5426 C 102 500 134 400 8 450 720 1 770 730 1 370 396 132 130 158 62 58 46 300 60 800 3 900 2 750 6 780 2 780 5 250 10 058 3 362 3 300 4 018 1 579 1 478 C5426 D E5426 D 102 000 133 700 8 900 720 1 ...

Page 25: ...ler Refrigerant leaving the oil cooler is then returned back to the evaporator The refrigerant and oil side of the oil cooler are provided with service valves for isolation during service WARNING Comply with local regulations when removing or disposing of refrigerant system oil An eductor based oil recovery system is part of the chiller circuit It returns oil rich refrigerant from the evaporator t...

Page 26: ...ping downstream of the pressure relief valve in Table 6 The ASHRAE 15 User s Manual provides that when the length of vent pipe exceeds approximately 220 diameters Equivalent Length Inside Diameter 220 use 0 7848 L 0 2 this equation is only true for relief valve setting of 200 psig relief valve discharge capacity of 75 5 lbm air min and average friction factor of 0 02 in order to compute the approx...

Page 27: ...ty of 75 5 lbm air min and average friction factor of 0 02 in order to compute the approximate required diameter of the common header diameter if this diameter is constant for the entire length of pipe for a required length L of the Sch 40 piping L Represents the distance in feet from the relief valves where they are vented to atmosphere Finally select a pipe I D from Table 6 equivalent or bigger ...

Page 28: ...ring 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 Specification R35999901 Power wiring to compressors must be in proper phase sequence Motor rotation is set up for clockwise rotation facing the motor end with phase sequence of U V W or 1 2 3 Care must be taken that the pr...

Page 29: ...cylindrical 4 Doing one terminal at a time brush the Scotchkote coating on the motor barrel to a distance of up to 2 around the terminal and on the wrapped terminal the rubber insulation next to the terminal and the lug and cable for approximately 10 Wrap additional Scotchfil insulation over the Scotchkote coating 5 Tape the entire wrapped length with electrical tape to form a protective jacket 6 ...

Page 30: ...Operation of the chilled water pump can be 1 Cycle the pump with the compressor 2 Operate continuously 3 Start automatically by a remote source The cooling tower pump must cycle with the machine The easiest way to accomplish this is to let the chiller MicroTechⅢ controller control the pump The controller is programmed to start and stop the pump at the correct times The holding coil of the cooling ...

Page 31: ...rotect compressor motors from electrical damage resulting from high voltage spikes For free standing starters factory or customer supplied the capacitors are mounted in the motor terminal box and must be connected to the motor terminals with leads less than 18 inches 460 mm long when the motor is being wired Field Wiring Diagram Figure 8 Field Wiring Diagram ...

Page 32: ...ounted flow switches are standard on WCT units Field installed flow switches must be wired as shown If field supplied pressure differential switches are used then these must be installed across the vessel and not the pump Paddle flow switches may also be field installed if desired 7 Customer supplied 24 to 230 VAC 20 amp power for optional evaporator and condenser water pump control power and towe...

Page 33: ...ned Controls 3 way bypass valves etc operable Water system operated and flow balanced to meet unit requirements Electrical All copper conductors connected to unit 220 volt service completed but not connected to control panel Power leads connected to starter load leads run to compressor ready for connection when service engineer is on hand for start up Do not connect starter or compressor terminals...

Page 34: ... Do not vent gases into the atmosphere Refrigerant type R134a GWP 1 value 1430 1 GWP global warming potential The refrigerant quantity is indicated on the unit name plate Periodical inspections for refrigerant leaks may be required depending on European or local legislation Please contact your local dealer for more information ...

Page 35: ...ses 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 Greenhouse gas emission of the total refrigerant charge expressed as tonnes of CO2 equivalent m Refrigerant type n GWP Global Warming Potential p Unit serial number 2 The filled out label must be adhered...

Page 36: ...ctions the refrigerant charge for each circuit 1 2 3 the total refrigerant charge 1 2 3 calculate the greenhouse gas emission with the following formula GWP value of the refrigerant x Total refrigerant charge in kg 1000 a Its functioning relies on fluorinated greenhouse gas b Circuit number c Factory charge d Field charge e Refrigerant charge for each circuit according to the number of circuits f ...

Page 37: ...enance intervals Follow the applicable legislation Formula to calculate the greenhouse gas emission GWP value of the refrigerant x Total refrigerant charge in kg 1000 Use the GWP value mentioned on the greenhouse gases label This GWP value is based on the 4th IPCC Assessment Report The GWP value mentioned in the manual might be outdated i e based on the 3rd IPCC Assessment Report ...

Page 38: ...posal The unit is made of metal and plastic parts All these parts must be disposed of in accordance with the local regulations in terms of disposal Lead batteries must be collected and taken to specific refuse collection centres ...

Page 39: ...D EIMWC01308 16EN 39 40 ...

Page 40: ... of its content and the products and services presented therein Specification are subject to change without prior notice Refer to the data communicated at the time of the order Daikin Applied Europe S p A explicitly rejects any liability for any direct or indirect damage in the broadest sense arising from or related to the use and or interpretation of this publication All content is copyrighted by...