Daikin WGZ030DW, Operating And Maintenance Manual

Page 1: ...Group Chiller Part Number OMM1130 2 Date March 2014 Water Cooled Scroll Compressor Chillers WGZ030DW to WGZ200DW Packaged Water Cooled Chiller WGZ030DA to WGZ200DA Chiller with Remote Condenser 30 to...

Page 2: ...al 78 Hot Gas Bypass Optional 78 System Maintenance 79 General 79 Electrical Terminals 79 POE Lubrication 80 Sightglass and Moisture Indicator 80 Crankcase Heaters 80 Maintenance Schedule 81 System Se...

Page 3: ...ftware operating with various refrigerants as follows R 410A used with the current D vintage of the WGZ chiller R 134a used with only with Model TGZ Templifiers The operating manual devoted exclusivel...

Page 4: ...31 4 351 0 27 7 21 9 82 8 WGZ080D I 146 8 3 9 9 2 11 6 234 9 9 5 14 7 28 4 391 5 25 1 24 5 74 9 WGZ090D J 163 3 3 8 10 2 11 3 261 3 9 2 16 3 27 5 435 5 24 3 27 2 72 6 WGZ100D K 183 4 3 8 11 5 11 3 29...

Page 5: ...8 17 8 80 1 WGZ060D G 113 4 4 5 7 2 13 5 181 5 11 6 11 5 34 7 302 5 32 3 19 1 96 5 WGZ070D H 132 8 4 1 8 4 12 3 212 4 10 4 13 4 31 1 354 0 29 0 22 3 86 7 WGZ080D I 146 8 3 7 9 3 11 1 234 9 9 5 14 8 28...

Page 6: ...1130 2 Components Figure 3 Compressor Locations NOTE Models WGZ150 to WGZ200 add a 5 compressor to circuit 1 and a 6 compressor to circuit 2 4 2 3 1 Circuit 2 Circuit 1 Control Panel Evaporator Evapor...

Page 7: ...d water cooled condenser interconnecting refrigerant piping and a control panel with associated sensors and transducers Figure 4 Schematic Piping Diagram One of Two Circuits for WGZ030D 130D NOTE WGZ...

Page 8: ...8 WGZ030D through WGZ200D OMM 1130 2 Field Wiring Diagrams Figure 5 WGZ030DW WGZ200DW Field Wiring Diagram Packaged Unit...

Page 9: ...OMM 1130 2 9 Figure 6 WGZ030DA WGZ200DA Field Wiring Diagram Remote Condenser...

Page 10: ...mistors located in the motor windings and the compressor discharge port If the windings experience an over temperature condition or the discharge temperature is excessive the module will trip and shut...

Page 11: ...water pressure drop across evaporator and condenser on pages 4 and 5 and check that water flow is correct per the system design flow rates 10 Check the actual line voltage to the unit to make sure it...

Page 12: ...ompressor crankcase heaters Extended Shutdown Close the manual liquid line shutoff valves After the compressors have pumped down turn off the water pumps Turn off all power to the unit Move the contro...

Page 13: ...The evaporator pressure is checked at the end of the low ambient start time frame If the pressure is less than the Low Pressure Unload set point then the low ambient start is not successful and the c...

Page 14: ...Timer times out additional compressors will stage off The last compressor will stage off when the LWT falls below the LWT Setpoint minus the Dead Band minus the Stop Delta T The stop Delta T is in eff...

Page 15: ...perator to manually enable and disable compressors When a compressor is disabled it is considered unavailable to start in the staging logic This allows a damaged compressor to be taken offline while t...

Page 16: ...2 Stage Fan 1 Fan 3 Fan 5 7 Stage Fan 1 Fan 3 Fan 5 7 Fan 9 Stage Fan 1 Fan 3 Fan 5 7 Fan 9 11 1 ON 1 ON 1 ON 2 ON ON 2 ON ON 2 ON ON 3 ON ON 3 ON ON 3 ON ON 4 ON ON ON 4 ON ON ON 4 ON ON ON 5 ON ON O...

Page 17: ...ameters setpoints 3 alarms Security protection prevents unauthorized changing of the setpoints and control parameters The MicroTech II controller continuously performs self diagnostic checks monitorin...

Page 18: ...ure 1 R410a C1 0 1 to 0 9 VDC 0 to 350 psi 2 Evaporator Refrigerant Pressure 2 R134a R22 C2 0 1 to 0 9 VDC 0 to 132 psi 2 Evaporator Refrigerant Pressure 2 R410a C2 0 1 to 0 9 VDC 0 to 350 psi 3 Conde...

Page 19: ...t Stop UT 0 VAC Stop 24 VAC Start 14 Condenser Water Flow Switch UT 0 VAC No Flow 24 VAC Flow 14 Open 15 Open 15 Motor Protection 1 R134a R410a C1 0 VAC Fault 24 VAC No Fault 16 Open 16 Motor Protecti...

Page 20: ...6 Condenser Fan 6 C2 Fan Contactor Fan OFF Fan ON 16 Condenser Fan 4 C2 Fan Contactor Fan OFF Fan ON 17 Condenser Fan 7 C1 Fan Contactor Fan OFF Fan ON 17 Condenser Fan 5 7 R134a R410a C1 Fan Contacto...

Page 21: ...5 0 F O Stop Delta T 0 5 F 0 to 3 0 F O Max Pulldown Rate 1 0 F 0 5 to 5 0 F M Evap Recirculate Timer 30 15 to 300 seconds M Evap Pump Refrigerant R410a R134a 1 Only 1 Only 2 Only Auto 1 Prim 2 Prim M...

Page 22: ...e Voltage Protection N N Y M Ground Fault Protection N N Y M Low OAT Start Time 60 sec 30 to 240 seconds M Condenser Fans Water Cooled N Number of fans 4 4 to 8 10 for R410a M Speedtrol Option No No Y...

Page 23: ...Mode Cool R134a R410A 36 to 42 F Unit Mode Cool w Glycol Ice w Glycol R134a 18 to 42 F Unit Mode Cool w Glycol Ice w Glycol R410A 12 5 to 42 F Ice Leaving Water Temperature Refrigerant Type Range R13...

Page 24: ...at require some action from the chiller or that should be logged for future reference Conditions that cause a shutdown and require manual reset is known as a stop alarm Other conditions can trigger wh...

Page 25: ...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 condenser pump stat...

Page 26: ...t point enable Action Taken Rapid stop circuit Reset Auto reset when PVM input is high Ground Fault Protection Alarm description as shown on screen Ground Fault Cir N Trigger GFP input is low and Grou...

Page 27: ...gger Sensor shorted or open Action Taken Normal stop all circuits Reset This alarm can be cleared manually via the keypad but only if the sensor is back in range Evaporator Water Freeze Protect Alarm...

Page 28: ...Alarm Log Low Evaporator Pressure Hold Event description as shown on screen Evap Press Low HoldN Trigger This event is triggered if all of the following are true circuit state Run circuit is not curre...

Page 29: ...0 psi N A 20 psi 10 psi Air Cooled 4 100 psi 70 psi N A 15 psi 6 80 psi N A N A 15psi Failed Pumpdown Event description as shown on screen Pumpdown Fail Cir N Trigger Circuit state pumpdown for time 6...

Page 30: ...it only Event description as shown on screen No EXB comm CP1 Trigger CP1 does not have communication with either EXB1 for 60 seconds after power up This event is only active when the expansion board i...

Page 31: ...ature is calculated as Stage Down Temperature Cool LWT Control Band 2 If the Cool Leaving Water Temperature set point is less than half the Control Band above 39 0 F the Stage Down temperature is calc...

Page 32: ...IN cool mode this will be Evap LWT and in heat mode this will be Heat LWT Reset Type 4 20 mA The Active Leaving Water set point is adjusted by the 4 to 20 mA reset analog input Cooling Mode The Activ...

Page 33: ...aporator water temperatures Cooling Mode Return Reset Evap LWT set point Clg MaxRes set point Evap LWT Clg MaxRes Clg StrtResDT setpoint range of reset action 54 F 10 F 44 F 0 F Active Evap LWT Set Po...

Page 34: ...et point represents the current control set point based on unit mode and reset If unit mode is ice then the active set point is equal to the ice set point If the unit mode is cool the active set point...

Page 35: ...Temperatures Templifiers only When R134a refrigerant is selected the refrigerant pressure will be fitted to a curve made up of 12 straight line segments The accuracy of calculated saturated temperatu...

Page 36: ...to BAS the most recent BAS mode request shall go into effect even if it changed while the Control source was set to KEYPAD or DIGITAL INPUTS Changing the Unit Mode Set Point can be accomplished accord...

Page 37: ...ng the power to the controller will clear the ice delay timer Low Ambient Lockout This feature is only available on air cooled units WaterCooled Off If the OAT drops below the low ambient lockout set...

Page 38: ...te Start AND Flow Switch Closed for time Evap Recirc Tmr Unit State Off AND No Evap Water Freeze Alarm Evaporator Pump State Diagram Pump Selection The pump output used will be determined by the Evap...

Page 39: ...r Flow and the evaporator water pump state changes to Start When flow is reestablished the Unit Status becomes Auto Recirculate while the Evaporator Flow Recirculation Timer counts down If there is co...

Page 40: ...up deadbands apply 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 Tar...

Page 41: ...requires that the unit be configured as water cooled in order to be active Condenser Water Pump State Control Cond State If the unit is configured as water cooled then the state transition diagram sh...

Page 42: ...all of the running compressors will be shutdown The Alarm indicators are turned On and the Circuit Status for any circuit with running compressors becomes Off Ready the Unit Status becomes Auto Wait...

Page 43: ...lowing graph Max Position Set Point 90 F Min Position Set Point 60 F Min Start Position Set Point 10 Initial Valve Position values are examples only Max Start Position Set Point 90 Operation After Sta...

Page 44: ...t Stop Timing This section determines when to start or stop a compressor There are two separate functions used one for staging up and one for staging down Stage Up Now The Stage Up Now flag is set bas...

Page 45: ...of a tie on number of starts the lower numbered compressor starts first In the event of a tie on run hours the lower numbered compressor shuts off first Run hours are compared in terms of tens of hou...

Page 46: ...expired which is one half the calculated freeze time lower pressure then shorter time If three compressors are running one compressor will stop after a this time delay which is one half the calculate...

Page 47: ...nd circuit number one is again allowed to load up Again its condenser pressure exceeds the High Condenser Pressure Unload set point and it unloads Because this is the second High Condenser Pressure Un...

Page 48: ...evaporator water pump will remain off and no compressors will start until the OAT rises to the lockout set point plus 5 F Manual Compressor Control The operator can manually enable and disable individ...

Page 49: ...line output shall be on any time a compressor on the circuit is running and the circuit is not performing a pump down This output should be off at all other times Hot Gas Bypass Solenoid This output...

Page 50: ...ontrol is set to manual the EXV position is equal to the manual EXV position setting Maximum EXV Operating Pressure This logic only applies to TGZ units Refrig R134a equipped with electronic expansion...

Page 51: ...re 10 One of these groups of screens can then be selected by pressing the key connected to it via the pathway shown in Figure 8 on page 18 For example selecting ALARM will go the next row of menus und...

Page 52: ...ociated with unit operation 4 Press the DOWN key to scroll down through the setpoint menus to the third menu which contains Evap LWT XX X F 5 Press the ENTER key to move the cursor down from the top l...

Page 53: ...T LIMIT ALARMS 2 SET FANS 2 STAGE ON SET TOWER 2 ALARM LOG SECOND TO LAST ACTIVE ALARM 3 CLEAR VIEW SET UNIT SPs 3 SET LIMIT ALARMS 3 SET FANS 3 STAGE OFF SET TOWER 3 ALARM LOG LAST 25 SHOWN SET UNIT...

Page 54: ...e OFF OFF ON OFF OFF ON and ON ON Evaporator Pump States can be OFF STRT or RUN When more than one screen are stacked i e relate to each other on the same subject they are numbered sequentially with t...

Page 55: ...IEW UNIT TEMP 1 Evap LWT XX X F Cond EWT XXX X F LWT Target XX X F The difference between the three screens above is that water cooled units and the TGZ units will give the entering condenser water te...

Page 56: ...t Mode VIEW UNIT TEMP 5 VIEW UNIT TEMP 5 Cond LWT XX X F Cond LWT XX X F Evap EWT XX X F Evap EWT XX X F View Circuit VIEW CIRCUIT 1 1 OFF VIEW CIRCUIT 1 2 Comp 1 OFF Hours XXXXX Starts XXXXX VIEW CIR...

Page 57: ...a R22 R410A R407C VIEW REFRG Cir 1 2 VIEW REFRG Cir 1 2 Sat Evap XXX X F Evap Dew XXX X F Sat Cond XXX X F i Cond Mid XXX X F VIEW REFRG Cir 1 3 SuctionTemp XXX X F Surperheat XXX X F EvapApproach XX...

Page 58: ...ndApproach XX X F Units with EEV only VIEW REFRG Cir 2 5 EXV Ctrl XXX EXV Pos XXX X SH Target XX X F TGZ Units Only R134a VIEW REFRG Cir 2 6 EXV Ctrl Range XX X XX X Water Cooled Y Only or TGZ Unit R1...

Page 59: ...running but in a limit alarm condition the cause and date will appear in the upper screen If there is a simultaneous occurrence of more than one alarm the others will appear in additional screens belo...

Page 60: ...g diagram page 8 or 9 NETWORK used with BAS signal which is wired to the three communication ports Unit Mode settings can be COOL normal setting used with chilled water air condition applications COOL...

Page 61: ...ly TGZ Units R134a SET UNIT SPs 6 Water Cooled Off LowAmbLock XXX X F Water Cooled On is the setting for units with on board water cooled condensers Pump choices are 1 Only 2 Only Auto 1 Primary 2 Pri...

Page 62: ...ure gauge or thermometer is used to determine the correct temperature or pressure A positive or negative offset value is then entered to make the controller reading agree with the measured value SET U...

Page 63: ...the SET screens The controller will automatically go from the screen with the setting change to this screen After the correct password has been entered the controller will automatically return to the...

Page 64: ...MaxOpPress XXX X psi Expansion Valve Type Electronic SET COMP SPs 6 Cir 1 EXV EXV Control Auto Manual EXV Pos XXX X Expansion Valve Type Electronic SET COMP SPs 7 Cir 2 EXV EXV Control Auto Manual EX...

Page 65: ...are Y Yes or N No depending on whether the options are on the unit CondFreeze is an alarm that reduces the chance of freezing the water in the condenser when compressors are not running An alarm is r...

Page 66: ...XX X F Water cooled Off SET FANS SPs 5 Fans On At Startup 75 F 90 F 105 F X X X Set Cooling Tower Control The MicroTech II controller is capable of controlling cooling tower water temperature on chill...

Page 67: ...re is not by the MicroTech II controller and assumed to be furnished elsewhere Tower Stages is the number of tower fans to be staged by the controller choices are 0 1 or 2 0 indicates control will be...

Page 68: ...tion analog output of full scale is updated according to the following equation New Position Old Position Increment 10 Valve Stage controls from the fan stage setpoint in use It is recommended that th...

Page 69: ...minimum tower water temperature acceptable default is 65 F Valve DB is the dead band in degrees default is 2 0 F Water cooled Y SET TOWER SPs 6 ValveStartPosition Min XXX XXX F Max XXX XXX F The Valve...

Page 70: ...4 TEST UNIT 4 Cond Pump 1 OFF Fan 1 OFF Fan 3 OFF Cond Pump 2 OFF Fan 5 7 OFF TwrFan1 OFF Fan2 OFF Fan 9 OFF Water Cooled ON Water Cooled OFF TEST UNIT 5 TEST UNIT 5 Twr Bypass XXX X Fan 2 OFF Fan 4...

Page 71: ...m can be cleared by pressing the Edit key A separate buffer is available for each alarm High Cond Pressure Evaporator Freeze Protect etc The alarm history buffer holds a chronological account of the l...

Page 72: ...oints are accessible Available Parameters Types A Analog I Integer D Digital I O I Input only O Output only I O Input Output Type Index I O Description LONWORKS BACnet Modbus A 1 I O Network Cool LWT...

Page 73: ...sor select x x x I 35 I O Clock year x x I 36 I O Clock month x x I 37 I O Clock day of month x x I 38 I O Clock day of week x x I 39 I O Clock hours x x I 40 I O Clock minutes x x I 45 O Compressor s...

Page 74: ...revision letter Compressor Select Compressor Select is used to select the compressor for which the associated parameters will be sent to the BAS interface The input should equal the number of the com...

Page 75: ...active Active events do not set this output D 4 O Chiller run enabled Set when the unit state is auto D 5 O Chiller local control Set when the unit control source is set to keypad or switches D 6 O Ch...

Page 76: ...g LED three times indicating the compressor has short cycled more than 48 times in 24 hours A short cycle is defined as compressor runtime of less than 1 minute The Warning will be activated when the...

Page 77: ...t will open the M2 M1 contacts The Alert will reset after 5 minutes and the M2 M1 contacts will close if the missing phase condition is not present The module will lockout the compressor after 10 cons...

Page 78: ...itch This may be necessary as the phase voltage monitor is sensitive to phase reversal Turn on the power The relay should now close after the appropriate delay Factory settings are as follows Voltage...

Page 79: ...vel is at the center of the oil sightglass located in the compressor s equalizing line or on the compressor itself Low oil level can cause inadequate lubrication and if oil must be added use oils refe...

Page 80: ...side the sight glass indicates what moisture condition corresponds to a given element color If the sight glass does not indicate a dry condition after about 12 hours of operation the unit should be pu...

Page 81: ...required X D Eddycurrent Test Tube Wall Thickness X E Seasonal Protection X IV Evaporator B Test Water Quality X C Clean Evaporator Tubes or as required X D Eddycurrent Test Tube Wall thickness or as...

Page 82: ...the refrigerant piping by moving pumpdown switch es PS1 and PS2 to the manual position The coil can then be removed from the valve body by simply removing a nut or snap ring located at the top of the...

Page 83: ...shell External finned copper tubes are rolled into steel tube sheets and to the center dividing tube sheet Integral subcoolers are incorporated on all units All condensers are equipped with 500 psig...

Page 84: ...onditions 17 Readjust temperature control or water regulating valve Investigate ways to increase water supply 18 Clean 19 EPA purge the noncondensables 20 Remove excess refrigerant 21 Open valve 22 Ch...

Page 85: ...causing unbalanced voltage 6 High ambient temperature around the overload relay 1 Check supply voltage for excessive line drop 2 Replace compressor motor 3 Check all connections and tighten 4 See cor...

Page 86: ......

Page 87: ......

Page 88: ...and click on training or call 540 248 9646 and ask for the Training Department Warranty All Daikin Applied equipment is sold pursuant to Daikin Applied standard terms and conditions of sale including...