Daikin Navigator WWV Installation, Operation And Maintenance Manual
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Daikin Navigator WWV Installation, Operation And Maintenance Manual

Daikin Navigator WWV Installation, Operation And Maintenance Manual

Water-cooled screw chillers. 120 to 300 tons (527 to 1055 kw) hfc-134a refrigerant 50/60 hz
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Installation, Operation,
and Maintenance Manual
Navigator
®
Water-cooled Screw Chillers
Model WWV
120 to 300 Tons (527 to 1055 kW)
HFC-134a Refrigerant
50/60 Hz
IOM 1264-1
Group: Chiller
Part Number: IOM1264-1
Date: September 2018

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  • Page 1 Installation, Operation, IOM 1264-1 and Maintenance Manual Group: Chiller Part Number: IOM1264-1 Date: September 2018 Navigator ® Water-cooled Screw Chillers Model WWV 120 to 300 Tons (527 to 1055 kW) HFC-134a Refrigerant 50/60 Hz...

  • Page 2: Table Of Contents

    Manufactured in an ISO 9001 & ISO 14001 certified facility ©2018 Daikin Applied. Illustrations and data cover the Daikin Applied product at the time of publication and we reserve the right to make changes in design and construction at any time without notice.
  • Page 3 Document Attached: Remote evaporator piping approval (if applicable) Notes: The most common problems delaying start-up and affecting unit reliability are: Field installed compressor motor power supply leads too small. Questions: Contact the local Daikin sales representative*. State size, number and type of conductors and conduits installed:...

  • Page 5: Introduction

    Operation of this equipment in a residential area may cause harmful interference in which case the owner will be required to correct the interference at the owner’s own expense. Daikin Applied disclaims any liability resulting from any interference or for the correction thereof. HAZARD IDENTIFICATION INFORMATION DANGER Dangers indicate a hazardous situation, which will result in death or serious injury if not avoided.
  • Page 6 (VVR ® ) series single screw compressor, flooded shell All Daikin Applied screw chillers must be commissioned by and tube evaporator, and a shell and tube condenser. The a Daikin Applied service technician or an authorized service compressor is designed to operate in a very wide operating provider.

  • Page 7: Installation And Application Considerations

    The contractor should obtain a copy of the Startup Scheduled Request Form from the sales representative or from the nearest Daikin Applied service office. A pre-start checklist is located at the front of this manual. Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.
  • Page 8 nsTallaTIon and pplICaTIon onsIderaTIons Mounting Hole Access vertical capacity equal to the total machine weight. 5. The machine must be lifted slowly and well leveled. It After positioning, the shipping rails should be removed and the is recommended to initially lift the unit to a low height machine must be firmly anchored to the ground or foreseen to verify all rigging equipment is properly installed and metal structure to support the machine.
  • Page 9 HVAC equipment without creating a hazard to operating personnel or the environment. Strainers must be used to protect the chiller systems from water-borne debris. Daikin will www.DaikinApplied.com IOM 1264-1 • NAVIGATOR MODEL WWV CHILLERS ®...
  • Page 10 Consult the change is less than 10 percent of the design flow per minute, local Daikin Applied sales office for performance outside and the minimum and maximum flow rates for the evaporator these temperatures. Leaving chilled fluid temperatures below are not exceeded.
  • Page 11 nsTallaTIon and pplICaTIon onsIderaTIons Table 3: Glycol Performance Factors Three-Way Bypass Valve Operation: To modulate the water temperature in the condenser, install a three-way by-pass Freeze Point Pressure Flow valve. Figure 5 shows how the three-way valve is applied in Drop °F °C...
  • Page 12 nsTallaTIon and pplICaTIon onsIderaTIons code requirements and ANSI/ASHRAE Standard 15 code CAUTION recommendations must be followed. Do not operate the system with the three-way valve stem in In order to ensure proper installation, it is important to know the Mid Position. how the three-way relief valve functions.
  • Page 13 The chiller must be stored in a dry location and protected from from running while the evaporator and condenser water pumps any damage or sources of corrosion. A Daikin Applied service come online and provide the correct water flow. representative must perform an inspection and leak test of the...
  • Page 14 nsTallaTIon and pplICaTIon onsIderaTIons Figure 10: Field Wiring Diagram - Single Point Power NOTE: ALL FIELD WIRING TO BE PANEL INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED POWER BLOCK CIRCUIT BREAKER 600 VOLTS (BY OTHERS) DISCONNECT SWITCH 3 PHASE POWER COMPRESSOR(S)

  • Page 15: Installation - Knockdown

    • Site reassembly must be supervised or completed • Suction and discharge lines have bolt-on flanges. by Daikin Applied service personnel. Cost for unit resassembly and supervision by Daikin Applied service • Unit ships with vessel and/or head insulation.
  • Page 16 nsTallaTIon noCKdown Table 6: Compressor Dimensions and Weights Compressor Dimensions Length Width Height Weight Model (in) (in) (in) (lbs) JNNS 60.5 27.1 28.0 1534 MNNS 61.6 28.0 29.1 1925 RNNS 64.6 30.5 31.4 2778 Unit Knockdown Dimensions Figure 13: Unit Dimensional Diagram for Typical WWV Knockdown Table 7: WWV Knockdown Dimensions Combined Unit Configurations E16/C18...
  • Page 17 10. Disconnect all solenoids from the chiller but leave Contact Daikin Applied service for this information. connected to the control box; the jet pump solenoid harness should include the solenoid coil.
  • Page 18 nsTallaTIon noCKdown Type B Knockdown Disassembly Type B knockdown units are shipped disassembled except for the vessel stack (“Figure 15: Vessel Blockoff Locations” on page 17) and are shipped without refrigerant. If the stack size or weight dictates further disassembly, the vessels can be separated by disconnecting any interconnecting wiring and tubing and then unbolting the tube sheet braces while ensuring the vessel weights are safely supported.

  • Page 19: Dimensional Drawings

    ImensIonal rawIngs ImensIonal rawIngs Figure 16: WWV Single Compressor Unit Figure 17: WWV Single Compressor Unit - Same End Condenser Connection Table 8: WWV Single Dimensions and Shipping Weights Evaporator Condenser Length Tube Tube Compressor Length same end Width Height Shipping Operating Size...

  • Page 20: Controller Operation

    During Evaporator Water Pump 1 Pump Off Pump On the initial startup of the chiller, the Daikin Applied service technician will be available to answer any questions and Alarm Relay Alarm not Alarm Active Active instruct the proper operating procedures.
  • Page 21 onTroller peraTIon Set Points The following parameters are remembered during power off (permanent memory), are factory set to the Default value, and can be adjusted to any value in the Range column. Unit Level Set Points All basic unit configuration settings require the unit switch to be off in order to make a change. Modifying the Ground Fault Protection and Comm Module settings require rebooting the controller in order to apply a change.
  • Page 22 onTroller peraTIon Tower Control Tower Control None None, Condenser EWT, Condenser LWT Number of Tower Fan Stages 1, 2 Tower Fan Stage 1 On Temperature 70°F (21.11°C) 66.2 to 120°F (19 to 48.89°C) Tower Fan Stage 2 On Temperature 75°F (23.89°C) 66.2 to 120°F (19 to 48.89°C) Tower Fan Stage Off Differential 3°F (1.67°C)
  • Page 23 onTroller peraTIon High Condenser Pressure Delay 5 sec 0 to 5 sec Low Pressure Ratio Delay 300 sec 30 to 300 sec Start Time Limit 60 sec 20 to 180 sec Low DSH Limit 10.8°F (6.0°C) 3.6 to 27.0°F (2.0°C to 15.0°C) BAS Control Inputs Network Unit Enable Disable...
  • Page 24 onTroller peraTIon Dynamic Set Point Ranges The following settings have different ranges of adjustment based on other settings. Table 21: Cool LWT and Network Cool Set Point Ranges Table 23: Low Evaporator Pressure Hold and Unload Available Mode Selection Range Available Mode Selection Range Cool, Test...

  • Page 25: Unit Functions

    unCTIons unCTIons Calculations Glycol Configuration Evaporator If the Available Modes Set Point is set to a value ‘w/Glycol’, then glycol limits should be enabled for the unit. This means Error that various pressure and temperature settings can be set LWT Error = Evaporator LWT - Active LWT Set Point to lower values as a result of the glycol limits being enabled.
  • Page 26 unCTIons Unit Status Unit Status is displayed to indicate the general condition of the unit. The following table lists the text displayed for each unit status and the conditions that enable each status. If more than one status is enabled at the same time, the highest numbered status overrides the others and is displayed.
  • Page 27 unCTIons Condenser Pump Control Evaporator Freeze Protection To protect the evaporator from freezing, the evaporator pump For control of the condenser pumps, three condenser pump will start if the manual reset flow loss alarm is not active and control states are used: either of the following are true: 1.
  • Page 28 unCTIons Condenser Freeze Protection The second fan stage should turn off when the following conditions are met: To protect the condenser from freezing, the condenser pump • Stage timer > Tower Fan Stage Off Delay set point will start if the manual reset flow loss alarm is not active and •...
  • Page 29 unCTIons Valve Stage Mode Table 28: LWT Targets Control Source “ This mode is enabled when the Valve/VFD Control set point Available Control Mode is set to Valve Stage. The valve position should be 0% when Modes Set Source Base LWT Target Input Request Point...
  • Page 30 unCTIons RapidRestore Option Cool Mode Operation ® In Cool Mode, unit capacity is adjusted via circuit staging RapidRestore is an option that can be added to WWV chillers. ® and capacity changes on each circuit. LWT error and The general purpose of the option is to allow the capability to EWT pulldown rate are the primary factors in unit capacity restart more quickly and to load faster than normal when power adjustments.

  • Page 31: Circuit Functions

    IrCuIT unCTIons IrCuIT unCTIons Circuit Functions Circuit Availability Components controlled at the circuit level include: A circuit is available to start if the following conditions are true: • Compressor VFD • No manual reset circuit fault alarms are active • Compressor VR Solenoid Valves •...
  • Page 32 IrCuIT unCTIons Circuit Status • Control Source = Network and BAS Circuit Mode = Off • Circuit Mode set point is set to Disable Circuit Status is displayed to indicate the general condition of T4 – Pumpdown to Off - Any of the following are required: the circuit.
  • Page 33 IrCuIT unCTIons Compressor Control will occur. The load and unload delay times are calculated values. The compressor is controlled via: Circuit State = Pumpdown - Speed will be set to 50 Hz or the • commands to the VFD via Modbus to start/stop the calculated Compressor Minimum Frequency value, whichever compressor is higher.
  • Page 34 IrCuIT unCTIons Circuit Capacity Overrides Manual VR Control VR can be controlled manually using settings on the variable The following conditions override automatic capacity control VR screen. VR control can be changed to Manual only when as described. These overrides keep the circuit from entering a the circuit state is Run.

  • Page 35: Alarms And Events

    larms and venTs larms and venTs Alarms Clearing Alarms/Faults Situations may arise that require some action from the chiller, Active alarms can be cleared through the unit controller HMI/ or that should be logged for future reference. The alarm digital display or a BAS network.
  • Page 36 larms and venTs Unit Alarms Evaporator Flow Loss Condenser Flow Loss Displayed Text: Evap Water Flow Loss Displayed Text: Cond Water Flow Loss Trigger: 1: Evap Pump State = Run AND Evap Flow Trigger: 1: Condenser Pump State = Run AND Digital Input = No Flow for time >...
  • Page 37 larms and venTs Evaporator/Condenser Water Freeze Evaporator/Condenser EWT Sensor Protect Fault Evap Water Freeze Evap EWT SenFault/ Displayed Text: Displayed Text: Cond Water Freeze Cond EWT SenFault Trigger: LWT or EWT equal to or less than Freeze Trigger: If any of the following occur: Protect set point for a time at least as long •...
  • Page 38 larms and venTs Compressor Controller (CC1) Module Bad LWT Reset Input Comm Failure Displayed Text: Bad LWT Reset Input Trigger: LWT Reset set point is Enable and LWT Displayed Text: CC1 Mod Comm Fail reset input is out of range. For this alarm Trigger: Communication with the CC1 module has out of range is considered to be a signal...
  • Page 39 larms and venTs High Condenser Pressure High Oil Pressure Difference Text: C1 CondPressHigh Displayed Text: C1 Oil PD High Trigger: Saturated Condenser Temp > Max Saturated Trigger: Circuit is in the Run state and Oil Pressure Condenser Value for time longer than High Difference >...
  • Page 40 larms and venTs No Pressure Change At Start High Motor Current Displayed Text: C1 No Press Chg Start Displayed Text: C1 MotorCurrent High Trigger: After start of compressor, at least a 7 kPa If all of the following are true, the alarm is drop in evaporator pressure or 25 kPa triggered: increase in condenser pressure has not...
  • Page 41 larms and venTs Compressor VFD Fault Mains Phase Loss Displayed Text: C1 Comp Vfd Fault Displayed Text: C1 CmpVfd Phase Loss Trigger: Trip flag from VFD is set and alarm flags Trigger: Compressor VFD sets the ‘Mains Phase for the following VFD alarms are NOT set: Loss’...
  • Page 42 larms and venTs Evaporator Pressure Sensor Fault Suction Temp Sensor Fault Displayed Text: C1 SuctTempSenFault Displayed Text: C1 EvapPressSenFault Trigger: Trigger if UC communication with EEXV1 Trigger: Trigger if all of the following are true: module is OK and any of the following are •...
  • Page 43 larms and venTs Power Loss While Running Low Evaporator Pressure - Unload Displayed Text: C1 PwrLossWhileRun Trigger: This event will trigger when the unit mode is Cool, the circuit state is Run, and evaporator Trigger: Circuit is running when controller loses pressure drops below the Low Evaporator power Pressure Unload set point.
  • Page 44 larms and venTs High Motor Current Hold High VFD Line Current Unload Trigger: This event will trigger when all of the following Trigger: This event will trigger when all of the following are true: are true for at least 5 seconds: •...

  • Page 45: Using The Controller

    “normal” operation. TheTechnician/Manager password allows similar access to Operator with the addition of more advanced status and commissioning set points. The Daikin Applied service technician has the highest level of access. www.DaikinApplied.com IOM 1264-1 •...

  • Page 46: Startup And Shutdown

    Complete the pre-start checklist at the front of pumpdown switches Q1 and Q2 to the “auto” position. this manual and return to Daikin Applied prior to startup date. 3. Observe the unit operation until the system has NOTICE stabilized.

  • Page 47: System Maintenance

    ysTem aInTenanCe ysTem aInTenanCe General Figure 25: Sight Glasses - Condenser On initial startup and periodically during operation, it will be necessary to perform certain routine service checks. Among these are checking the liquid line sight glasses, and the compressor oil level sight glass. In addition, check the MicroTech III controller temperature and pressure readings ®...
  • Page 48 ysTem aInTenanCe 3. Pull the oil filter off of the spigot and withdraw the oil filter WARNING from the housing and clean the housing. After the compressor has been pumped down and isolated, the oil contained inside the filter housing will remain hot enough to cause burns for some time afterwards.
  • Page 49 ysTem aInTenanCe refrigerant flow. Refrigerant gas flashing in the sight glass following problems: could also indicate an excessive pressure drop in the liquid 1. If any device, other than the chiller, should try to start line, possibly due to a clogged filter-drier or a restriction the chiller without first starting the pumps, the chiller will elsewhere in the liquid line.
  • Page 50 ysTem aInTenanCe Figure 29: Preventative Maintenance Schedule Monthly Annual Operation Weekly (Note 1) (Note 2) General Complete unit log and review (Note 3) Inspect unit for loose or damaged components and visible leaks Inspect thermal insulation for integrity Clean and paint as required Electrical ( * including the VFDs) Sequence test controls * Check contactors for pitting, replace as required *...
  • Page 51 (collectively “Owner”) that Company, at it’s option, will repair or replace defective parts in the event any product manufactured by Company, including products sold under the brand name Daikin and used in the United States or Canada, proves defective in material or workmanship within twelve (12) months from initial startup or eighteen (18) months from the date shipped by Company, whichever occurs first.
  • Page 52 Now that you have made an investment in modern, efficient Daikin Applied equipment, its care should be a high priority. For training information on all Daikin Applied HVAC products, please visit us at www.DaikinApplied.com and click on Training, or call 540-248-9646 and ask for the Training Department.

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