Daikin WGZ030DW Installation, Operation And Maintenance Manual
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Daikin WGZ030DW Installation, Operation And Maintenance Manual

Water-cooled scroll compressor chillers
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Installation, Operation,
and Maintenance Manual
Water-Cooled Scroll Compressor Chillers
WGZ030DW - WGZ200DW, Packaged Water-Cooled Chillers
30 - 200 Tons (105 - 700 kW)
R-410A
50/60 Hz
IOM 1322-1
Group: Chiller
Part Number: IOM1322-1
Date: January 2022

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Summary of Contents for Daikin WGZ030DW

  • Page 1 Installation, Operation, IOM 1322-1 and Maintenance Manual Group: Chiller Part Number: IOM1322-1 Date: January 2022 Water-Cooled Scroll Compressor Chillers WGZ030DW - WGZ200DW, Packaged Water-Cooled Chillers 30 - 200 Tons (105 - 700 kW) R-410A 50/60 Hz...

  • Page 2: Table Of Contents

    Manufactured in an ISO 9001 & ISO 14001 certified facility ©2022 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 piping approval 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: From Power supply to chiller * Refer to NFPA 70-2017, Article 440.35...

  • Page 5: Introduction And Installation

    WARNING Polyolester Oil, commonly known as POE oil is a synthetic oil used in many refrigeration systems, and may be present in this Daikin product. POE oil, if ever in contact with PVC/CPVC, will coat the inside wall of PVC/CPVC pipe causing environmental stress fractures. Although there is no PVC/CPVC piping in this product, please keep this in mind when selecting piping materials for your application, as system failure and property damage could result.
  • Page 6 DANGER If refrigerant leaks from the unit, there is a potential danger of suffocation Daikin Applied WGZ water chillers are designed for indoor since refrigerant will displace the air in the immediate area. Be sure to installations Equipment room temperature for operating and follow all applicable industry related published standards and local, state standby conditions is 40°F to 122°F (4.4°C to 50°C).
  • Page 7 Introduction and Installation control panel. Left-hand condenser connections are an option. Figure 1: Lifting the Unit For shell and tube evaporators, the water connections are on the back side of the unit. A clearance of at least 3 feet (1219 mm), or more if codes require, should be provided beyond this piping and on all other sides and ends of the unit for general servicing or for changing the compressors, if it ever becomes...

  • Page 8: Chilled Water Piping Guidelines

    Polyolester Oil, commonly known as POE oil is a synthetic oil used in many • Vibration eliminators to reduce vibration and noise refrigeration systems, and may be present in this Daikin product. POE oil, if transmission to the building. ever in contact with PVC/CPVC, will coat the inside wall of PVC/CPVC pipe •...
  • Page 9 Application Considerations Figure 3: Typical Evaporator Field Water Piping (WGZ030 - WGZ130) Figure 4: Typical Evaporator Field Water Piping (WGZ150 - WGZ200) For normal comfort cooling applications where the cooling load Variable Chilled Water Flow changes relatively slowly, a minimum system volume of two Reducing chilled water flow in proportion to load can reduce to three minutes times the flow rate (GPM) is recommended.

  • Page 10: Condenser Water Piping

    2. A “paddle” type flow switch is available from Daikin greater than 35% are not recommended due to the higher Applied for field mounting and wiring. Wire from switch pressure drops and losses of capacity and efficiency.

  • Page 11: Packaged Unit Refrigerant Piping

    Application Considerations Components Condensers are drained of water in the factory and are shipped with the condenser drain plugs in the heads removed and Figure 6: Compressor Locations stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid.

  • Page 12: Relief Valve Piping

    Application Considerations Relief Valve Piping Water Pressure Drop The ANSI/ASHRAE Standard 15, Safety Standard for Water flow rates should be maintained as closely as possible Refrigeration Systems, specifies that pressure relief valves to job design values. The vessel flow rates must fall between on vessels containing Group 1 refrigerant (R-410A) “shall the minimum and maximum values shown on the appropriate discharge to the atmosphere at a location not less than 15 feet...
  • Page 13 Application Considerations Figure 9: WGZ-D Condenser Pressure Drop Curves www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 14 Application Considerations Table 2: WGZ-D Evaporator Pressure Drop Curves IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...
  • Page 15 Application Considerations Table 3: WGZ-D Condenser Pressure Drop Data Table 4: WGZ-D Evaporator Pressure Drop Data www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...

  • Page 16: Dimensions And Weights - Packaged Units

    Dimensions and Weights - Packaged Units Dimensions and Weights - Packaged Units Figure 10: WGZ030DW - 060DW (Packaged) IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...
  • Page 17 Dimensions and Weights - Packaged Units Figure 11: WGZ070DW (Packaged) www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 18 Dimensions and Weights - Packaged Units Figure 12: WGZ080DW - 130DW (Packaged) IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...
  • Page 19 Dimensions and Weights - Packaged Units Figure 13: WGZ150DW - 200DW (Packaged) www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 20 Dimensions and Weights - Packaged Units Figure 14: Lifting Locations, WGZ030-060D Packaged Table 5: Lifting Weights, WGZ030-060D Packaged Figure 15: Lifting Locations, WGZ070-130D Packaged Table 6: Lifting Weights, WGZ070-130D Packaged IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...

  • Page 21: Isolator Information

    Dimensions and Weights - Packaged Units Figure 16: Lifting Locations, WGZ150-200D Packaged Table 7: Lifting Weights, WGZ150-200D Packaged NOTE: Refer to “Moving the Unit” on page 7 for details on transferring/lifting the unit. Do not lift unit by mounting holes in feet.
  • Page 22 Dimensions and Weights - Packaged Units Table 9: Vibration Isolator Mounting Locations (Packaged Chillers) Unit Spring-Flex Mountings R-I-S Mountings Size ID-900 ID-900 ID-900 ID-900 RP-3 RP-3 RP-3 RP-3 WGZ030DW Green Green Green Green Gray Gray Gray Gray ID-900 ID-900 ID-900 ID-900 RP-3...

  • Page 23: Physical Data - Packaged Units

    Physical Data - Packaged Units Physical Data - Packaged Units Table 10: Physical Data - WGZ030D - WGZ040D Table 11: Physical Data - WGZ045D - WGZ055D www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 24 Physical Data - Packaged Units Table 12: Physical Data - WGZ060D - WGZ070D Table 13: Physical Data - WGZ080D - WGZ090D IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...
  • Page 25 Physical Data - Packaged Units Table 14: Physical Data - WGZ100D - WGZ130D Table 15: Physical Data - WGZ150D - WGZ200D www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...

  • Page 26: Electrical Notes

    Electrical Data Electrical Data Electrical Notes Panel Ratings Notes for “Electrical Data Single Point” Power: Table 16: Multi-point Power Standard Panel Ratings 1. If a separate 115V power supply is used for the control WGZ-D Model Size circuit, then the wire sizing amps is 10 amps for all unit Voltage WGZ 030-040 WGZ 045-200...
  • Page 27 Electrical Data Figure 18: Field Wiring Diagram (Packaged Units) NOTE: Points 904, 910, 908, and 909 are only provided if dual pump output option is selected. www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...

  • Page 28: Control Panel Layout

    Unit Configuration Control Panel Layout Figure 19: Typical Control Panel, 4-Compressor Unit NOTE: 1. Additional space provided in the upper right section for optional multiple point power connection and optional circuit breakers. NOTE: 2. Front door has a slot opening at the top for access to the MicroTech II controller for viewing display and making keypad entries without opening the panel door.

  • Page 29: Microtech Ii Controller

    Unit Configuration MicroTech II Controller Equipment Protection The unit is protected by alarms that shut it down and require Controller Software Version manual reset, and also by limit alarms that limit unit operation in response to some out-of-limit condition. Shut down alarms The version installed in a unit can be viewed by pressing the activate an alarm signal that can be wired to a remote device.

  • Page 30: Unit Controller

    Unit Controller Unit Controller Inputs/Outputs The unit controller is also used for TGZ Templifier (R-134a) in HEAT mode, see IOM 1319 on www.DaikinApplied.com for further information. Controller menu information related to HEAT mode or R-134a do no apply to WGZ-D packaged units. Table 21: Analog Inputs C1 = Refrigerant Circuit #1, C2 = Refrigerant Circuit #2, UT = Unit, *n = Refrig.
  • Page 31 Unit Controller Table 23: Digital Inputs The following parameters are digital inputs to this controller. C1 = Refrigerant Circuit #1, C2 = Refrigerant Circuit #2, UT = Unit, *n = Refrigerant Dependent Description Type Signal Signal Unit OFF Switch 0 VAC (Stop) 24 VAC (Auto) Pump Down Switch #1 0 VAC (Stop)
  • Page 32 Unit Controller Description Type Load Output OFF Output ON Liquid Line #1 Solenoid Cooling OFF Cooling ON Tower Fan #1-Water Cooled=Y Fan Contactor Fan OFF Fan ON Motor Control Relay #2 = Compr#2 Starter Compressor OFF Compressor ON Motor Control Relay #4 = Compr#4 Starter Compressor OFF Compressor ON...

  • Page 33: Setpoints

    The PW (password) column indicates the password level that must be active in order to change the set point. Passwords are: O = Operator, M = Manager Table 25: Set points (set points with * are set at Daikin Applied factory) www.DaikinApplied.com...
  • Page 34 Unit Controller NOTE: Temperature sensor SO 5 is Condenser Entering water sensor when Water Cooled = ON . IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...

  • Page 35: Events & Alarms

    Unit Controller Events & Alarms Automatic Adjusted Limits The following are set points that will be limited based on the Situations may arise that require some action from the chiller option selected. or that should be logged for future reference. Conditions that cause a shutdown and require manual reset is known as a stop Evaporator Leaving Water Temperature alarm.
  • Page 36 Unit Controller Reset: This alarm can be cleared at anytime manually via the Reset: This alarm can be cleared manually via the keypad. keypad or via the BAS clear alarm signal. Mechanical High Pressure/Motor Protect If active via trigger condition 1: Alarm description: MHP or Motor Prot N When the alarm occurs due to this trigger, it can auto reset Trigger: MHP/MP input is low and over 150 seconds lapsed...
  • Page 37 Unit Controller EXB Comm Failure on CP1 Trigger: Sensor shorted or open AND Expansion Valve Type = Electronic Alarm description: No EXB comm CP1 Action Taken: Rapid stop circuit Trigger: CP1 does not have communication with either EXB1 for 60 seconds after power up. This alarm will only occur if 10 Reset: This alarm can be cleared manually via the keypad, but Fan , evaporator pump #2, or condenser pump #2 operation only if the sensor is back in range.

  • Page 38: Controller Operation

    Unit Controller Condenser Freeze Event Reset: While still running, the event will be reset if evaporator pressure > (Low Evaporator Pressure - Hold set point + 8 psi Event description: Cond Freeze Circ N for R134a or 13 psi for R410A). The event is also reset if the Trigger: Cond Sat Refr Temperature <...
  • Page 39 Unit Controller If the Unit mode is Cool: mA reset analog input. When the Cool Leaving Water Temperature set point is more Parameters used: than half the Control Band above 39.0° F the Stage Up 1. Evaporator Leaving Water Temperature set point (Evap temperature is calculated as follows: LWT) Stage Up Temperature = Cool LWT + (Control Band/2)
  • Page 40 Unit Controller Pull Down Rate Pump Down Pressure The slope value calculated above will be a negative value as The pressure to which a circuit will pump down is based on the the water temperature is dropping. For use in some control Low Evaporator Pressure Unload set point.
  • Page 41 Unit Controller Low Ambient Lockout Control Mode Keypad Available Unit Mode Source Set Input Entry Request Modes Set This feature is only available on air cooled units Point Point (WaterCooled=Off).If the OAT drops below the low ambient COOL COOL lockout set point, then all running circuits will do a normal stop. Once the lockout has been triggered, no compressors will start COOL w/ COOL w/...
  • Page 42 Unit Controller Evaporator Water Flow Loss Evaporator Water Pump State Control (Evap State) The state-transition diagram shown below controls operation of The Evaporator Water Flow Loss logic allows the Unit to the evaporator pump. shutdown compressors on a loss of flow up to two times every twenty-four hours before locking the unit out on a Evaporator Figure 22: Evaporator Pump State Diagram Flow Loss Alarm.
  • Page 43 Unit Controller Figure 23: Condenser Pump State Diagram Water Flow Loss is indicated the Unit Status changes to Auto: Wait for flow. The condenser water pump state changes to Start and no alarms are indicated. • If a Condenser Water Flow Loss occurs while a compressor is running all of the running compressors will be shutdown.
  • Page 44 Unit Controller The ECWT is < Stage #X ON (Temp) set point – Stage following equation. Differential (Temp) set point Increment = [(Error) * (Error Gain set point)] + [(Slope) * (Slope Bypass valve position is < the Stage Down @ set point (only if Gain set point)] Valve/VFD Control set point = Valve Stage) Where: Error = ECWT –...
  • Page 45 Unit Controller If Unit mode = Heat AND unavailable for any reason, the other circuit shall be allowed no compressors are running AND to stage the second compressor on. When staging down, one LWT error > Start delta + 0.5 * Control Band AND compressor on each circuit shall be left on until each circuit has Motor Protect Timer expired AND only one compressor running.
  • Page 46 Unit Controller Initial Offset & Step Increase stopped after a time delay has 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 calculated freeze time and, ten seconds later, if the pressure has not risen above the unload set point an additional compressor will be stopped.
  • Page 47 Unit Controller Network Limit The maximum unit capacity can be limited by a network signal. This function is only enabled if the unit control source is set to network. The maximum unit capacity stage is based on the network limit value received from the BAS, and is determined as shown in the following graph.
  • Page 48 Unit Controller Manual Compressor Control EXV Control The operator can manually enable and disable individual The EXV control logic is active regardless of the expansion compressors. When a compressor has been disabled it is valve type setting. While a circuit is in the run state, the EXV considered unavailable to start in the staging logic.

  • Page 49: Using The Controller

    Unit Controller ENTER Key to work through the matrix hierarchy. From any menu screen, pressing the MENU key will take you to the top level of the Pressing the ENTER key changes the function of the ARROW hierarchy. The display will show ALARM, VIEW, and SET as keys to the editing function as shown below: shown in Figure 8.
  • Page 50 Unit Controller Either password must be entered before a protected setting blinking cursor under it. The arrow keys shall then operate as can be changed. Once the correct password has been entered, defined below. the previously selected screen will reappear. Once a password CANCEL (Right) Reset the current field to the value it had has been entered, it will remain valid for 15 minutes after the when editing began.
  • Page 51 Unit Controller This menu gives the status of digital inputs (D.I.), 1=ON, 0=OFF. Numbers are 1 through 18. See Table 5 on page 19 for number reference. Water Cooled = Y Only VIEW TOWER (2) Bypass Valve = XXX% VFD Speed = XXX% The Bypass Valve value shall be “None”...
  • Page 52 Unit Controller Unit Mode settings can be COOL, COOL w/Glycol, or ICE w/ # of Compressors = 6 Glycol, as determined from the Unit Mode set point. SET COMP SPs (3) Source settings can be KEYPAD, SWITCHES, or NETWORK Comp 1 = Enable as determined from the Mode Source set point.
  • Page 53 Unit Controller conditions are met: Water-cooled On The stage up timer completes SET TOWER SPs (3) The ECWT is > Stage #1 ON set point StageDiff = XX.X°F Bypass valve position is > the Stage Up @ set point (only if Valve/VFD Control set point = Valve Stage) Additional stages Stage Up Tmr=XX min can turn on (up to the number specified by the Tower Stages...
  • Page 54 Unit Controller set point is set to Valve Stage. In this mode the valve output Water-cooled = Y is controlled as for Valve Set point mode (above), except that SET TOWER SPs (5) the active set point for the controlled parameter is selected according to the following table.

  • Page 55: Bas Interface

    Unit Controller Screen Definitions – ALARM unit capacity The last action to take place is the shutoff of all compressors ALARM ACTIVE (X) running when the LowEvPrStop setting is reached (default is Time Date 58 psi). Reducing these time intervals will increase detrimental compressor cycling.

  • Page 56: Unit Controller Operation

    Unit Controller Operation Unit Controller Operation Modbus® the protocol selected. With the protocol set to Modbus, the baud rate and ident set Parameter Modbus BACnet LONworks points are accessible. Type Units Units Units Temperature °F X 10 °F X 10 °C X 100 Parameter Details Pressure...
  • Page 57 Unit Controller Operation www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 58 Unit Controller Operation Network Defaults Chiller Mode - Applies to Integer 17 and Integer 19. Network Chiller Mode Set Point and Active Chiller Mode use the same The network set point default values are used only for the numbering scheme to represent ice mode or cool mode. LONworks protocol.
  • Page 59 Unit Controller Operation Alert/Lockout Codes (Red LED Flash Code) Code 1 – Motor High Temperature: The module will flash the red Alert LED one time indicating the motor PTC circuit has exceeded 4.5K Ohms. A code 1 Alert will open the M2-M1 contacts.
  • Page 60 Unit Controller Operation Hot Gas Bypass (Optional) Code 8 – Reserved For Future Use Code 9 – Module Low Voltage This option allows passage of discharge gas to the evaporator, permitting operation at lower loads than available with The module will fl ash the red Alert LED nine times indicating compressor unloading.

  • Page 61: Startup And Shutdown Procedures

    Dyes used for refrigerant leak detection are not tested or recommended for 1. Open the compressor discharge shutoff valves until use in Daikin chillers. Use of these products may damage and/or degrade backseated. Always replace valve seal caps. the performance of the equipment and will void the manufacturer warranty.
  • Page 62 Startup and Shutdown Procedures Start-up after Extended Shutdown returned to the Daikin Applied service through your sales representative. 1. Inspect all equipment to see that it is in satisfactory operating condition. Weekend or Temporary Shutdown 2. Remove all debris that has collected on the surface of Move pumpdown switches PS1 and PS2 to the “manual...
  • Page 63 NOTE: DO NOT alter or relocate factory installed flow pressure switches but care must be taken regarding wiring. switches. If issues exist, contact Chiller Technical The thermal dispersion flow switch supplied by Daikin Applied, Response at TechResponse@DaikinApplied.com. shown in Figure 27, comes as a 2 part unit consisting of a flow switch and an adapter labeled E40242 by the supplier.
  • Page 64 Startup and Shutdown Procedures Step 2: Once steady state minimum desired operating flow is obtained, perform the ‘Teach’ function on the flow switch. The ‘Teach’ function is initiated by holding down the minus ‘-’ button on the face of the flow switch for 15 seconds. During this 15 second period, LEDs ‘0’...
  • Page 65 Startup and Shutdown Procedures In Step 3, the ‘Teach’ function re-adjusted the flow switch set Figure 33: Display for Flow Below Range point (SP) while flow was at the minimum desired operating flow. The chiller will not operate at this flow because the flow switch is OPEN after performing the ‘Teach’...

  • Page 66: Sequence Of Operation

    Sequence of Operation Sequence of Operation The following sequence of operation is typical for WGZ water compressors will eventually stage on after the Stage Up Timer chiller models. The sequence can vary slightly depending upon times out between each stage. options.
  • Page 67 Sequence of Operation Manual Pump Down Figure 36: Staging in Cool and Glycol Mode When the Pump Down Switch is in the pump down position, Description Occurs When: Action Taken all compressors except #1 and #2 will shut off. Then the Liquid Stage #1 ON Lvg Evap T >...

  • Page 68: Unit Maintenance

    • Clean the tip using a soft cloth. Stubborn buildup - such to the atmosphere to prevent this problem. For more details as lime - can be removed using a common vinegar on acceptable oil types, contact your Daikin Applied service cleaning agent. representative.
  • Page 69 Unit Maintenance Sight Glass and Moisture Indicator of the rated three-phase line-to-line voltage. 2. If these voltages are extremely low or widely unbalanced, The refrigerant sight glasses should be observed periodically. check the power system to determine the cause of the A monthly observation should be adequate.
  • Page 70 Unit Maintenance Turn the screw clockwise (when viewed from the adjustment DANGER screw end) to increase the superheat and counterclockwise to LOCKOUT/TAGOUT all power sources prior to servicing the unit. reduce superheat. Allow time for system rebalance after each Disconnect all power before performing any service inside the unit or superheat adjustment.
  • Page 71 Unit Maintenance www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...

  • Page 72: Troubleshooting Chart

    Troubleshooting Chart Troubleshooting Chart IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...

  • Page 73: Warranty Registration Form (Scroll)

    Warranty Registration Form (Scroll) Warranty Registration Form (Scroll) www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 74 Troubleshooting Chart IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...
  • Page 75 Troubleshooting Chart www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 76 Troubleshooting Chart IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...
  • Page 77 Troubleshooting Chart www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 78 Troubleshooting Chart IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR www.DaikinApplied.com...

  • Page 79: Limited Product Warranty

    Limited Product Warranty Limited Product Warranty www.DaikinApplied.com IOM 1322-1 • WATER-COOLED SCROLL COMPRESSOR...
  • Page 80 Daikin Applied Training and Development Now that you have made an investment in modern, efficient Daikin equipment, its care should be a high priority. For training information on all Daikin 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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