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Summary of Contents for Daikin DWSC079
- Page 1 Date January 2020 Supersedes D-EIMC00808-16_08EN Installation, Operation and Maintenance Manual D-EIMWC00808-16_09EN Original Instructions Single/Dual Compressor Centrifugal Chillers – Vintage B DWSC/DWDC 079, 087, 100, 113, 126, Cooling Only...
- Page 2 Technicians performing this work must be properly trained on Daikin WSC, WDC, DWSC, DWDC Centrifugal equipment. Important Note: In case of any procedure requires accessing the refrigerant circuit of these units, remember that refrigerant is under pressure and oils are contained in these circuits.
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Page 3: Warnings For The Operator
• Commissioning of the unit (first start up) must be performed by Daikin representative • It is absolutely forbidden to remove all the protections of the moving parts of the unit •... - Page 4 The operator must strictly follow all instruction and limitation given for the unit. The operator is not authorized to perform maintenance. Maintenance has to be performed only by trained technicians, please contact DAIKIN representative. The operator must apply all the safety standard regarding personal protective equipment and working tools.
- Page 5 Description of the labels applied to the electrical panel Compressor Starter Panel 1 – Manufacturer’s logo 3 – Cable tightening warning 2 – Hazardous Voltage warning 4 – Electrical hazard symbol Unit Control Panel 1 – Non flammable gas symbol 5 –...
- Page 6 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 D–EIMWC00808-16HU - 7/64...
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Page 7: Table Of Contents
Warranty Statement ........................64 Important information regarding the refrigerant used .............. 65 Information and illustrations cover the Daikin products at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. - Page 8 D–EIMWC00808-16HU - 9/64...
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Page 9: Introduction
MicroTech II unit controller. All Daikin centrifugal chillers are factory tested prior to shipment and must be initially started at the job site by a factory trained Daikin service technician. Failure to follow this startup procedure can affect the equipment warranty. -
Page 10: Installation
Receiving and Handling The unit should be inspected immediately after receipt for possible damage. All Daikin centrifugal water chillers are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee. Insulation corners from the evaporator's rigging hole locations are shipped loose and should be glued in place after the unit is finally placed. -
Page 11: Location And Mounting
Figure 2, DWDC Major Component Location Note: 1. Chilled water and condenser connection location can vary. Check markings on unit or consult unit certified drawings for connection locations on specific units. Location and Mounting The unit must be mounted on a level concrete or steel base and must be located to provide service clearance at one end of the unit for possible removal of evaporator tubes and/or condenser tubes. -
Page 12: Safety
Note: Units are shipped with refrigerant and oil valves closed to isolate these fluids for shipment. Valves must remain closed until start-up by the Daikin technician. Nameplates There are several identification nameplates on the chiller: •... -
Page 13: System Water Volume
Lower temperatures will improve chiller performance. Daikin centrifugal chillers all across the range are equipped with electronic expansion valves (EXV) and will start and run with entering condenser water temperatures as low as shown in Figure 3 or as calculated from the following equation on which the curves are based. - Page 14 Figure 3, Minimum Entering Condenser Water Temperature (EXV) Minimum Entering Condenser Water Temperature - 10 F Range 65,0 LChWT LChWT 60,0 55,0 50,0 45,0 40,0 35,0 30,0 Percent Load Min. ECWT = 5.25 + 0.88*(LWT) - DT (PLD/100) + 22*(PLD/100) •...
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Page 15: Water Piping
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 1750/1460 rpm (four-pole) pump motors. Vessel Drains at Start-up Unit vessels are drained of water in the factory and are shipped with the drain plugs in the heads removed and stored in the control panel or with open ball valves in the drain hole. - Page 16 They also serve to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze- up or excessive discharge pressure. Thermal dispersion flow switches are available from Daikin as a factory-mounted option. It is mounted in an evaporator and condenser water nozzle and factory wired.
- Page 17 Figure 6, Flow Switch Mounting Flow direction marked on switch I in. (25mm) NPT flow switch connection If flow switches, by themselves, are being used, electrical connections in the Unit Control Panel must be made from the common T3-S terminal to terminal CF for the condenser switch and T3-S to terminal EF for the evaporator switch. See Figure 14, Field Wiring Diagram on page 34.
- Page 18 Cooling Towers The condenser water flow rate must be checked to be sure that it conforms to the system design. Some form of temperature control is also required if an uncontrolled tower can supply water below about 65F (18C). If tower fan control is not adequate, a tower bypass valve is recommended.
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Page 19: Field Insulation Guide
Field Insulation Guide Figure 7, Insulation Requirements, Cooling-only Units D–EIMWC00808-16HU - 20/64... - Page 20 D–EIMWC00808-16HU - 21/64...
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Page 21: Physical Data And Weights
The evaporator charge includes the maximum condenser charge available with that evaporator and is therefore the maximum charge for a total unit with the evaporator. Actual charge for a specific selection can vary with tube count and can be obtained from the Daikin Selection Program. The program will not allow a selection where the unit charge exceeds the condenser pumpdown capacity. -
Page 22: Oil Coolers
150 psi (1034 kPa) on all. Pumpdown To facilitate compressor service, all Daikin centrifugal chillers are designed to permit pumpdown and isolation of the entire refrigerant charge in the unit’s condenser. Dual compressor units and single compressor units equipped with the optional suction shutoff valve can also be pumped down into the evaporator. - Page 23 Field water piping to the inlet and outlet connections must be installed according to good piping practices and include stop valves to isolate the cooler for servicing. A cleanable filter (40 mesh maximum), and drain valve or plug must also be field-installed.
- Page 24 Compressors using chilled water for oil cooling will often start with warm "chilled water" in the system until the chilled water loop temperature is pulled down. Data given above includes that condition. As can be seen, with cooling water in the 45F to 65F (7C to 18C) range, considerably less water will be used, and the pressure drop will be greatly reduced.
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Page 25: Oil Heater
Figure 10, Oil Cooler Connections, DWSC Units Compressor Reservoir Controller & Lub Control Box Solenoid Valve Inlet Connection (Inside) Temperature Control Valve Outlet Connection (Outside) Figure 11, Oil Cooler Connections, DWDC 100/126, 16 Foot Shells Solenoid Valves Note: All other DWDC units Temperature have oil cooler Control Valves... -
Page 26: Relief Valves
Relief Valves As a safety precaution and to meet code requirements, each chiller is equipped with pressure relief valves located on the condenser, evaporator, and oil sump vessel for the purpose of relieving excessive refrigerant pressure (caused by equipment malfunction, fire, etc.) to the atmosphere. -
Page 27: Electrical
Daikin centrifugal units have relief valve settings of 180 psi, 200 psi, and 225 psi, and resultant valve discharge capacities of 68.5 # air/min, 75.5 # air/min, and 84.4 # air/min respectively. Using the ASHRAE formula and basing calculations on the 225 psi design yields a conservative pipe size, which is summarized in Table 9. - Page 28 It is the installing contractor's responsibility to insulate the compressor motor terminals when the unit voltage is 600 volts or greater. This is to be done after the Daikin start-up technician has checked for proper phase sequence and motor rotation.
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Page 29: Remote Starter Display Wiring
Figure 13, Field Wiring for Optional Display Control Power Wiring The control circuit on the Daikin centrifugal packaged chiller is designed for 115-volts. Control power can be supplied from three different sources: If the unit is supplied with a factory-mounted starter or VFD, the control circuit power supply is factory-wired from a transformer located in the starter or VFD. - Page 30 A freestanding starter or VFD furnished by Daikin, or by the customer to Daikin specifications, will have a control transformer in it and requires field wiring to terminals in the compressor terminal box. Power can be supplied from a separate circuit and fused at 20 amps inductive load. The control circuit disconnect switch must be tagged to prevent current interruption.
- Page 31 If starters are freestanding, then field wiring between the starter and 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.
- Page 32 BACnet IM 736-0 The “Full Metering” or “Amps Only Metering” option will require some field wiring when free-standing starters are used. Wiring will depend on chiller and starter type. Consult the local Daikin sales office for information on specific selections.
- Page 33 Figure 14, Field Wiring Diagram MICROTECH CONTROL BOX TERMINALS (115V) (24V) POWER * NOTE 7 NEUTRAL * NOTE 10 * COOLING TOWER FOURTH STAGE STARTER * NOTE 10 * COOLING TOWER THIRD STAGE STARTER * NOTE 10 * COOLING TOWER SECONDH STAGE STARTER...
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Page 34: Multiple Chiller Setup
All that is required is simple field RS485 interconnecting wiring, the addition of accessory communication isolation board(s) 485OPDR (Daikin P/N 330276202), and some MicroTech II control settings. The 485OPDR isolation board can be purchased with the unit or separately, during or after chiller installation. The number of chillers minus one boards are required. - Page 35 Figure 15, Communication Wiring PIGTAIL Chiller A J10 J11 OPDR UNIT CONTROL BLU/WHT WHT/BLU SHIELD Chiller B PORT OPDR J11 PORT UNIT CONTROL BLU/WHT WHT/BLU SHIELD Chiller C (+) (-) J11 Port UNIT CONTROL NOTE: A fourth chiller, Chiller D would be connected to chiller C same as chiller C to chiller B. Table 11, Address DIP Switch Settings for Controllers Using pLAN.
- Page 36 MicroTech II Operator Interface Touch Screen (OITS) Settings Settings for any type of linked multiple compressor operation must be made to the MicroTech II controller. Settings on a dual compressor unit are made in the factory prior to shipment, but must be verified in the field before startup. Settings for multiple chiller installations are set in the field on the Operator Interface Touch Screen as follows: Maximum Compressors ON –...
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Page 37: Prestart System Checklist
Minimum system load of 80% of machine capacity available for testing and adjusting controls ....................... (*) Includes heating hot water on heat recovery units. Note: This checklist must be completed and sent to the local Daikin service location two weeks prior to start-up. D–EIMWC00808-16HU - 38/64... -
Page 38: Operation
During the initial startup of the chiller the Daikin technician will be available to answer any questions and instruct in the proper operating procedures. - Page 39 Figure 17, Unit Control Panel Figure 18, Compressor Control Panel D–EIMWC00808-16HU - 40/64...
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Page 40: Capacity Control System
Capacity Control System The opening or closing of the inlet vanes controls the quantity of refrigerant entering the impeller thereby controlling the compressor capacity. The vane movement occurs in response to oil flow from the SA or SB 4-way solenoid valves, which in turn, respond to instructions from the unit microprocessor as it senses leaving chilled water temperature. - Page 41 Figure 20, Oil Sump and Compressor Controller Panel Back Seat Port Oil Pump Contactor Relief Valve Oil Pump Capacitor Oil Sump Compressor MicroTech II Solenoid controller Valve Cooling Water Inlet Temperature Control Valve Cooling Water Outlet NOTE: 4-way solenoid valve and vane close switches are located on the compressor suction inlet.
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Page 42: Surge And Stall
Figure 22, Vane Control Solenoid Operation, Continued LEGEND OPENING Oil Under Pressure Oil Sump Pressure To Oil Pump Sump #3 Outlet Drain From Piston Section “SB” Energized Section “SA” De-energized #1 Intlet From Oil Pump Discharge CLOSING Piston Drain To Oil Pump Sump #3 Outlet Section “SB”... -
Page 43: Hot Gas Bypass
070200106, Rev OB NOTES: 1. Approved oil from two suppliers can be mixed, although they have slightly different viscosity. 2. Lubricant from either supplier can be furnished when ordering by Daikin part number. Figure 23, Typical Oil Flow Diagram NOTES: Diagram does not apply to CE 050 compressors, which have self-contained lubrication systems. -
Page 44: Condenser Water Temperature
When the ambient wet bulb temperature is lower than design, the entering condenser water temperature can be allowed to fall, improving chiller performance. Daikin chillers will start with entering condenser water temperature as low as 55F (42.8C) providing the chilled water temperature is below the condenser water temperature. -
Page 45: Maintenance
Maintenance Pressure/Temperature Chart HFC-R134a Temperature Pressure Chart °F PSIG °F PSIG °F PSIG °F PSIG 41.1 97.0 187.3 10.8 43.2 100.6 192.9 12.0 45.4 104.3 198.7 13.2 47.7 108.1 204.5 14.4 50.0 112.0 210.5 15.7 52.4 115.9 216.6 17.1 54.9 120.0 222.8 18.4... -
Page 46: Routine Maintenance
The local Daikin service office can recommend suitable facilities for performing these tests. Table 14 gives the upper limits for metals and moisture in the polyolester lubricants required by Daikin chillers. D–EIMWC00808-16HU - 47/64... - Page 47 Changing Oil Filters Daikin chillers are at positive pressure at all times and do not leak contaminated moist air into the refrigerant circuit, thereby eliminating the need for annual oil changes. An annual laboratory oil check is recommended to check overall compressor condition.
- Page 48 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. D–EIMWC00808-16HU - 49/64...
- Page 49 Figure 25. Typical Refrigerant Flow Diagram Connections are not necessarily in correct relative location. D–EIMWC00808-16HU - 50/64...
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Page 50: Annual Shutdown
If the operator has any reason to suspect that the power system connections have been altered, (phases reversed) the compressor must be jogged to check rotation. For assistance, call the local Daikin service location. Cleaning and Preserving A common cause of service calls and equipment malfunction is dirt. -
Page 51: Annual Startup
The use of untreated water can result in corrosion, erosion, sliming, scaling or algae formation. It is recommended that the service of a reliable water treatment company be used. Daikin assumes no responsibility for the results of untreated or improperly treated water. - Page 52 approximately 20 psig. It is possible that the unit might experience a mild surge condition prior to cutout. If this should occur, immediately shut off the compressor. Use a portable condensing unit to complete the pump down, condense the refrigerant, and pump it into the condenser or pumpout vessel using approved procedures. A pressure regulating valve must always be used on the drum being used to build the system pressure.
- Page 53 Any work on compressor has to be carried out only by trained technicians, please refer to DAIKIN representative. Once recovered the refrigerant from the compressor, service gauges must to be used to check if residual pressure is still present inside the three section of compressor: Suction/Discharge –...
- Page 54 Motor Housing Pressure Port Flanged joints disassembly When accessing any flanged connection never loosen and remove individual 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 pressure should be present, STOP, retighten the bolts and determine why pressure is present.
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Page 55: Oil Analysis
Table 1 indicates these parameters. In general Daikin does not recommend changing lubricating oils and filters on a periodic basis. The need to change lubricating oil and filters should be based on a careful consideration of oil analysis, vibration analysis and knowledge of the operating history of the equipment. - Page 56 Lead The source of lead in Daikin centrifugal chillers is the thread sealant compounds used during chiller assembly. The presence of lead in the lubricating oil in Daikin chillers does not indicate bearing wear. Silicon Silicon can originate from residual particles of silicon left from the manufacturing process, filter drier material, dirt or anti-foam additives from residual mineral oil which may be present in machines that have been converted to R-134a.
- Page 57 Table 15, Upper Limit For Wear Metals And Moisture In Polyolester Oils In Daikin Centrifugal Chillers Elements Upper Limit (ppm) Action Aluminum Copper Iron Moisture 2 &3 Silica Total Acid Number (TAN) Key To Action Re-sample after 500 hours of unit operation. If content increases less than 10%, change oil and filter and re- sample at normal interval.
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Page 58: Maintenance Schedule
Maintenance Schedule Maintenance Check List Item I. Unit · Operational Log · Analyze Operational Log · Refrigerant Leak Test Chiller · Test Relief Valves or Replace II. Compressor · Vibration Test Compressor A. Motor · Meg. Windings (Note 1) · Ampere Balance (within 10% at RLA) ·... - Page 59 Daikin's high efficiency heat exchangers have very low design approach temperatures, in the order of one to one and one half degrees F.
- Page 60 D–EIMWC00808-16HU - 61/64...
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Page 61: Service Programs
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, its worldwide service organization, and can tailor these services to suit the needs of the building owner. Most popular among these services is the Daikin Comprehensive Maintenance Contract. -
Page 62: Operator Schools
Staunton, Virginia. The school duration is three and one-half days and includes instruction on basic refrigeration, MicroTech controllers, enhancing chiller efficiency and reliability, MicroTech troubleshooting, system components, and other related subjects. Further information can be found on www.daikineurope.com or call Daikin at 540-248- 0711 and ask for the Training Department. -
Page 63: Warranty Statement
Warranty Statement Limited Warranty Consult your local Daikin Representative for warranty details. Refer to Form 933-43285Y. To find your local Daikin Representative, go to www.daikineurope.com. The following are trademarks or registered trademarks of their respective companies: Loctite from Henkel Company;... -
Page 64: Important Information Regarding The Refrigerant Used
Important information regarding the refrigerant used This product contains fluorinated greenhouse gases. Do not 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 for refrigerant leaks may be required depending on European or local legislation. - Page 65 Factory and Field charged units instructions (Important information regarding the refrigerant used) The refrigerant system will be charged with fluorinated greenhouse gases. Do not vent gases into the atmosphere. 1 Fill in with indelible ink the refrigerant charge label supplied with the product as following instructions: the refrigerant charge for each circuit (1;...
- Page 66 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.
- Page 67 The present publication is drawn up by of information only and does not constitute an offer binding upon Daikin Applied Europe S.p.A.. Daikin Applied Europe S.p.A. has compiled the content of this publication to the best of its knowledge. No express or implied warranty is given for the completeness, accuracy, reliability or fitness for particular purpose of its content, and the products and services presented therein.
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