Water-Cooled Screw Compressor Chillers

Installation and Maintenance Manual

IMM 1157 Group: Chiller Part Number: 331373601 Effective: March 2012 Supercedes: November, 2011

Water-Cooled Screw Compressor Chillers WGS 130AW to WGS 190AW, Packaged Water-Cooled Chiller WGS 130AA to WGS 190AA, Chiller with Remote Condenser 120 to 200 Tons, 420 to 700 kW R-134A, 60 Hz

Table of Contents Introduction . ......................................3

Electrical Data................................. 30

General Description..................................... 3 Nomenclature. .............................................. 3 Inspection . ................................................... 3

Wiring Diagrams. .......................................38 Control Panel Layout................................. 46

Installation . ........................................4 Vibration Isolators ....................................... 6

Sequence of Operation.................... 49 Start-Up and Shutdown. ................ 50

Flow Switch. .............................................. 12 Glycol Solutions ........................................ 13 Condenser Water Piping ............................ 14 Water Pressure Drop.................................. 15

Pre Start-up . ............................................... 50 Start-up .......................................................50 Weekend or Temporary Shutdown............. 51 Start-up after Temporary Shutdown........... 51 Extended Shutdown . ..................................51 Start-up after Extended Shutdown. ............51

Refrigerant Piping. ..........................18

System Maintenance ....................... 52

Unit with Remote Condenser..................... 18 Factory-Mounted Condenser ..................... 21

General. ...................................................... 52 Electrical Terminals ................................... 53 POE Lubrication ........................................ 53 Sight Glass and Moisture Indicator . ..........54 Sump Heaters. ............................................54

Water Piping . ...................................10

Dimensional Data . ...........................22 Physical Data. ...................................25 WGS-AW, Water-Cooled........................... 25 WGS-AA Remote Condenser.................... 26

Unit Configuration . .........................27 Components . .............................................. 27

Wiring. ..............................................28

Maintenance Schedule .................... 55 System Service................................. 56 Troubleshooting Chart . ..............................58

Warranty Statement ....................... 59

BAS Interface ............................................ 29 Remote Operator Interface Panel............... 29

Unit controllers are LONMARK certified with an optional LONWORKS communications module.

Manufactured in an ISO Certified Facility

© 2013 Daikin Applied . Illustrations and data cover the Daikin product at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. Units with remote condensers (Models AA) are not included in the scope of AHRI certification. Unit controllers are LONMARK certified with an optional LONWORKS communications module.  The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; LONMARK , LonTalk and LONWORKS and the LONMARK logo are managed, granted, and used by LONMARK International under a license granted by Echelon Corporation; Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choices™, and SpeedTrol from Daikin .

2

WGS 130A to WGS 190A

IMM 1157

Introduction General Description

Daikin Type WGS water chillers are designed for indoor installations and are available with factorymounted water-cooled condensers (Model WGS AW), or arranged for use with remote air-cooled or evaporative condensers (Model WGS AA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing. They consist of two semi-hermetic rotary screw compressors, a two-circuit shell-and-tube evaporator, two shell-and-tube water-cooled condensers (WGS-AW), and complete refrigerant piping. Units manufactured for use with remote condensers (Models WGS-AA) have all refrigerant specialties factory-mounted and connection points for refrigerant discharge and liquid lines. Liquid line components are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and electronic expansion valves. The electrical control center includes a MicroTech II microprocessor control system and equipment protection and operating controls necessary for dependable, automatic operation. The compressor circuits are equipped with individual compressor isolation circuit breakers on single point power connection options. A unit disconnect switch is available as an option over the standard power block.

Nomenclature W G S 130 A W Water-Cooled Condensing W = Water-Cooled Condenser A = Unit Less Condenser Global Design Vintage

Rotary Screw Compressor Nominal Capacity (Tons)

Inspection When the equipment is received, carefully check all items against the bill of lading to be sure of a complete shipment. Carefully inspect all units for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. Check the unit serial plate before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of Daikin Note: Unit shipping and operating weights are given in the physical data tables beginning on page 25.

IMM 1157

WGS 130A to 190A

3

Installation WARNING 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. Avoid contact with sharp edges. Personal injury can result.

Start-up by Daikin Factory Service is included on all units sold for installation within the USA and Canada and must be performed by them to initiate the standard limited product warranty. Two-week prior notification of start-up is required. The contractor should obtain a copy of the Start-up Scheduled Request Form from the sales representative or from the nearest office of Daikin Service.

Handling

Every model WGS-AW water chiller with water-cooled condensers is shipped with a full refrigerant charge. For shipment, the charge is contained in the condensers and is isolated by the condenser liquid shutoff valves and the compressor discharge valves. A nitrogen/helium holding charge is applied to remote condenser models to maintain a slight positive system pressure. After installation, the unit must be leak-tested, vacuumed, and charged with the operating charge of refrigerant. The operating charge is field-supplied and charged on remote condenser models. WARNING Escaping refrigerant can displace air and cause suffocation. Immediately evacuate and ventilate the equipment area. If the unit is damaged, follow Environmental Protection Agency (EPA) requirements. Do not expose sparks, arcing equipment, open flame or other ignition source to the refrigerant.

Moving the Unit If optional factory-installed skids are not used, some means such as dollies or skids must be used to protect the unit from damage and to permit easy handling and moving. Figure 1, Lifting the Unit Water-Cooled Chiller

Remote Condenser Chiller 48.0 (1219.2)

48.0 (1219.2)

108.0 (2743.2)

84.0 (2133.6)

62.0 (1574.8) 62.0 (1574.8)

WGS 130-190 PACKAGE

WGS LESS CONDENSER LIFT ONLY WITH HOLES PROVIDED IN BASE

Notes: 1. You must use lifting halo or "I" spreader equal to the dimensions shown. 2. Each lifting cable alone must be strong enough to lift chiller. 3. Perform all moving and handling with skids or dollies under the unit when possible, and do not remove them until the unit is in the final location. (continued next page) 4

WGS 130A to 190A

IMM1157

4. 5.

In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit. Do not drop the unit at the end of the roll. Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers.

Table 1, Lifting Loads WGS Model 130A 140A 160A 170A 190A

AW, Package Units, lbs. (kg)

AA, Less Condenser Units, lbs (kg)

Shipping Weight

RF

RB

LF

LB

2276 (1032) 2276 (1032) 2368 (1074) 2471 (1096) 2471 (1096)

1699 (770) 1699 (770) 1794 (813) 1813 (822) 1813 (822)

2213 (1003) 2213 (1003) 2300 (1042) 2350 (1065) 2350 (1065)

1651 (749) 1651 (749) 1742 (790) 1763 (799) 1763 (799)

7840 (3556) 7840 (3556) 8206 (3722) 8345 (3785) 8345 (3785)

RF

RB

LF

LB

1428 (647) 1428 (647) 1515 (687) 1515 (687) 1515 (687)

1444 (655) 1444 (655) 1543 (700) 1543 (700) 1543 (700)

1386 (629) 1386 (629) 1470 (667) 1470 (667) 1470 (667)

1402 (636) 1402 (636) 1496 (679) 1496 (679) 1496 (679)

Shipping Weight 5659 (2567) 5659 (2567) 6024 (2732) 6024 (2732) 6024 (2732)

NOTES: 1. RF=right front, RB=right back, LB=left back, LF=left front, when view from the control panel. See Figure 2 on page 6. 2. The optional sound enclosure adds 650 lbs (295 kg) to the lifting weight, evenly distributed.

Location WGS chillers are designed for indoor application and must be located in an area where the surrounding ambient temperature is 40°F to 122°F (4.4°C to 50°C). Because of the NEMA 1 electrical control enclosures, do not expose the units to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the water chiller. If necessary, provide additional structural members to transfer the weight of the unit to the nearest beams. Note: Unit shipping and corner weights are given in Table 1. Operating weights are in the physical data tables beginning on page 25.

Space Requirements for Connections and Servicing The chilled water piping enters and leaves the unit from the right side when looking at the front of the unit (control panel end). Left-hand connections are available as an option. Condenser water connections are located at the rear of the unit, opposite the control panel. Provide clearance of at least 4 feet (1625 mm), or more if codes require in front of the panel. Three feet (1219 mm) clearance should be provided on all other sides and ends of the unit for general servicing. The National Electric Code (NEC) may require additional clearance in front of the control panel and should be consulted. On units equipped with a water-cooled condenser (Type WGS-AW), also provide clearance for cleaning or removal of condenser tubes on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (10 feet, 3050 mm). Tube replacement requires the tube length of condenser plus one to two feet of workspace. This space can often be provided through a doorway or other aperture.

Placing the Unit The small amount of vibration normally encountered with the water chiller makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure.

IMM 1157

WGS 130A to 190A

5

Vibration Isolators It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration. Figure 2, Isolator Locations 3 LF

LB

Control Panel End

1

Transfer the unit as indicated under “Moving the Unit.” on page 4. In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports.

4 Condenser Connections

RF

FRB 2

The unit should be set initially on shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims, which are then removed. Use a rubber anti-skid pad under isolators if hold-down bolts are not used. Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining the piping and transmitting vibration and noise. NOTE: All spring isolators have four, same color springs per housing. Table 2, Weights & Vibration Isolators, Packaged Unit, w/o Sound Enclosure ARRANGEMENT WGS-AW, WITH WATER-COOLED CONDENSERS, WITHOUT SOUND ENCLOSURE CORNER WEIGHT LBS OPR. UNIT (KG) WT. SIZE Lbs. (kg) 1 2 3 4

SPRING-FLEX MOUNTINGS 1

2

3

RUBBER-IN-SHEAR MOUNTINGS 4

1

2

3

4

RP-4

RP-4

RP-4

130AW

8557 (3881)

1778 2556 1732 2491 1D-2040 1D-3600 1D-2040 (806) (1159) (786) (1130) Black Green Black

1D-3600 Green Brick Red Lime Brick Red

RP-4

140AW

8557 (3881)

1778 2556 1732 2491 1D-2040 1D-3600 1D-2040 (806) (1159) (786) (1130) Black Green Black

RP-4 RP-4 RP-4 1D-3600 Green Brick Red Lime Brick Red

RP-4 Lime

160AW

9314 (4225)

1910 2805 1863 2736 1D-2700 1D-3600 1D-2700 (866) (1272) (845) (1241) Purple Green Purple

RP-4

170AW

9505 (4311)

1959 2852 1911 2783 1D-2700 1D-3600 1D-2700 (889) (1294) (867) (1262) Purple Green Purple

190AW

9505 (4309)

1959 2852 1911 2783 1D-2700 1D-3600 1D-2700 (889) (1294) (867) (1262) Purple Green Purple

RP-4 1D-3600 Green Brick Red RP-4 1D-3600 Green Brick Red RP-4 1D-3600 Green Brick Red

RP-4

RP-4

Lime Brick Red RP-4 RP-4 Lime Brick Red RP-4 RP-4 Lime Brick Red

Lime

Lime RP-4 Lime RP-4 Lime

NOTE: ID 2040, ID 2700 and ID 3600 have four same color springs per housing.

6

WGS 130A to 190A

IMM1157

Table 3, Weights & Vibration Isolators, Packaged Unit, w/ Sound Enclosure ARRANGEMENT WGS-AW, WITH WATER-COOLED CONDENSERS, WITH SOUND ENCLOSURE UNIT SIZE

130AW

140AW

160AW 170AW 190AW

OPR. WT. Lbs. (kg)

CORNER WEIGHT LBS (KG) 1 2 3 4

SPRING-FLEX MOUNTINGS 1

2

3

RUBBER-IN-SHEAR MOUNTINGS 4

1

2

3

4

RP-4

RP-4

RP-4

RP-4

9205

1928

2730

1882 2665 1D-2700 1D-3600 1D-2700 1D-3600

4179

875

1239

854

9205

1928

2730

1882 2665 1D-2700 1D-3600 1D-2700 1D-3600

4179

875

1239

854

9962

2060

2979

2013 2910 1D-2700 1D-3600 1D-2700 1D-3600

RP-4

RP-4

RP-4

RP-4

4523

935

1352

914

Lime

Charcoal

Lime

Charcoal

10153

2109

3026

2061 2957 1D-2700 1D-3600 1D-2700 1D-3600

RP-4

RP-4

RP-4

RP-4

4609

957

1374

936

Lime

Charcoal

Lime

Charcoal

10153

2109

3026

2061 2957 1D-2700 1D-2700 1D-2700 1D-2700

RP-4

RP-4

RP-4

RP-4

4609

957

1374

936

Lime

Charcoal

Lime

Charcoal

1210

1210

1321 1342 1342

Purple

Purple

Purple Purple Purple

Green

Green

Green Green Green

Purple

Purple

Purple Purple Purple

Green Brick Red RP-4

Green Brick Red

Green Green Green

Lime RP-4 Lime

Brick

Lime

Red RP-4

RP-4

Brick

Lime

Red

NOTE: ID 2700 and ID 3600 have four same-color springs per housing.

Table 4, Weights & Vibration Isolators, Remote Condenser, Without Sound Enclosure ARRANGEMENT WGS-AA, FOR REMOTE CONDENSER, WITHOUT SOUND ENCLOSURE (SEE NOTE) UNIT OPR. WT. CORNER WEIGHT LBS (KG) SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGS SIZE LBS. (KG) 1 2 3 4 1 2 3 4 1 2 3 4 RP-4 RP-4 RP-4 RP-4 6265 1572 1603 1530 1560 1D-2040 1D-2040 1D-2040 1D-2040 130AA Brick Brick Brick Brick (2842) (713) (727) (694) (708) Black Black Black Black Red Red Red Red RP-4 RP-4 RP-4 RP-4 6265 1572 1603 1530 1560 1D-2040 1D-2040 1D-2040 1D-2040 140AA Brick Brick Brick (2842) (713) (727) (694) (708) Black Black Black Black Brick Red Red Red Red RP-4 RP-4 RP-4 RP-4 7022 1752 1800 1708 1758 1D-2040 1D-2040 1D-2040 1D-2040 160AA Brick Brick Brick (3185) (794) (818) (775) (797) Black Black Black Black Brick Red Red Red Red RP-4 RP-4 RP-4 RP-4 7022 1752 1800 1708 1758 1D-2040 1D-2040 1D-2040 1D-2040 170AA Brick Brick Brick (3185) (794) (818) (775) (797) Black Black Black Black Brick Red Red Red Red RP-4 RP-4 RP-4 RP-4 7022 1752 1800 1708 1758 1D-2040 1D-2040 1D-2040 1D-2040 190AA Brick Brick Brick (3185) (794) (818) (775) (797) Black Black Black Black Brick Red Red Red Red

NOTE: ID 2040 has four same-color springs per housing.

Table 5, Weights & Vibration Isolators, Remote Condenser, With Sound Enclosure UNIT SIZE 130AA

140AA

160AA

170AA

190AA

ARRANGEMENT WGS-AA, FOR REMOTE CONDENSER, WITH SOUND ENCLOSURE (SEE NOTE) CORNER WGT RUBBER-IN-SHEAR OPR. WT. SPRING-FLEX MOUNTINGS LBS (KG) MOUNTINGS LBS. (KG) 1 2 3 4 1 2 3 4 1 2 3 4 RP-4 RP-4 RP-4 RP-4 6913 1722 1777 1680 1734 1D-2040 1D-2040 1D-2040 1D-2040 Brick Brick Brick Brick 3139 782 807 763 787 Black Black Black Black Red Red Red Red RP-4 RP-4 RP-4 RP-4 6913 1722 1777 1680 1734 1D-2040 1D-2040 1D-2040 1D-2040 Brick Brick Brick Brick 3139 782 807 763 787 Black Black Black Black Red Red Red Red RP-4 RP-4 RP-4 RP-4 7666 1902 1974 1858 1932 1D-2040 1D-2040 1D-2040 1D-2040 Brick Brick Brick Brick 3480 864 896 844 877 Black Black Black Black Red Red Red Red RP-4 RP-4 RP-4 RP-4 7666 1902 1974 1858 1932 1D-2040 1D-2040 1D-2040 1D-2040 Brick Brick Brick Brick 3480 864 896 844 877 Black Black Black Black Red Red Red Red RP-4 RP-4 RP-4 RP-4 7666 1902 1974 1858 1932 1D-2040 1D-2040 1D-2040 1D-2040 Brick Brick Brick Brick 3480 864 896 844 877 Black Black Black Black Red Red Red Red

NOTE: ID 2040 has four same color springs per housing. IMM 1157

WGS 130A to 190A

7

Table 6, Isolator Kit Part Numbers Model AW, w/o Sound Enclosure

WGS 130AW

WGS 140AW

WGS 160AW

WGS 170AW

WGS 190AW

Spring Part Number

332320601

332320601

332320602

332320602

332320602

R-I-S Part Number

332325601

332325601

332325601

332325601

332325601

Model AW, w Sound Enclosure

WGS 130AW

WGS 140AW

WGS 160AW

WGS 170AW

WGS 190AW

Spring Part Number

332320602

332320602

332320602

332320602

332320602

R-I-S Part Number

332325601

332325601

332325602

33232562

332325602

Model AA, w/o Sound Enclosure

WGS 130AA

WGS 140AA

WGS 160AA

WGS 170AA

WGS 190AA

Spring Part Number

332320603

332320603

332320603

332320603

332320603

R-I-S Part Number

332325603

332325603

332325603

332325603

332325603

Model AA, w/ Sound Enclosure

WGS 130AA

WGS 140AA

WGS 160AA

WGS 170AA

WGS 190AA

Spring Part Number

332320603

332320603

332320603

332320603

332320603

R-I-S Part Number

332325603

332325603

332325603

332325603

332325603

NOTE: Model AW = packaged, water-cooled, Model AA = remote condenser, air-cooled

Figure 3, CP-4, Spring Flex Mounting

Figure 4, RP-4, R-I-S Mounting 6.25 5.00 3.75 3.00

ø .500-13NC-2B

R4

VM&C

.56 TYP.

VM&C

4.63 3.87

R.28 TYP.

R4

RECESSED GRIP RIBS DURULENE MATERIAL

R.250 TYP. R.750 TYP.

1.13 ± .25 APPROX. 1.63 .38

NOTES: 1.

8

2.

MOLDED STEEL AND ELASTOMER MOUNT FOR OUTDOOR SERVICE CONDITIONS.

3.

RP-4 MOUNT VERSION WITH STUD IN PLACE.

WGS 130A to 190A

RAISED GRIP RIBS

MOUNT MATERIAL TO BE DURULENE RUBBER.

DRAWING NUMBER 3314814 ALL DIMENSIONS ARE IN DECIMAL INCHES

IMM1157

Figure 5, WGS-AA, Remote Condenser Configuration

Discharge Connections

Liquid Return Connections

IMM 1157

WGS 130A to 190A

9

Water Piping Vessel Drains at Start-up Evaporators are drained of water in the factory and shipped with an open ball valve in the drain hole. The drain is located on the bottom of the vessel. Be sure to close the valve prior to filling the vessel with fluid. Condensers: Units are drained of water in the factory and are shipped with condenser drain plugs in the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid.

General Due to the variety of piping practices, follow the recommendations of local authorities for code compliance. They can supply the installer with the proper building and safety codes required for a proper installation. The piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. Other piping design considerations include: 1. All piping should be installed and supported to prevent the chiller connections from bearing any strain or weight of the system piping. 2. Vibration eliminators to reduce vibration and noise transmission to the building. 3. Shutoff valves to isolate the unit from the piping system during unit servicing. 4. Manual or automatic air vent valves at the high points of the system. Drains should be placed at the lowest points in the system. 5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve). 6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of the vessels to aid in unit servicing. 7. A strainer or some means of removing foreign matter from the water before it enters the pump. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). A strainer can prolong pump life and help maintain system performance. Important Note A cleanable 20-mesh strainer must also be placed in the water line just prior to the inlet of the evaporator. This will aid in preventing foreign material from entering the unit and decreasing the performance of the evaporator. 8. If the unit is used as a replacement chiller on a previously existing piping system, flush the system thoroughly prior to unit installation. Regular water analysis and chemical water treatment on the evaporator and condenser are recommended immediately upon equipment start-up. 9. In the event glycol is added to the water system as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance will be less, and water side pressure drop will be higher. If the percentage of glycol is large, or if propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 32°F (0°C). Reset the freezestat setting to approximately 8° to 10°F (4.4° to 5.5°C) below the leaving chilled water setpoint temperature. See the section titled “Glycol Solutions” on page 13 for additional information concerning the use of glycol. 10. Make a preliminary leak check of the water piping before filling the system. 10

WGS 130A to 190A

IMM1157

!

WARNING

This unit contains POE lubricants that must not come into contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate piping).

Note: A water flow switch or pressure differential switch must be mounted in the evaporator outlet water line to signal that there is water flow before the unit will start.

Figure 6, Typical Field Evaporator Water Piping Vent

Water Strainer

In

Valved Pressure Gauge

Vibration Eliminator

Out

Drain

Flow Gate Valve

Flow

Protect All Field Piping Against Freezing

Vibration Flow Balancing Gate Eliminator Switch Valve Valve

NOTE: Water piping must be supported independently from the unit.

System Water Volume All chilled water systems need adequate time to recognize a load change, respond to that load change and stabilize, without undesirable short cycling of the compressors or loss of control. In air conditioning systems, the potential for short cycling usually exists when the building load falls below the minimum chiller plant capacity or on close-coupled systems with very small water volumes. Some of the things 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 often used. A properly designed storage tank should be added if the system components do not provide sufficient water volume.

Variable Chilled Water Flow Reducing chilled water flow in proportion to load can reduce total system power consumption. Certain restrictions apply to the amount and rate of flow change. The rate of flow change should be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the minimum flows listed in the pressure drop data on page 16.

Chilled Water Piping The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. A 1.0 mm (16 to 20 mesh) strainer must be installed in the return water line before the inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into the evaporator inlet.

IMM 1157

WGS 130A to 190A

11

The return water line must be piped to the evaporator inlet connection and the supply water line must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse direction, a substantial decrease in capacity and efficiency of the unit will be experienced. A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to prove water flow before starting the unit. Provide drain connections at all low points in the system to permit complete drainage. Air vents should be located at the high points in the system to purge air out of the system. The evaporator is equipped with vent and drain connections. Install pressure gauges in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator can be measured to determine water flow from the flow/pressure drop curves on page 16. Vibration eliminators are recommended in both the supply and return water lines. Insulate chilled water piping to reduce heat loss and prevent condensation. Perform complete unit and system leak tests prior to insulating the water piping. Insulation with a vapor barrier is recommended. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility.

Flow Switch Field Installed A water flow switch must be mounted in the leaving evaporator and condenser water line to prove adequate water flow before the unit can start. This will protect against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up. A flow switch is available from Daikin under part number 01750330. It is a “paddle” type switch and adaptable to any pipe size from 1 in. (25 mm) to 6 in. (152 mm) nominal. Certain flow rates are required to open the switch and are listed in Table 7. Switch terminals Y and R should be made to panel terminals 60 and 67 (chilled water) and 60 and 76 (condenser water). There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a “no flow” condition exists. 1. Apply pipe sealing compound to only the threads of the switch and screw unit into the 1-in. (25-mm) reducing tee. The flow arrow must be pointed in the correct direction. 2. Piping should provide a straight length before and after the flow switch of at least five times the pipe diameter without any valves, elbows, or other flow restricting elements. 3. Trim the flow switch paddle if needed, to fit the pipe diameter. Make sure the paddle does not hang up in the pipe. !

CAUTION

Make sure the arrow on the side of the switch is pointed in the direction of flow. Connect the flow switch according to the wiring diagram (see wiring diagram inside control box door). Incorrect installation will cause improper operation and possible evaporator damage.

12

WGS 130A to 190A

IMM1157

Table 7, Flow Switch Flow Rates Pipe Size (NOTE !) Min. Adjst.

Max. Adjst.

Flow No Flow Flow No Flow

inch mm gpm Lpm gpm Lpm gpm Lpm gpm Lpm

1 1/4 32 (2) 5.8 1.3 3.7 0.8 13.3 3.0 12.5 2.8

1 1/2 38 (2) 7.5 1.7 5.0 1.1 19.2 4.4 18.0 4.1

2 51 13.7 3.1 9.5 2.2 29.0 6.6 27.0 6.1

2 1/2 63 (3) 18.0 4.1 12.5 2.8 34.5 7.8 32.0 7.3

3 76 27.5 6.2 19.0 4.3 53.0 12.0 50.0 11.4

4 102 (4) 65.0 14.8 50.0 11.4 128.0 29.1 122.0 27.7

5 127 (4) 125.0 28.4 101.0 22.9 245.0 55.6 235.0 53.4

6 153 (4) 190.0 43.2 158.0 35.9 375.0 85.2 360.0 81.8

8 204 (5) 205.0 46.6 170.0 38.6 415.0 94.3 400.0 90.8

NOTES: 1. A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose. 2. Flow rates for a 2-inch paddle trimmed to fit the pipe. 3. Flow rates for a 3-inch paddle trimmed to fit the pipe. 4. Flow rates for a 3-inch paddle. 5. Flow rates for a 6-inch paddle

Optional Factory-Mounted The chiller may be equipped with the optional factory-mounted flow switch. The 24 Vac powered flow sensors are a solid state alternative to mechanical switches for sensing the acceptable flow rate of water. The flow sensors are extremely reliable with no moving parts that can become stuck or break in the flow process. These compact units are constructed of corrosion-resistant materials and 316 stainless steel parts and are factory-installed directly through a ¼ inch NPT into the flow. No field adjustments are required. The flow sensors operate on the calorimetric principle. The sensors use the cooling effect of a flowing fluid to provide reliable flow rate detection of liquids over a very wide flow range. The amount of thermal energy that is removed from the tip determines the local flow rate and when it exceeds a setpoint it changes the output-state.

Glycol Solutions When using a glycol solution, the chiller capacity, flow rate, evaporator pressure drop, and chiller power input can be calculated using the following formulas. Refer to Table 8 for ethylene glycol and Table 9 for propylene glycol. Capacity, Capacity is reduced compared to that of plain water. To find the reduced value, multiply the chiller’s capacity when using water by the capacity correction factor C to find the chiller’s capacity when using glycol. Flow, Multiply the water flow by the G correction factor to determine the glycol flow required to give the same Delta-T as water. To determine evaporator gpm (or T) knowing T (or gpm) and capacity: Glycol GPM 

24 x Glycol Capacity x Flow Correction G From Tables T

For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps) and kW: Glycol Lps 

kW x Flow Correction G from Tables 4.18 x T

Pressure Drop, To determine glycol pressure drop through the cooler, enter the water pressure drop graph on page 16 at the actual glycol flow. Multiply the water pressure drop found there by correction factor P to obtain corrected glycol pressure drop. Power, To determine glycol system kW, multiply the water system kW by factor K.

IMM 1157

WGS 130A to 190A

13

Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point found in Table 8. On glycol applications the supplier normally recommends that a minimum of 25% solution by weight be used for protection against corrosion or the use of additional inhibitors. Note: The effect of glycol in the condenser is negligible. As glycol increases in temperature, its characteristics have a tendency to mirror those of water. Therefore, for selection purposes, there is no derate in capacity for glycol in the condenser. Table 8, Ethylene Glycol % Ethylene Glycol 10 20 30 40 50

Freeze Point °F °C 26 -3.3 18 -7.8 7 -13.9 -7 -21.7 -28 -33.3

C Capacity

K Power

G Flow

P Pressure Drop

0.996 0.986 0.978 0.966 0.955

0.999 0.998 0.996 0.993 0.991

1.035 1.060 1.092 1.131 1.182

1.096 1.219 1.352 1.530 1.751

C Capacity

K Power

G Flow

P Pressure Drop

0.987 0.975 0.962 0.946 0.929

0.992 0.985 0.978 0.971 0.965

1.010 1.028 1.050 1.078 1.116

1.068 1.147 1.248 1.366 1.481

Table 9, Propylene Glycol % Percent Glycol 10 20 30 40 50

Freeze Point °F °C 26 -3 19 -7 9 -13 -5 -21 -27 -33

!

CAUTION

Do not use automotive grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors, which cause plating on copper tubes. The type and handling of glycol used must be consistent with local codes.

Condenser Water Piping Arrange the condenser water so the water enters the condensers’ bottom connections or the single bottom manifold connection if the optional manifold has been ordered. The condenser water will discharge from the top condenser connections or the single top connection of the optional manifold. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency. Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine flow on the pressure drop/flow curves on page 17. Vibration eliminators are recommended in both the supply and return water lines. Water-cooled condensers can be piped for use with cooling towers or well water. Cooling tower applications should be made with consideration of freeze protection and scaling problems. Contact the cooling tower manufacturer for equipment characteristics and limitations for the specific application. Head pressure control must be provided if the entering condenser water can fall below the curve values on page Error! Bookmark not defined.. The MicroTech II unit controller can provide this function, using entering condenser water as the control point. The control will work with or without the optional condenser manifolds. The water sensors are factoryinstalled.

14

WGS 130A to 190A

IMM1157

The controller setpoints have to be adjusted for water control and certain output connections made to the tower components. See the operating manual OM WGS and the field wiring diagram in this manual for further details.

Condenser Water Sensors Packaged WGS chillers are supplied with one ECWT sensor and one LCWT sensor. The option the unit is ordered with will determine the sensor location requirements. Listed below are the two possibilities. WGS Ordered Without the Condenser Manifold: If the unit is ordered without the condenser manifold option, the entering and leaving water sensors will have to be field-installed in their respective condenser water piping, at a common location. Since each WGS is supplied with an independent condenser vessel per refrigerant circuit, the water temperature sensors must be installed in a location prior to the water piping split on the entering water side and after the piping is rejoined on the leaving water side. The sensors ship with the chiller, temporarily attached to the condenser vessel. The sensors will be landed on the control panel end and provided with additional lead length for field installation. WGS Ordered With the Condenser Manifold: If the unit is ordered with the condenser manifold option, both sensors will be factoryinstalled in the manifolds.

Water Pressure Drop The vessel flow rates must fall between the minimum and maximum values shown on the appropriate evaporator and condenser curves. Flow rates below the minimum values shown will result in laminar flow that will reduce efficiency, cause erratic operation of the electronic expansion valve and could cause low temperature cutoffs. On the other hand, flow rates exceeding the maximum values shown can cause erosion in the evaporator and condenser. Measure the chilled water pressure drop through the evaporator at field-installed pressure taps. It is important not to include valves or strainers in these readings.

IMM 1157

WGS 130A to 190A

15

Figure 7, Evaporator Pressure Drop WGS 130 – WGS 190

WGS 130, 140

WGS 160, 170, 190

WGS Model

Minimum Flow Flow Rate

Nominal Flow

Pressure Drop

Flow Rate

Maximum Flow

Pressure Drop

Flow Rate

Pressure Drop

gpm

L/s

Ft.

kPa

gpm

L/s

Ft.

kPa

gpm

L/s

Ft.

kPa

130AW/AA

195

12.3

5.8

17.4

312

19.7

13.5

40.4

520

32.9

33.9

101.1

140AW/AA

211

13.4

6.7

20.0

338

21.4

15.6

46.6

563

35.6

39.0

116.5

160AW/AA

235

14.9

4.6

13.8

376

23.8

10.8

32.3

627

39.7

27.3

81.6

170AW/AA

254

16.1

5.3

15.9

407

25.8

12.5

37.3

678

42.9

31.6

94.2

190AW/AA

273

17.3

6.1

18.1

437

27.7

14.2

42.5

728

46.1

35.9

107.2

Note: Minimum, nominal, and maximum flows are at a 16F, 10F, and 6F chilled water temperature range respectively and at ARI tons.

16

WGS 130A to 190A

IMM1157

Figure 8, Condenser Pressure Drop WGS 130 – WGS 190

WGS 170, 190 with Manifold WGS 130, 140, 160 with Manifold

WGS 170, 190 without Manifold WGS 130, 140, 160 without Manifold

Pressure Drop Without Optional Condenser Manifold WGS Model

Minimum Flow Flow Rate Pressure Drop gpm L/s Ft. kPa

Nominal Flow Flow Rate Pressure Drop gpm L/s Ft. kPa

Maximum Flow Flow Rate Pressure Drop gpm L/s Ft. kPa

130AW 140AW 160AW 170AW 190AW

304 304 304 372 372

390 422 470 509 546

650 704 784 848 911

WGS Model

Minimum Flow Flow Rate Pressure Drop gpm L/s Ft. kPa

Nominal Flow Flow Rate Pressure Drop gpm L/s Ft. kPa

Maximum Flow Flow Rate Pressure Drop gpm L/s Ft. kPa

130AW 140AW 160AW 170AW 190AW

304 304 304 372 372

390 422 470 509 546

650 704 784 848 911

19.2 19.2 19.2 23.5 23.5

4.1 4.1 4.1 4.3 4.3

12.2 12.2 12.2 12.8 12.8

24.7 26.7 29.8 32.2 34.6

6.5 7.4 9.0 7.9 9.0

19.3 22.2 26.9 23.7 26.9

41.1 44.5 49.6 53.7 57.6

16.0 18.5 22.4 19.8 22.5

47.9 55.1 66.8 59.1 67.1

Pressure Drop With Optional Condenser Manifold

IMM 1157

19.2 19.2 19.2 23.5 23.5

4.7 4.7 4.7 5.3 5.3

14.0 14.0 14.0 15.8 15.8

24.7 26.7 29.8 32.2 34.6

7.4 8.5 10.3 9.4 10.7

WGS 130A to 190A

22.0 25.3 30.7 28.1 32.0

41.1 44.5 49.6 53.7 57.6

18.5 21.3 25.8 23.8 27.1

55.1 63.5 77.1 71.1 80.9

17

Refrigerant Piping Unit with Remote Condenser General For remote condenser application (WGS-AA), the chillers are shipped with a nitrogen/helium holding charge of 20 psi is used to pressurize the system with a slight positive pressure to prevent contaminants from entering the unit. This holding charge should not be mistaken as a refrigerant charge, and can not be used as part of the final total refrigerant charge. After installation, the unit should be pressurized and tested for leaks, vacuumed and charged with the correct refrigerant operating charge, taking into consideration the length of refrigerant piping.

The operating charge is field-supplied and charged for remote condenser models. It is important that the unit be kept tightly closed until the remote condenser is installed and piped to the unit. It is the contractor’s responsibility to install the interconnection piping, leak-test the entire system, evacuate the system, and supply the system refrigerant charge. The system should be held under vacuum until it is charged under supervision of the Daikin authorized service technician who will supervise unit commissioning. The unit operating charge (less piping and condenser) can be found on page 26. !

IMPORTANT NOTE

!

Service Form SF99006 and an isometric sketch of the Remote Piping Layout showing pipe size, location of fittings, measured lengths and elevations MUST BE SUBMITTED TO Daikin Technical Response Center and reviewed before order entry. Daikin Factory Service will not perform startup without reviewed Service Form SF99006 and drawing. Installation must match reviewed drawing. All field piping, wiring and procedures must comply with design guidelines set forth in the product literature, and be performed in accordance with ASHRAE, EPA, local codes and industry standards and per included sizing tables. Any product failure caused, or contributed to, by failure to comply with appropriate design guidelines will not be covered by manufacturer’s warranty. Daikin Technical Response: Fax: 763-509-7666; Phone : 540-248-9201; e-mail: [email protected]

The following notes apply to all size units:     

Maximum linear line length shall not exceed 75 feet. Maximum Total Equivalent Length (TEL) shall not exceed 180 feet. The condenser shall not be located more than 15 feet above the indoor unit. The condenser shall not be located more than 20 feet below the indoor unit. No underground piping.

It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility. The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory-mounted as standard equipment with the water chiller. After the equipment is properly installed, leak tested, and evacuated, it can be charged with R-134a and started under Daikin service supervision. Total operating charge will depend on the air-cooled condenser used and volume of the refrigerant piping. Note: On the arrangement WGS-AA units (units with remote condensers), the installer must record the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate in the appropriate blocks provided for this purpose.

18

WGS 130A to 190A

IMM1157

The following discussion is intended for use as a general guide to the piping of air-cooled and evaporative condensers. Use the tables shown in this manual for sizing the discharge and liquid lines. Discharge lines must be designed to handle oil properly and to protect the compressor from damage that can result from condensing liquid refrigerant in the line during shutdown. Careful consideration must be given for sizing each section of piping so that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is too low, considerable oil can collect in the riser and the horizontal header, causing the compressor to lose its oil and result in damage due to lack of lubrication. When the compressor load is increased, the oil that had collected during reduced loads can be carried as a slug through the system and back to the compressor, where a sudden increase of oil concentration can cause liquid slugging and damage to the compressor. Any horizontal run of discharge piping should be pitched away from the compressor approximately 1/8-inch per foot (10.4 mm per m) or more. This is necessary to move, by gravity, any oil lying in the header. Any discharge line coming into a horizontal discharge header should rise above the centerline of the discharge header. This is necessary to prevent liquid refrigerant from draining from the condenser when the compressor is not operating. If the compressors are lower than the condenser, or refrigerant migration is possible, a check valve should be installed at the condenser. A check/relief valve may be necessary in the liquid line at the condenser for applications where the liquid line is higher than the condensing unit or where refrigerant migration is an issue. The liquid line should be insulated when it is routed where the ambient exposure is higher than the condenser’s ambient temperature. A relief device may also be required in the discharge line piping. Figure 9 illustrates a typical piping arrangement involving a remote air-cooled condenser located at a higher elevation than the compressor. This arrangement is commonly encountered when the air-cooled condenser is on a roof and the compressor is on grade level or in a basement equipment room. Notice in Figure 9 that the discharge line is looped at the bottom and top of the vertical run. This is done to prevent oil and condensed refrigerant from flowing back into the compressor and causing damage. The highest point in the discharge line should always be above the highest point in the condenser coil. Include a purging vent at this point to extract non-condensables from the system. This method should also be employed if the air-cooled condenser is located on the same level as the compressor.

Head Pressure Control The MicroTech II circuit controllers are capable of controlling the fans of remote air-cooled condensers connected to each of the unit’s two refrigerant circuits. Control is based on condensing temperature and uses a combination of fan variable frequency drive (VFD) and fan cycling.

Recommended Refrigerant Pipe Sizes NOTES: 1. 2.

Pressure drop is in equivalent degrees F. On WGS 140 and 170, the # 1 circuit is always the smallest and is closest to the control panel.

Horizontal or Downflow Discharge Line Sizes Unit, Circuit WGS 130, Both WGS 140, Cir #1

Nominal

Conn.

Circuit

Size

Tons

At Unit

65

2 5/8

80

2 5/8

95

2 5/8

WGS 140, Cir #2 WGS 160, Both WGS 170, Cir #1 WGS 170, Cir #2 WGS 190, Both

IMM 1157

Recommended Discharge Line Size, inch, O.D. Up to

Up to

Up to

Up to

Up to

50 Equiv.Ft 75 Equiv.Ft 100 Equiv.Ft. 125 Equiv.Ft. 150 Equiv.Ft. Line Size

2 5/8

2 5/8

2 5/8

2 5/8

2 5/8

Press Drop, F

0.55

0.82

1.10

1.37

1.64

Line Size

2 5/8

2 5/8

2 5/8

2 5/8

3 1/8

Press Drop,  F

0.80

1.21

1.61

2.01

1.04

Line Size

2 5/8

2 5/8

2 5/8

3 1/8

3 1/8

Press Drop, F

1.08

1.62

2.16

1.17

1.40

WGS 130A to 190A

19

Recommended Vertical Upflow Discharge Line Sizes Unit, Circuit

Nominal

Connection

Circuit

Size, O.D.

Tons

at WGS Unit

65

2 5/8

80

2 5/8

95

2 5/8

WGS 130, Both WGS 140, Cir #1

Recommended Discharge Line Size, inch, O.D.

WGS 170, Cir #1 WGS 170, Cir #2 WGS 190, Both

Up to

Up to

75 Equiv. Ft

100 Equiv. Ft.

Line Size

2 1/8

2 1/8

2 1/8

Press Drop, F

1.52

2.28

3.03

WGS 140, Cir #2 WGS 160, Both

Up to 50 Equiv. Ft

Line Size

2 5/8

2 5/8

2 5/8

Press Drop, F

0.80

0.99

1.32

Line Size

2 5/8

2 5/8

2 5/8

Press Drop, F

0.94

1.41

1.88

Recommended Liquid Line Size Nominal Conn. Unit, Circuit WGS 130, Both WGS 140, Cir #1

Circuit

Size,

Tons

at Unit

65

1 3/8

80

1 3/8

95

1 3/8

Recommended Liquid Line Size, inch O.D. Up to

WGS 170, Cir #1 WGS 170, Cir #2 WGS190, Both

Up to

Up to

Up to

Line Size

1 3/8

1 3/8

1 3/8

1 3/8

1 3/8

Press Drop, F

0.76

1.14

1.52

1.89

2.27

WGS 140, Cir #2 WGS 160, Both

Up to

50 Equiv.Ft 75 Equiv.Ft 100 Equiv.Ft. 125 Equiv.Ft. 150 Equiv.Ft.

Line Size

1 3/8

1 3/8

1 3/8

1 3/8

1 3/8

Press Drop, F

1.11

1.67

2.23

2.78

3.34

Line Size

1 3/8

1 3/8

1 5/8

1 5/8

1 5/8

Press Drop, F

1.50

2.25

1.33

1.66

1.99

Figure 9, Condenser Above Compressor (One of Two Circuits Shown) Check Valve (Preferred)



Relief Valve Pressure Tap

Condenser

Pitch

 

Discharge Line



Maximum linear line length shall not exceed 75 ft. Maximum Total Equivalent Length (TEL) shall not exceed 180 ft. The condenser shall not be located more than 15 ft above the indoor unit. The condenser shall not be located more than 20 ft below the indoor unit.

Loop

To Evaporator

20

WGS 130A to 190A

IMM1157

Factory-Mounted Condenser Units with the standard factory-mounted, water-cooled condensers are provided with complete refrigerant piping and full operating refrigerant charge at the factory. There is a possibility on water-cooled units utilizing low temperature pond or river water as a condensing medium that if the water valves leak, the condenser and liquid line refrigerant temperature could drop below the equipment room temperature on the “off” cycle. This problem arises only during periods when cold water continues to circulate through the condenser and the unit remains off due to satisfied cooling load. If this condition occurs: 1. Cycle the condenser pump off with the unit. 2. Check the liquid line solenoid valve for proper operation.

Relief Valve Piping The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-134a) “shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 20 feet (6.1 meters) from any window, ventilation opening or exit in any building.” The piping must be provided with a rain cap at the outside terminating point and with a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. In addition, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s). The size of the discharge pipe from the pressure relief valve should not be less than the size of the pressure relief outlet. When two or more valves are piped together, the common header and piping to the atmosphere should not be less than the sum of the area of each of the lines connected to the header. The locations of the unit relief valves are shown on the piping schematic drawing on page 27. There are six valves on the water-cooled units, one for each circuit on the compressor oil separator (54 lb. air/min., 350 psi), suction line (17.3 lb. air/min., 200 psi), and condenser (54 lb. air/min., 350 psi). Remote condenser models have four valves. NOTE: Provide fittings to permit vent piping to be easily disconnected for inspection or replacement of the relief valve. Figure 10, Relief Valve Piping

IMM 1157

WGS 130A to 190A

21

Dimensional Data WGS-AW Water-Cooled Figure 11, WGS 130AW through WGS 190AW Packaged Chiller Without Optional Condenser Water Manifolds

REMOVABLE LIFTING BRACKETS

13.8 (350.5) 8.3 (210.8)

20.5 (520.7) 169.9 (4315.5)

29.0 (736.6)

“X” RELIEF VALVE

RELIEF VALVE

CONTROL PANEL CIRC. #1

RELIEF VALVES (ONE HIDDEN)

CIRC. #2

FIELD POWER KNOCKOUTS VENT

“A”

EVAPORATOR

“C”

WATER OUT DRAIN

“Y”

“Z” FIELD CONTROL KNOCKOUTS

120.0" (3048.0) RECOMMENDED CLEARANCE FOR CONDENSER TUBE SERVICING

34.0 (863.6)

31.8 (807.7)

16.2 (411.5)

“D” WATER OUT

RELIEF VALVES 1 PER CIRCUIT

CONDENSER

“B”

WATER IN

WATER IN 4.0 IN. (101.6) SCH 40 PIPE VICTAULIC GROOVED. INLET AND OUTLET

0 .88 (22.4) MOUNTING HOLES TYP. 4 114.8 (2915.9) 11.75 (298.4) 14.75 (374.6) REMOVABLE LIFTING BRACKETS

330643201D010B WGS 130-190 Packaged

Notes: 1. Unit water connection handing is oriented facing the control panel. 2. Unit shown with standard right-hand evaporator connections. Left-hand available as option. 3. Condenser connections available only as shown.

Victualic

Inches (mm)

Models

22

Evaporator

Dimensions

WGS

Center of Gravity

Additions for Sound Enclosure

Inches (mm)

Inches (mm)

Inches (mm)

“A”

“B”

“C”

“D”

“X”

“Y”

“Z”

Length

Width

WGS 130AW-

74.6

29.3

95.0

6.0

83.9

35.8

16.8

4.0

2.5

Height 3.0

140AW

(1894.8)

(744.2)

(2413.0)

(152.4)

(2131.1)

(909.3)

(426.7)

(101.6)

(63.5)

(76.2)

WGS 160AW-

76.6

30.4

92.9

8.0

84.0

36.0

16.8

4.0

2.5

5.0

190AW

(1945.6)

(772.2)

(2359.6)

(203.2)

(2133.6)

(914.4)

(426.7)

(101.6)

(63.5)

(127.0)

WGS 130A to 190A

IMM1157

WGS-AW, Water-Cooled with Optional Condenser Manifolds Figure 12 WGS 130AW through 190AW with Optional Condenser Manifolds

REMOVABLE LIFTING BRACKETS

13.8 (350.5) 8.3 (210.8)

20.5 (520.7)

169.9 (4315.5)

“X”

29.0 (736.6)0 RELIEF VALVE

RELIEF VALVE RELIEF VALVES (ONE HIDDEN)

CONTROL PANEL CIRC. #1

CIRC. #2

FIELD POWER KNOCKOUTS

VENT

“A”

EVAPORATOR WATER OUT

DRAIN

“C”

WATER IN

“D”

“Y” 31.8 (807.7)

“Z”

“B”

0 .88 (22.4) MOUNTING HOLES TYP. 4

16.2 (411.5)

34.0 FIELD CONTROL (863.6) KNOCKOUTS

WATER OUT

RELIEF VALVES 1 PER CIRCUIT

CONDENSER

114.8 (2915.9)

WATER IN 4.0 IN. (101.6) SCH 40 PIPE VICTAULIC GROOVED. INLET AND OUTLET

32.0 (812.8) 35.0 (889.0)

330643601D010B WGS 130-190 w/Manifold

REMOVABLE LIFTING BRACKETS

Notes: 1. Unit water connection handing is oriented facing the control panel. 2. Unit shown with standard right-hand evaporator connections. Left-hand available as option. 3. Condenser connections available only as shown.

Victualic

Inches (mm)

Models “A”

IMM 1157

Evaporator

Dimensions

WGS

“B”

Center of Gravity

“D”

Enclosure

Inches (mm)

Inches (mm) “C”

Additions for Sound

“X”

“Y”

Inches (mm) “Z”

Length

Width

Height

WGS 130AW-

74.6

29.3

95.0

6.0

83.9

35.8

16.8

4.0

2.5

3.0

140AW

(1894.8)

(744.2)

(2413.0)

(152.4)

(2131.1)

(909.3)

(426.7)

(101.6)

(63.5)

(76.2)

WGS 160AW-

76.6

30.4

92.9

8.0

84.0

36.0

16.8

4.0

2.5

5.0

190AW

(1945.6)

(772.2)

(2359.6)

(203.2)

(2133.6)

(914.4)

(426.7)

(101.6)

(63.5)

(127.0)

WGS 130A to 190A

23

WGS-AA Remote Condenser Figure 13, Dimensions, WGS 130AA through WGS 190AA Remote Condenser 85.6 (2174.2) 77.8 (1976.1)

REAR VIEW “E”

19.3 (490.2)

0 2.625" DISCHARGE #1 FIELD CONNECTION

0 1.375" LIQUID #2 FIELD CONNECTION

“D”

0 2.625" DISCHARGE #2 FIELD CONNECTION

0 1.375" LIQUID #1 FIELD CONNECTION

“F”

32.0 (812.8) 179.3 (4554.2) “X”

FRONT VIEW

RELIEF VALVE

RELIEF VALVE

CONTROL PANEL FIELD POWER KNOCKOUTS

CIRC. #1

RELIEF VALVES (ONE HIDDEN)

CIRC. #2

“A”

VENT

“Y”

“C” EVAPORATOR

WATER OUT

“Z”

18.0 (457.2)

0 .88 MOUNTING HOLES 4 PLACES

34.0 (863.6)

WATER IN

DRAIN

LIFTING HOLES 4 PLACES

VICTAULIC GROOVED INLET AND OUTLET 6.00 SCH 40 PIPE for WGS 130-140

“B”

FIELD CONTROL KNOCKOUTS

12.0 (304.8)

155.3 (3944.6)

8.00 SCH 40 PIPE FOR WGS 160-190 330643401D010B WGS 130-190 Less Condenser

Notes: 1. 2.

Unit water connection handing is oriented facing the control panel. Unit shown has right hand evaporator water connections.

Dimensions Inches (mm)

WGS Models WGS 130140AW WGS 160190AW

24

Center of Gravity Inches (mm)

Additions for Sound Enclosure Inches (mm)

“A”

“B”

“C”

“D”

“E”

“F”

“X”

“Y”

“Z”

Length

Width

Height

60.8 (1544.3)

38.1 (967.7)

95.0 (2413.0)

33.1 (840.7)

26.1 (662.9)

19.7 (500.4)

92.3 (2344.4)

32.3 (820.4)

16.8 (426.7)

4.0 (101.6)

2.5 (63.5)

3.0 (76.2)

62.8 (1595.1)

39.6 (1005.8)

92.9 (2359.7)

32.7 (830.6)

25.7 (652.8)

21.7 (551.2)

92.5 (2349.5)

32.5 (825.5)

16.7 (424.2)

4.0 (101.6)

2.5 (63.5)

5.0 (127.0)

WGS 130A to 190A

IMM1157

Physical Data WGS-AW, Water-Cooled Table 10, WGS-130AW - WGS-190AW WGS UNIT SIZE Unit capacity @ ARI conditions tons, (kW) (1) No. Circuits COMPRESSORS, Frame 3 Nominal Horsepower Number (2) % Minimum Capacity (Modulated) Oil Charge per Compressor oz., (l) CONDENSER Number No. Refrigerant Circuits Diameter, in., (mm) Tube Length, in., (mm)

130AW

140AW

160AW

170AW

190AW

130.0 (457.1)

140.7 (494.7)

156.7 (551.0)

169.6 (596.3)

182.1 (640.3)

2

2

2

2

2

65 1

65 1

65 1

80 1

80 1

80 1

80 1

95 1

95 1

95 1

15 256 (7.6)

13/17 256 (7.6)

15 256 (7.6)

14/16 256 (7.6)

15 256 (7.6)

2 1 12 (305) 120 (3048)

2 1 12 (305) 120 (3048)

2 1 12 (305) 120 (3048)

2 1 12 (305) 120 (3048)

2 1 12 (305) 120 (3048)

Design W.P. psig, (kPa): Refrigerant Side 350 (2413) 350 (2413) 350 (2413) 350 (2413) 350 (2413) Water Side 150 (1034) 150 (1034) 150 (1034) 150 (1034) 150 (1034) No. of Passes 2 2 2 2 2 Pump-Out Capacity per Circuit, lb., 330 (150) 330 (150) 330 (150) 296 (134) 296 (134) (kg) (3) Connections: Water In & Out, in, (mm) victaulic 4.0 (101) 4.0 (101) 4.0 (101) 4.0 (101) 4.0 (101) Relief Valve, In., (mm) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) Purge Valve, Flare In., (mm) .625 (15.9) .625 (15.9) .625 (15.9) .625 (15.9) .625 (15.9) Vent & Drain, in. (mm) FPT 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) Liquid Subcooling Integral Integral Integral Integral Integral EVAPORATOR Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons, (l) 68 (257) 68 (257) 115 (435) 115 (435) 115 (435) Refrig. Side D.W.P., psig, (kPa) 354 (2441) 354 (2441) 354 (2441) 354 (2441) 354 (2441) Water Side D.W.P., psig, (kPa) 152 (1048) 152 (1048) 152 (1048) 152 (1048) 152 (1048) Water Connections: Inlet & Outlet, in., (mm) victaulic 6.0 (152) 6.0 (152) 8.0 (203) 8.0 (203) 8.0 (203) Drain & Vent (NPT INT.) 0.5 0.5 0.5 0.5 0.5 UNIT DIMENSIONS (4) Length In., (mm) 169.9 (4315.5) 169.9 (4315.5) 169.9 (4315.5) 169.9 (4315.5) 169.9 (4315.5) Width In., (mm) 34 (864) 34 (864) 34 (864) 34 (864) 34 (864) Height In., (mm) 74 (1880) 74 (1880) 75.5 (1918) 75.5 (1918) 75.5 (1918) UNIT WEIGHTS (5) Operating Weight, lb., (kg) 8557 (3881) 8557 (3881) 9314 (4225) 9505 (4311) 9505 (4311) Shipping Weight, lb., (kg) 7840 (3556) 7840 (3556) 8206 (3722) 8345 (3785) 8345 (3785) Operating Charge per Circuit, 127 (58) 127 (58) 128 (58) 124 (56) 124 (56) R-134a, lb., (kg) Notes: 1. Certified in accordance with ARI Standard 550/590-98. 2. All units have one compressor per circuit. 3. 80% full R-134a at 90°F (32°C) per refrigerant circuit. 4. Dimensions are without the optional sound enclosure. See dimension drawings for enclosure dimensions. 5. The optional sound enclosure adds 650 lbs (295 kg) to the shipping and operating weights.

IMM 1157

WGS 130A to 190A

25

WGS-AA Remote Condenser Table 11, WGS-130AA - WGS-190AA WGS UNIT SIZE 130AA 140AA 160AA 170AA Unit capacity @ 44F LWT, 116.0 (407.9) 125.9 (442.7) 136.1 (478.5) 148.0 (520.4) 125F SDT, tons, (kW) No. Circuits 2 2 2 2 COMPRESSORS, FRAME 3 Nominal Horsepower 65 65 65 80 80 80 80 95 Number (2) 1 1 1 1 1 1 1 1 % Minimum Capacity (Modulated) 15 13/17 15 14/16 Oil Charge per Compressor oz., (l) 256 (7.6) 256 (7.6) 256 (7.6) 256 (7.6) CONDENSER (Remote) EVAPORATOR Number 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 Water Volume, gallons, (l) 68 (257) 68 (257) 115 (435) 115 (435) Refrig. Side D.W.P., psig, (kPa) 354 (2441) 354 (2441) 354 (2441) 354 (2441) Water Side D.W.P., psig, (kPa) 152 (1048) 152 (1048) 152 (1048) 152 (1048) Water Connections: Inlet & Outlet, in., (mm) victaulic 6.0 (152) 6.0 (152) 8.0 (203) 8.0 (203) Drain & Vent (NPT INT.) 0.5 0.5 0.5 0.5 UNIT DIMENSIONS (3) Length In., (mm) 179.3 (4554.2) 179.3 (4554.2) 179.3 (4554.2) 179.3 (4554.2) Width In., (mm) 34 (864) 34 (864) 34 (864) 34 (864) Height In., (mm) 60 (1524) 60 (1524) 61.8 (1570) 61.8 (1570) UNIT WEIGHTS (4) Operating Weight, lb., (kg) 6265 (2841) 6265 (2841) 7022 (3185) 7022 (3185) Shipping Weight, lb., (kg) 5659 (2567) 5659 (2567) 6024 (2732) 6024 (2732) Operating Charge per Circuit, 35 (15.9) 35 (15.9) 36 (16.5) 36 (16.5) lb., (kg) R-134a Notes: 1. Certified in accordance with ARI Standard 550/590-98. 2. Dimensions are without the optional sound enclosure. See dimension drawings for enclosure dimensions. 3. The optional sound enclosure adds 650 lbs (295 kg) to the shipping and operating weights.

26

WGS 130A to 190A

190AA 160.1 (562.9) 2 95 1

95 1

15 256 (7.6)

1 2 115 (435) 354 (2441) 152 (1048) 8.0 (203) 0.5 179.3 (4554.2) 34 (864) 61.8 (1570) 7022 (3185) 6024 (2732) 36 (16.5)

IMM1157

Unit Configuration The chiller unit has two refrigerant circuits, each with a single semi-hermetic rotary screw compressor, a shared two-circuited shell-and-tube evaporator, a water-cooled condenser, interconnecting refrigerant piping and refrigerant specialties. A single two-section control panel contains the control and starting equipment. Figure 14, Schematic Piping Diagram (One of Two Circuits) DISCHARGE TUBING

DISCHARGE SHUT-OFF AND CHECK VALVE SCHRADER VALVE

SUCTION SHUT-OFF VALVE (OPTIONAL)

SCREW COMPRESSOR PRESSURE RELIEF VALVE

CHARGING VALVE

SCHRADER VALVE SUCTION TUBING WATER OUT

PRESSURE RELIEF VALVE

WATER IN

ELECTRONIC EXPANSION VALVE DX EVAPORATOR

PRESSURE RELIEF VALVE

CHARGING VALVE

SCHRADER VALVE

WATER OUT

WATER COOLED CONDENSER

LIQUID TUBING

WATER IN

PACKAGE UNIT ONLY LIQUID SIGHT GLASS

LESS CONDENSER UNIT ONLY FIELD DISCHARGE CONNECTION.

SCHRADER VALVE (LESS CONDENSER ONLY) LIQUID FILTER DRYER

LIQUID SHUT-OFF VALVE

FIELD LIQUID CONNECTION.

330643901 -C010A WGS REFRIGERANT PIPING

Components Table 12, Major Components Unit Size

IMM 1157

Compressor Size Frame 3200 System #1

Condenser Size

Evaporator Size

System #2

System #1

System #2

130A

Small

Small

EV40271212

C1210-101

C1210-101

140A

Small

Medium

EV40271212

C1210-101

C1210-101

160A

Medium

Medium

EV50271313

C1210-101

C1210-101

170A

Medium

Large

EV50271313

C1210-121

C1210-121

190A

Large

Large

EV50271313

C1210-121

C1210-121

WGS 130A to 190A

27

Wiring Field Wiring, Power The WGS “A” vintage chillers are built standard with: 

Multi-point (2) power supply to a terminal block per circuit with no compressor isolation circuit breakers.

Optional power connections include:      

Multi-point power connection to a non-fused disconnect switches with through-the-door handle mounted in the control box in lieu of the power block Multi-point power connection to high interrupt rated disconnect switches with throughthe-door handle Multi-point power connection to high interrupt disconnect switches with through-thedoor handle in a high short circuit current rated panel Single point power connection to a terminal block with individual compressor isolation circuit breakers per circuit Single point power connection to high interrupt circuit breakers with through-the-door handles and with individual compressor isolation circuit breakers per circuit Single point power connection to a high interrupt rated disconnect switch in a high short circuit current rated panel and with individual compressor isolation circuit breakers per circuit.

A factory installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit. Circuit breakers for backup compressor short circuit protection are standard on all units. Wiring and conduit selections must comply with the National Electrical Code and/or local requirements. An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 30) give specific information on recommended wire sizes. NOTE: Use only copper conductors in main terminal block. Terminations are sized for copper only.

Field Wiring, Control A factory-mounted control transformer is provided to supply the correct control circuit voltage. The transformer power leads are connected to the power block PB1 or disconnect switch DS1.

Interlock Wiring, Condenser Pump Starter or Air-Cooled Condenser Fan Starter The MicroTech II controller can interlock a condenser pump starter, and tower fans, and control a tower bypass valve on water-cooled units. Up to six air-cooled condenser fan contactors per circuit can be controlled by the MicroTech II unit controller on remote condenser applications. Pressure switches supplied with the condenser can also control condenser fan operation. Coil voltage must be 115 volts with a maximum of 20 VA. An evaporator and condenser (water-cooled units only) flow switch is necessary on all units. It is also advisable to wire a chilled water pump interlock in series with the flow switch for additional evaporator freeze protection.

28

WGS 130A to 190A

IMM1157

Ambient Air Sensor Units with a remote air-cooled condenser will have an outdoor air sensor furnished with the unit inside the control panel and wired to the correct terminals. It must be installed outdoors in a location that will give the true outdoor temperature that the condenser coils will see. Splicing of the sensor lead may be required. The sensor must be installed for the unit to operate.

BAS Interface Connection to the chiller for all building automation systems (BAS) protocols is at the unit controller. An optional interface module, depending on the protocol being used, may have been factory-installed in the unit controller (or it can be field installed). Protocols Supported

Table 13, Standard Protocol Data Protocol

Physical Layer

Data Rate

Controller

Other

BACnet/IP or BACnet/Ethernet

Ethernet 10 Base-T

10 Megabits/sec

MicroTech II

Reference ED 15062

BACnet MSTP

RS-485

MicroTech II

Reference ED 15062

MicroTech II

Reference ED 15062

MicroTech II

Reference ED 15063



LONWORKS

FTT-10A

Modbus RTU

RS-485 or RS-232

9600, 19200 or 38400 bits/sec 78kbits/sec 9600 or 19200 bits/sec

The interface kits on the MicroTech II controller are as follows:  BACnet Kit P/N 350147404: BACnet/IP, BACnet MS/TP, or BACnet Ethernet  LONWORKS  Units equipped with a pCo2 (with DIP switches) for CP1 require Kit P/N 350147401.  Units equipped with a pCo3 (no DIP switches) for CP1 require Kit P/N 350147409.  Modbus: Modbus RTU Optional Open Choices™ BAS interfaces. The locations and interconnection requirements for the various standard protocols are found in their respective installation manuals. Modbus IM 743-2

LONWORKS IM 735-2

BACnet IM 736-2

Referenced documents may be obtained from the local Daikin sales office, from the local Daikin Service office, or from the Daikin Technical Response Center, located in Staunton, Virginia (540-248-0711). These documents can also be found on www.DaikinApplied.com under Product Information > (chiller type) > Control Integration.  The following are trademarks or registered trademarks of their respective companies: BACnet from the American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., LonTalk, LONMARK and LONWORKS from Echelon Corporation, and Modbus and Modbus RTU from Schneider Electric.

Remote Operator Interface Panel The box containing the optional remote interface panel will have installation instructions, IOM MT II Remote, shipped with it. The manual is also available for downloading from www.DaikinApplied.com .

IMM 1157

WGS 130A to 190A

29

Electrical Data Table 14, Electrical Data, Water-cooled, Single-Point Connection WGS UNIT SIZE

130AW

140AW

160AW

170AW

190AW

VOLTS

208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

POWER SUPPLY FIELD WIRE

MINIMUM CIRCUIT AMPACITY (MCA)

QTY

n/a n/a 243 201 162 n/a n/a 253 209 169 n/a n/a 261 216 174 n/a n/a 276 228 182 n/a n/a 288 237 189

n/a n/a 3 3 3 n/a n/a 3 3 3 n/a n/a 3 3 3 n/a n/a 3 3 3 n/a n/a 3 3 3

MIN. WIRE GAUGE n/a n/a 250 4/0 2/0 n/a n/a 250 4/0 2/0 n/a n/a 300 4/0 2/0 n/a n/a 300 4/0 3/0 n/a n/a 350 250 3/0

FIELD FUSE SIZE or BREAKER SIZE RECOMMENDED n/a n/a 300 225 200 n/a n/a 300 250 200 n/a n/a 300 250 200 n/a n/a 350 300 225 n/a n/a 350 300 225

MAXIMUM n/a n/a 350 250 225 n/a n/a 350 300 225 n/a n/a 350 300 250 n/a n/a 400 300 250 n/a n/a 400 300 250

Notes 1. Table based on 75°C field wire. 2. Complete notes are on page 40.

30

WGS 130A to 190A

IMM1157

Table 15, Electrical Data, Water-cooled, Multiple-Point Connection ELECTRICAL CIRCUIT 1 (COMP 1) WGS UNIT SIZE

130AW

140AW

160AW

170AW

190AW

ELECTRICAL CIRCUIT 2 (COMP 2)

MINIMUM POWER SUPPLY FIELD FUSING MINIMUM POWER SUPPLY VOLTS CIRCUIT FIELD WIRE FIELD WIRE CIRCUIT REC MAX AMPS AMPS FUSE FUSE MIN. WIRE MIN.WIRE QTY (MCA) QTY GAUGE (MCA) SIZE SIZE GAUGE

FIELD FUSING REC FUSE SIZE

MAX FUSE SIZE

208

247

3

250

300

400

247

3

250

300

400

230

223

3

4/0

300

400

223

3

4/0

300

400

380

135

3

1/0

175

225

135

3

1/0

175

225

460

112

3

2

150

200

112

3

2

150

200

575

90

3

3

110

150

90

3

3

110

150

208

247

3

250

300

400

267

3

300

350

450

230

223

3

4/0

300

400

240

3

250

300

400

380

135

3

1/0

175

225

145

3

1/0

175

250 200

460

112

3

2

150

200

120

3

1

150

575

90

3

3

110

150

97

3

3

125

150

208

267

3

300

350

450

267

3

300

350

450

230

240

3

250

300

400

240

3

250

300

400

380

145

3

1/0

175

250

145

3

1/0

175

250

460

120

3

1

150

200

120

3

1

150

200

575

97

3

3

125

150

97

3

3

125

150

208

267

3

300

350

450

292

3

350

350

500

230

240

3

250

300

400

263

3

300

350

450

380

145

3

1/0

175

250

160

3

2/0

200

250

460

120

3

1

150

200

132

3

1/0

175

225

575

97

3

3

125

150

105

3

2

150

175

208

292

3

350

350

500

292

3

350

350

500

230

263

3

300

350

450

263

3

300

350

450

380

160

3

2/0

200

250

160

3

2/0

200

250

460

132

3

1/0

175

225

132

3

1/0

175

225

575

105

3

2

150

175

105

3

2

150

175

NOTES: 1. Table based on 75°C field wire. 2. Complete notes are on page 40. 3/0 wire is required for the disconnect switch option, 2/0 may be used for power block connection. 3.

IMM 1157

WGS 130A to 190A

31

Table 16, Electrical Data, Remote Condenser, Single-Point Connection WGS UNIT SIZE

130AA

140AA

160AA

170AA

190AA

VOLTS

MINIMUM CIRCUIT AMPACITY (MCA)

208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

n/a n/a n/a 252 192 n/a n/a n/a 265 203 n/a n/a n/a 275 212 n/a n/a n/a 299 236 n/a n/a n/a 318 255

POWER SUPPLY FIELD WIRE MIN. WIRE QTY GAUGE n/a n/a n/a n/a n/a n/a 3 250 MCM 3 3/0 AWG n/a n/a n/a n/a n/a n/a 3 300 MCM 3 4/0 AWG n/a n/a n/a n/a n/a n/a 3 300 MCM 3 4/0 AWG n/a n/a n/a n/a n/a n/a 3 350 MCM 3 250 MCM n/a n/a n/a n/a n/a n/a 3 (2) 250 MCM 3 250 MCM

FIELD FUSE SIZE or BREAKER SIZE RECOMMAXIMUM MENDED n/a n/a n/a n/a n/a n/a 300 350 225 250 n/a n/a n/a n/a n/a n/a 300 350 250 250 n/a n/a n/a n/a n/a n/a 350 350 250 300 n/a n/a n/a n/a n/a n/a 350 400 300 300 n/a n/a n/a n/a n/a n/a 400 450 300 350

Notes 1. Table based on 75°C field wire. 2. Complete notes are on page 40.

32

WGS 130A to 190A

IMM1157

Table 17, Electrical Data, Remote Condenser, Multiple-Point Connection ELECTRICAL CIRCUIT 1 (COMP 1) WGS UNIT SIZE

130AA

140AA

160AA

170AA

190AA

ELECTRICAL CIRCUIT 2 (COMP 2)

MINIMUM POWER SUPPLY FIELD FUSING MINIMUM POWER SUPPLY VOLTS CIRCUIT FIELD WIRE FIELD WIRE REC. MAX CIRCUIT AMPS AMPS MIN.WIRE FUSE FUSE MIN. WIRE (MCA) QTY GAUGE (MCA) QTY GAUGE SIZE SIZE

FIELD FUSING REC. FUSE SIZE

MAX FUSE SIZE 500

208

290

3

350

350

500

290

3

350

350

230

263

3

300

350

450

263

3

300

350

450

380

160

3

2/0

200

250

160

3

2/0

200

250

460

140

3

1/0

175

250

140

3

1/0

175

250

575

107

3

2

150

175

107

3

2

150

175

208

290

3

350

350

500

334

3

400

450

600

230

263

3

300

350

450

300

3

350

400

500

380

160

3

2/0

200

250

182

3

3/0

225

300

460

140

3

1/0

175

250

153

3

2/0

200

250

575

107

3

2

150

175

118

3

1

150

200

208

334

3

2-250

450

600

334

3

2-250

450

600

230

300

3

350

400

500

300

3

350

400

500

380

182

3

3/0

225

300

182

3

3/0

225

300

460

153

3

2/0

200

250

153

3

2/0

200

250

575

118

3

1

150

200

118

3

1

150

200

208

334

3

2-250

450

600

390

6

2-250

500

700

230

300

3

350

400

500

353

3

2-250

450

600

380

182

3

3/0

225

300

223

3

4/0

300

400

460

153

3

2/0

200

250

177

3

3/0

225

300

575

118

3

1

150

200

142

3

1/0

175

250

208

390

6

2-250

500

700

390

6

2-250

500

700

230

353

3

2-250

450

600

353

3

2-250

450

600

380

223

3

4/0

300

400

223

3

4/0

300

400

460

177

3

3/0

225

300

177

3

3/0

225

300

575

142

3

1/0

175

250

142

3

1/0

175

250

NOTES: 1. Table based on 75°C field wire. 2. Complete notes are on page 40. 3/0 wire is required for the disconnect switch option, 2/0 may be used for power block connection. 3.

IMM 1157

WGS 130A to 190A

33

Table 18, Water-cooled, Compressor Amp Draw WGS UNIT SIZE

130AW

140AW

160AW

170AW

190AW

34

RATED LOAD AMPS VOLTS 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

CIRCUIT #1 CIRCUIT #2 197 178 108 89 72 197 178 108 89 72 213 192 116 96 77 213 192 116 96 77 233 210 128 105 84

197 178 108 89 72 213 192 116 96 77 213 192 116 96 77 233 210 128 105 84 233 210 128 105 84

WGS 130A to 190A

Table 19, Remote Condenser, Compressor Amp Draw WGS UNIT SIZE

130AA

140AA

160AA

170AA

190AA

RATED LOAD AMPS VOLTS 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

CIRCUIT #1 CIRCUIT #2 232 210 128 112 85 232 210 128 112 85 267 240 145 122 94 267 240 145 122 94 312 282 178 141 113

232 210 128 112 85 267 240 145 122 94 267 240 145 122 94 312 282 178 141 113 312 282 178 141 113

IMM1157

Table 20, Water-cooled, Field Wiring Information with Single-Point Power WGS UNIT SIZE

130AW

140AW

160AW

170AW

190AW

WIRING TO STANDARD UNIT POWER BLOCK VOLTS

208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

TERMINAL SIZE AMPS n/a n/a 400 400 400 n/a n/a 400 400 400 n/a n/a 400 400 400 n/a n/a 400 400 400 n/a n/a 400 400 400

CONNECTOR LUG RANGE PER PHASE (COPPER WIRE ONLY) n/a n/a #6-350 #6-350 #6-350 n/a n/a #6-350 #6-350 #6-350 n/a n/a #6-350 #6-350 #6-350 n/a n/a #6-350 #6-350 #6-350 n/a n/a #6-350 #6-350 #6-350

WIRING TO OPTIONAL NONFUSED DISCONNECT SWITCH IN UNIT CONNECTOR LUG RANGE SIZE PER PHASE AMPS (COPPER WIRE ONLY) n/a n/a n/a n/a 400 3/0-500 250 #6-350 250 #6-350 n/a n/a n/a n/a 400 3/0-500 250 #6-350 250 #6-350 n/a n/a n/a n/a 400 3/0-500 250 #6-350 250 #6-350 n/a n/a n/a n/a 400 3/0-500 250 #6-350 250 #6-350 n/a n/a n/a n/a 400 3/0-500 250 #6-350 250 #6-350

Table 21, Remote Condenser, Field Wiring Information with Single-Point Power WGS UNIT SIZE

130AA

140AA

160AA

170AA

190AA

IMM 1157

WIRING TO STANDARD UNIT POWER BLOCK VOLTS

208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

TERMINAL SIZE AMPS n/a n/a n/a 400 400 n/a n/a n/a 400 400 n/a n/a n/a 400 400 n/a n/a n/a 400 400 n/a n/a n/a 400 400

CONNECTOR LUG RANGE PER PHASE (COPPER WIRE ONLY) n/a n/a n/a #6-350 #6-350 n/a n/a n/a #6-350 #6-350 n/a n/a n/a #6-350 #6-350 n/a n/a n/a #6-350 #6-350 n/a n/a n/a #6-350 #6-350

WIRING TO OPTIONAL NONFUSED DISCONNECT SWITCH IN UNIT CONNECTOR LUG RANGE SIZE PER PHASE AMPS (COPPER WIRE ONLY) n/a n/a n/a n/a n/a n/a 400 3/0-500 250 #6-350 n/a n/a n/a n/a n/a n/a 400 3/0-500 250 #6-350 n/a n/a n/a n/a n/a n/a 400 3/0-500 250 #6-350 n/a n/a n/a n/a n/a n/a 400 3/0-500 250 #6-350 n/a n/a n/a n/a n/a n/a 400 3/0-500 400 3/0-500

WGS 130A to 190A

35

Table 22, Water-cooled, Field Wiring to Multiple-Point Power Block WIRING TO UNIT POWER BLOCK CONNECTOR WIRE RANGE PER VOLTS TERMINAL SIZE (AMPS) PHASE (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 1 CKT 2 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 130AW 380 #6-350 #6-350 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 140AW 380 #6-350 #6-350 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 160AW 380 #6-350 #6-350 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 170AW 380 #6-350 #6-350 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 190AW #6-350 #6-350 380 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 WGS UNIT SIZE

Table 23, Remote Condenser, Field Wiring to Multiple-Point Power Block WIRING TO UNIT POWER BLOCK CONNECTOR WIRE RANGE PER VOLTS TERMINAL SIZE (AMPS) PHASE (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 1 CKT 2 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 130AA #6-350 #6-350 380 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 140AA #6-350 #6-350 380 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 160AA #6-350 #6-350 380 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 170AA #6-350 #6-350 380 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350 208 400 400 #6-350 #6-350 230 400 400 190AA #6-350 #6-350 380 400 400 #6-350 #6-350 460 400 400 #6-350 #6-350 575 400 400 WGS UNIT SIZE

36

WGS 130A to 190A

IMM1157

Table 24, Water-cooled , Field Wiring to Multiple-Point Disconnect Switc WGS UNIT SIZE

130AW

140AW

160AW

170AW

190AW

VOLTS 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

WIRING TO UNIT DISCONNECT SWITCH TERMINAL SIZE CONNECTOR WIRE RANGE PER PHASE (AMPS) (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 1 CKT 2 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 400 #6-350 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 250 400 #6-350 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350

Table 25, Remote Condenser, Field Wiring to Multiple-Point Disconnect Switch WGS UNIT SIZE

130AA

140AA

160AA

170AA

190AA

IMM 1157

VOLTS 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575 208 230 380 460 575

WIRING TO UNIT DISCONNECT SWITCH TERMINAL SIZE CONNECTOR WIRE RANGE PER PHASE (AMPS) (COPPER WIRE ONLY) CKT 1 CKT 2 CKT 1 CKT 2 400 400 3/0-500 3/0-500 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350 400 400 3/0-500 3/0-500 400 400 3/0-500 3/0-500 250 250 #6-350 #6-350 250 250 #6-350 #6-350 250 250 #6-350 #6-350

WGS 130A to 190A

37

Wiring Diagrams Figure 15, WGS 130AW – 190AW Field Wiring Diagram UNIT MAIN DISCONNECT (BY OTHERS) TERMINAL BLOCK

GND LUG

3 PHASE

TO COMPRESSOR(S)

POWER SUPPLY

FUSED CONTROL CIRCUIT TRANSFORMER FU4

FU5 120 VAC

NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 600 VOLTS

FU7

TB1 (115 VAC)

TB1-2 ALARM BELL RELAY

1

BELL

2 82 CHWR

EVAP. PUMP RELAY #1 (BY OTHERS) 120 VAC 1.0 AMP MAX

2

85 CHWR

EVAP. PUMP RELAY #2 (BY OTHERS) 120 VAC 1.0 AMP MAX

2

86 CWR

COND. PUMP RELAY #1 (BY OTHERS) 120 VAC 1.0 AMP MAX

2

87 CWR

COND. PUMP RELAY #2 (BY OTHERS) 120 VAC 1.0 AMP MAX M11

TOWER FAN #1 (BY OTHERS) 120 VAC 1.0 AMP MAX

2

88 2

89 M12

TOWER FAN #2 (BY OTHERS) 120 VAC 1.0 AMP MAX

78 77

COOLING TOWER BYPASS (BY OTHERS)

FACTORY SUPPLIED ALARM FIELD WIRED ALARM BELL OPTION

80 79

(BY OTHERS)

ABR

81

ALARM BELL RELAY

ICE MODE SWITCH (BY OTHERS) EVAP. FLOW SWITCH (BY OTHERS)

OFF AUTO

NO

120 VAC N

120 VAC N

120 VAC N

120 VAC N

120 VAC N

120 VAC N

0-10VDC N 0-10VDC N 24 VAC

TB1 (24 VAC OR 30 VDC)

ON MANUAL OFF AUTO ON

NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL)

NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL)

*MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED 4-20MA FOR + EVAP. WATER RESET (BY OTHERS) 4-20MA FOR DEMAND LIMIT (BY OTHERS)

60 66

897

IF REMOTE STOP CONTROL IS USED, REMOVE LEAD 897 FROM TERM. 40 TO 53.

60

MANUAL

*MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED COND. FLOW SWITCH (BY OTHERS)

COM

2 ALARM BELL OPTION

75

TIME CLOCK

REMOTE STOP SWITCH (BY OTHERS)

2

1

+ -

68 60 67

60 76

72 70 71 70

DWG. 330588201 REV. 0B GND

38

WGS 130A to 190A

IMM1157

Figure 16, WGS 130AA – 190AA Field Wiring Diagram (Remote Condenser) UNIT MAIN DISCONNECT (BY OTHERS) TERMINAL BLOCK

GND LUG

3 PHASE

TO COMPRESSOR(S)

POWER

SUPPLY

FUSED CONTROL CIRCUIT TRANSFORMER FU4

FU5 120 VAC

NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 600 VOLTS

FU7

TB1 (115 VAC)

TB1-2 ALARM BELL RELAY

1

BELL

2

EVAP. PUMP RELAY #2 (BY OTHERS) 120 VAC 1.0 AMP MAX

FACTORY SUPPLIED ALARM FIELD WIRED

ALARM BELL OPTION

ABR

N

2

EVAP. PUMP RELAY #1 (BY OTHERS) 120 VAC 1.0 AMP MAX CHWR

120 VAC

82

CHWR

120 VAC

85

N

2

24 VAC

81

ALARM BELL RELAY

COM NO

2 ALARM BELL OPTION

1

75

CIRCUIT #1

CIRCUIT #2 TB6

M11

92

98

145

CONDENSER FAN CONTACTOR COIL #193 M12

98

146 145

CONDENSER FAN CONTACTOR COIL #294 M13

TB7 144

98

148

145

CONDENSER FAN CONTACTOR COIL #3

95 M14

98

CONDENSER FAN CONTACTOR COIL #4 96 M15

98

CONDENSER FAN CONTACTOR COIL #597 M16

98

150 145

152 145

154

145

CONDENSER FAN CONTACTOR COIL #6

NO1 2 NO2

2

NO3

2 C

120 VAC N

M21

N

J12 120 VAC

98

245

CONDENSER FAN CONTACTOR COIL #294 M23

246

98

248

245

CONDENSER FAN CONTACTOR COIL #3

C

NO4 2

NO5 2

NO6 2

95

120 VAC N

M24

120 VAC N

J13 (LOCATED ON CIRCUIT CONTROLLER)

98

M25

M26

OFF AUTO

98

97

254

245

NO1 2 NO2

2

NO3

2 C C NO4 2

NO5 2

NO6

2

120 VAC N 120 VAC N

J12 120 VAC

N

(LOCATED ON CIRCUIT CONTROLLER)

120 VAC N

120 VAC N

J13 (LOCATED ON CIRCUIT CONTROLLER)

120 VAC

N

TB1 (24 VAC)

ON

60

MANUAL

252 245

CONDENSER FAN CONTACTOR COIL #6

REMOTE STOP SWITCH (BY OTHERS)

96

98

CONDENSER FAN CONTACTOR COIL #5

120 VAC

250 245

CONDENSER FAN CONTACTOR COIL #4

N

TIME CLOCK

897

66

IF REMOTE STOP CONTROL IS USED, REMOVE LEAD 897 FROM TERM. 40 TO 53.

OFF AUTO

ICE MODE SWITCH (BY OTHERS)

EVAP. FLOW SWITCH (BY OTHERS)

(LOCATED ON CIRCUIT CONTROLLER)

M22

244

245

CONDENSER FAN CONTACTOR COIL #193

120 VAC

N

92

98

ON

60

MANUAL

68

60

NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL)

*MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED.

4-20MA FOR EVAP. WATER RESET (BY OTHERS) 4-20MA FOR DEMAND LIMIT (BY OTHERS)

+ -

67

72

70

+ -

71

70 GND

DWG. 330588101 REV. 0C

See notes on page 40.

IMM 1157

WGS 130A to 190A

39

Notes for “Electrical Data Single/Multiple Point” Power: 1. Wire sizing amps is 10 amps if a separate 115V power supply is used. 2. Unit wire size ampacity is equal to 125% of the largest compressor motor, plus 100% of the RLA of all other loads in the circuit, including the control transformer. 3. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Voltage drop has not been included. Therefore, power leads should be kept short. All terminal block connections must be made with copper (type THW) wire. 4. The recommended power lead wire sizes are based on an ambient temperature of 86°F (30°C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook. 5. The recommended fuse size or HACR circuit breaker size is equal to 150% of the largest compressor motor RLA plus 100% of the remaining compressor RLA. 6. The maximum fuse size or HACR circuit breaker size is equal to 225% of the largest compressor motor RLA plus 100% of the remaining compressor RLA. 7. Must be electrically grounded according to national and local electrical codes.

Power Limitations: 1. Voltage within  10 percent of nameplate rating. 2. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important requirement and must be adhered to.

Notes for “Electrical Data” 1. Requires a disconnect switch per circuit to supply electrical power to the unit. If field supplied, this power supply must either be fused or use an HACR type circuit breaker. 2. Use copper wiring to unit power block or optional non-fused disconnect switch. 3. All field wire size values given in table apply to 75°C rated wire per NEC.

Notes for Wiring Diagram Remote Condenser Units On remote condenser units, head pressure control by cycling fans can be accomplished several ways. The MicroTech II controller in the unit can be used. It senses discharge pressure and will stage up to 6 condenser fans when wired in accordance with Figure 16 on page 39. If the condenser has more than 6 fans, 2 can be operated on a step. For example, a condenser with 10 fans would have 2 fans on steps #1 through #4 and one fan each on steps #5 and #6. Condensers with less than 6 fans would use the appropriate MicroTech II steps beginning with #1. Wire so that the first-on, last-off fan stage has one fan on it. The Daikin ACD condensers have unit-mounted and wired single fan motor VFD combined with fan cycling by pressure switches for the balance of the fans available as an option. They can be used for staging fans instead of the WGS MicroTech II controller. See Ambient Air Sensor note on page 29.

Circuit Breakers The circuit breaker used in the High Short Circuit panel option may have a higher trip rating than the unit Maximum Overload Protection (MOP) value shown on the unit nameplate. The circuit breaker is installed as a service disconnect switch and does not function as branch circuit protection, mainly that the protection device must be installed at the point of origin of the power wiring. The breaker (disconnect switch) is oversized to avoid nuisance trips at high ambient temperature conditions.

40

WGS 130A to 190A

IMM1157

Figure 17, Schematic Diagram Legend Designation

Standard Location

Designation

Description

Standard Location

ABR

Alarm Bell Relay

Field Mounted

M12

Tower Fan 1

Field Mounted

BB

Bias Block

Outer Panel

PB1 / 2

Power Block

Inner Panel

CB1 / 2

Circuit Breaker

Inner Panel

REC

115V Outlet (Optional)

Outer Panel

Output Panel

RS1

Remote Stop Switch

Field Mounted

Output Panel

S1

System Shut-Off Switch

Outer Panel

Field Mounted

S01

Suction Pressure

Compressor

CB11 / 211 CB12 / 22 CHW1

Circuit Controller Output Breaker Circuit Controller Compr. Heater Chilled Water Flow Switch

CHWR

Chilled Water Relay

Field Mounted

S02

Discharge Pressure

Compressor

CWR

Cond. Water Relay

Field Mounted

S03

Liquid Pressure

Liquid Line

Field Mounted

S04

Suction Temperature

Compressor

Outer Panel

S05

Discharge Temperature

Compressor

S06

Liquid Temperature

Liquid Line

Outside Ambient

Behind Control

Temperature

Box

CWI Cir. Contr. 1 / 2

Cond. Water Flow Switch Circuit Controller

Behind Control

Compr 1 / 2

Compressors

DS ½

Disconnect Switch

Inner Panel

S07

FU4

T1 Primary Fuse

Inner Panel

S08

Box

FU5

T1 Primary Fuse

Inner Panel

S09

FU6

T1 Secondary Fuse

Inner Panel

FU7

Leaving Water Sensor Entering Water

Leaving Water Nozzle Entering Water

Temperature

Nozzle

S10

Demand Limit Reset

Field Mounted

S11

Leaving Water Reset

Field Mounted

CS

Circuit System Switch

Outer Panel

T1 Secondary Fuse

Inner Panel

115v Outlet Fuse

Cir. #2 Outer

(Optional)

Panel

GRD

Ground

Inner Panel

Load/Unload

Load/Unload Solenoid

Compressor

Htr-Compr

Compressor Heater

Compressor

T1

Control Transformer

Inner Panel

F3

MHP MHPR MS1 SSS ½

IMM 1157

Description

High Pressure Switch Mechanical High Pressure Relay Mode Switch Comp. Solid State Starter

Compressor

T2

Outer Panel

T13 / T23

Field Mounted

T14 / T24

Inner Panel

T15 / T25

Unit Contr. 24V Transformer Circuit Contr. 24V Transformer Comp. Load/Unload 24V Transformer EXV Driver 24V Transformer

Outer Panel Outer Panel Outer Panel Outer Panel

MJ

Mechanical Jumper

Control Box

TB1 – TB2

Terminal Blocks

Outer Panel

M11

Tower Fan 2

Field Mounted

WJ

Wire Jumper

Control Box

WGS 130A to 190A

41

Figure 18, WGS 130 - 190, Circuit Controller Schematic Wiring Diagram (SEE LINE 693) TO T15 116

114 20

120

1

T13 120V

2

5

24V

6

113 40

121

139

(SEE LINE 687)

MJ MJ

40 123

122

0-5 VDC

RED WHT BLK

0-5 VDC

RED WHT BLK

GO J1 G

EVAP PRESS TRANSDUCER (S01) J1 CONDENSER PRESS TRANSDUCER (S02) J2

J2

J3 BIAS 5 BIAS 6 SLIDE LOAD INDICATOR

21 VDC DC GROUND

1 2

25 26

SUCTION TEMP. (S04)

882 883

3

137 138

3

J4

1

J5

1

J11

DISCHARGE TEMP. (S05)

BLK RED

B120 OHMS

B4 BC4 B5 J3 BC5

BLK RED

A+ GND

PE

SHIELD 124

VG

125

VGD C1 Y1

J4

Y2

0-10VDC

EXV DRIVER

126

(SEE DETAIL 1)

J12

Y4

D3

SA-

BLACK

SB+

WHITE

A+

GREEN

B-

SCOM SHLD CIRCUIT SWITCH

NO1

Y3

127

GND

128

CS

NO2

NO3

C1

WJ

ID1 ID2

C4

ID3

NO4

FLT 164

165 TB1-6

TB1-7 PE

GRN

DIFFERENTIAL PRESSURE SWITCH

J5

DPS

BLK

WHT C

ID4

21

129

ID5

131

ID6

1

MHPR

MECHANICAL HIGH PRESSURE FAULT

130 2

4

ID7 ID8

132

IDC1

D I G IT A L O UT P U T S

STARTER FAULT

J13

NO5

NO6

C4

C7

J14

NO7

B6

C7

B7

NO8

MJ SLIDE LOAD INDICATOR

24

4-20MA

3

133

CONDENSER LEAVING WATER TEMP. (S12)

J6 BLK RED 134

3 2

PE

J15

B8

22 20

135

GND

C8

NC8

ID9

C9

ID10

NO9

OLS 1

GREEN

ID11 J7

J16

ID12

40

MOTOR GUARDISTOR

136

IDC9 NO12

J3-2

1

ID13H

2

J17

ID13

LP* REMOTE EVAP. ONLY. IN SERIES WITH 170

IDC13 ID14

42

OIL SEP. HEATER

C9

188

171

170

NOTES:

COMPRESSOR SSS CONTACT

NO10 NO11

DETAIL 2 - THERMISTOR CARD J3-1

MJ

1) * - REPRESENTS CIRCUIT 2) ONE HUNDRED SERIES FOR CIRCUIT #1 3) TWO HUNDRED SERIES FOR CIRCUIT #2

WGS 130A to 190A

C12 NC12

J8

NO13

J18

C13 NC13

ID14H

(LOWER LEVEL) CONTROLLER

IMM1157

Schematic Wiring Diagram (Continued) LINE NO. -601 -602 -603

TB1 1

105, 114, 116, 160

-604 -605

1 2

180

-606 -607

2 2

101, 113, 117,183 161, 187 177

-608 -609

3 4

181, MHP-1 182, 184, MHP-2

-610 -611

20 20

-612 -613

21 22

WHT, 129 3-OIL, 135

-614 -615

24 25

3-SLIDE, 133

-616 -617

26 27

-618 -619

28 30

172, 1-LOAD 173, 1-UNLOAD 176, 177

-620 -621

49 40

188, 189 123, 125

-622 -623

40 40

-624 -625

50 90

(RESISTOR USED ONLY AT END OF DAISY CHAIN)

-626 -627

91 92

WHITE

-628 -629

93

1

FU7

105 1

NB

103

T1 115V

102 2

101

(SEE LINE 694)

2

117

MJ

(p LAN) TO OTHER CIRCUIT CONTROLLERS AND UNIT CONTROLLER BLACK

GROUND

MHP

3 180

-630 -631

(TERMINATE AT EACH CONTROLLER)

CB11 1

TERMINAL BLOCK AND LEAD NUMBERS

181

1

-632 -633

MHPR

4 182

2

-634 -635

183 0

1

-636 -637

184 92 M*1

M*2

171 144 146

94 95

148 150

96 97

152

PE PE PE PE

154 GRN - OIL GRN - DPS GRN - LOAD GRN - UNLOAD

-642 -643

94 148

RED, 1-OIL, 136, 139 132, 134, RED 163, 2-LOAD, 2-UNLOAD, 190 170

-640 -641

93 146

1-SLIDE, 137 2-SLIDE, 138

-638 -639

98

144

122, 124 127, BLK, 130, 2-OIL

-644 -645

M*3

-646 -647 -648 -649 -650 -651

95 150 152

-652 -653 -654 -655

M*4 96

M*5

-656 -657

97 154

M*6

REMOTE COND.

-658 -659

T14 160 162

1

120V

5

24V

2

6

161

-660 -661

163

-662 -663 -664 -665

172

27

1

-666 -667

PE

(SEE LINE 690)

185

1 2 SV

LOAD SOLENOID PE

28 1

173

-668 -669

GRN

-670 -671

2

-672 -673

GRN 1

UNLOAD SOLENOID

-674 -675

2

SV

2

-676 -677

50

-678 -679

SSS RUN 186

CB12 176

177

189

-684 -685

197

HEATER

1

49

-682 -683

HTR-OIL SEP.

30 175

2

INT

ANALOG OUTPUT J4-Y3 126 TB1-40 139

SV

BLACK

190

-680 -681

187

K1

50

EXV MOTOR

185 TO: TB1-1

1 5

120V TO: TB1-2

117

-

195

+ 24V AC

196

- 24V AC

DETAIL 1 EXV DRIVER

T15 2 6

PUMPDOWN PUMPDOWN

192

SCHEM. 330588401 REV. 0B

IMM 1157

PID

WHITE GREEN RED

116

191

+

WGS 130A to 190A

-686 -687 -688 -689 -690 -691 -692 -693 -694 -695 -696 -697 -698 -699 -700

43

Figure 19, WGS 130 - 190, Unit Controller Schematic Wiring Diagram

812 75

813

60

MJ

801

PE 802 GO G

PE OUTSIDE AIR TEMP or COND. ENTERING WATER TEMP. (S07)

73

DEMAND LIMIT (S10)

BLK RED

B1

MJ

71

4-20MA

EVAP. WATER TEMP. RESET (S11)

70 72

4-20MA

804

B2

806

B3 GND

805 70

814 PE

J1

SHIELD

J2 J11 B-

+VDC

A+

SHIELD

EVAP. LEAVING WATER TEMP (S08) EVAP. ENTERING WATER TEMP (S09)

GND

BLK

B4

RED

BC4

BLK

B5

RED

BC5

884

VG

885

VG0

887

Y1

889

Y2

J3 C1

NO1

COOLING TOWER BYPASS

886

COOLING TOWER VFD

888

77

(0-10VDC)

78

79

(0-10VDC)

80

J4

Y3

Y4

UNIT SWITCH

S1

807

808

ID1

809

ID2

810

ID3

811

ID4

D IG IT AL OU T P UT S

J12

NO3 C1

C4

NO4

J13

CHWI

EVAP. FLOW SWITCH

RS1

66

C7

68

J14

CWI

COND. FLOW SWITCH

76 60 FACTORY INSTALLED FLOW SWITCHES

BRN BLU

60

BRN BLU

75

WHT

67

815

ID5

C7 ID6

ID7

75

WHT

NO7

J5

NO8

76

800

NOTE: J2-B1 OUTSIDE AIR TEMP. IS FOR TGS UNITS ONLY AND CONDENSER ENTERING WATER TEMP. IS FOR WGS UNITS ONLY.

44

C4

67

MS1

MODE SWITCH

NO5

NO6

897 REMOTE SWITCH

60

NO2

WGS 130A to 190A

ID8

J15

C8

NC8

IDC1

CONTROLLER

IMM1157

WGS 130 - 190, Unit Controller Schematic Wiring Diagram (Continued) 1

2

LINE NO.

CONTACT LOCATION

TERMINAL BLOCK AND LEAD NUMBERS

-301 -302

FU12

890 115V OUTLET

B

1

2

REC

W

891

PE

G

1

820, 822, 890

-304

2 60

821, 891 801, 807, 884

60 60

897, 830 812

75 75

800, 885 802, 886

75 75

813, 888

-305 -306 -307

MJ

-308 -309 -310 -311 -312

820

1

LINE 1

5

LOAD 1

T2 120V

2

24V

6

-313 -314

821

LINE 2

-315

LOAD 2

-316

MJ BIAS BLOCK

-317 -318 -319

-

(p LAN) TO CIRCUIT CONTROL BOXES BLACK

+

WHITE GROUND

(TERMINATE AT EACH CONTROLLER)

880

-320

TO UNIT CONTROLLER B-

-321

881

TO UNIT CONTROLLER A+

5

882

G

883 TO CIRCUIT CONTROLLER J4

-322 -323

TO CIRCUIT CONTROLLER J4

-324 -325 -326 -327

1 822

SEE LINE 301

-328 -329

EVAPORATOR PUMP 1

823

82

2

120V CHWR

-330 -331

EVAPORATOR PUMP 2 COND. PUMP 1

824 825

85

CHWR

120V

-332 -333

86

CWR

120V

TB1

-303

60 60 2 2 2 66

897, 809

67 68 70

810 811

70 71

806 804

72 73

805 814

76 77

815 886

78 79

887 888

80

889

81 82 83

829 823

84 85 86

824 825

87 88 89

826 827 828

-334 -335 -336 -337

WJ

-338 -339 -340

COND. PUMP 2

826

87

CWR

120V

-341 -342

TOWER FAN 1

TOWER FAN 2

827

828

88

M11

89

M12

120V

NOTE: TB1-75 THRU TB1-89 ARE FIELD WIRING TERMINALS.

-343 -344

120V

-345 -346 -347 -348 -349 -350 -351 -352 -353 -354 -355 -356

UNIT ALARM

829 830

81 60

ABR

75

SEE LINE 306

-357 -358 -359

SEE LINE 307

-360 -361 -362 -363 -364

SCHEM. 330588301 REV. 0B

IMM 1157

WGS 130A to 190A

-365

45

Control Panel Layout Figure 20, Outer (Microprocessor) Panel T2, Unit Controller T13, Circ#1 Controller T14, Circ#1 Load Solenoid T15, Circ#1 EXV Power T23, Circ#2 Controller T24, Circ#2 Load Solenoid T25, Circ#2 EXV Power Unit Controller MHPR11 &12, Mechanical High Pressure Relay

Circ#1 Controller Circuit Breaker & Switch Panel External Disconnect Handle Circ#1 & 2 EXV Drivers

Circ#2 Controller

TB3, Circ#2 Controller Terminal Board TB2Circ#1 Controller Terminal Board TB1 Unit Controller Terminal Board

NOTES: 1. 2. 3.

46

Transformers T2 through T25 are class 100, 120V to 12V. Switches for MHPR 11 and 12 (Mechanical High Pressure Switches) are located on the compressors. Mechanical High Pressure Switches Open at 310 psi, Close at 250 psi

WGS 130A to 190A

IMM1157

Figure 21, Inner (Power) Panel Circ#1 Solid State Starter

Circ#2 Solid State Starter

SSS1 Bypass Contactor SSS2 Bypass Contactor

Secondary Fuses External Disconnect Handle Circ#1 Circuit Breaker Circ#2 Circuit Breaker

Unit Disconnect Switch W/ External Handle T1, Supply Voltage to 120V Transformer Primary Fuses

Outside (Microprocessor) Panel

IMM 1157

WGS 130A to 190A

47

Figure 22, Circuit Breaker/Fuse Panel Open Location S1 Main Unit On-Off Switch CS2, Circuit#2 On-Off Switch CS1, Circuit#1 On-Off Switch CB11 Circ#1 Circuit Breaker CB12, Circ#1 Sump Heater Open Location CB21, Circ#2 Circuit CB22, Circ#2 Sump Heater Open Locations Location for Optional 115V Receptacle

Figure 23, Inner and Outer Panel Diagrams OUTER PANEL T2

T13

T14

T15

INNER PANEL

T23

T24

T25

MHPR 1

MHPR 2

UNIT CONTROLLER

SSS #1 D3 CONTR. BRD.

S 1

SSS #2 D3 CONTR. BRD.

THERMISTOR CARD

BYPASS CONTACTOR

CS2

CS1

EXV. DRIVER #1

SINGLE POINT OR CIR. #1 DS HANDLE (MULTIPOINT)

S P

CT3

THERMISTOR CARD

BYPASS CONTACTOR

CT1

CT3

CT2

CT1 CT2

CB11 CB12

CIRCUIT CONTROLLER #1

SP CB21 CB22

MODBUS CARD

SP

CONVERTER BOARD

CIR. #2 DS HANDLE (MULTIPOINT)

F U 6

FU7 F3

EXV. DRIVER #2

T1

C B 1

C B 2 DS1

CIRCUIT CONTROLLER #2

TB1

TB11

REC OPTION

F U 4

F U 5

(DS1 DS2 MULTIPOINT POWER)

G N D

TB21

330589001 REV. 00 - Legend

48

WGS 130A to 190A

IMM1157

Sequence of Operation Compressor Heaters With the control power on, 120V power is applied through the control circuit Fuse FU7 to the compressor oil separator heater(HTR-OIL SEP).

Startup/Compressor Staging During cool mode the following must be true to start a circuit operating. The evaporator and condenser pump outputs must be energized and flow must be established for a period of time defined by the evaporator recirculate setpoint. Established flow will be detected by evaporator and condenser water flow switches. The water temperature leaving the evaporator must be greater than the Active Leaving Water Temperature setpoint, plus the Startup Delta-T, before a circuit will start. The first circuit to start is determined by sequence number. The lowest sequence numbered circuit will start first. If all sequence numbers are the same (default), then the circuit with the fewest number of starts will start first. During operation the slides for load and unload will be pulsed such that the active leaving water temperature setpoint is maintained. The second circuit start will occur once the first circuit has loaded to 75% slide capacity or is in Capacity Limit and the water temperature leaving the evaporator is greater than the active leaving water temperature Setpoint plus Stage Delta-T. The circuits will load or unload simultaneously through a continuous capacity control to maintain the evaporator leaving water temperature. If all sequence numbers are the same, the circuit with the most run hours will be shutdown first. The circuit with the most run hours will stop when the water temperature leaving the evaporator is less than the Active Leaving Water Temperature Setpoint minus Stage Delta-T. The last remaining circuit will shutdown when the water temperature leaving the evaporator is greater than the Active Leaving Water Temperature Setpoint minus the Stop Delta-T.

Automatic Pumpdown The WGS has separate refrigerant circuits so the refrigerant charge is stored in the condenser when the circuit is off. Pumpdown to the condenser helps keep refrigerant from migrating to the compressor. It also helps establish a pressure differential on start for oil flow. In a normal shutdown, each circuit will close its expansion valve, causing the evaporator pressure to reach a low-pressure setpoint. Once this setpoint is reached, or a specified amount of time has elapsed, the running circuit will be shut down.

Chilled Water and Condenser Water Pumps The chiller’s MicroTech II controller has a total of four pump outputs, two for the evaporator and two for the condenser. There is a manual setting in the software for the user to select either pump output 1 or 2. It is recommended that the chiller’s outputs control the water pumps, as this will offer the most protection for the unit.

Cooling Tower Control The MicroTech II controller can control the cooling tower fans and/or a tower bypass valve. This provides a simple and direct method to control the unit’s discharge pressure. Programming directions and the sequence of operation can be found in the MicroTech II manual. Some means of discharge pressure control must be installed if the condenser water temperature can fall below the values shown on page Error! Bookmark not defined..

Condenser Fan Control The MicroTech II controller can be programmed to cycle on and off condenser fans based on the discharge pressure. Details are in the MicroTech II manual.

IMM 1157

WGS 130A to 190A

49

Start-Up and Shutdown Pre Start-up 1. Flush and clean the chilled-water system. Proper water treatment is required to prevent corrosion and organic growth. 2. With the main disconnect open, check all electrical connections in control panel and starter to be sure they are tight and provide good electrical contact. Although connections are tightened at the factory, they can loosen enough in shipment to cause a malfunction. 3. Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser. 4. Open all water flow valves to the condenser and evaporator. 5. Flush the cooling tower and system piping to be sure the system is clean. Start evaporator pump and manually start condenser pump and cooling tower. Check all piping for leaks. Vent the air from the evaporator and condenser water circuit, as well as from the entire water system. The cooler circuit should contain clean, treated, noncorrosive water. 6. Check to see that the evaporator water temperature sensor is securely installed. 7. Make sure the unit control switch S1 is open (off) and the circuit switches CS1 and CS2 are open. Place the main power disconnect switch to “on.” This will energize the compressor sump heaters. Wait a minimum of 12 hours before starting the unit. 8. Measure the water pressure drop across the evaporator and condenser, and check that water flow is correct (on pages 16 and 17) per the design flow rates. 9. Check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate, within + 10%, and that phase voltage unbalance does not exceed 2%. Verify that adequate power supply and capacity is available to handle load. 10. Make sure all wiring and fuses are of the proper size. Also make sure that all interlock wiring is completed per Daikin diagrams. 11. Verify that all mechanical and electrical inspections by code authorities have been completed. 12. Make sure all auxiliary load and control equipment is operative and that an adequate cooling load is available for initial start-up.

Start-up 1. Open the compressor discharge shutoff valves until backseated. Always replace valve seal caps. 2. Open the two manual liquid line shutoff valves (king valves). 3. Verify that the compressor sump heaters have operated for at least 12 hours prior to start-up. Crankcase should be warm to the touch. 4. Check that the MicroTech II controller is set to the desired chilled water temperature. 5. Start the system auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch and water pumps. 6. Switch on the unit circuit breakers. 7. Set circuit switches CS1 and CS2 to ON for normal operation. 8. Start the system by setting the unit system switch S1 to ON. 9. After running the unit for a short time, check the oil level in each compressor, rotation of condenser fans (if any), and check for flashing in the refrigerant sight glass.

50

WGS 130A to 190A

IMM1157

Weekend or Temporary Shutdown Move circuit switches CS1 and CS2 to the off pumpdown position. After the compressors have shut off, turn off the chilled water pump if not on automatic control from the chiller controller or building automation system (BAS). With the unit in this condition, it will not restart until these switches are turned back on. Power to the unit (disconnect closed) so that the sump heaters will remain energized.

Start-up after Temporary Shutdown 1. Start the water pumps. 2. Check compressor sump heaters. Compressors should be warm to the touch. 3. With the unit switch S1 in the “ON” position, move the circuit switches CS1 and CS2 to the ON position. 4. Observe the unit operation for a short time, noting unusual sounds or possible cycling of compressors.

Extended Shutdown 1. 2. 3. 4. 5. 6.

Close the manual liquid line shutoff valves. After the compressors have shut down, turn off the water pumps. Turn off all power to the unit. Move the unit control switch S1 to the “OFF” position. Close the discharge shutoff valves. Tag all opened disconnect switches to warn against start-up before opening the compressor suction and discharge valves. 7. Drain all water from the unit evaporator, condenser and chilled water piping if the unit is to be shut down during the winter and exposed to below-freezing temperatures. Do not leave the vessels or piping open to the atmosphere over the shutdown period to help prevent excessive corrosion.

Start-up after Extended Shutdown 1. Inspect all equipment to see that it is in satisfactory operating condition. 2. Remove all debris that has collected on the surface of the condenser coils (remote condenser models) or check the cooling tower, if present. 3. Open the compressor discharge valves until backseated. Always replace valve seal caps. 4. Open the manual liquid line shutoff valves. 5. Check circuit breakers. They must be in the “OFF” position. 6. Check to see that the circuit switches CS1 and CS2 and the unit control switch S1 are in the “OFF” position. 7. Close the main power disconnect switch. The circuit disconnects switches should be off. 8. Allow the sump heaters to operate for at least 12 hours prior to start-up. 9. Start the chilled water pump and purge the water piping as well as the evaporator in the unit. 10. Start the system auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch. 11. Check that the MicroTech II controller is set to the desired chilled water temperature. 12. Switch the unit circuit breakers to “ON.” 13. Start the system by setting the system switch S1 and the circuit switches to “ON”. !

IMM 1157

WGS 130A to 190A

CAUTION

51

Most relays and terminals in the control center are powered when S1 is closed and the control circuit disconnect is on. Therefore, do not close S1 until ready for start-up or serious equipment damage can occur.

14. After running the unit for a short time, check the oil level in the compressor oil sight glass and check the liquid line sight glass for bubbles.

System Maintenance General To provide smooth operation at peak capacity and to avoid damage to package components, set and follow a program of periodic inspections. The following items are intended as a guide to be used during inspection and must be combined with sound refrigeration and electrical practices to help provide trouble-free performance. The liquid line sight glass/moisture indicator on all circuits must be checked to be sure that the glass is full and clear and that the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed. Water supplies in some areas can foul the water-cooled condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high condenser approach temperature (saturated discharge temperature minus leaving condenser water temperature) and can result in nuisance trip-outs. To clean the condenser, mechanical cleaning or a chemical descaling solution should be used according to the manufacturer’s directions. Systems with remote air-cooled condensers require periodic cleaning of the finned surface of the condenser coil. Cleaning can be accomplished by using a cold water spray, brushing, vacuuming, or high-pressure air. Do not use tools that could damage the coil tubes or fins. The compressor oil level must be checked periodically to be sure that the level is near the center of the oil sight glass located on the compressor (see Figure 24). Low oil level can cause inadequate lubrication and if oil must be added, use oils referred to in the following “Compressor Lubrication” section. A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid valve but before the expansion valve. An accurate subcooled liquid pressure and temperature can be taken here. The pressure read here could also provide an indication of excessive pressure drop through the filter-drier and solenoid valve due to a clogging filterdrier. Note: A normal pressure drop through the solenoid valve is approximately 3 psig (20.7 kPa) at full load conditions. !

CAUTION

A blown fuse or tripped protector indicates a short ground or overload. Correct the problem before replacing fuses or restarting compressor. The control panel must be serviced by a trained and qualified technician. Improper service can damage equipment.

52

WGS 130A to 190A

IMM1157

CAUTION

!

The panel is always energized, even when the system switch is off. Pull the main unit disconnect to de-energize the panel and crankcase heaters. Failure to do so can result in severe personal injury or death. If motor or compressor damage is suspected, do not restart until qualified service personnel have checked the unit.

Electrical Terminals DANGER

!

To avoid severe injury or death from electric shock, turn off all power and lockout and tagout electric source before continuing with the following service. Note unit might be powered from multiple sources.

POE Lubrication !

WARNING

This unit contains POE lubricants that must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate piping).

No routine lubrication is required on WGS units. Compressor oil must be ICI RL68HB, Daikin Part Number 735030446 in a 1-gallon container. This is synthetic polyolester oil with anti-wear additives and is highly hygroscopic. Care must be taken to minimize exposure of the oil to air when charging oil into the system. Figure 24, Compressor Oil Filter The Lub Control measures the pressure drop across the lubricant filter and shuts off the compressor if the differential pressure becomes too high. It is reset through the circuit controller. Change oil when pressure drop exceeds 15 psig. Compressor Oil Filter Lub Control Oil Level Sight Glass

IMM 1157

WGS 130A to 190A

53

Sight Glass and Moisture Indicator The refrigerant sight glasses should be observed periodically. A monthly observation should be adequate. A clear glass of liquid indicates that there is adequate refrigerant charge in the system to provide proper feed through the expansion valve. The sight glass should be clear when the ambient temperature is above 75F (23C) and all fans on a circuit are running, when air cooled. Bubbling refrigerant in the sight glass may occur at other conditions and may indicate that the system is short of refrigerant charge. Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. An element inside 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 pumped down and the filter-driers changed. If the system is suspected of being short of refrigerant, a qualified service technician with EPA certification should be contacted to thoroughly check out the unit and add refrigerant if necessary.

Sump Heaters The compressors are equipped with sump lubricant heaters. The function of the heater is to keep the temperature in the crankcase high enough to prevent refrigerant from migrating to the crankcase and condensing in the lubricant during the off-cycle. When a system is to be started up initially, the power to the heaters should be turned on for at least 12 hours before the compressors are started. The sump should be up to about 80°F (26.7°C) before the system is started up (warm to the touch), to minimize lubrication problems or liquid slugging of compressor on start-up. If the crankcase is cool (below 80°F) (26.7°C) and the oil level in the sight glass is full to top, allow more time for oil to warm before starting the compressor. The crankcase heaters are on whenever power is supplied to the unit and the compressor is not running.

54

WGS 130A to 190A

IMM1157

Maintenance Schedule

I. Compressor A. Performance Evaluation (Log & Analysis) * B. Motor  Meg. Windings  Ampere Balance (within 10%)  Terminal Check (tight connections, porcelain clean)  Motor Cooling (check temperature) C. Lubrication System  Oil Level  Oil Appearance (clear color, quantity)  Oil change if indicated by oil analysis II. Controls A. Operating Controls  Check Settings and Operation B. Protective Controls  Test Operation of: Alarm Relay Pump Interlocks High and Low Pressure Cutouts III. Condenser B. Test Water Quality C. Clean Condenser Tubes (or as required) D. Eddy current Test - Tube Wall Thickness E. Seasonal Protection IV. Evaporator B. Test Water Quality C. Clean Evaporator Tubes (or as required) D. Eddy current Test - Tube Wall thickness (or as required) E. Seasonal Protection V. Expansion Valves A. Performance Evaluation (Superheat Control) VI. Compressor - Chiller Unit A. Performance Evaluation B. Leak Test:  Compressor Fittings and Terminal  Piping Fittings  Vessel Relief Valves C. Vibration Isolation Test D. General Appearance:  Paint  Insulation VII. Starter(s) A. Examine Contactors (hardware and operation) B. Verify Overload Setting and Trip C. Test Electrical Connections Key: O = Performed by in-house personnel

IMM 1157

O X X X X O O

X X

X

X X X X X X X X X X X X O X X X X X X X X X

X = Performed by service personnel

WGS 130A to 190A

55

System Service DANGER

!

Service on this equipment must be performed by trained, experienced technicians. Causes for repeated tripping of equipment protection controls must be investigated and corrected. Disconnect all power (there may be multiple sources) before doing any service inside the unit or severe personal injury or death can occur.

NOTE: Anyone servicing this equipment must comply with the requirements set forth by the EPA concerning refrigerant reclamation and venting.

Filter-Driers Figure 25, FIlter-Drier Assembly There is a filter-drier assembly for each circuit located in the liquid line. The cartridges should be changed when the pressure drop across them exceeds the values shown in Table 26 below, when measured at the Schrader fittings before and after the housing. To change the filter:

Expansion Valve

Evaporator

Sensor Schrader Fitting

Filter-Drier Sight Glass

Schrader Fitting Condenser

Liquid Line Valve

Expansion Valve

1. Shut off the circuit. This will close the expansion valve. 2. Shut off the condenser liquid shutoff valve, isolating the filterdrier. 3. Remove any remaining refrigerant from one of the Schrader valves using approved EPA procedures.

4. Remove the housing cover, after checking that there is no positive pressure in the filterdrier. 5. Replace the filters, reinstall the cover, evacuate, and open the liquid line valve. Table 26, Liquid Line Filter-Drier Pressure Drop

56

PERCENT CIRCUIT

MAXIMUM RECOMMENDED PRESSURE

100% 75%

7 (48.3) 5 (34.5)

50%

3 (20.7)

25%

3 (20.7)

WGS 130A to 190A

IMM1157

Electronic Expansion Valve The electronic expansion valve is located in the liquid line entering the evaporator. The expansion valve meters the amount of refrigerant entering the evaporator to match the cooling load. It does this by maintaining constant condenser subcooling. (Subcooling is the difference between the actual refrigerant temperature of the liquid as it leaves the condenser and the saturation temperature corresponding to the condenser pressure.) All WGS chillers are factory set at 20F subcooling at 100% slide position and 10F (12.2C) subcooling at minimum slide position. These settings can be offset by discharge superheat. When the control panel is first powered, the microprocessor will automatically step the valve to the fully closed (shut) position and the indicator light on the EXV will show closed position. The valve can also be heard closing as it goes through the steps. The valve will take approximately 30 seconds to go from a full open position to a full closed position. The position of the valve can be viewed at any time by using the MicroTech II controller keypad through the View Refrigerant menus. There are 6386 steps between closed and full open. There is also a sight glass on the EXV to observe valve movement. If the problem can be traced to the power element only, it can be unscrewed from the valve body without removing the valve, but only after pumping the unit down.

Evaporator The evaporator is a shell-and-tube unit. Normally no service work is required on the evaporator.

Water-cooled Condenser The condensers are of the shell-and-tube type with water flowing through the tubes and refrigerant in the shell. External finned copper tubes are rolled into steel tube sheets. Integral subcoolers are incorporated on all units. All condensers are equipped with 350 psig (2413 kPa) relief valves. Normal tube cleaning procedures can be followed.

IMM 1157

WGS 130A to 190A

57

Troubleshooting Chart PROBLEM 1. 2.

Compressor Noisy or Vibrating

3.

6. 7. 8.

No cooling required. Liquid line solenoid will not open. Motor electrical trouble.

6. 7. 8.

9.

Loose wiring.

9.

1.

Flooding of refrigerant into compressor.

1.

2.

Improper piping support on suction or liquid line. Worn compressor. Condenser water insufficient or temperature too high.

2.

2.

3. 4. 5. 6.

Fouled condenser tubes (water-cooled condenser). Clogged spray nozzles (evaporative condenser). Dirty tube and fin surface (air cooled condenser). Noncondensables in system. System overcharge with refrigerant. Discharge shutoff valve partially closed. Condenser undersized (air-cooled).

7.

High ambient conditions (air-cooled).

7.

1. 2. 3.

Faulty condenser temp. regulation. Insufficient refrigerant in system. Low suction pressure.

1. 2. 3.

4.

Condenser too large.

4.

5.

Low ambient conditions (air-cooled)

5.

1.

Excessive load.

1.

2. 1. 2. 3. 4.

Expansion valve overfeeding. Lack of refrigerant. Evaporator dirty. Clogged liquid line filter-drier. Expansion valve malfunctioning.

2. 1. 2. 3. 4.

5.

Condensing temperature too low.

5.

6.

Compressor will not unload.

6.

7. 1. 2.

Insufficient water flow. Clogged suction oil strainer. Excessive liquid in crankcase.

7. 1. 2.

3. 4.

Low oil level. Flooding of refrigerant into crankcase.

3. 4.

4. 5.

3. 1. 2. High Discharge Pressure

Low Discharge Pressure

High Suction Pressure

Low Suction Pressure

1. 2.

Thermal overloads tripped or fuses blown. Defective contactor or coil. System shut down by equipment protection devices.

3. Compressor Will Not Run

POSSIBLE CAUSES Main switch, circuit breakers open. Fuse blown.

4. 5.

3. 1.

3. 4. 5. 6.

Little or No Oil Pressure

58

WGS 130A to 190A

POSSIBLE CORRECTIVE STEPS Close switch Check electrical circuits and motor winding for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected. Overloads are auto reset. Check unit closely when unit comes back on line. Repair or replace. Determine type and cause of shutdown and correct it before resetting protection switch. None. Wait until unit calls for cooling. Repair or replace coil. Check motor for opens, short circuit, or burnout. Check all wire junctions. Tighten all terminal screws. Check superheat setting of expansion valve. Relocate, add or remove hangers. Replace. Readjust temperature control or water regulating valve. Investigate ways to increase water supply. Clean.

EPA purge the noncondensables. Remove excess refrigerant. Open valve. Check condenser rating tables against the operation. Check condenser rating tables against the operation. Check condenser control operation. Check for leaks. Repair and add charge. See corrective steps for low suction pressure below. Check condenser rating table against the operation. Check condenser rating tables against the operation. Reduce load or add additional equipment. Check remote bulb. Regulate superheat. Check for leaks. Repair and add charge. Clean chemically. Replace cartridge(s). Check and reset for proper superheat. Replace if necessary. Check means for regulating condensing temperature. See corrective steps for failure of compressor to unload. Adjust flow. Clean. Check sump heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation. Add oil. Adjust expansion valve.

IMM1157

PROBLEM Compressor Loses Oil

Motor Overload Relays or Circuit Breakers Open

Compressor Thermal Switch Open Freeze Protection Opens

1.

POSSIBLE CAUSES Lack of refrigerant.

1.

2. 3.

Velocity in risers too low (A-C only). Oil trapped in line.

2. 3.

1.

Low voltage during high load conditions.

1.

2.

Defective or grounded wiring in motor or power circuits. Loose power wiring. High condensing temperature.

2.

5.

Power line fault causing unbalanced voltage.

5.

6.

6.

1.

High ambient temperature around the overload relay Operating beyond design conditions.

2. 1. 2. 3.

Discharge valve partially shut. Thermostat set too low. Low water flow. Low suction pressure.

2. 1. 2. 3.

3. 4.

3. 4.

1.

POSSIBLE CORRECTIVE STEPS Check for leaks and repair. Add refrigerant. Check riser sizes. Check pitch of lines and refrigerant velocities. Check supply voltage for excessive line drop. Replace compressor-motor. Check all connections and tighten. See corrective steps for high discharge pressure. Check Supply voltage. Notify power company. Do not start until fault is corrected. Provide ventilation to reduce heat. Add facilities so that conditions are within allowable limits. Open valve. Reset to 42°F (6°C) or above. Adjust flow. See “Low Suction Pressure.”

Warranty Statement Limited Warranty Daikin International’s written Limited Product Warranty and any other expressly purchased Extended Warranty are the only warranties applicable. Consult your local Daikin Representative for warranty details. Refer to Form 933-430285Y. To find your local Daikin Representative, go to www.DaikinApplied.com .

IMM 1157

WGS 130A to 190A

59

60

WGS 130A to 190A

IMM1157

Daikin 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 to speak to the Training Department. Warranty All Daikin equipment is sold pursuant to Daikin’s Standard Terms and Conditions of Sale and Limited Product Warranty. Consult your local Daikin Representative for warranty details. Refer to form 933-430285Y. To find your local representative, go to www.DaikinApplied.com This document contains the most current product information as of this printing. For the most up-to-date product information, please go to www.DaikinApplied.com .

(800) 432-1342  www.DaikinApplied.com

IMM 1157 (3/12)