WGS 130AW to WGS 190AW, Packaged Water-Cooled Chiller .... The electrical
control center includes a MicroTech II™ microprocessor control system ... The
contractor should obtain a copy of the Start-up Scheduled Request Form from the
.
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 16F, 10F, and 6F 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 @ 44F LWT, 116.0 (407.9) 125.9 (442.7) 136.1 (478.5) 148.0 (520.4) 125F 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 75F (23C) 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 20F subcooling at 100% slide position and 10F (12.2C) 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)