Water Cooled Two-Stage Centrifugal Chillers HTV M, L, G, K ... · Water Cooled Two-Stage...

Water Cooled Two-Stage Centrifugal Chillers

HTV M, L, G, K Cooling Only

400 to 1500 TONS (1400 to 5275 kW)

HFC - 134a

Thanks for purchasing DAIKIN chiller.

The Manual specifies precautions about safety,

installation and maintenance.

Please read it carefully before installation and use.

For future reference, please be sure to keep it well.

Engineered for Flexibility and Performance

HTV

Group: Water Cooled Chiller

Time: May 2015

New Part No.: Z8050007-02

Old Part No.: Z8050007-01

Installation and Maintenance Manual

Installation and Maintenance Manual for Water Cooled Two-Stage Centrifugal Chillers

Engineered for Flexibility and Performance i

Table of Contents

SAFETY INSTRUCTIONS ............................................................................................................................................... 1

I. INTRODUCTION ....................................................................................................................................................... 2

1.1 GENERAL DESCRIPTION ................................................................................................................................................... 2 1.2 APPLICATION ................................................................................................................................................................. 2 1.3 NOMENCLATURE ............................................................................................................................................................ 3

II．COMPONENTS AND OPERATION ........................................................................................................................... 4

2.1 CONDENSER/SUBCOOLER ................................................................................................................................................ 5 2.2 EXPANSION VALVE .......................................................................................................................................................... 5 2.3 ECONOMIZER AND TWO-STAGE COMPRESSOR ..................................................................................................................... 6 2.4 EVAPORATOR ................................................................................................................................................................ 6 2.5 LUBRICATION SYSTEM ..................................................................................................................................................... 7 2.7 MOTOR COOLING .......................................................................................................................................................... 8 2.8 OIL RETURN CONTROL .................................................................................................................................................... 9

III. FEATURES OF THE CONTROL PANEL ...................................................................................................................... 11

3.1 RESPONSIBILITY OF OPERATOR ........................................................................................................................................ 11 3.2 STANDBY POWER ......................................................................................................................................................... 11 3.3 MICROTECH II CONTROL ............................................................................................................................................... 11 3.4 CAPACITY CONTROL SYSTEM .......................................................................................................................................... 13

IV. INSTALLATION ...................................................................................................................................................... 14

4.1 RECEIVING AND HANDLING ............................................................................................................................................ 14 4.2 LOCATION AND MOUNTING ........................................................................................................................................... 16 4.3 OPERATING/STANDBY LIMITS ......................................................................................................................................... 17 4.4 INSTALLATION SITE SELECTION AND FOUNDATION WORKS .................................................................................................... 18

Vibration Pads .......................................................................................................................................................... 18 Mounting .................................................................................................................................................................. 18 Installation Base ....................................................................................................................................................... 18 Spring damper .......................................................................................................................................................... 21 Nameplates .............................................................................................................................................................. 22

4.5 SYSTEM WATER VOLUME............................................................................................................................................... 22 4.6 LOW CONDENSER WATER TEMPERATURE OPERATION ......................................................................................................... 23 4.7 WATER PIPING ............................................................................................................................................................ 24

Water Pumps ............................................................................................................................................................ 24 Vessel Drains at Start-up ........................................................................................................................................... 24 Draining Vessels ........................................................................................................................................................ 24 Evaporator and Condenser Water Piping ................................................................................................................. 24 Water Flow Sensors .................................................................................................................................................. 25 Cooling Towers.......................................................................................................................................................... 25

4.8 THERMAL INSULATION .................................................................................................................................................. 25 4.9 LUBRICATION SYSTEM ................................................................................................................................................... 27 4.10 RELIEF VALVES ........................................................................................................................................................... 28

Refrigerant Vent Piping ............................................................................................................................................. 28 4.11 PUMPDOWN ............................................................................................................................................................. 29

V. ELECTRICAL ........................................................................................................................................................... 30

5.1 WIRING AND CONDUIT ................................................................................................................................................. 30 Power Wiring ............................................................................................................................................................ 30 Electrical Construction .............................................................................................................................................. 31 Motor Terminal Insulation above 600 Volts .............................................................................................................. 35 Application Procedure: ............................................................................................................................................. 35

5.2 CONTROL POWER WIRING ............................................................................................................................................. 35 Flow Switches ........................................................................................................................................................... 37

Installation and Maintenance Manual for Water Cooled Two-Stage Centrifugal Chillers

Engineered for Flexibility and Performance 2

System Pumps ........................................................................................................................................................... 37 Control Panel Switches ............................................................................................................................................. 37 Surge Capacitors ....................................................................................................................................................... 37

5.3 FIELD WIRING DIAGRAM............................................................................................................................................. 38 Wiring Diagram Notes .............................................................................................................................................. 42

VI. MAINTENANCE .................................................................................................................................................... 44

6.1 ROUTINE MAINTENANCE ............................................................................................................................................... 44 Oil Charging.............................................................................................................................................................. 44 Oil Analysis ............................................................................................................................................................... 45

Aluminum ................................................................................................................................................................................46 Copper ..................................................................................................................................................................................... 47 Iron .......................................................................................................................................................................................... 47 Zinc .......................................................................................................................................................................................... 47 Silicon ...................................................................................................................................................................................... 47 Moisture .................................................................................................................................................................................. 47

Changing Oil Filters .................................................................................................................................................. 48 Refrigerant Cycle ...................................................................................................................................................... 48 Electrical System ....................................................................................................................................................... 48

6.2 EQUIPMENT CLEANING AND PRESERVING ......................................................................................................................... 49 Seasonal Servicing .................................................................................................................................................... 49 Annual Shutdown ..................................................................................................................................................... 49 Tube Fouling and Cleaning........................................................................................................................................ 50 Tube Leak Detection ................................................................................................................................................. 51 Annual Startup .......................................................................................................................................................... 51

6.3 REPAIR OF SYSTEM ....................................................................................................................................................... 52 Pumping Down ......................................................................................................................................................... 52 Pressure Relief Valve Replacement ........................................................................................................................... 52 Leak Testing .............................................................................................................................................................. 53 Evacuation of the System .......................................................................................................................................... 53

6.4 CHARGING THE SYSTEM ................................................................................................................................................. 55

PRESTART SYSTEM CHECKLIST ................................................................................................................................... 58

XIV OPERATING LIMITS ..............................................................................................................................................59

14.1 OPERATING LIMITS ..................................................................................................................................................... 59 Operation of low condenser water temperature ................................................................................................ 59

14.2 WATER FLOW SCOPE ................................................................................................................................................... 61 14.3 MINIMUM WATER CONTENT IN PIPING SYSTEM ................................................................................................................ 62 14.4 APPLICATION STANDARD ............................................................................................................................................. 62 14.5 WATER QUALITY MANAGEMENT ................................................................................................................................... 62 14.6 ABOUT NON-AQUEOUS COOLANT ................................................................................................................................. 63

MAINTENANCE SCHEDULE ........................................................................................................................................ 64

EVAPORATOR ...................................................................................................................................................... 66

CONDENSER ........................................................................................................................................................ 66

WATER SIDE ......................................................................................................................................................... 67

OIL SIDE ................................................................................................................................................................. 67

OPERATING LOG SHEET ............................................................................................................................................. 68

SERVICE PROGRAMS ..................................................................................................................................................69

WARRANTY STATEMENT ............................................................................................................................................69

Installation and Maintenance Manual for Two-stage Centrifugal Water Chillers


Safety Instructions

The following recommendations should be carefully observed as part of installation, operation, maintenance or service.

• This equipment must be installed by trained and qualified personnel experienced in the installation of similar centrifugal chillers.

• This manual contains important information on operation, safety, maintenance, installation, service and warranty.

• Prior to performing any task on this equipment, the information in this manual and any other referenced material must be carefully read and understood.

• This manual is intended for use by owner or Daikin authorized service personnel.

Cautions and Warnings

At several points in the manual, items of special interest or significant impact are highlighted by one of the following notices in the appropriate section of the manual.

! DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

! WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

! CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

! NOTE

Important information used to obtain best results



I. Introduction

! CAUTION

It is important that the operator reads this manual to become familiar with the equipment before attempting to operate the chiller..

! NOTE

During the initial startup of the chiller the Daikin technician will be available to answer any questions and instruct in the proper operating procedures.

This Daikin centrifugal chiller represents a substantial investment and deserves the attention and care normally given to keep this equipment in good working order. If abnormal or unusual operating conditions occur, it is recommended that a Daikin service technician be consulted.

1.1 General Description

The Daikin Two-Stage Centrifugal Water Chillers are complete, self-contained, automatically controlled, fluid chilling units. Each unit is completely assembled and factory tested before shipment.

The Daikin Model HTV chillers use model L, G and K compressors Cooling only and provide a cooling capacity range from 400 tons (1400 kW) to 1500 tons (5275 kW). Each unit has one compressor connected to a condenser, `an economizer and an evaporator.

The standard HTV chillers use the R134a refrigerant, which is a green and environment-friendly refrigerant. The standard water chillers run at positive pressure, which makes sure the refrigerant is purity, improves the availability of the refrigerant and running stability, and reduces the dimension and weight of chiller.

The controls are pre-wired, adjusted and tested. Only normal field connections such as water and relief valve piping, electrical and interlocks, etc. are required, thereby simplifying installation and increasing reliability. Most of the necessary equipment protection and operating controls are factory installed in the control panel.

1.2 Application

The installation, operation and maintenance procedures are applicable to HTV series chillers. The following recommendations should be carefully observed as part of installation, operation, maintenance or service.

• This equipment must be installed by trained and qualified personnel experienced in the installation of similar centrifugal chillers.

• This manual contains important information on operation, safety, maintenance, installation, service and warranty.

• If any change is required to the structure and installation of the chiller, please be sure to contact DAIKIN for inquiry.

• All Daikin HTV centrifugal chillers must be initially started at the job site by a factory-trained Daikin authorized technician. Failure to follow this startup procedure can affect the equipment warranty.

• Prior to performing any task on this equipment, the information in this manual and any other referenced material must be carefully read and understood.

The warranty contains the parts certified to be caused by material defect or be the inferior product



manufactured by factory. For the details about the warranty, see the accompanying Warranty or the final party of this Manual.

1.3 Nomenclature

HTV L KDKD 40 F / E3616 / C3616

Condenser Evaporator Hertz / Voltage Code

Motor Power (nominal kW) 1st stage Impeller: K- Shroud Pattern

D-Impeller Head 2nd stage Impeller:K- Shroud Pattern D-Impeller Head L-Main Frame Compressor

Water-cooled Two stage Chiller

Fig. 1



II．Components and Operation

Fig. 2

Fig. 3



! NOTE

Chilled water and condenser connection location can vary. Check markings on unit and consult unit certified drawings for connection locations on specific units.

2nd

Stage

Expansion

Valve

Condenser

1st Stage

Evaporator

Economizer

Subcooler

Fig. 4

2.1 Condenser/Subcooler

The condenser is a shell-and-water tube heat exchanger with the refrigerant in the shell side.

Starting at the inlet of the condenser, the high-pressure, high temperature refrigerant vapor is forced into the condenser and as it passes through the condenser shell, it gives up its latent heat of condensation, heat of compression and other heat absorbed to the cooling tower water flowing inside the condenser tubes i.e. Isobaric/Isothermal ( constant pressure, temp ) Heat Rejection process. The decrease in the refrigerant’s latent heat content equals the increase in the water’s sensible heat. This heat removal changes the phase of the refrigerant and it becomes liquid at constant pressure and temperature. As the condensed refrigerant liquid enters the condenser’s internal subcooler at the bottom of the condenser, just before it leaves the condenser, it loses its sensible heat further and becomes subcooled liquid at a lower temperature due to heat transfer to the water in the subcooler tubes. Allowing any refrigerant vapor to enter the subcooler decreases the efficiency of the subcooler because the rate of convection heat transfer in the vapor phase is much less than in the liquid phase. Further, allowing vapor to enter the subcooler may allow vapor to leave the condenser, thereby decreasing the efficiency of the system. Therefore, the liquid level must extend far enough above the subcooler entrance to prevent vapor within vortex, which is typically formed at high flow rates, from entering the subcooler.

When the chiller is operating at load, the most reliable source of liquid refrigerant is the condenser. Liquid refrigerant in the evaporator will be boiling.

2.2 Expansion Valve

The liquid refrigerant travels through the liquid line to the expansion valve where the pressure is reduced and part of the refrigerant flashes into vapor creating of a two-phase refrigerant mixture downstream of the expansion valve. The vapor absorbs the liquid’s latent heat of vaporization and lowers the liquid temperature flowing to the economizer. Therefore, the net latent heat content of the refrigerant is unchanged or no heat loss to the outside due to this heat exchange between the liquid and vapor. This is the first expansion process in the two-stage cycle. Since the decrease in the refrigerant liquid’s sensible heat content equals the increase in the refrigerant vapor’s latent heat of vaporization, the total enthalpies before and after expansion are the same. This part of the refrigeration cycle is called the Isenthalpic – constant enthalpy Expansion process.



2.3 Economizer and Two-stage Compressor

An economizer is a flash tank consisting of baffles to separate the refrigerant vapor from liquid and mechanical float-type expansion valve(s) for liquid control.

The expanded liquid-vapor mixture from the expansion valve enters the economizer where vapor and liquid separate from each other.

The liquid, being denser than the vapor, accumulates at the bottom of the economizer and the vapor bubbles through liquid refrigerant to the top of the economizer. As the second stage impeller of the compressor exerts a suction and draws vapor from the economizer, it reduces the pressure of the economizer. As the pressure is lowered, so is the temperature or boiling point of the refrigerant in the economizer to a temperature corresponding to the suction pressure of the second stage. This vapor is piped to the inlet of the second stage impeller, thereby maintaining the economizer at interstage pressure.

As the liquid level rises, it lifts the float valve and opens it. The liquid exiting the float valve opening expands second time and its pressure drops further and more latent heat is absorbed by the vapor from liquid – a zero heat loss from the refrigerant to the ambient, and lowers the refrigerant liquid’s temperature further flowing into the evaporator.

Because of this additional refrigerant liquid temperature drop, there will not be a capacity penalty to the chiller even though the mass flow of the refrigerant is less than a single-cycle system compared with the same capacity. The shrinkage of refrigerant mass, on the other hand is, due to the refrigerant vapor separating in the economizer and leaving the economizer to the inlet of the second stage suction of the compressor where it mixes with and desuperheats the discharge vapor from the first stage impeller. The two incoming refrigerant vapor streams mix together in the interstage elbow before flowing into the second stage compression ( Isentropic ( constant entropy ) Compression process ).

As the economizer vapor decreases the temperature of the first stage discharge vapor entering the second stage, it reduces the required compression energy input by utilizing energy that would otherwise be wasted which gives an efficiency advantage to the two-stage over single-stage.

The terms “intercooler” and “economizer” are interchangeably used in the industry for the liquid/vapor separator tank.

At startup or at part load with the IGV closed (compressor suction affect is reduced and therefore evaporator pressure does not reduce) and with the economizer exposed to the inlet pressure at the intermediate pressure stage of the compressor (exposed to the suction of the second stage and therefore pressure reduced due to suction), the economizer pressure will drop below the evaporator pressure.

2.4 Evaporator

The evaporator is a flooded type shell-and-water tube heat exchanger.

Liquid refrigerant in the evaporator covers all but the upper tube rows in the tube bundle when the chiller is not operating. When the compressor starts, it creates a suction and draws some of the refrigerant gas from the evaporator, thus decreasing the pressure of the evaporator. As the refrigerant pressure is lowered, so is the temperature or boiling point of the refrigerant in the evaporator, and it is this factor that creates a difference in temp between the refrigerant and the water which is to be cooled. Thus, a flow of heat from the warmer water to the refrigerant is set up.

The refrigerant enters the evaporator at or near the bottom of the shell with vapor quality in the range of 0 to 30 %. In order to boil the greatest possible amount of refrigerant in the evaporator, it is necessary that the entire surface of the evaporator be kept wet with refrigerant liquid. Under this condition of operation the refrigerant vapor from the vaporized liquid leaves the evaporator outlet in a saturated condition, which means it is the same temperature as the liquid in the evaporator (Isobaric/Isothermal



( constant pressure, temp ) heat addition process ). The warm water to be chilled from the cooling load circulating through the evaporator tubes causes the pool of liquid refrigerant to boil and for a horizontal tube arrangement, the refrigerant then flows upward throughout the tube bundle, changing phase and emerging from the top tube row at or near a vapor quality of 100 %. This boiling displaces the liquid level upwards until the entire bundle is just submerged in boiling refrigerant. This boiling provides a natural exciting force to cause tube vibration or motion. The increased boiling takes place where the tube depth is greater in the bundle at the center. The greater the tube depth, the greater the amount of heat transfered causing boiling.

The flow is then directed out of the evaporator shell and routed to the inlet of the compressor. It is possible that a small amount of liquid refrigerant generally in the form of droplets could be entrained in the saturated vapor going to the compressor, but this will vaporize in the suction line without any useful cooling effect being obtained. Any entrained liquid in the vapor flow stream can fall back to the evaporator tube bundle by gravity and may not be carried over to the compressor suction. Wave formation on liquid structures adhering to solid surfaces and subsequent shear exerted by the gas flow were found to be a primary cause of liquid droplet entrainment into the core flows. Droplet formation and dynamics are strongly influenced by factors such as the surface interaction with the fluid, turbulence, and velocity gradients in the gas field. In particular, the flow emerging from the tube bundle (where some droplets are formed) is both turbulent and spatially developing. Additionally, the process of droplet generation at the top of a flooded evaporator bundle occurs in the presence of heat transfer, often with bubbles due to boiling present on the solid tube surfaces.

As the load across the evaporator increases the available refrigerant will boil off more rapidly, if it is completely evaporated prior to exiting the evaporator, the vapor itself will continue to absord heat. This heat is referred to as superheat which is the heat added to a substance above its saturation temperature itself will continue to absorb heat.

The vaporized refrigerant, that is, the “suction gas,” is compressed by the first stage of the compressor to the second stage to complete the cycle. Chilled water leaving the evaporator flows to the air handling unit to cool air incoming from the facility and outside.

The evaporator is the coldest portion of the chiller at the time the chiller shuts down, not only will refrigerant migrate to that location, it will condense there to liquid form. Therefore, when the chiller next starts up, at least the majority of the refrigerant in the chiller system can be expected to reside in the evaporator in the liquid state.

When a chiller is shutdown or is operating at extremely low load conditions, liquid refrigerant will reliably be found to exist in the evaporator.

2.5 Lubrication System

The lubrication system provides lubrication and heat removal for compressor bearings and internal parts. Lubricant must be visible in the oil sump sight glass at all times and must be added during the operation for any oil loss.

B type Oil must be used in the centrifugal two-stage compressor. The nominal oil charge for M compressors is 57L(15 gallons), 57L(15 gallons) for L, 72L(19 gallons) for G and 83L(22 gallons) for K.

The internal oil sump for the compressor is completely self-contained within the compressor housing. The assembly includes a motor driven submersible 1 HP, 4 pole oil pump (200V, 3 phase, 50/60 Hz), a 1000 Watt (200V,1 phase, 50/60 Hz) cartridge type immersion oil heater and a 10 micron oil filter.

During normal chiller operation, the unit control center operates and controls the oil pump at all times. The oil heater is only energized during compressor shutdown. The oil pump operates prior to compressor run (prelub) to provide oil to the bearings. It also runs after compressor shutdown to lubricate the bearings during coastdown (postlub).

During idle periods, the oil in the sump tends to absorb as much refrigerant as it can hold, depending upon the oil temperature and sump pressure. Lower oil temperature will increase of amount of



refrigerant absorbed that can cause violent foaming during start-up, as the system pressure is lowered. Refrigerant bubbles out of the oil during that time and the subsequent foaming can affect the oil pump operation and system oil differential pressure.

The oil is pumped to the internal oil filter in the compressor casting and then to the external refrigerant-cooled oil cooler through a factory pre-set pressure regulator valve. It maintains above 22 psi minimum oil differential pressure (the difference between the oil sump and oil supply pressure).

A plate-type oil cooler maintains the proper oil temperature under normal operating conditions. A TXV valve maintains less than max 140°F (60°C) oil supply temperature by regulating the flow of subcooled refrigerant liquid from the condenser to the cooler.

A typical flow diagram is shown in Fig. 5.

Manual isolation stop valves in the oil line and drain connections on the lubricant sump are provided for ease of servicing.

2.7 Motor Cooling

The high pressure subcooled refrigerant flows through a filter-drier to the low pressure area in the motor housing. The refrigerant gas returns to the evaporator after cooling the motor.

The flow is motivated by the pressure difference between the condenser and the evaporator.

Fig. 5 Oil & Motor Cooling and Drain Lines

Note: Connections are not necessarily in correct relative location.



2.8 Oil Return Control

Two eductor circuits are provided to properly return oil and refrigerant mixture from the refrigeration circuits to the oil sump for separation. See Fig. 6.

Oil migration is often the result of operating conditions. A portion of the oil used within the compressor will be carried out of the compressor entrained in the high pressure discharge gas. Any oil entrained in the compressor discharge gas will fall or drain to the bottom of the condenser and make its way into the condensed refrigerant pooled there. The two-phase refrigerant mixture downstream of the expansion valve as a result of pressure reduction carries entrained oil with it into economizer. The refrigerant liquid exiting economizer will drop in pressure as it goes through the second expansion and will carry oil into the evaporator.

A small amount of oil is normal in the refrigerant, however, if not properly controlled the oil can accumulate and be trapped, over time, in the evaporator between the incoming liquid refrigerant from the economizer below, and boiling refrigerant above.

The evaporator acts similar to the oil sump where the refrigerant boils off as a result of the heat it picks up from the water, leaving the oil behind.

The excess oil in the refrigerant will cause foaming and high evaporator approach temperature and as a result the oil foam may entrain liquid refrigerant and will carry into the compressor. As a result, liquid-carry over through the first stage suction will lower the discharge superheat and temperature which in turn will decrease the chiller capacity. The evaporator is equipped with sight glass(es) through which the amount of foaming can be viewed.

As the compressor pulls the refrigerant up from the evaporator into the IGV plenum to be compressed, the oil normally drops out at this point and falls to the bottom of the plenum where it accumulates. However, under part load conditions, the refrigerant going up to the compressor suction does not have enough velocity to bring oil along and as a result oil collects in a greater concentration at the top level of the refrigerant in the evaporator.

In Eductor Circuit 1, high pressure discharge refrigerant gas flows continuously through the eductor inducing any low pressure oil accumulated in the inlet guide vane plenum to the oil sump.

In Eductor Circuit 2, high pressure condenser gas flows continuously through the eductor inducing low pressure oil-contaminated refrigerant liquid from the evaporator through the filter to the oil sump.

There are no moving parts in the eductors. They create a reduced pressure area inside which draws lubricant into the compressor.

Manual isolation stop valves in the Eductor Circuit 2 are provided for filter servicing.

! NOTE

Change the eductor filter-drier when excessive amount of lubricant is noticeable in the refrigerant charge as viewed in the liquid line sight glass. The filter drier PN is 735028828.



Ref

Gas

Eductor

1

Gear Case

Oil Sump

Oil/Ref

Eductor

2

Filter

Drier

2nd

Scroll Drain ( do not

exist for G & K )

Oil/Ref Liq

Ref

Gas

Ref

1st

Scroll

Drain

Eductor

Circuit 1

Eductor

Circuit 2

Compressor

Ref

Evaporator

Condenser

1st

Scroll Drain ( do not

exist for G & K )

Fig. 6 Eductor Circuits and Scroll Drain Lines

Note: Connections are not necessarily in correct relative location and can vary depending upon specific model.



III. Features of the Control Panel

3.1 Responsibility of Operator

Operator shall be familiar with the equipment and system and shall read the Two-Stage Centrifugal Chillers Operating Manual Z8100196 and control principle drawing and relevant data carefully to master the power on, operation, power off procedures and safety disconnection mode before operating the chiller.

The technical service personnel of DAIKIN will debug the chiller on site and answer your question together with simple training of operation and introduction of correct operation procedures and notices at the first time of power on.

It is recommended that operator shall retain operational log of each chiller and the log sheet is included in this Manual. In addition, the regular inspection and maintenance shall be recorded.

The DAIKIN centrifugal water chiller shall be maintained within good operating state for it’s expensive. Any abnormal or rare conditions of the chiller shall be reported to the technical personnel of DAIKIN Service Department for consultation.

DAIKIN international body provides indoor factory training for operators of DAIKIN centrifugal water chiller for many times each year, including practical operation and problem solving; contact DAIKIN agencies for more information.

Microtech /ⅢTouch Full-Color Screen Control Panel

Fig.7

Note: For the detailed information of MicroTeach control, please see the operation manual of centrifugal control.

3.2 Standby Power

It is essential that any centrifugal chiller connected to standby power come to a complete stop on grid power and then be restarted with the standby power. Attempting to switch from regular grid line power to auxiliary power while the compressor is running can result in extreme transient torque that will severely damage the compressor.

3.3 MicroTech Control

The HTV MicroTech II/Ⅲ microprocessor control of the DAIKIN centrifugal water chiller includes the

microprocessor which can provide all monitoring and control functions of water chillers to realize



high-efficiency running. The control includes:

● Touch operation screen, which is a device used for setting and inputting information and main parameters of each water chiller. The screen has no control function.

● chiller control, which is a device used for controlling the function of each water cooling water chiller and communicating with other controls. If the screen does not work, the parameter settings can be inputted. The water chiller control is installed in the control cabinet adjacent with the touch operation screen.

● Compressor control for controlling each compressor, which can still run when there is no chiller control or operation interface. The control is installed in the control cabinet adjacent with the compressor. The compressor control includes the control system of the oil pump. The running condition of the oil pump is also monitored by the compressor control system.

HTV Microtech Compressor Control

HTV Microtech Ⅲ Compressor Control

Oil Pump

Overloads

Oil Pump

Relay (2) IGV relays

Compressor Relay

Oil Heater Relay

Latch Relay

Touchscreen

Controller

Signal

Converter

Unit Controller

Control

Transformers

#2, #3, #4, #5

Unit Switch

Comp. Switch

Circuit Bkr.

Expansion

Module

Compressor

Controller



Fig. 8

3.4 Capacity Control System

The motor-driven inlet guide vanes (IGV) located at the entrance to the compressor first stage impeller control the quantity of refrigerant entering the impeller thereby controlling the compressor capacity in the first-stage. There is a motor driven variable diffuser geometry or discharge diffuser control (DDC ) in the second stage.

The operating range is from 20% to 100% of the specified nominal capacity.

The major components of the two-stage system are evaporator, condenser, expansion valve, economizer and compressor.

There are two compression stages in a single compressor by two impellers mounted on a single common shaft within a single casing. The discharge of one stage feeds the input of the next stage.

The driveline of the HTV is made up of one two-stage compressor, gear train and a 2 pole, 3 phase squirrel cage induction semi-hermetic motor.



IV. Installation

4.1 Receiving and Handling

The unit should be inspected immediately after receipt for possible damage.

All Daikin centrifugal water chillers are shipped FOB factory and all claims for handling and shipping damage are the responsibility of the consignee.

Insulation corners from the evaporator's rigging hole locations are shipped loose and should be glued in place after the unit is finally placed. Neoprene vibration pads are also shipped loose. Check that these items have been delivered with the unit.

If so equipped, leave the shipping skid in place until the unit is in its final position. This will aid in handling the equipment.

Extreme care must be used when rigging the equipment to prevent damage to the control panels or refrigerant piping. See the certified dimension drawings included in the job submittal for the center of gravity of the unit. Consult the local Daikin sales office for assistance if the drawings are not available.

The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the rigging eyes are located. Spreader bars must be used between the rigging lines to prevent damage to the control panel, piping and motor terminal box.

Fig. 9



Table1 Unit shipping weight and operating weight

Chiller Model Shipping Weight (kg) Operating Weight

(kg)

HTVMEDED28G/E3012 /C2612 8136 8937

HTVMEDED28G/E3012/C2612 8028 8729

HTVMGDGD28G/E3012/C3012 8699 9574

HTVMGDGD28G/E3012/C2612 7996 8749

HTVMJDHD40G/E3012/C3012 8699 9574

HTVMJCHC40G/E3012/C3012 9125 9952

HTVLLDLD40G/E3016/C3016 11083 12122

HTVLLDLD40G/E3012/C3012 9821 10696

HTVLMDMD47G/E3616/C3016 11758 13183

HTVLMEME47G/E3612/C3012 10943 12134

HTVGNDND52G/E3616/C3016 12318 13743

HTVGNCNC52G/E3612/C3012 11423 12614

HTVGADAD58G/E3616/C3616 13386 15017

HTVGACAC58G/E3612/C3612 11847 13140

HTVGRCAC715/E3616/C3616 13345 14976

HTVGRFAF715/E3612/C3612 11885 13256

HTVKBDBD785/E4216/C3616 16977 18891

HTVKBCBC785/E4212/C3612 15207 16818

HTVKBDBD785/E4216/C3616 17127 19343

HTVKBCBC785/E4212/C3612 15263 16989

HTVKCDCD785/E4216/C3616 17053 19120

HTVKCCCC875/E4212/C3612 15263 16989

HTVKDDCD785/E4216/C4216 18530 20711

HTVKDCCC875/E4212/C4212 16253 18094

Notes:

1. Shipping weight does not include crating weight.The crating weight may be 200kg-600kg for vary



chiller. 2. Request a certified drawing for exact dimensions, charge, and weight. 3. Please re-confirm the weight specified in the nameplate before lifting.

! WARNING

Do not use lifting lug of control cabinet and compressor to hoist the whole chiller.The lifting rope is not allowed to contact the pipes of the chiller. It may cause the pipe damaged or broken.

4.2 Location and Mounting

The unit must be mounted on a concrete or steel base which is level end-to-end to within ¼” (6.4 mm) and must be located to provide service clearance at one end of the unit for possible removal and replacement of evaporator and/or condenser tubes, and if necessary, to permit brush cleaning of evaporator and condenser tubes as required. Doors, removable wall sections and piping should be arranged for ease of disassembly at the chiller for tube clearance and cleaning. Minimum clearance at all other points, including the top, is1 meter (3 feet). The National Electric Code (NEC) can require four feet or more clearance in and around electrical components and must be checked. Follow is the unit overall dimension of the HTV Chiller and the service clearance which the surrounding of the chiller needs to insure.

蒸发器冷凝器

出

进

出

进

Fig. 10

Table2 Unit Overall Dimensions

Model Boundary Dimension (mm)

Evaporator Location Dimension (mm)

Condenser Location Dimension (mm)

A B C D E H F G AA DN J K BB DN

HTV-M-E3012-C2612 4291 2195 2524 3752 1646 102 758 356 222 250 1341 708 184 200

HTV-M-E3012-C3012 4291 2187 2527 3752 1748 102 758 356 222 250 1392 758 222 250

HTV-L-E3012-C3012 4327 2273 2552 3752 1748 102 708 356 222 250 1392 708 222 250

HTV-L-E3612-C3012 4329 2273 2705 3752 1900 102 785 432 248 300 1544 708 222 250

HTV-L-E3016-C3016 5538 2273 2552 4999 1748 102 708 356 222 250 1392 708 222 250

HTV-L-E3616-C3016 5576 2273 2705 4999 1900 102 785 432 248 300 1544 708 222 250

HTV-G-E3612-C3012 4582 2262 2650 3752 1900 102 813 432 248 300 1544 708 197 300

HTV-G-E3612-C3612 4582 2367 2650 3752 2052 102 813 432 248 300 1621 785 248 300

HTV-G-E3616-C3016 5576 2264 2650 4999 1900 102 813 432 248 300 1544 708 197 300

HTV-G-E3616-C3616 5576 2367 2650 4999 2052 102 813 432 248 300 1621 785 248 300

HTV-K-E4212-C3612 4598 2552 2927 3726 2235 102 914 508 267 400 1803 838 248 350

HTV-K-E4212-C4212 4598 2704 2927 3726 2388 102 914 508 267 400 1880 914 267 400

HTV-K-E4216-C3616 5592 2552 2927 4974 2235 102 914 508 267 400 1803 838 248 350

HTV-K-E4216-C4216 5592 2704 2927 4974 2388 102 914 514 267 400 1880 914 267 400



Notes:

1. Drawings included in this section are for rough layout purposes only. Detailed certified drawings, as .pdf or .dgn files, are available from the local Daikin sales office. Do not use catalog drawings for final construction. 2. A 13mm manufacturing tolerance for the contour sizes A, B and C of the chiller must be accounted for in the design and installation process. 3. Obtain specific unit certified drawings for detailed dimensions of water, and relief valve connections. 4. The unit control panel/touch screen side is the “FRONT” of the unit. “RIGHT” and “LEFT” are determined looking at the front. 5. The adjustable control interface panel is shipped unmounted from the unit. When mounted, it can be folded back within the confines of the unit width and height and still be viewable.

Fig. 11

Table3 The Service Clearance

Evaporator/Condenser Shell Length (ft/m) A(ft/m) B(ft/m) C(ft/m) D(ft/m) E(ft/m)

12/3.66 3/1 3/1 3/1 14/4.27 3/1

16/4.88 3/1 3/1 3/1 18/5.49 3/1

4.3 Operating/Standby Limits

Equipment room temperature, standby:

• Water in vessels : 4C to 50C (40F to 120F)

• Without water in vessels : -18C to 49C (0F to 120F)

• Equipment room temperature, operating: 0C to 40C (32F to 104F )

• Maximum entering condenser water temperature, startup: 35C (95F )

• Maximum entering condenser water temperature, operating: job specific design temperature



• Minimum entering condenser water temperature, operating: see page 23.

• Minimum leaving chilled water temperature: 4.4 C (40F)

• Maximum entering chilled water temperature, operating: 21C (70F)

Note : Some of limits above may apply depending on customer specification – consult factory.

4.4 Installation Site Selection and Foundation Works

Vibration Pads

The unit is shipped with neoprene vibration pads having a nominal 9.5 mm (0.375 inch) operating height. They are to be placed under the steel foot supports for contact with the foundation, and to be flush with the sides and outside edge of the foot supports affixed to the chiller tube sheets.

Mounting

Make sure that the floor or structural support is adequate to support the full operating weight of the complete unit.

The pads should be located in accordance with the unit dimensional drawing. After the pads have been placed into position on the floor, lower the unit onto the pads which are to be centered under the foot supports. When the unit is in place, remove the rigging equipment and check that the chiller is level, both longitudinally and transversely.

First, check the longitudinal alignment of the unit by placing a “level gage” at top center of the evaporator shell which has more compressor/motor load. Second, check the transverse alignment by placing a level gage on top of the tube sheets at both ends of the unit. Their alignment should be within ¼” (6.4 mm) and if not, lift the unit and place shims between the neoprene pads and the foot supports.

It is not necessary to bolt the unit to the mounting slab but should this be desirable, 1-1/8" (28.5 mm) mounting holes are provided in the unit feet. See dimension drawing for location

Each pad deflection is around 0.06 inch (2 mm) and if necessary, shims should be placed between the unit foot supports and pads to equally deflect all pads.

Installation Base

A) The chiller shall be installed in a site without being affected by wind and rain and shall not be installed in a site with direct sun lights. Such chiller components as circuit board and finishing coat will be corroded if the chiller is installed in sites near sea and chemical plant with strong corrosivity. Special area has special operating requirements to air-conditioning; please confirm technical details with the local branch.

B) Please install a proper ventilation equipment to avoid deficit accidents in some parts of the equipment room due to unexpected refrigerant leakage.

C) The chiller is not specially designed for explosion-proof sites; therefore the chiller shall not be installed in a site with combustible gas gathered or with the danger of leakage.

D) The chiller shall not be installed in a site with a temperature more than 40°C or less than 0°C and a relative humidity more than 90%. And the chiller is not suitable to be installed in a site with more than 8°C of temperature change within 1 hour.

When install the chiller in a cold area, corresponding freeze-proofing measures shall be taken for the chiller and chilled water and cooling water equipment.

E) The chiller cannot be installed in the same room with heat source equipment such as a boiler by principle. If installing in the same room, the chiller operation may be affected; please confirm with the branch or dealer if it needs to install in the same room.



F) The cooling tower shall not be installed in a site where the metal and electric components are easy to be corroded.

Please pay attention to the installation site of the cooling tower for avoiding polluting the cooling water. The cooling tower shall not be installed in the sites directly sucking the harmful gas nearing the polluted river, coast, electroplating plant and chemical plant; and please increase the frequency of water quality detection. The cooling tower shall not be installed at the exhaust port of ammonia equipment or toilet or nearing the hospital operating room and sewage treatment equipment. The corrosion of condenser heat transfer pipe will cause the gas leakage accident. If water sources from the river, lake and sea are used as the cooling water sources, the corrosion effect of the water quality to the condenser shall be considered.

G) The chiller shall be installed in the site insensitive to the running noise and vibration.

The anti-vibration device and silencing apparatus can be installed according to the installation condition.

The vibration comes from the installation part and the sounds come from the ground and wall.

It would be best to set the equipment room at the bottom of the basement.

H) Please set in the site capable of bearing the chiller weight.

The surface of the foundation shall be horizontal and smooth. ( levelness ＜2mm/1,000mm )，please

refer to GB 50209.

Please construct according to the foundation drawing for the foundation sizes. As shown in Fig. 12 and Table 4.

Fig. 12



Table4 Chiller Foundation Drawing Parameters mm

Model A B C D E F G H I

HTV-M-E3012-C2612 700 750 170 3752 4092 250 1646 2146 665

HTV-M-E3012-C3012 700 750 170 3752 4092 250 1748 2248 665

HTV-L-E3012-C3012 700 750 170 3752 4092 250 1748 2248 665

HTV-L-E3612-C3012 700 750 170 3752 4092 250 1900 2400 665

HTV-L-E3016-C3016 700 750 170 4999 5339 250 1748 2248 665

HTV-L-E3616-C3016 700 750 170 4999 5339 250 1900 2400 665

HTV-G-E3612-C3012 700 750 170 3752 4092 250 1900 2400 665

HTV-G-E3612-C3612 700 750 170 3752 4089 250 2052 2552 665

HTV-G-E3616-C3016 700 750 170 4999 5339 250 1900 2400 665

HTV-G-E3616-C3616 700 750 170 4999 5339 250 2052 2552 665

HTV-K-E4212-C3612 700 750 220 3726 4166 250 2235 2735 665

HTV-K-E4212-C4212 700 750 220 3726 4189 250 2388 2894 665

HTV-K-E4216-C3616 700 750 220 4974 5414 250 2235 2735 665

HTV-K-E4216-C4216 700 750 220 4974 5414 250 2388 2894 665



Spring damper

Fig. 13

Note: This is the location where the operator observe the display screen.

Table5 Recommend Selected Specifications of Spring Isolators Chiller: kg

Model

Leg 1 Leg 2 Leg 3 Leg 4 Leg 5 Leg 6 Leg 7 Leg 8

A B A B A B A B A B A B A B A B

HTV-L/E3616/C3616 1745 2181 1931 2414 1965 2457 1748 2185 1749 2186 1963 2454 1934 2417 1745 2181

HTV-G/E4216/C3616 1757 2197 1945 2432 1980 2474 1761 2201 1762 2202 1977 2472 1947 2434 1757 2197

HTV-K/E4216/C4216 1770 2212 1959 2449 1994 2492 1773 2216 1774 2218 1991 2489 1961 2452 1770 2212

HTV-K/E4816/C4216 2094 2617 2317 2897 2358 2948 2097 2622 2099 2623 2356 2944 2320 2900 2094 2617

Notes:

1. A stands for calculation load-bearing of spring isolator,B stands for the Recommend load-bearing of spring

isolator

2. As the chiller produces little vibration, generally a base is not needed and it can be installed on the concrete ground directly to operate. 3. If a base is required by customers, it can be installed by reference to the above table. 4. If it is installed on a floor slab, the floor shall be strong enough to bear the operating weight of water chiller. 5. When building the concrete base, a drain ditch shall be built around the base (as shown in Fig. 13) to facilitate drainage. The margin of base shall be level and smooth. 6. The standard concrete mixing ratio: cement, sand to gravel 1:1:4.

Installation Method of spring isolator



Fig. 14

The Fig. 14 is the installation way figure of the spring isolator used by DAIKIN, wherein S is the side length of the spring isolator and L is the distance between two bolt holes on the baseplate; joint the bolts of the spring isolator and the bolt holes of the baseplate and then screw up by the lock nut.

The bottom of the spring isolator is provided with a rubber anti-vibration pad for isolating the vibration and anti-skidding; therefore it can be directly placed on the concrete ground. The chiller installed with the spring isolator does not need to be installed with a foundation bolt.

The relative positions of four spring isolators are as shown in the Fig. 13, and two holes on each corner are matched with two bolts of the spring isolator in the Fig.13.

! NOTE

Units may or may not be shipped with refrigerant and oil. All valves must remain open until start-up by the authorized commissioning technician.

Nameplates

There are several identification nameplates on the chiller:

• The unit nameplate is located on the side of the Unit Control Panel. It has a Style No. XXXX, Model No. XXXX and Serial No. XXXX. These numbers are unique to the unit and should be used to identify the unit for service, parts, or warranty questions. This plate also lists the unit operating refrigerant charge.

• Vessel nameplates are located on the evaporator, economizer and condenser. Along with other information, they have a National Board Number (NB) and a vessel serial number, either of which identify the vessel (but not the entire unit).

• A compressor nameplate is located on the compressor itself and contains identification numbers.

4.5 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 temperature 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 or due to improperly operating system controls.

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.

4.6 Low Condenser Water Temperature Operation

When the ambient wet bulb temperature is lower than design, the condenser water temperature can be allowed to fall. The resultant lower condensing temperature will improve chiller performance.

HTV chillers are equipped with electronic expansion valves (EEV) and will operate with entering condenser water temperatures as low as calculated by the following equation and shown in the chart following.

Note: Provisions or modifications need to be made in the event of inverted starts (condenser water colder than chilled water). For example, 3 way bypass valve controlled by the chiller, or tower controls.

Min. ECWT = 10.973 + LCHWT – 0.17 * CHWDTFL(PLD/100) + 8 * (PLD/100)2

ECWT = Entering condenser water temperature, F

LCHWT = Leaving chilled water temperature, F

CHWDTFL = Chilled Water Delta-T at full load, F

PLD = The percent chiller load point to be checked, F

45.00

50.00

55.00

60.00

65.00

70.00

0 10 20 30 40 50 60 70 80 90 100 110

Percent Load

EC

WT

, (F

)

46.0 F LCHWT44.6 F LCHWT44.0 F LCHWT42.0 F LCHWT

Fig.15 Minimum Operating Entering Condenser Water Temperature (10F Range)



Note : Some limitation in control may apply when operating chiller in the condition that ECWT is same or above but still around minimum ECWT

For example; at 44F LCHWT, 10-degree F chilled water Delta-T, and 50% full load operation, the

entering condenser water temperature could be as low as 56 F.

The operating strategy for cooling tower fans requires some analysis. Regardless of power consumption considerations, the minimum allowable entering condenser water temperature must be maintained.

Depending on local climatic conditions, using the lowest possible entering condenser water temperature may be more costly in total system power consumed than the expected savings in chiller power would suggest, due to the excessive fan power required.

Even with tower fan control, some form of water flow control, such as tower bypass, is recommended and is required if fan control alone will not maintain minimum water temperatures.

For cold weather operation, the bypass valve and piping is required and should be inside the building.

4.7 Water Piping

Water Pumps

Avoid the use of 3600/3000-rpm (two-pole motor) pump motors. It is not uncommon to find that these pumps operate with objectionable noise and vibration.

It is also possible to build up a frequency beat due to the slight difference in the operating rpm of the pump motor and the Daikin centrifugal motor. Daikin encourages the use of 1750/1460 rpm (four-pole) pump motors.

Both the condenser and chilled water pumps’ discharge connections should be located to supply water through the chiller at positive pressure.

In cases where the water pump noise can be objectionable, vibration isolation sections are recommended at both the inlet and outlet of the pump. In most cases, it will not be necessary to provide vibration eliminator sections in the condenser inlet and outlet water piping. But they can be required where noise and vibration are critical or if spring isolators are used.

Vessel Drains at Start-up

Unit vessels are equipped with ball-type drain valves in the bottom of each head chamber and shipped with the valves open. Be sure to close the valves prior to filling the vessels with fluid.

Draining Vessels

If the chiller can be subject to freezing temperatures (possibly when stored prior to installation), the condenser and evaporator must be drained of all water. Dry air blown through them will aid in forcing all water out. Removal of condenser heads is also recommended. The condenser and evaporator are not self-draining and tubes must be blown out. Water permitted to remain in the piping and vessels can rupture these parts if subjected to freezing temperature and cause corrosion.

Evaporator and Condenser Water Piping

Be sure that water inlet and outlet connections match certified drawings and stenciled nozzle markings. The tower water supply connection is always the bottom connection of the condenser to maximize refrigerant sub cooling.

All evaporators and condensers come with optional flange connections or standard Victaulic ANSI/AWWA C-606 groove water nozzles (also suitable for welding). Since the companion flanges, bolts, nuts and gaskets are not included, the installing contractor must provide matching mechanical



connections or transitions of the size and type required.

If welding is to be performed on the mechanical or flange connections, remove the solid-state temperature sensor and thermostat bulbs from the wells to prevent damage to those components. Also properly ground the unit or severe damage to the MicroTech II unit controller can occur.

Water pressure gauge connection taps and gauges must be provided in the field piping at the inlet and outlet connections of both vessels for measuring the water pressure drops. The pressure drops and flow rates for the various evaporators and condensers are job specific and the original job documentation can be consulted for this information. Refer to the unit nameplate on the control panel for identification. The piping should also include thermometers at the inlet and outlet connections and air vents at the high points.

The piping must be installed and supported to eliminate weight and strain on the fittings and connections. Cold piping must also be adequately insulated. All water piping should be thoroughly cleaned of dirt and debris before being connected to the chiller. A cleanable 20-mesh water strainer must be installed in both water inlet lines as close as possible to the vessels. The strainer will attempt to retain any possible dirt/debris coming from the cooling tower, deterioration of piping, or from water source entering the chiller tubes. This can result in a reduction of flow and subsequent reduction of chiller performance or tube freezing.

Water Flow Sensors

Temperature-based (thermal dispersion) flow sensors are factory mounted in the evaporator and condenser outlet water nozzles and are factory wired to the control panel. The sensor tip houses thermistors and a heating element that when power is applied, heats the tip of the probe. How fast the heat is carried away from the sensor tip by the water flow is detected by the thermistors and they provide an output when the flow rate falls below the setpoint. This indicates whether there is an adequate water flow to the vessels before the unit can start. They also serve to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up or excessive discharge pressure.

Cooling Towers

Check the condenser water flow rate to be sure that it conforms to the system design. Some form of

temperature control is also required if an uncontrolled tower can supply water below about 65F (18C). A tower bypass valve is recommended. Unless the system and the chiller unit are specifically designed for condenser bypass or variable condenser flow, it is not recommended, since low condenser flow rates can cause unstable operation and excessive tube fouling.

The condenser water pumps must cycle on and off with the unit. Controlling the pumps with the unit

MicroTech controller is an easy way to accomplish this and is highly recommended. See 5.3.1 MTⅢ

chiller:

for wiring details.

The quality of the water to both the condenser and evaporator should be analyzed by a water treatment specialist. If not available in-house, competent water treatment specialists can be contracted. Water treatment is essential for continued efficient and reliable chiller operation. Chiller performance can be degraded by poor water quality due to rust, sludge, corrosion, mineral deposits, sedimentation, organic growth etc. Proper chiller performance can be maintained by corrective water treatment when and if necessary, and periodic cleaning of tubes. If fouling or contaminants may become an issue then it may be necessary to allow a larger fouling factor for the chiller provided, and/or specific construction materials for the job site.

4.8 Thermal Insulation

Insulation of cold surfaces is required to prevent condensation. These surfaces include the evaporator, economizer, evaporator water heads and nozzles, suction piping, motor housing, oil cooler refrigerant



supply and return, economizer gas line, expansion valve, piping between economizer and evaporator and the motor drain line.

Optional factory installed insulation is available in ¾- inch (19 mm) and 1 ½-inch (38 mm) thickness. It is

UL recognized (File # E55475) ABS/PVC flexible foam with a skin. The K factor is 0.28 BTU/hr x F x sq

ft (W/m2 x C) at 75°F (23.9C). Sheet insulation is fitted and cemented in place forming a vapor barrier and then painted with a resilient finish that resists cracking. Double insulation is available as an option.

In the event insulation is to be field-installed, none of the cold surfaces identified above will be factory insulated. Required field insulation is shown beginning on Fig. 16. Approximate total square footage of insulation surface required for individual packaged chillers is tabulated by evaporator code and can be found below.

Fig. 16 Insulation Requirements



Table6 Insulated Parts Description

INSULATED PARTS

BUB. NO.

DESCRIPTION THICKNESS ( Depend on Customer)

Probable Surface Temperature in Rating Operation

USE 2 LAYERS OF .75 THICK SHEET

001 MOTOR BARREL- BACK PLATE TO GEAR HOUSING

1.50" 36 – 45 oF ( 2 – 7

oC )

002 EVAPORATOR SHELL- TUBESHEET TO TUBESHEET

1.50" 36 – 45

oF ( 2 – 7

oC )

003 NOZZLE HEAD & NOZZLE TO BACK OF FLANGE

1.50" 36 – 45

oF ( 2 – 7

oC )

004 RETURN HEAD 1.50" 36 – 45 oF ( 2 – 7

oC )

005 ECONOMIZER- HEAD TO HEAD AND NOZZLES

1.50" 59 – 77 oF ( 15 – 25

oC )

006 ECONOMIZER GAS LINE 1.50" 59 – 77 oF ( 15 – 25

oC )

007 EXPANSION VALVE TO ECONOMIZER 1.50" 59 – 77 oF ( 15 – 25

oC )

008 ALL PIPING LEAVING ECONOMIZER TO EVAPORATOR

1.50" 36 – 45

oF ( 2 – 7

oC )

009 SUCTION LINE- COMPRESSOR TO EVAPORATOR

1.50" 36 – 45

oF ( 2 – 7

oC )

010 EVAPORATOR TUBESHEETS 1.50" 36 – 45 oF ( 2 – 7

oC )

011 BOTH SIDES OF BRACKETS TO BOTTOM OF WIREWAY

1.50" 36 – 45

oF ( 2 – 7

oC )

012 FRONT END OF COMPRESSOR 1.50" 36 – 45 oF ( 2 – 7

oC )

USE TUBE INSULATION

020 OIL COOLER SUPPLY LINE (1.125 ID)

021 OIL COOLER RETURN LINE (1.125 ID)

022 MOTOR DRAIN (.375 ID)

023 EDUCTOR LINE-FROM EVAP. TO OIL SUMP (0.375 id)

Notes: 1. Drawings included in this section are for rough layout purposes only. Detailed certified drawings, as .pdf or .dgn files, are available from the local Daikin sales office. Do not use catalog drawings for final construction. 2. Obtain specific unit certified drawings for detailed dimensions of water, and relief valve connections. 3. Allow three feet of service access on all four sides, plus allow the length of the tubes, plus two feet on one end, for tube removal. The last two numbers in the vessel code are the tube length in feet. The NEC or local code may require more than 3 feet clearance in front of control panels or starting equipment depending on voltage and layout. 4. The adjustable control interface panel is shipped unmounted from the unit. When mounted, it can be folded back within the confines of the unit width and height and still be viewable. 5. A 1-inch manufacturing tolerance must be accounted for in the design and installation process. 6. To determine overall operating height, add the dimension in Table 6 for the appropriate isolator. 7. The shipping skid when used adds 4.00 inches [105 mm] to the overall unit height. 8. If main power wiring is brought up through the floor, this wiring must be outside the envelope of the unit. 9. The unit control panel/touch screen side is the “FRONT” of the unit. “RIGHT” and “LEFT” are determined looking at the front. 10. Neoprene pad isolators (with deflection) add an average of 0.375 in (9.5 mm) to height.



4.9 Lubrication System

Emkarate RL68H Polyolester Oil must be used in the centrifugal two-stage compressor. The nominal oil charge for M and L compressors is 16 gallons, 19 gallons for G and 22 gallons for K.

An internal oil sump is part of the compressor and contains a 750 W submersible fixed-speed oil pump and a 1 kW immersion-type oil heater that is thermostatically controlled. A pre/adjusted oil pressure regulator valve located in the pump discharge line controls the proper oil pressure to all bearings, gears, and rotating parts. The oil pump operates prior to start-up and continuously operates during the chiller operation and coast down.

! CAUTION

When the oil pump operates without any oil or with an insufficient amount of oil, it might cause vibration and become extremely noisy and pump damage can occur.

Oil is filtered by an externally mounted 10 micron replaceable cartridge oil filter and is cooled via refrigerant-cooled oil cooler. Subcooled refrigerant liquid is provided by a pressure differential between the condenser and evaporator to the oil cooler. The supply flow of refrigerant to the oil cooler is regulated with a thermal expansion valve, by monitoring the temperature of oil coming out of the oil cooler. Refrigerant leaving the oil cooler is then returned back to the evaporator.

The refrigerant and oil side of the oil cooler are provided with service valves for isolation during service.

! WARNING

Comply with EPA and local regulations when removing or disposing of refrigerant system oil.

An eductor-based oil recovery system is part of the chiller circuit. It returns oil-rich refrigerant from the evaporator to the oil sump for separation and reduces or eliminates oil contamination in the evaporator. A filter drier is installed at the inlet of the eductor.

Both the oil lubrication piping and oil cooler refrigerant piping are completely factory-installed, thus eliminating the need for any field piping.

4.10 Relief Valves

As a safety precaution and to meet ASME or applicable pressure vessel code requirements, each chiller is equipped with spring-loaded pressure relief valves in accordance with ANSI/ASHRAE Standard 15 safety code for the purpose of relieving excessive refrigerant pressure (caused by equipment malfunction, fire, etc.) as noted on the pressure vessel name plate. The relief valve should be replaced with a new one whenever such a release occurs.

Table7 Relief Valve Data

Comp Vessel Pressure Setting Min. Required Discharge Capacity

( lb-air/min )

M Evaporator 200 psi

57

Condenser 200 psi

58

L Evaporator 200 psi

70

Condenser 200 psi

58

G Evaporator 200 psi

102

Condenser 200 psi

90

K Evaporator 200 psi

121

Condenser 200 psi

115



Refrigerant Vent Piping

Codes require that relief valves be vented to the outside of a building, and this is a desirable practice for all installations. Relief piping connections to the relief valves must have flexible connectors to minimize strain, as well as vertical drop legs to retain condensation.

Remove plastic shipping plugs (if installed) from the inside of the valves prior to making pipe connections. Whenever vent piping is installed, the lines must be run in accordance with local code requirements. Where local codes do not apply, follow the latest issue of ANSI/QHVAC Standard 15 code recommendations.

4.11 Pumpdown

To facilitate compressor service, all Daikin centrifugal chillers are designed to permit pumpdown and isolation of the entire refrigerant charge in the unit’s condenser. In no case would a combination of evaporator and condenser sizes require more refrigerant than the pumpdown capacity of the condenser. There is a factory-installed check valve in the compressor discharge line leading to the condenser and a liquid line valve in the condenser refrigerant outlet liquid line, to allow isolation and storage of the refrigerant charge in the condenser for servicing for the compressor, economizer, and evaporator. This feature eliminates extra labor, time and the usage of remote storage vessels. Any tubing lines connected to the condenser should also be isolated by closing off the factory provided service angle valves only after the compressor shuts off as a result of pumpdown.



V. Electrical

5.1 Wiring and Conduit

Wire sizes must comply with local and state electrical codes. Where total amperes require larger conductors than a single conduit would permit, limited by dimensions of motor terminal box, two or more conduits can be used. Where multiple conduits are used, all three phases must be balanced in each conduit. Failure to balance each conduit will result in excessive heating of the conductors and unbalanced voltage.

An interposing relay can be required on remote mounted starter applications when the length of the conductors run between the chiller and starter is excessive.

Use only copper supply wires with ampacity based on 75°C conductor rating. (Exception: for equipment rated over 2000 volts, 90°C or 105°C rated conductors shall be used).

Power Wiring

! WARNING

Only qualified and licensed electricians should perform wiring. Shock hazard exists.

! CAUTION

Voltage unbalance is not to exceed 2% with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. Failure to comply can cause extensive equipment damage.

Wiring, fuse and wire size (must be in accordance with the National Electric Code (NEC). Standard NEMA motor starters require modification to meet Daikin specifications.

Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for clockwise rotation facing the motor end with phase sequence of U-V-W or1-2-3. Care must be taken that the proper phase sequence is carried through the starter to compressor.

The start-up technician will verify the phase sequence.

! NOTE

Connections to terminals must be made with copper lugs and copper wire.

Care must be taken when attaching leads to compressor terminals.

Use only copper supply wires with ampacity based on 75°C conductor rating. (Exception: for equipment rated over 2000 volts. use 90°C or 105°C rated conductors).

Note:! Do not make final connections to motor terminals until wiring has been checked and approved by the authorized startup technician.

! CAUTION

Under no circumstances should a compressor be brought up to speed unless proper sequence and rotation have been established. Serious damage can result if the compressor starts in the wrong direction. Such damage is not covered by product warranty.



Electrical Construction

A) Accessories have indeed connection.

Confirm the correct wiring, prevent inverse phase or phase.

Please note do not let the port connection under external force.

All the wiring shall be confirmed after completion of wiring.

The wiring specification shall meet the following requirement:

Table 8

Maximum Length ft (m) Cross section of Conductor (mm2)

0 (0) — 50 (15.2) 2.5

50 (15.2) — 75 (22.9) 4.0

75 (22.9) —120 (36.6) 4.0

120 (36.6) — 200 (61.0) 6.0

200 (61.0) — 275 (83.8) 6.0

275 (83.8) — 350 (106.7) 6.0

Notes:

1. The maximum length of the cable is the distance between the power source and the water chiller control box.

2. The terminal block can accommodate one 4.0mm2 conductor, and for larger conductor, the adapting

box is added.

3. When the compressor does not enter the operation state, the chiller running switch on the water chiller control box shall be closed.

4. For the length over 100m, it’s necessary to consult the plant.

5. Shielded twisted pair should be used for MODBUS communication between VFD starter and the unit control cabinet. The shielding layer in the unit control cabinet side of grounding.

Table 9.1

Starting Method

Maximum Working Current (A)

Length of Electric Wire (Cable) (m)

Wire Inlet Area of Starter Cabinet (mm2)

Area of Cable between Starter Cabinet and Motor (mm2)

Star

– Delta 646

L<15 240 150

15≤L<50 ≥370 ≥240

Star

– Delta 724

L<15 300 190

15≤L<50 ≥480 ≥285

Star

– Delta 913

L<15 360 240

15≤L<50 ≥600 ≥340



Star

– Delta 1180

L<15 480 300

15≤L<50 ≥780 ≥450

Solid Starting

1320 L<15 540 360

15≤L<50 ≥870 ≥520

Table 9.2

starting

mode

Max. Working Current

(A)

Cable Length

(m)

Inlet Wire

Diameter (mm2)

Wire Diameter

of Ground (mm2)

wire diameter of

Motor (mm2)

VFD

290

＜15 150 70 150

≥15 ≥200 ≥100 ≥200

360

＜15 150 70 200

≥15 ≥200 ≥100 ≥250

415

＜15 200 100 200

≥15 ≥250 ≥125 ≥325

520

＜15 250 125 325

≥15 ≥325 ≥185 ≥400

585

＜15 325 185 325

≥15 ≥400 ≥200 ≥500

650

＜15 200×2 200 200×2

≥15 ≥200×2 ≥200 ≥250×2

VFD

740

＜15 200×2 200 250×2

≥15 ≥250×2 ≥200 ≥325×2

840

＜15 250≥2 200 250×2

≥15 ≥325×2 ≥200 ≥250×3

960

＜15 325×2 200 325×2

≥15 ≥250×3 ≥200 ≥325×3

1170

＜15 300×4 250 300×4

≥15 ≥325×3 ≥200*2 ≥325×3

1370

＜15 300×4 250 300×4

≥15 ≥325×4 ≥200*2 ≥325×4

Notes: (1)Table 9 shows specifications of power wire, and data is only for reference. Refer to the local standards when executing, BVR, VVR, YJVR of the cable type is recommended to use. (Parallel connect several cables can meet the requirement of sectional area), no pipe use for truss wiring, for



specific wires (cable), the heat-dissipating condition shall be taken into considering (If required to wear a tube the sectional area of cable shall be enlarged)

(2) Power line installation should satisfy both lateral of the power line which is through bolt connection should have flat washer. Adjacent bolt washer should have the clear distance more than 3 mm, The side of nut should be equipped with spring washer or lock nut. The contact surface between the bus bar should be compact connected, The connection bolt should be fastened by the torque wrench and the torque values should comply with provisions of the table 2.3.2.

B）Ground cable must be wired

To prevent electrical shock, control cabinet grounding terminals and chiller foot print shall be grounded.

Cable wiring work shall be done by qualified and professional engineers.

Grounding Terminal

1. Chiller Grounding Terminal

The water chiller grounding terminal is installed on the water chiller bottom plate, and the size of the connecting thread hole is M20, see Fig. 18.

2. Motor Grounding Terminal

The motor grounding terminal is installed in the motor terminal box, and the size of the connecting thread hole is M12, see Fig. 19.

3. chiller Control Box Grounding Terminal

The chiller control box grounding terminal is arranged on the control box wiring terminal block, see Fig. 20.

4. Chiller Starter cabinet Grounding Terminal

The chiller starter cabinet grounding terminal, see Fig. 20

It’s recommended to separately ground the four grounding wires of the chiller. If the starter cabinet is in the onboard mode, the two or four grounding wires can be connected to the common grounding point.



★ Grounding resistance shall be less than 0.1Ω.

Attention: Grounding cable shall be kept certain distance with natural gas \lightening rod and telephone cables. And don’t connect water pipes to earthing cable.

Gas pipe---gas leak can cause explosions or fires.

Water pipe--- there is no ground effect if hard vinyl material is used.

Telephone grounding line and the lightning rod--- under thunderstorm weather, it may cause abnormal rise of grounding voltage.

The grounding of the chiller electric cabinet can refer to national standard GB50169;

The diameter of the grounding inlet wire (cable) is generally half of that of the three-phase line (cable) (for one, two and four wiring terminals).

The diameter of the chiller control box grounding line is 2mm2.

Fig. 17 Chiller Grounding Terminal Fig.18 Motor Grounding Terminal

Fig. 19 Control Box Grounding Terminal Fig. 20 chiller Starter Cabinet Grounding Terminal

C) Attentions during the wiring construction of power cable AC power cable should not be worn in the metal conduit (metal trough) alone The same AC loop cable should be worn in the same metal conduit (metal trough), and the connectors

Control Box Grounding Terminal

compressor Grounding Terminal



should not be found with the cable inside the metal conduit(metal trough) The wiring construction of power cable for example:

Note: the PE cable could be worn in any metal conduit (trough), T1, T2, T3, T4, T5, T6 corresponds to the compressor motor terminal 1, 2, 3, 4, 5, 6 which draws forth the power cable.

Motor Terminal Insulation above 600 Volts

It is the installing contractor's responsibility to insulate the compressor motor terminals when the unit voltage is 600 volts or greater. This is to be done after the Daikin start-up technician has checked for proper phase sequence and motor rotation.

Following this verification by the Daikin technician, the contractor should obtain and apply the following items on medium voltage (above 600 volts) applications.

Materials Required:

1. Loctite brand safety solvent (12 oz. package available as Daikin part number 350A263H72)

2. 3M Co. Scotchfil brand electrical insulation putty

3. 3M Co. Scotchkote brand electrical coating

4. Vinyl plastic electrical tape

5. The above items are available at most electrical supply outlets.

Application Procedure:

1. Disconnect and lock out the power source to the compressor motor.

2. Using the safety solvent, clean the motor terminals, motor barrel adjacent to the terminals, lead lugs, and electrical cables within the terminal box to remove all dirt, grime, moisture and oil.

3. Wrap the terminal with Scotchfil putty, filling in all irregularities. The final result should be smooth and cylindrical.

4. Doing one terminal at a time, brush the Scotchkote coating on the motor barrel to a distance of up to 2" around the terminal and on the wrapped terminal, the rubber insulation next to the terminal, and the lug and cable for approximately 10". Wrap additional Scotchfil insulation over the Scotchkote coating.

5. Tape the entire wrapped length with electrical tape to form a protective jacket.

6. Finally, brush on one more coat of Scotchkote coating to provide an extra moisture barrier.

5.2 Control Power Wiring

The control circuit on the Daikin centrifugal packaged chiller requires both 200Vac 3-phase and 115Vac 1-phase. Control power can be supplied from three different sources:



1. A freestanding starter furnished by Daikin, or the customer to Daikin specifications, will have a control transformer in it requiring field wiring to terminals in the control box.

2. Power can be supplied from separate circuits and fused at 20 amps inductive load. The control circuit disconnect switch must be tagged to prevent current interruption. Other than for service work, the switch is to remain on at all times in order to keep oil heaters operative and prevent refrigerant from diluting in oil.

! DANGER

If a separate control power source is used, the following must be done to avoid severe personal injury or death from electrical shock: Place a notice on the unit that multiple power sources are connected to the unit. Place a notice on the main and control power disconnects that additional sources of power to the unit exist



In the event a transformer supplies control voltage, it must be rated at 3 KVA, with an inrush rating of 12 KVA minimum at 80% power factor and 95% secondary voltage. For control wire sizing, refer to NEC Articles 215 and 310. In the absence of complete information to permit calculations, the voltage drop should be physically measured.

Flow Switches

The unit has factory-mounted flow switches. Water flow interlock terminals are provided on the unit control panel terminal strip for additional devices such as pump interlocks if so desired. See the Field Wiring Diagram or on the cover of the control panel for proper connections.

System Pumps

Operation of the chilled water pump can be:

1. Cycle the pump with the compressor,

2. Operate continuously

3. Start automatically by a remote source.

The cooling tower pump must cycle with the machine. The easiest way to accomplish this is to let the chiller MicroTech controller control the pump. The controller is programmed to start and stop the pump at the correct times. The holding coil of the cooling tower pump motor starter must be rated at 115 volts, 60 Hz, with a maximum volt-amperage rating of 100. A control relay is required if the voltage-amperage rating is exceeded. See the Field Wiring Diagram or in the cover of control panel for proper connections.

All interlock contacts must be rated for no less than 10 inductive amps. The alarm circuit provided in the control center utilizes 115-volts AC. The alarm used must not draw more than 10 volt amperes.

Control Panel Switches

Three On/Off switches are located in the Control Panel, which is adjacent to the operator interface panel, and have the following function:

UNIT shuts down the chiller through the normal shutdown cycle of unloading the compressor(s) and provides a post-lube period.

COMPRESSOR one switch for the compressor on a unit, executes an immediate shutdown without the normal shutdown cycle.

CIRCUIT BREAKER disconnects optional external power to system pumps and tower fans.

A fourth switch located on the front of the Control box and labeled EMERGENCY STOP SWITCH stops the compressor immediately. It is wired in series with the COMPRESSOR On/Off switch.

Surge Capacitors

All low voltage units (except those with solid state starters) are supplied with standard surge capacitors to protect compressor motors from electrical damage resulting from high voltage spikes.

For free-standing starters, factory or customer supplied, the capacitors are mounted in the motor terminal box and must be connected to the motor terminals with leads less than 18 inches (460 mm) long when the motor is being wired.



5.3 Field Wiring Diagram

5.3.1 MTⅢ chiller:



Wiring Diagram Notes

• Compressor motor starters are either factory mounted and wired or shipped separate for field

mounting and wiring. All line and load side power conductors must be copper, with ampacity based on 75°c conductor rating. (Exception: for equipment rated over 2000 volts, 90°c or 105°c rated conductors shall be used.

• Field control wiring between the starter and the control panel is required. Minimum wire size

for 110 VAC and 220 VAC is 12 ga. for a maximum length of 50 feet. If greater than 50 feet refer to McQuay for recommended wire size minimum. Wire size for 24 VAC is 18 ga. All wiring to be installed as NEC class 1 wiring system. All 20 VAC wiring must be run in separate conduit from 110 VAC and 200 VAC wiring. Main power wiring between starter and motor terminal is factory installed when units are supplied with unit mounted starters. Wiring of free standing starter must be wired in accordance with NEC and connection to compressor motor terminals must be made with copper wire and copper lugs only.

• For optional sensor wiring see unit control diagram. It is recommended that DC wires be run

separately from 110 VAC and 220 VAC wiring.

• A customer furnished 24 or 120 VAC power for alarm relay coil may be connected between

TB3 terminals 28 power and 26 neutral of the control panel. For normally open contacts wire between 29 and 26, for normally closed wire between 27 and26. The alarm is operator programmable. Maximum rating of the alarm relay coil is 25 VA.

• Remote on/off control of unit can be accomplished by installing a set of dry contacts between

terminals 19 and 36.

• Evaporator and condenser flow switches are required. Field installed flow switches must be

wired as shown. If field supplied pressure differential switches are used then these must be installed across the vessel and not the pump. Factory mounted flow switches are standard on WTC



units. Paddle flow switches may also be field installed if desired.

• Customer supplied 24 to 230VAC 20 amp power for optional evaporator and condenser water

pump control power and tower fans is supplied to unit control terminals (TB3) 31 power / 30 neutral, PE equipment ground.

• Optional customer supplied 24-220 VAC 25 VA maximum coil rated chilled water pump relay

(EP 1 and 2) may be wired as shown. This optional will cycle the chilled water pump in response to chiller demand.

• The condenser water pump must cycle with the unit. A customer supplied 24-220VAC 25 VA

maximum coil rated condenser water pump relay (CP 1 and 2) is to be wired as shown.

• Optional customer supplied 24-220 VAC 25 VA maximum coil rated cooling tower fan relays

(C1 – C2 standard, C3 – C4 optional) may be wired as shown. This option will cycle the cooling tower fans in order to maintain unit head pressure.

• Auxiliary 24 VAC rated contacts in both the chilled water and condenser water pump starters

should be wired as shown and remove MJ.

• Terminal 1、2、11、12、22 are only for fix-speed unit, terminal 20、21 are only for VFD unit,

terminal 38,39 are only for 3-11kV unit. Wire 20 and 21 use Modbus communication wire, with 120

Ω characteristic impedance, and wire size is 0.5mm ².

• For VFD , Shielded twisted pair (STP-120) must be used for Modbus RTU communication

between the VFD starter and unit controller RS485 port.



5.3.2 MTⅡ chiller:



Wiring Diagram Notes

1. COMPRESSOR MOTOR STARTERS ARE EITHER FACTORY MOUNTED AND WIRED OR SHIPPED SEPARATE FOR FIELD MOUNTING AND WIRING.IF PROVIDED BY OTHERS STARTERS MUST COMPLY WITH MCQUAY SPECIFICATION 359A999.ALL LINE AND LOAD SIDE POWER CONDUCTORS MUST BE COPPER.WITH AMPACITY BASED ON 75℃ CONDUCTOR RATING.

（EXCEPTION:FOR EQUIPMENT RATED OVER 2000 VOLTS.90℃OR 105℃ RATED

CONDUCTORS SHALL BE USED.）

2.IF STARTERS ARE FREE STANDING,THEN FIELD WIRING BETWEEN THE STERTER AND THE CONTROL PANEL IS REOUIRED .MINIMUM WIRE SIZE FOR 110 VAC IS 12GA.FOR A MAXIMUM LENGTH OF 50 FEET.IF GREATER THAN 50 FEET REFER TO MCQUAY FOR RECOMMENDED WIRE SIZE MINIMUM.WIRE SIZE FOR 24 VAC IS 18 GA.ALL WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM.ALL 24 VAC WIRING MUST BE RUN IN SEPARATE CONDUIT FROM FROM 110 VAC VAC WIRING.MAIN POWER WIRING BETWEEN STARTER AND MOTOR TERMINAL IS FACTORY INSTALLED WHEN UNITS ARE SUPPLIED WITH MOUNTED STARTERS.WIRING OF



FREE STANDING STARTER MUST BE WIRED IN ACCORDANCE WITH NEC AND CONNECTION TO COMPRESSORMOTOR TERMINALS MUST BE MADE WITH COPPER WIRE AND COPPER LUGS ONLY.

3.FOR OPTIONAL SENSOR WIRING SEE UNITS CONTROL DIAGRAM.IT IS RECOMMENDED THAT DC WIRES BE RUN SEPARATELY FORM 110 VAC WIRING.

4.A CUSTOMER FURNISHED 24 OR 110 VAC POWER FOR ALARM RELAY COIL WAY BE XONNECTED BETWEEN UTB1 TERMINALS 84 POWER AND 81 NEUTRAL OF THE CONTROL PANEL.FOR NORMALLY OPEN CONTACTS WIRE BETWEEN 82 & 81.FOR NORMALLY CLOSED WIRE BETWEEN 83 & 81.THE ALARM IS OPERATOR PROGRAMMABLE.MAXIMUM RATING OF THE ALARM RELAY COIL IS 25VA.

5.REMOTE ON/OFF CONTROL OF UNIT CAN BE ACCOMPLISHED BY INSTALLING A SET OF DRY CONTACTS BETWEEN TERMINALS 70 AND 54.PRESSURE DIFFERENTIAL SWITCHES ARE USED THEN THE SE MUST BE INSTRALLED ACROSS THE VESSEL AND NOT THE PUMP.

6.EVAPORATOR AND CONDENSER PADDLE TYPE FLOW SWITCHS OR WATER PRESSURE DIFFERENTIAL SWITCHES ARE REQUIRED AND MUST BE WIRED AS SHOWN.IF FIELD SUPPLIED

7.CUSTOMER SUPPLIED 110 VAC 20 AMP POWER FOR OPTIONAL EVAP AND COND WATER PUMP CONTROL POWER AND TOWER FANS IS SUPPLIED TO UNIT CONTROL TERMINALS (UTB1) 85 POWER/ 86 NEUTRAL.PE EQUIPMENT GROUND.

8.OPTIONAL CUSTOMER SUPPLIED 110 VAC 25 VA MAXIMUM COIL RATED CONDENSER WATER PUMP RELAY (EP1 & 2) MAY BE WIRED AS SHOWN.THIS OPTION WILL CYCLE THE CHILLED WATER PUMPIN RESPONSE TO CHILLED DEMAND.

9.THE CONDENSER WATER PUMP MUST CYCLE WITH THE UNIT.A CUSTOMER SUPPLIED 110 VAC 25 VA MAXIMUM COIL RATED CONDENSER WATER PUMP RELAY (CP1 & 2) IS TO BE WIRED AS SHOWN.UNITS WITH FREE COOLING MUST HAVE CONDENSER WATER ABOVE 60℉ BEFORE STARTING.

10.OPTIONAL CUSTOMER SUPPLIED 110 VAC 25 VA MAXIMUM COIL RATED COOLING TOWER FAN RELAYS (C1 - C2 STANDARD,C3 -C4 OPTIONAL) MAY BE WIRED AS SHOWN. THIS OPTION WILL CYCLE THE COOLING TOWER FANS IN ORDER TO MAINTAIN UNIT HEAD PRESSURE.

11.AUXILIARY 24 VAC RATED CONTACTS IN BOTH THE CHILLED WATER AND CONDENSER WATER PUMP STARTERS SHOULD BE WIRED AS SHOWN AND REMOVE MJ.

12.FOR VFD, WYE-DELTA, AND SOLID STATE STARTERS CONNECTED TO SIX (6) TERMINAL MOTORS, THE CONDUCTORS BETWEEN THE STARTER AND MOTOR CARRY PHASE CURRENT AND THEIR AMPACITY MUST BE BASED ON 58 PERCENT OF THE MOTOR RATED LOAD AMPERES (RLA) TIMES 1.25. WIRING OF FREE-STANDING STARTER MUST BE IN ACCORDANCE WITH THE NEC AND CONNECTION TO THE COMPRESSOR MOTOR TERMINALS SHALL BE MADE WITH COPPER WIRE AND COPPER LUGS ONLY. MAIN POWER WIRING BETWEEN THE STARTER AND MOTOR TERMINALS IS FACTORY-INSTALLED WHEN CHILLERS ARE SUPPLIED WITH UNIT-MOUNTED STARTERS.

13.PRESS SWITCH ARE FACTORY WIRED.

14. • For VFD , Shielded twisted pair (STP-120) must be used for Modbus RTU communication

between the VFD starter and unit controller RS485 port.



VI. Maintenance

Table10 R-134a Pressure/Temperature Chart

HFC-134a Temperature Pressure Chart

°F PSIG °F PSIG °F PSIG °F PSIG

6 9.7 46 41.1 86 97.0 126 187.3

8 10.8 48 43.2 88 100.6 128 192.9

10 12.0 50 45.4 90 104.3 130 198.7

12 13.2 52 47.7 92 108.1 132 204.5

14 14.4 54 50.0 94 112.0 134 210.5

16 15.7 56 52.4 96 115.9 136 216.6

18 17.1 58 54.9 98 120.0 138 222.8

20 18.4 60 57.4 100 124.1 140 229.2

22 19.9 62 60.0 102 128.4 142 235.6

24 21.3 64 62.7 104 132.7 144 242.2

26 22.9 66 65.4 106 137.2 146 249.0

28 24.5 68 68.2 108 141.7 148 255.8

30 26.1 70 71.1 110 146.3 150 262.8

32 27.8 72 74.0 112 151.1 152 270.0

34 29.5 74 77.1 114 155.9 154 277.3

36 31.3 76 80.2 116 160.9 156 284.7

38 33.1 78 83.4 118 166.0 158 292.2

40 35.0 80 86.7 120 171.1 160 299.9

42 37.0 82 90.0 122 176.4 162 307.8

44 39.0 84 93.5 124 181.8 164 315.8

6.1 Routine Maintenance

Oil Charging

! CAUTION

Improper servicing of the oil system, including the addition of excessive or incorrect oil, substitute quality oil filter, or any mishandling can damage the equipment. Only authorized and trained service personnel should attempt this service. For qualified assistance, contact your local Daikin service location. Failure to do so can cause severe compressor damage.

After the system is once placed into operation, no additional oil is required except in the event that repair work becomes necessary to the oil pump or unless a large amount of oil is lost from the system due to a leak.

During operation, the oil level must be visible in the oil sump sight glass(es). Otherwise, shut down the unit and charge oil into the sump as follows:

1. Since the system is under pressure, use a hand pump.

2. Immerse the suction of the hand pump in a clean container of Emkarate RL68H polyolester oil.

3. Connect its discharge line to the oil charging/drain valve on the condenser side of the lubricant sump.

! CAUTION

The POE oil used with R-134a is hygroscopic and care must be exercised to avoid exposure to moisture (air).



4. Pump a few strokes of the oil to fill the connection line with oil to purge air just before tightening the connection at the charging valve.

5. Open the sump charging valve and bring the oil level to be visible on the sight glass.

6. Close the charging valve while the oil pump is still connected.

7. Manually start the oil pump to fill the oil lines, oil cooler and oil filter to check the “true” lubricant level since this will lower the oil level in the sump.

If it is necessary to make up the lost oil in the lines then shut down the oil pump and repeat steps 5 through 7.

After oil charging is completed and if the oil is visible on the sight glass(es) while the oil pump is operating, shut down the oil pump and disconnect the hand pump.

! CAUTION

The oil heater should be immersed in oil all the time it is energized. Therefore, as a caution de-energize the oil heater during the oil charging process to minimize the possibility of damage to the oil heater.

! CAUTION

When the machine is operated again, and on a regular basis during operation, the oil level must be checked to determine if oil needs to be added to maintain the proper operating level. Failure to do so can cause compressor damage.

Oil Analysis

The condition of compressor oil can be an indication of the general condition of the refrigerant circuit and compressor wear. Dark color or cloudy oil, rather than clear, is an indication of contamination and should be further investigated. An annual oil check by a qualified laboratory is essential for maintaining a high level of maintenance. It is useful to have an oil analysis at initial startup to provide a benchmark from which to compare future tests. Oil analysis has long been recognized as a useful tool for indicating the internal condition of rotating machinery and continues to be a preferred method for Daikin centrifugal chillers. The local Daikin service office can recommend suitable facilities for performing these tests.

To accurately estimate the internal condition it is essential to properly interpret the lubricant wear test results.

Most of the elements and contaminants in a system end up in the oil. Polyolester oils are excellent solvents and can readily dissolve trace elements and contaminants. Also, the polyolester oils used in R-134a chillers are more hygroscopic than mineral oils and can contain much more water in solution. For this reason, it is imperative that extra care be used when handling polyolester oils to minimize their exposure to ambient air. Extra care must also be used when sampling to ensure that sample containers are clean, moisture-free leak proof and non-permeable.

Daikin International has done extensive testing in conjunction with refrigerant and oil manufacturers and has established guidelines to determine action levels and the type of action required. Table gives the upper limits for metals and moisture in the polyolester lubricants required by Daikin chillers.



Table11 Metal and Moisture Limits in Polyolester Lubricants

ELEMENT UPPER LIMIT (PPM) ACTION

Aluminum 50 1

Copper 100 1

Iron 100 1

Moisture 150 2 & 3

Silica 50 1

Total Acid Number (TAN) 0.19 3

Key to Action

1) Re-sample after 500 hours of unit operation.

a) If content increases less than 10%, change lubricant and lubricant filter and re-sample at normal interval (usually annual).

b) If content increases between 11% and 24%, change lubricant and lubricant filter and re-sample after an additional 500 hours of operation.

c) If content increases more than 25%, inspect compressor for cause.

2) Re-sample after 500 hours of unit operation.

a) If content increases less than 10%, change filter-drier and re-sample at normal interval (usually annual).

b) If content increases between 11% and 24%, change filter-drier and re-sample after an additional 500 hours of operation.

c) If content increases more than 25%, monitor for a water leak.

Since POE lubricants are hygroscopic, many times the high moisture level is due to inadequate handling and packaging. The TAN reading MUST BE USED in conjunction with moisture readings

3) If TAN is less than 0.10, system is safe as far as acid is concerned.

a) For TAN between 0.10 and 0.19, re-sample after 1000 hours of operation.

b) For TAN above 0.19, change lubricant, lubricant filter, and filter-drier and resample at normal interval

In general Daikin International does not recommend changing oil and filters on a periodic basis. The need should be based on a careful consideration of oil analysis, vibration analysis and knowledge of the operating history of the equipment. A single oil sample is not sufficient to estimate the condition of the chiller. Oil analysis is only useful if employed to establish wear trends over time. Changing oil and the filter prior to when its needed will reduce the effectiveness of oil analysis as a tool in determining machinery condition.

The following metallic elements or contaminates and their possible sources will typically be identified in an oil wear analysis.

Aluminum

Typical sources of aluminum are impellers, seals or casting material. An increase in aluminum content in the lubricant may be an indication of impeller or other wear. A corresponding increase in other wear metals may also accompany an increase in aluminum content.



Copper

The source of copper can be the evaporator or condenser tubes, copper tubing used in the lubrication system such as oil cooler lines, scroll or motor drain lines or motor cooling systems or residual copper from the manufacturing process. The presence of copper may be accompanied by a high TAN (total acid number) and high moisture content. Lubricants containing an anti-wear formulation might react with copper and result in high copper content in the oil.

Iron

Iron in the oil may originate from compressor castings, oil pump components, shells, tube sheets, tube supports, shaft material and rolling element bearings.

Zinc

The source, if any may be from additives in lubricant.

Silicon

Silicon can originate from residual particles of silicon left from the manufacturing process, filter drier material, or dirt.

Moisture

Moisture in the form of dissolved water can be present in lubricating oil to varying degrees. Some polyolester lubricants may contain up to 50 parts per million (ppm) of water from new unopened containers. Other sources of water may be the refrigerant (new refrigerant may contain up to 10 ppm water), leaking evaporator or condenser tubes, or moisture introduced by the addition of either contaminated oil or refrigerant or improperly handled oil.

Liquid R-134a has the ability to retain up to 1400 ppm of water in solution at 100 F. With 225 ppm of water dissolved in liquid R-134a, free water would not be released until the liquid temperature reached

-22 F. Liquid R-134a can hold approximately 470 ppm at 15F (an evaporator temperature which could be encountered in ice applications). Since free water is what causes acid production, moisture levels should not be of a concern until they approach the free water release point.

A better indicator of a condition which should be of concern is the TAN (Total Acid Number). A TAN below 0.09 requires no immediate action. TANs above 0.09 require certain actions. In the absence of a high TAN reading and a regular loss of oil (which may indicate a heat transfer surface leak), a high moisture content in an oil analysis is probably due to handling or contamination of the oil sample. It should be noted that air (and moisture) can penetrate plastic containers. Metal or glass containers with gasket in the top will slow moisture entry.

In conclusion, a single element of an oil analysis should not be used as the basis to estimate the overall internal condition of a Daikin chiller. The characteristics of the oil and refrigerant, and knowledge of the interaction of wear materials in the chiller must be considered when interpreting a wear metal analysis. Periodic oil analysis performed by a reputable laboratory and used in conjunction with compressor vibration analysis and operating log review can be helpful tools in estimating the internal condition of a Daikin chiller.

Daikin International recommends that an oil analysis be performed annually. Professional judgment must be exercised under unusual circumstances, for example, it might be desirable to sample the oil shortly after a unit has been placed back into operation after it has been opened for service, as recommended from previous sample results or after a failure. The presence of residual materials from a failure should be taken into consideration in subsequent analysis. While the unit is in operation, the sample should be taken from a stream of oil, not in a low spot or quiet area.



Changing Oil Filters

The oil filter in these compressors can be changed by simply isolating the filter cavities. Close the oil discharge line service valve and the oil pressure regulator valve. Remove any refrigerant using EPA approved methods, Remove the filter cover, remove the filter and replace with new element. Reopen the valve in the pump discharge line and purge air from the lubricant filter cavity. Re-adjust the oil pressure regulator valve for the right pressure differential setting above 22 psid after starting the oil pump manually and before restarting the chiller.

Refrigerant Cycle

Maintenance of the refrigerant cycle includes maintaining a log of the operating conditions, and checking that the unit has the proper lubricant and refrigerant charge.

At every inspection, all system pressures and temperatures should be recorded on a copy of the Log Sheet on page 54.

The first stage suction temperature at the compressor should be taken at least once a month. Subtracting the saturated temperature equivalent of the suction pressure from this will give the suction superheat. Extreme changes in subcooling and/or superheat over a period of time may indicate losses of refrigerant or possible deterioration or malfunction of the expansion valves. Proper superheat setting is 0 to 1 degree F (0.5 degree C) at full load. Such a small temperature difference can be difficult to measure accurately. Another method is to measure the compressor discharge superheat, the difference between the actual second stage discharge temperature and the saturated condenser temperature. The discharge superheat should be between 14 and 16 degrees F (8 to 9 degrees C) at full load.

The MicroTech II interface panel can display all superheat and subcooling temperatures.

Electrical System

Maintenance of the electrical system involves the general requirement of keeping contacts clean and connections tight and checking on specific items as follows:

The compressor current draw should be checked and compared to nameplate RLA value. Normally, the actual current will be lower, since the nameplate rating represents full load operation. Also check all pump and motor amperages, and compare with nameplate ratings.

Inspection must verify that the lubricant heaters are operative. The heaters are insert-cartridge type and can be checked by ammeter reading. They should be energized whenever power is available to the control circuit, when the lubricant temperature sensor calls for heat, and when the compressor is inoperative. When the compressor runs, the heaters are de-energized. The Digital Output screen and second View screen on the operator interface panel both indicate when the heaters are energized.

At least once a quarter, all equipment protection controls except compressor overloads should be made to operate and their operating points checked. A control can shift its operating point as it ages, and this must be detected so the controls can be adjusted or replaced. Pump interlocks and flow sensors should be checked to be sure they interrupt the control circuit when tripped.

The motor starter contactors should be maintained per starter manufacturer’s recommendations.

The compressor motor resistance to ground should be checked and logged semi-annually. This log will track insulation deterioration. A reading of 50 megohms or less indicates a possible insulation defect or moisture and must be further checked.

The centrifugal compressor must rotate in the direction indicated by the arrow on the back of the motor as viewed through the rotation sight glasses located in the rear motor cover.



! CAUTION

Never meg a motor while in a vacuum. Severe motor damage can result. It is recommended to meg the motor after 24 hours of sitting idle at ambient temperature

! CAUTION

Anytime external leads from motor are removed for servicing etc. the compressor must be jogged to check rotation after leads are reconnected at the start-up.

6.2 Equipment Cleaning and Preserving

A common cause of service calls and equipment malfunction is dirt. This can be prevented with normal maintenance. The system components most subject to dirt are:

1. Permanent or cleanable filters in the air handling equipment must be cleaned in accordance with the manufacturer’s instructions; throwaway filters should be replaced. The frequency of this service will vary with each installation.

2. Remove and clean strainers in chilled water system and condenser water system at every inspection.

Seasonal Servicing

Prior to shutdown periods and before starting up again, the following service procedures must be completed.

Annual Shutdown

Where the chiller can be subject to freezing temperatures, the chiller must be drained of all water. Water permitted to remain in the piping and vessels can rupture these parts if subjected to freezing temperature. The condenser and evaporator are not self-draining and therefore, first drain the condenser and evaporator heads. Then, remove the heads and blow dry air through the evaporator and condenser tubes to force out all water out.

1. Take measures to prevent the shutoff valve in the water supply line from being accidentally turned on.

2. If a cooling tower is used, and if the water pump will be exposed to freezing temperatures, be sure to remove the pump drain plug and leave it out so any water that can accumulate will drain .

3. Open the compressor disconnect switch, and remove the fuses. If the transformer is used for control voltage, the disconnect switch must remain on to provide power to the oil heater. Set the manual UNIT ON/OFF switch in the unit control panel to the OFF position.

4. Check for corrosion and clean and paint rusted surfaces.

5. Clean and flush the water tower. Make sure tower blowdown or bleed-off is operating. Set up and use a good maintenance program to prevent scaling of both tower and condenser. It should be recognized that atmospheric air contains many contaminants that increase the need for proper water treatment. The use of untreated water can result in corrosion, erosion, sliming, scaling or algae formation. It is recommended that the service of a reliable water treatment company be used. Daikin International assumes no responsibility for the results of untreated or improperly treated water.

6. Drain water from the chiller and remove water heads at least once a year to inspect the condenser and evaporator tubes and clean if required.

7. Test all chiller joints with an R-134a compatible electronic leak detector to be sure all joints are tight. All leaks found should be repaired before a prolonged shutdown for a season



Tube Fouling and Cleaning

Fouling is generally defined as the deposit of solid insulating material on a heat transfer surface, or accumulation of unwanted material on solid surfaces. Over a period of time, due to poor water quality caused by dirty strainers, unclean cooling tower conditions or environmental factors, drawing water from lakes, rivers, and oceans, moisture or acidic conditions for tube corrosion may exist. An accumulation of rust, debris, aquatic organisms or sludge inside the tubes may plug tubes and will decrease heat transfer. The formation of thin mineral compounds or “scaling” such as calcium carbonate, manganese compounds and silicates build up on the inner tube surfaces are other type of deposits will cause tube fouling and poor heat transfer. The fouling results in a raised tube temperature and condensing saturation temperature, with a resulting increase in the system power requirement.

Once formed, scale must be treated chemically with an acid solution treated water to remove these types of hard deposits. Tubes can be cleaned with a nylon brush.

! CAUTION

Do not clean with a steel bristle brush, which can cause tube damage. Always clean with a brush before acid cleaning of tubes. Cleaning tubes with water and brush together will improve results

! CAUTION

Acid cleaning of tubes must only be performed by authorized and trained service personnel. For qualified assistance, contact your local Daikin Factory Service office.

Types of In-Tube Fouling :

Biological : The attachment of macro- and/or micro-organisms to the heat transfer surfaces. slime deposits such as bacteria, fungi and algae.

Particulate : The accumulation of finely divided solids suspended in the fluid onto the heat transfer surface. Formation of agglomerates (a jumbled mass or collection) at low velocities. Airborne particles in cooling towers, rusting in pipes. Impurities such as chemicals, salts, pollutants, dirt, rust are typically contained in the cooling water flowing inside a tube will adhere to the tube inner surface. These impurities cause fouling in the heat transfer tubes after a period of time and reduces the heat transfer across the tube wall.

Particulate fouling occur in evaporators.

Precipitation (Scale) : The precipitation of dissolved substances on the heat transfer surface. When the dissolved substances have inverse rather than normal solubility – vs. – temperature behavior, the precipitation occurs on superheated rather than subcooled surfaces and the process is often referred to as scaling. Warmer the surface less soluble. Deposits on cold surfaces if bulk solubilities are exceeded. In precipitation fouling, which may occur simultaneously with particulate fouling, chemicals (dissolved solids) that are contained in the cooling water will deposit on the inner surface of the tube if the concentration of the chemicals is higher than the solubility limit at the water temperature. The precipitation of the chemicals onto the warmer tube inner surface is caused by this reverse solubility of the chemicals typically found in cooling water. The presence of precipitate fouling often results in an increase in the rate of particulate fouling, because particles such as rust or dirt will more easily adhere to the inner tube surface if chemicals have already adhered to the inner tube surface.

Fouling of the precipitation type is not as large of a problem in evaporators as in condenser because the tube walls have a lower temperature than the water circulating inside. Because of the lower temperature of the tube walls, the chemicals do not undergo inverse solubility as they do in the condenser.

Corrosion : Corrosion of the heat transfer surface that produces products fouling the surface and/or



roughens the surface, promoting attachment of other foulants.Causes surface roughness, adds corrosion products and promotes combinations of several fouling types.

Chemical Reaction : Deposits formed on the surface by a chemical reaction not involving the surface material.

Freezing : The solidification of a liquid or some of its higher – melting point constituents on the heat transfer surface. Freezing fouling is due to the solidification of vapor condensing from the gas stream onto a below-freezing temperature heat transfer surface.

Examples of harmful deposits (tubercles) are:

High amount of iron or metallic deposits due to corrosion occurring inside the iron/carbon steel piping in the water circuit can be carried by the water to the tubes. These metallic deposits often adhere or fuse themselves to the tube.

Molybdenum which is used as an iron corrosion inhibitor in water systems.

Sulfur which is known as an aggressive element in corrosion reactions, is a result of environmental factors transferred to the water systems such as acid rain, auto exhaust etc.

The signs of tube fouling due to deposits can be observed as a decrease of evaporator capacity and an increase of evaporator and/or condenser small temperature difference. In addition, lubricant loss to the evaporator and refrigerant leak will also deteriorate the performance of evaporator. Therefore, it is usually hard to isolate tube fouling as the only main cause for bad evaporator performance.

Water velocity, turbulence, or high temperature will cause erosion and combined with metal loss created by corrosion might cause condenser tube foul.

Tube Leak Detection

Tubes can be ruptured or broken due to vibration, freezing, or corrosion etc.. Depends on the shell and tube side pressures refrigerant might leak through the tubes to the cooling tower or water might enter the shells.

Refrigerant leaks from the tubes can be detected at the heads using a refrigerant leak detector whereas water leaks in the shells can be detected visually through the sight glasses or poor chiller capacity.

Eddy current testing is recommended based on site conditions to determine any defective tubes.

Annual Startup

A dangerous condition can exist if power is applied to a faulty compressor motor starter that has been burned out. This condition can exist without the knowledge of the person starting the equipment.

This is a good time to check all the motor winding resistance to ground. Semi-annual checking and recording of this resistance will provide a record of any deterioration of the winding insulation. All new units have well over 100 megohms resistance between any motor terminal and ground.

Whenever great discrepancies in readings occur, or uniform readings of less than 50 megohms are obtained, the motor cover must be removed for inspection of the winding prior to starting the unit. Uniform readings of less than 5 megohms indicate motor failure is imminent and the motor should be replaced or repaired. Repair before failure occurs can save a great deal of time and labor spent in the cleanup of a system after a motor burnout.

1. The control circuit must be energized at all times, except during service. If the control circuit has been off and lubricant is cool, energize lubricant heaters and allow 8 hours for heater to remove refrigerant from the lubricant before starting.



2. Check and tighten all electrical connections.

3. Replace the drain plug in the cooling tower pump if it was removed at shutdown time the previous season.

4. Install fuses in main disconnect switch (if removed).

5. Reconnect water lines and turn on supply water. Flush condenser and check for leaks.

6. Refer to the startup section of this manual before energizing the compressor circuit.

6.3 Repair of System

! NOTE

It is at utmost importance that all local, national, and international regulations concerning the handling and emission of refrigerants are observed.

Pumping Down

If a major repair is necessary on the chiller other than condenser, refrigerant charge can be isolated and stored in the condenser by pumping down. When pumping the system down, extreme care must be used to avoid damage to the evaporator from freezing. Always make sure that full water flow is maintained through the chiller and condenser while pumping down. To pump the system down, close the main liquid line valve and set the MicroTech II control to the manual load. The vanes must be open while pumping down to avoid a surge or other damaging condition. Pump the unit down until the MicroTech II controller cuts out at approximately 26 psig. It is possible that the unit might experience a mild surge condition prior to cutout. If this should occur, immediately shut off the compressor. Then, close the following lines only after the compressor stops:

1. Oil cooling supply line

2. Motor cooling supply line

3. Eductor gas supply line

4. Second stage/scroll drain line

Use a portable recovery unit to complete the pump down, condense the refrigerant, and pump it into the condenser or pumpout vessel using approved procedures.

! CAUTION

Always open IGV at least 30% right after compressor stops during pump down.

Pressure Relief Valve Replacement

Relief valves are separated by a three-way shutoff valve on the vessel. This three-way valve allows either relief valve to be shut off, but at no time can both be shut off. This makes it possible to replace the a relief valve while the refrigerant charge is still in the condenser.



Fig. 22 Evaporator and Condenser 3-Way Valve

! WARNING Under no circumstances should relief valves be replaced while the unit is running. Property damage, severe personal injury, or death can result.

Leak Testing

After a service repair, the unit must be checked for leaks prior to recharging the complete system. This can be done by charging enough refrigerant R-134a into the system to build the pressure up to approximately 10 psig (69 kPa) and adding sufficient dry nitrogen to bring the pressure up to a maximum of 125 psig (860 kPa). Leak test with an R-134a compatible electronic leak detector to be sure all joints are tight. Halide leak detectors do not function with R-134a.

Leak testing should be focused on the areas worked on. Leaks around tubing or fitting connections can often be stopped by simply tightening them. However, for any leaks that are found in welded or brazed joints, or if it is necessary to replace a gasket, relieve the test pressure in the system before proceeding. Brazing is required for copper joints.

After it has been determined that there are no refrigerant leaks, the system must be evacuated as described in the following section starting from step 3 in the following Evacuation section.

! WARNING

Do not use oxygen or a mixture of refrigerants and air to build up pressure as an explosion can occur causing serious personal injury.

Evacuation of the System

If there is a need for major service work on the chiller or on the condenser and the whole charge must be evacuated then proceed as follows:

1) Connect the service valve at the bottom of the condenser to the refrigerant cylinder and start taking charge out while running the unit at full load with high condenser water inlet temperature until the unit shuts down on low evaporator pressure.

2) Continue taking liquid charge out after shutdown while circulating warm condenser water in the unit to keep the condenser pressure higher than the cylinder pressure.



3) Once the pressures between the cylinder and unit equalizes, connect a recovery unit with a capacity that will reduce the vacuum to the acceptable EPA standards.

4) An electronic or other type of micron gauge, must be connected at the farthest point from the vacuum pump. For readings below 1000 microns, an electronic or other micron gauge must be used.

5) To improve evacuation circulate warm water not to exceed 122 F ( 50 C ) through the condenser and evaporator tubes to thoroughly dehydrate the shells. A portable water heater can be employed as an alternative source for hot water. A suggested method is to connect a hose between the source of hot water under pressure and the evaporator head drain connection, out the evaporator vent connection, into the condenser head drain and out the condenser vent back to the inlet of the water heater.

6) The triple evacuation method may be necessary due to severe contamination of the refrigerant.

7) The system is first evacuated to approximately 500 microns. Dry nitrogen is then added to the system to bring the pressure up to zero pounds.

8) Then the system is once again evacuated to approximately 500 microns.

9) After evacuation is completed to 500 microns, a vacuum hold test should be conducted.

10) Close the condenser service valve to the vacuum pump and hold the vacuum in the system for 4 hours. The slightest rise in pressure is an indication of either a leak to the atmosphere or the moisture in the chiller or both. If, after 4 hours the micron gauge has not risen above 1000 microns, the system may be considered tight.

11) If the vacuum hold test fails then do another leak test.

12) If the vacuum hold test fails use Table 32 to determine if the failure is due to a leak or water/moisture in the unit. If the vacuum level rises above water saturation point then do another leak test. If it stops at water saturation temperature, continue evacuation until dry or source determined.



Table12 Pressure Chart

Notes:

1. psia ( pounds per square inch absolute ): sum of gage and atmospheric pressures 2. psig ( pounds per square inch gage ): pressure over atmospheric pressure 3. vacuum: pressure below atmospheric i.e. negative gage pressure (always stated as positive

numbers) 4. in. Hg: inches of mercury, mm Hg: millimeters of mercury

6.4 Charging the System

HTV water chillers are leak tested at the factory and the correct charge of refrigerant is indicated on the nameplate. The refrigerant charge amount is specified for each chiller model in Table.

In the event the refrigerant charge was lost due to leak(s) or the unit exhibits a lack of performance due to insufficient amount of charge, the system should be charged or trimmed.

In order to ease the evacuation, charging and trimming, service connection valves are provided at the top and bottom of condenser and evaporator and at the bottom of economizer as well as sight glasses on the evaporator, economizer, and condenser.

If there are any leaks found then first repair the leaks.

Table12 Refrigerant R-134a Charge

SHELLS COMPRESSOR EST. MAX. REFRIGERANT CHARGE

lb. (kg)

E3012/C3012 M 1433(650)

E3616/C3616 L 2630 (1200)

E4216/C3616 G 3290 (1500)

E4216/C4216 K

3507 (1600)

E4816/C4216 4385 (2000)

GAGE PRESSURE ABSOLUTE PRESSURE WATER TEMPERATURE AT

SATURATION oF

VACUUM in. Hg

psia in. Hg mm Hg Microns

0 14.696

( Std. at Sea Level ) 29.921 760 760,000 212 (Water Boiling Temperature)

10.24 9.668 19.68 500 500,000 192

22.05 3.867 7.87 200 200,000 152

25.98 1.934 3.94 100 100,000 125

27.95 0.967 1.97 50 50,000 101

28.94 0.483 0.98 25 25,000 78

29.53 0.193 0.39 10 10,000 52

29.72 0.097 0.20 5 5,000 34

29.74 0.089 0.18 4.58 4,580 32 (Water Freezing Temperature)

29.842 0.039 0.08 2 2,000 15

29.882 0.019 0.04 1 1,000 1

29.901 0.010 0.02 0.50 500 -11

29.909 0.006 0.01 0.30 300 -20

29.917 0.002 0.004 0.10 100 -38

29.919 0.001 0.002 0.05 50 -50

29.9206 0.0002 0.0004 0.01 10 -73

29.921 0 0 0.00 0



If the system is evacuated due to service and is still under a vacuum then in order to put charge back into the system follow these steps:

1. Make up a suitable charging connection from new copper tubing or yellow jacket/flexible hose to fit between the chiller charging valve and the fitting on the refrigerant charging cylinder. This connection should be as short as possible but long enough to permit sufficient flexibility for charging cylinders.

2. Stand the refrigerant cylinder with the connection up. In order to avoid possibility of freezing the liquid within the evaporator tubes when charging an evacuated system, only refrigerant vapor from the top of the refrigerant cylinder must be admitted first.

3. Just before connecting the charging line to the service valve on top of the evaporator, open the valve on the cylinder and purge any air in the charging line.

4. After purging the charging connection and connecting the line to the evaporator, keep the evaporator service valve closed while the cylinder valve is open. The charging line should be filled with refrigerant and with very little or no air at this point.

! NOTE

While charging, every precaution must be taken to prevent moisture laden air from entering the system.

5. Turn on both the cooling tower water pump and chilled water pump and allow water to circulate through the chiller. In order to lower the chiller system pressure, low water temperature is recommended to accelerate the charging. Chiller system pressure as well as refrigerant cylinder pressure should be monitored during charging process. Make sure the cylinder pressure is always higher than the chiller system pressure in order to maintain refrigerant flow by pressure differential.

6. If there is oil in the oil sump, then energize the oil heater before charging with any refrigerant. This will keep the oil hot and prevent any refrigerant concentration in the oil by boiling of the refrigerant from the oil.

7. Then open the service valve on top of the evaporator to the mid-position and break the vacuum with refrigerant gas to a saturated pressure above the point corresponding to the freezing point of the liquid to avoid the possibility of freezing liquid within the evaporator tubes. If the liquid is water, then the system pressure corresponding to the freezing point would be 28 psig ( 0.19 MPaG ) for R-134a ( at sea level ). Therefore, keep charging with refrigerant vapor until the chiller pressure is well above 28 psig.

8. After the chiller pressure is above 28 psig by gas charging, the rest of the charge could be put into the system by refrigerant liquid form and without water circulation even though running water pumps until the end of charging process is strongly recommended.

9. Reconnect the refrigerant cylinder and charging line to the service valve on the bottom of the evaporator. Again purge the connecting line, stand the cylinder with the connection up, and place the service valve in the open position.

10. At some point both the chiller and cylinder pressures might equalize with each other during the charging process and in return that might slow or stop the process. However, there a few ways to prevent situations like this (see #11 – 14 below).

11. Circulate cold water through the evaporator and condenser tubes to keep the chiller system pressure lower.

12. If there is a crane in the facility, invert the charging cylinder and elevate the cylinder above the evaporator. With the cylinder in this position, valves open, water pumps operating, liquid refrigerant



will flow into the evaporator by gravitational force.

13. If there is no crane capability in the facility, heat lamps are recommended to heat the cylinder to raise the pressure. A recovery unit can be used to create a pressure difference.

14. If there are no crane or heat lamps available, then start the chiller and run at part load and low condenser water temperature. Low evaporator pressure will improve and accelerate the rest of the charging rapidly.

15. If charge needs to be added to improve performance, repeat Step 8 above while the chiller is running at full load capacity and check the refrigerant charge level through sight glasses. The level on the condenser sight glass should be about an inch above the subcooler trough cover plate without any condenser tubes at the bottom immersed in the liquid, and about an inch above the evaporator tubes all wetted but not totally immersed. Capacity of the chiller and discharge superheat should also be monitored through the main control console in order to manage the process.

If charge needs to be taken out during trimming for optimum performance then repeat Step 8 with connection to the bottom of the condenser during running at high load/high head condition or at full load with high condenser water inlet temperature. The refrigerant charge level and capacity should be monitored as explained above in order to regulate trimming.

! NOTE

Record the charge amount and level of charge in the evaporator and condenser sight glasses if refrigerant amount has been changed.



Prestart System Checklist

Yes No N/A

Unit

Visible damages to unit…………………………………………………………………… o o o

Unit structural support adequate and level per IM……………..………………………… o o o

Vibration pads installed per IM………………………………………………………..…. o o o

Adequate clearances for service and code requirements……………………………….. o o o

Chilled Water

Piping complete, vent drain, & gauge connections installed…………………………… o o o

Piping properly supported and stress free……………………………………………… o o o

Water system flushed, filled, vented, glycol and water treatment applied necessary o o o

Pumps installed, (rotation checked), strainers cleaned………………………………… o o o

Controls (3-way, face and bypass dampers, bypass valves, etc.) operable……………… o o o

Water system operated and flow balanced to meet unit design requirements o o o

Condenser Water

Piping complete, vent drain, & gauge connections installed,

Piping properly supported and stress free o o o

Cooling tower flushed, filled and vented, water treatment complete o o o

Condenser water piping flushed, filled and vented o o o

Pumps installed, (rotation checked), strainers cleaned o o o

Controls (3-way, bypass valves, etc.) operable o o o

Water system operated and flow balanced to meet unit requirements o o o

Electrical

All copper conductors connected to unit ……………………………………….……….. o o o

115-volt service completed, but not connected to control panel o o o

200-volt service completed, but not connected to control panel o o o

Power leads connected to starter; load leads run to compressor ready for

connection when service engineer is on hand for start-up o o o

(Do not connect starter or compressor terminals)

All interlock wiring complete between control panel and complies with specifications o o o

Starter complies with specifications o o o

Pump starters and interlock wired o o o

Cooling tower fans and controls wired o o o

Wiring complies with National Electrical Code and local codes o o o

Condenser pump starting relay (CWR) installed and wired o o o

Miscellaneous

Relief valve piping complete o o o

Thermometer wells, thermometers, gauges, control wells, controls, etc., installed o o o

BAS control sequences, functions and settings confirmed……………………….............. o o o

Minimum system load of 80% of machine capacity available for testing

and adjusting controls o o o

Note: The checklist must be completed and sent to the local D service location two weeks prior to start.



Operating Limits

1 Operating Limits

Operation of low condenser water temperature

If the wet bulb temperature of the ambient temperature is lower than the designed conditions, the water temperature of condenser can be reduced. The low temperature can improve the chiller performance.

A) Use electronic expansion valve chiller

DAIKIN centrifugal chiller applying HTS063-087 compressor is equipped with electronic expansion valve (EXV), and the condenser entering water temperature curve is shown in the figure below, and can be obtained by the formula edited by the curve. The formula is shown as follows.

Lowest entering water temperature of cooling water (EXV)

Fig. 38

For example, if the leaving water temperature is 6.7 °C, and when the chilled water is under full load, the △t=5.6 °C. In case of 50% of full load, the cooling entering water temperature can reach as low as 6.9 °C. This provision can ensure the economy of water circuit system.



B) Use thermal expansion valve + main expansion valve chiller

DAIKIN centrifugal water chiller applying HTS100-126 and HTD compressor is equipped with thermal expansion valve, and the condenser entering water temperature curve is shown in the Fig. below, and can be obtained by the formula edited by the curve. The formula is shown as follows.

Lowest entering water temperature of cooling water (TXV)

Fig. 39

For example, if the leaving water temperature is 6.7 °C, △t=5.6 °C, in case of 50% of full load, the cooling entering water temperature can be as low as 10.3 °C. This provision can ensure the economy of water circuit system.

In accordance with local climatic conditions, the lowest inlet temperature of cooling water may increase the electricity consumption of the entire system, because the electricity consumption of the fan will rises up significantly. When the outdoor wet bulb temperature is lower, and the chiller runs under full load, the fan of cooling tower must continue running. At this time, when the chiller is under full load, the motor energy consumption of the motor accounts for a large percentage in total energy consumption, so the energy efficiency of the chiller is lower. DAIKIN’s Energy Analyzer can optimize the chiller/cooling tower combination based on different cold sites and building categories, which can even control the fan of



cooling tower, water control in some forms, such as the bypass of cooling tower, and deliver an optical recommendation to the customer.

Fig. 40 has shown the operation of cooling tower bypass at two temperatures. Thereinto, “Cold Climate” figure is easier to start up when the ambient temperature is lower, and the check valve can prevent air from flowing in the pump inlet.

Operating mode of cooling tower bypass

Fig. 40

Condenser Water Temperature

When the ambient wet bulb temperature is lower than design, the entering condenser water temperature can be allowed to fall, improving chiller performance.

DAIKIN chillers will start with entering condenser water temperature as low as 12.8°C providing the chilled water temperature is below the condenser water temperature.

Depending on local climatic conditions, using the lowest possible entering condenser water temperature can be more costly in total system power consumed than the expected savings in chiller power would suggest due to the excessive fan power required.

Control cooling tower fan or adopt some measures to control water flow rate: for example, the water bypass passing through the cooling tower.

2 Water flow scope

For the cooling water: the turbulent condition cannot be reached in the slow flow velocity, and the heat exchange efficiency drops greatly;

In the fast flow velocity, the chiller water pressure drop enlarges, the waste work of the water pump raises and the lifetime of the heat exchange tube shortens.

V min=3 ft/s =0.9 m/s

V max=10 ft/s=3.0 m/s

For the chilled water: D

V7500

min , wherein - kinematic viscosity; D – pipeline diameter;

V max=12 ft/s=3.6 m/s



3 Minimum water content in piping system

To obviate the frequent start and stop of the chiller, and keep the running steady, the minimum water retaining capacity of the chilled water system shall exceed the following calculation value.

The minimum water retaining water calculation formula Ｑ(m3)＝(Ｔ×６０)×Ｈ/(Δｔ×Ｃｐ×ρ)

WhereinＴ: Compressor’s minimum running time (time) is calculated by 5 min

H: Chiller’s capacity control capacity (kW) = cooling capacity under full load (kW) ×0.3

Δt: Chiller’s automatic stop temperature*2 = 3.4°C.

Cp: Secondary refrigerant specific heat (kJ/kg°C) ρ: secondary refrigerant proportion (kg/m3)

The cooling capacity under full load: calculated by the chiller’s maximum cooling capacity as for the single compressor chiller; calculated by 50% of the maximum cooling capacity as for the double compressor chiller.

4 Application Standard

Using standard benchmark chiller running environment is as follows:

Table 23

Supply Voltage 400V±10%

Phase Unbalance Rate 2%

Frequency 50Hz ± 2%

Operating Temperature 3-40°C

Relative Humidity ≤90%

Atmospheric Corrosive Gas Contents

Sulfur Dioxide: ≤10 mg/m3

Hydrogen Fluoride: ≤5 mg/m3

Hydrogen Sulfide: ≤5 mg/m3

Nitrogen Oxides: ≤5 mg/m3

Nitrogen: ≤1 mg/m3

Hydrogen Chloride: ≤5 mg/m3

Installation Indoor installation, no rain or direct sunlight (for installations of the outdoor, seaside, chemical plant, or places of high concentration of corrosive gas, please contact the local DAIKIN office and distributors)

Water Temperature Range of water chiller

See 14.1

Water Capacity Range See 14.2

Heat Exchange Tube Waterside Pressure

Standard chiller 1.0Mpa (may be designed as per the customer’s requirements)

5 Water Quality Management

When the chiller is running, the water quality of cooling water, chilled water will directly affect the machine performance and service life.So you must survey water quality in advance. And manage the water quality.

The following table contains some parameters of the water quality of open system:



Table 24

Item Chiller Reference Value

Item

Corrosion Scaling

Basic

Item

pH (25°C) — 6.5-8.0 O O

Specific (25°C) s/cm ＜800 O O

Chloridion Cl Mg( Cl )/L ＜200 O

Sulfate ion 2

4SO mg

2

4SO /L ＜200 O

Acid consumption (pH=4.8) mg( 3CaCO )/L ＜100 O

Full hardness mg( 3CaCO )/L ＜200 O

Reference

Item

Iron Fe) Mg(Fe)/L ＜1.0 O O

Sulphion 2S Mg( 2S )/L Not Detected O

Ammonium ion NH mg( NH )/L ＜1.0 O

Silicon oxide 2SiO mg( 2SiO )/L ＜50 O

Notes: 1. Water quality indicators with reference to the vapor compression cycle cold water (heat pump) unit of GB/T18430.1, appendix D cooling water quality

2. "O" in the table the relevant factors of corrosion or scaling tendency.

3. Such as water quality can not meet the above requirements, reference GB50050-2007 specification for design of industrial circulating cooling water treatment for processing.

6 About Non-aqueous Coolant

When the referigerating is ethylene glycol, please according to the evaporator outlet water temperature to correspond recommended ethylene glycol,please check table, and due to the temperature condition of the concentration of the cold should not be less than the recommended value:

Table 25

Evaporator Leaving Water Temperature Range (°C)

Recommended Glycol Concentration (%)

-3--3 15

-5--3 20

-8--5 25

-10--8 30

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Maintenance Schedule

Maintenance Check List Item Daily Weekly Monthl

y

Quarte

rly

Annual

ly 5-Yr

As

Req’d

I. Unit

· Operational Log O

· Analyze Operational Log O

· Refrigerant Leak Test Chiller O

· Test Relief Valves or Replace X

II. Compressor

· Vibration Test Compressor X

A. Motor

· Meg. Windings (Note 2) X

· Ampere Balance (within 10% at RLA) O

· Terminal Check (Infrared temperature measurement) X

· Motor Cooling Filter Drier Pressure Drop X

B. Lubrication System

· Lubricant Appearance (clear color, quantity) O

- Lubricant Filter Pressure Drop O

· Lubricant Analysis (Note 6) X

· Lubricant change if indicated by lubricant analysis X

III. Controls

A. Operating Controls

· Calibrate Temperature Transducers X

· Calibrate Pressure Transducers X

· Check Vane Control Setting and Operation X

· Verify Motor Load Limit Control X

· Verify Load Balance Operation X

· Check Lubricant Pump Contactor X

B. Protective Controls

· Test Operation of:

Alarm Relay X

Pump Interlocks X

Guardistor and Surgeguard Operation X

High and Low Pressure Cutouts X

Lubricant Pump Pressure Differential Cutout X

Lubricant Pump Time Delay X

IV. Condenser

A. Evaluation of Temp Approach (NOTE 3) O

B. Test Water Quality O

C. Clean Condenser Tubes (NOTE 3) X X

D. Eddy current Test - Tube Wall Thickness V

E. Seasonal Protection X

V. Evaporator

A. Evaluation of Temp Approach (NOTE 3) O

B. Test Water Quality V

C. Clean Evaporator Tubes (NOTE 3) X

D. Eddy current Test - Tube Wall thickness V X

E. Seasonal Protection X

VI. Starter(s) – See vendor requirements(NOTE8)



NOTES:

1. It is recommended that the operator maintain an operating log for each individual chiller unit. In addition, a separate

maintenance log should be kept of the periodic maintenance and servicing activities.

2. Some compressors use power factory correction capacitors and all have a surge capacitor (excepting units with solid state

starters). The surge capacitor can be installed out of sight in the compressor motor terminal box. In all cases, capacitors must be

disconnected from the circuit to obtain a useful megger reading. Failure to do so will produce a low reading. In handling

electrical components, only fully qualified technicians must attempt service.

3. Approach temperature (the difference between the leaving water temperature and the saturated refrigerant temperature) of

either the condenser or evaporator is a good indication of tube fouling, particularly in the condenser, where constant flow

usually prevails. Daikin's high efficiency heat exchangers have very low design approach temperatures, in the order of one to

one and one half degrees F.

4. It is recommended that benchmark readings (including condenser pressure drop to confirm future flow rates) be taken during

startup and then periodically afterward. An approach increase of two-degrees or more would indicate that excessive tube

fouling could be present. Higher than normal discharge pressure and motor current are also good indicators

5. Evaporators in closed fluid circuits with treated water or anti-freeze are not normally subject to fouling; however it is prudent

to check the approach periodically. Evaporators in open systems may require additional evaporator cleaning.

6. Not part of standard initial warranty service.

7. Lubricant filter change and compressor teardown and inspection should be done based on the results of the annual lubricant test

performed by a company specializing in this type of test. Consult Daikin Factory Service for recommendations.

8. Check the electrolytic capacitor of VFD annually. If capacitor work more than 20000hours(or 5 yeras), or capacitor leak, or

safety valve swell, or the capacitance value is below the nominal capacitance 85%,replace the electrolytic capacitor.

KEY:

O = Performed by in-house personnel.

X = Performed by Daikin authorized service personnel. (NOTE 5)

V = Normally performed by third parties.



EVAPORATOR

SYMPTOM RESULTS Possible Cause Remedy

Extreme Low Suction

Pressure

High Evaporator

Approach Temperature

with High Discharge

Temperature

Low Charge Check for leaks and add charge

EXV problem Remove obstruction

High Evaporator

Approach Temperature

with Normal Discharge

Temp

Dirty or restricted evaporator

tubes

Clean Evaporator Tubes and/or

Check water conditioning

Low Evaporator water

leaving Temperature

with w/ Low Motor

Current

Insufficient Load for system

capacity

Check IGV motor operation and

set point of Evaporator water

leaving temperature cutout

Check Cutout setting and

increase it if necessary so

Evaporator water leaving

temperature will not be so low

and the unit will shut down NOT

causing low suction pressure

anymore

IGV might not be Full Open but

not give enough load due to

linkage slippage etc.

High Evaporator pressure Low Evaporator water

leaving Temperature

IGV failed to open Check the IGV motor

positioning circuit

System Overload

Be sure the vanes are wide open

without overloading the motor

until the load decreases

Low discharge superheat

Overall reduced

performance due to

refrigerant

accumulation in

Evaporator

Economizer float valves are

stuck open

Adjust EXV until system

stabilizes

CONDENSER


Extreme High Discharge

Pressure

Condenser Approach

temperature is higher

than normal

Air in Condenser

Take refrigerant charge out and

put the unit on a vacuum pump

and then recharge

High Condenser water

range with normal

Evaporator temperature

Insufficient Condenser water

flow rate

Increase Condenser water flow

rate

Overall performance

loss

Condenser Tubes are

dirty/scaled

Clean Condenser tubes and/or

check water conditioning

High Condenser water

entering temperature

Reduce Condenser water

entering Temperature (check

cooling tower and water

circulation)



WATER SIDE


Small Evaporator water

pressure difference

between water entering

and leaving

Capacity Loss and high

Evaporator approach

temperature

Evaporator pass baffle gasket

damage

Stop unit operation, drain water,

remove water box and replace

gasket

Fluctuating unsteady

water flow

Pass baffle gasket

damage Air in water boxes

Vent any air from the chiller

water boxes prior to starting the

water pumps

OIL SIDE


No oil pressure when

system start button pushed

Low oil press displayed

on control center and

compressor will not

start

Oil pump running in wrong

direction

Check rotation of oil pump -

electrical connections

Oil pump not running Troubleshoot electrical problem

with oil pump

Oil pressure regulator valve is

not adjusted

Adjust oil pressure regulator

valve to maintain proper oil

pressure differential before the

start-up

Unusually high oil

pressure develops when oil

pump runs

High oil pressure is

displayed on control

center when the oil

pump is running

Defective oil pressure

transducer or oil pressure

regulator valve is not

adjusted

Adjust oil pressure regulator

valve to maintain proper oil

pressure differential and/or

check oil pressure transducer

Oil pump vibrates or is

noisy

Oil pump vibrates or is

extremely noisy with

some oil pressure

Oil not reaching pump suction

inlet in sufficient quantity Check Oil Level

Worn or Failed Pump Repair/Replace Oil Pump

Reduced Oil Pump

Capacity

Oil pump pumping

capacity

Excessive end clearance

pump Inspect and replace worn parts

Other worn pump parts

Partially blocked oil supply

inlet Check oil inlet for blockage

Oil Pressure Gradually

Decreases Oil filter is dirty Change oil filter

Oil loss during operation Oil level is decreasing

in oil sump

Filter-drier in oil return

system dirty

Replace old filter-drier with a

new one.

Orifice of oil return jet

clogged

Remove orifice, inspect for dirt,

remove dirt using solvent and

replacement

No oil pressure display

No oil pressure

registers on the

control panel when oil

pump runs

Faulty oil pressure transducer Replace oil pressure transducer

Faulty wiring/connectors Inspect oil transducer wiring

connections to the panel



OPERATING LOG SHEET

OPERATING LOG SHEET

HTV CENTRIFUGAL CHILLER

HTV Model No.__________ Chiller ID No. __________ Date __________ Operator ________________

DATA POINT VALUE SOURCE

EVAPORATOR

1. WATER PRESSURE DROP ACROSS CHILLER Gauges

2. ENTERING CHILLED WATER TEMPERATURE VIEW #2

3. LEAVING CHILLED WATER TEMPERATURE VIEW #2

4. DELTA TEMPERATURE (LINE 2 – 3) Calculate

5. SUCTION PRESSURE VIEW #2

6. EVAP. SATURATION TEMPERATURE (FROM #5) R 134a Chart

7. SUCTION TEMPERATURE (LINE 8 + 6) VIEW #2

8. SUPERHEAT (LINE 7 – 6) Calculate

9. APPROACH TEMPERATURE (LINE 3 – 6) Calculate

10. EVAPORATOR G.P.M. Note 1

CONDENSER 11. WATER PRESSURE DROP ACROSS CONDENSER Gauges

12. ENTERING CONDENSER WATER TEMPERATURE VIEW #2

13. LEAVING CONDENSER WATER TEMPERATURE VIEW #2

14. DELTA TEMPERATURE (LINE 13 – 12) Calculate

15. COMPRESSOR DISCHARGE PRESSURE VIEW #2

16. COMPRESSOR DISCHARGE TEMPERATURE VIEW #2

17. COND. SATURATION TEMPERATURE (FROM #15) R-134a Chart

18. APPROACH TEMPERATURE (LINE 17 – 13) Calculate

19. DISCHARGE SUPERHEAT (LINE 16 – 17) Calculate

20. LIQUID LINE TEMPERATURE VIEW #2

21. SUBCOOLING (LINE 17 – 20) Calculate

22. CONDENSER G.P.M. Note 1

23 Economizer Pressure

COMPRESSOR 24 COMPRESSOR MOTOR CURRENT (%RLA) VIEW #2

25 OIL FEED PRESSURE (PSIG) VIEW #2

26 OIL SUMP TEMPERATURE VIEW #2

27 OIL FEED TEMPERATURE VIEW #2

28 OUTDOOR DRY BULB AIR TEMPERATURE Thermometer

29 UTDOOR WET BULB AIR TEMPERATURE Thermometer

30 Oil Level

NOTES: 1. Flow can be determined from a Flow/Pressure Drop curve from flow meters if available.

2. To convert FT H20 to PSIG, multiply FT. X .434 OR ÷ BY 2.31

To convert PSIG to FT H20, multiply PSIG. X 2.31 OR ÷ .434

3. “VIEW #2” refers to the second VIEW screen on the operator interface panel.



Service Programs

It is important that an air conditioning system receive adequate maintenance if the full equipment life and full system benefits are to be realized.

Maintenance should be an ongoing program from the time the system is initially started. A full inspection should be made after 3 to 4 weeks of normal operation on a new installation, and on a regular basis thereafter.

Daikin offers a variety of maintenance services through the local Daikin service office, its worldwide service organization, and can tailor these services to suit the needs of the building owner. Most popular among these services is the Daikin Comprehensive Maintenance Contract.

For further information concerning the many services available, contact your local Daikin service office.

Warranty Statement

Limited Warranty

Consult your local Daikin Representative for warranty details. Refer to Form 933-43285Y. To find your local Daikin Representative, go to www.Daikin.com.

The following are trademarks or registered trademarks of their respective companies: Loctite from Henkel Company; 3M, Scotchfil and Scotchkote from the 3M Company; Victaulic from Victaulic Company; Megger from Megger Group Limited; Distinction Series, MicroTech II and Protocol Selectability from Daikin International.



Service Procedure

The proper maintenance prolongs service life and enhances performance of the AC system.

The maintenance starts basically as the chiller starts. 3 to 4 weeks after the first start-up, it must be overall inspected, followed by periodical maintenance.

DAIKIN provides diversified maintenance service according to different customer needs.

Contact

DAIKIN INDUSTRIES,LTD.

Head Office: Umeda Center Bldg., 2-4-12, Nakazaki-Nishi, Kita-ku, Osaka, 530-8323 Japan

★The printing may deviates from the real products, please refer to the real object when purchasing.

★All material is carefully reviewed. In case of any printing errors, DAIKIN bears no responsibility. Models, parameters and performance may change due to product improvement without further notification. Please refer to the nameplate for detail.

Water Cooled Two-Stage Centrifugal Chillers HTV M, L, G, K ... · Water Cooled Two-Stage...

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