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Daikin AGZ 190D, Operating & Maintenance Manual

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Daikin AGZ 190D Operating & Maintenance Manual Download Page 1

 

   

 Operating & Maintenance Manual 

OMM 1166-1

 

 

Group: 

Chiller

 

 

Part No. 

OMM1166-1 

 

Effective: 

March 2014

 

 

 

 

 

Air-Cooled Scroll Compressor Chiller 

AGZ025D 

– AGZ190D (Rev 0A)   25 to 190 Tons 

50 - 60-Hertz, R-410A 

Software Version 251699201 

 

 

 

© 2014 Daikin Applied                                                                                                           

 

Summary of Contents for AGZ 190D

Page 1: ...ance Manual OMM 1166 1 Group Chiller Part No OMM1166 1 Effective March 2014 Air Cooled Scroll Compressor Chiller AGZ025D AGZ190D Rev 0A 25 to 190 Tons 50 60 Hertz R 410A Software Version 251699201 201...

Page 2: ...Bypass Solenoid Valve 35 Capacity Overrides Limits of Operation 35 Alarms 35 Unit Fault Alarms 35 Unit Problem Alarms 37 Unit Warning Alarms 38 Circuit Fault Alarms 38 Circuit Events 40 Circuit Warnin...

Page 3: ...res include compressor crankcase heaters an evaporator heater for chilled water freeze protection automatic compressor lead lag to alternate the compressor starting sequence and sequenced starting of...

Page 4: ...lves changing the water flow through the evaporator as the load changes Daikin Applied chillers are designed for this duty provided that the rate of change in water flow is slow and the minimum and ma...

Page 5: ...glycol from the freezing point tables below It is recommended that a minimum of 25 solution by weight be used for protection against corrosion or that additional compatible inhibitors be added Concent...

Page 6: ...han sea level refer to Table 6 and Table 7 Evaporator Temperature Drop Factors Performance tables are based on a 10 F 5 C temperature drop through the evaporator Adjustment factors for applications wi...

Page 7: ...10 5 6 0 998 1 009 0 995 1 007 0 982 1 003 0 959 0 996 12 6 7 1 007 1 011 1 004 1 010 0 991 1 006 0 967 0 998 14 7 7 1 014 1 014 1 011 1 013 0 998 1 009 0 974 1 001 16 8 9 1 022 1 016 1 018 1 014 1 00...

Page 8: ...025 0 949 1 014 0 879 0 995 16 8 9 1 006 1 031 0 992 1 027 0 952 1 016 0 882 0 996 8000 feet 6 3 3 0 979 1 034 0 966 1 031 0 927 1 019 0 859 1 000 8 4 4 0 984 1 036 0 971 1 032 0 932 1 021 0 863 1 002...

Page 9: ...er controller operation The software setting of Variable Evap Flow equals YES or NO is located just below the Full Cap D T setting screen The Full Cap D T setting will continue to allow settings from...

Page 10: ...d for each unit Occasionally the same evaporator is used on multiple units resulting in overlapping lines The nominal and maximum flow and pressure drop are the same for a given unit size regardless o...

Page 11: ...3 15 3 134 6 12 5 8 5 37 3 224 3 33 0 14 2 98 6 065D I 55 8 1 9 3 5 5 8 87 1 4 5 5 5 13 4 139 4 11 0 8 8 32 8 232 3 29 0 14 7 86 7 070D J 61 5 2 3 3 9 7 0 96 1 5 4 6 1 16 3 153 8 13 3 9 7 39 7 256 3 3...

Page 12: ...12 AGZ 025D through 190D OMM 1166 1 Figure 2 Typical Field Control Wiring...

Page 13: ...election 22 Unit States 22 Start Delays 23 Evaporator Pump Control 24 Leaving Water Temperature LWT Reset Target 25 Unit Capacity Control 26 Unit Capacity Overrides 27 Circuit Control Functions 29 Cir...

Page 14: ...n memory and can be easily displayed in plain English for operator review The MicroTech III chiller controller will also retain and display the date time the fault occurred In addition to displaying a...

Page 15: ...it Enable X7 Circuit 1 MHP Switch Fault No fault X8 Circuit 1 Motor Protection Fault No fault DI1 Circuit 1 or Unit PVM GFP Fault No fault Digital Outputs Description Output Off Output On DO1 Compress...

Page 16: ...Coil 1 M2 M2 EXV Stepper Coil 2 Sensor Information Temperature All temperature sensors will be Daikin Applied part number 1934146 Pressure Pressure inputs will be read using 0 to 5 volt ratiometric s...

Page 17: ...0 2 to 4 9 F min Nominal Evap Delta T 5 6 C 10 1 F 3 3 to 8 9 C 5 9 to 16 F Demand Limit Enable Off Off On Network Capacity Limit 100 0 to 100 LWT Reset Enable Off Off On Configuration Power Input Sin...

Page 18: ...l Auto Auto manual EXV position See Special Setpoints page 19 0 to 100 Suction SH Target 5 56 C 10 F 4 44 to 6 67 C 8 to 12 F Max Evap Pressure 1076 KPA 156 1 PSI 979 to 1172 KPA 142 to 170 PSI Conden...

Page 19: ...orator Pressure Hold and Unload Available Mode Selection Range Without Glycol 669 to 793 KPA 97 to 115 PSI With Glycol 407 to 793 KPA 59 to 115 PSI Special Set Point Operations The following setpoints...

Page 20: ...roller setpoints may be changed If the operator attempts to edit a setpoint for which the necessary password level is not active no action will be taken Once a password has been entered it remains val...

Page 21: ...ature LWT target Control Band LWT target 3 9 C If the unit is configured for use with glycol the compressor staging temperatures are calculated as shown below Stage Up Temperature LWT target Control B...

Page 22: ...changing modes of operation inadvertently while the chiller is running Unit Mode is set according to the following table Control Source Set Point Mode Input BAS Request Available Modes Set Point Unit...

Page 23: ...avoid tripping a false alarm Ice Mode Start Delay An adjustable start to start ice delay timer will limit the frequency with which the chiller may start in Ice mode The timer starts when the first com...

Page 24: ...o max pulldown rate has been met or exceeded 16 Auto Unit Cap Limit Unit State Auto unit capacity limit has been met or exceeded 17 Auto High Ambient Limit 18 Config Changed Reboot Required A configur...

Page 25: ...e greater than the recirculate timeout set point and there is no flow then the primary pump will shut off and the standby pump will start When the evaporator is in the run state if flow is lost for mo...

Page 26: ...performed as described in this section All unit capacity limits described in following sections must be applied as described Compressor Staging in Cool Mode The first compressor on the unit should be...

Page 27: ...compressors running the next compressor to start will be on the circuit with the least compressors running if it has at least one compressor available to start Within that circuit the available compr...

Page 28: ...75 3 75 Limit 50 2 50 Limit 1 Six compressors Network Limit Stage Limit Limit 100 6 100 Limit 83 3 5 83 3 Limit 66 7 4 66 7 Limit 50 3 50 Limit 33 3 2 33 3 Limit 1 Maximum LWT Pulldown Rate The maxim...

Page 29: ...ow Evaporator Pressure Unload set point The equation is as follows Pumpdown pressure Low Evap Pressure Unload set point 103KPA 15 PSI Circuit Control Logic Circuit Enabling A circuit should be enabled...

Page 30: ...commanded to stop Unit State Pumpdown Circuit switch is open Circuit mode is disable Circuit Pumpdown alarm is active T4 Pumpdown to Off Any of the following are required Evaporator Pressure Pumpdown...

Page 31: ...hutdown Multiple Low Ambient Start attempts are allowed On the third failed Low Ambient Start attempt the Restart Alarm is triggered and the circuit will not attempt to restart until the Restart alarm...

Page 32: ...ling of power to the chiller This means that if power is cycled the cycle timers should not be active These timers may be cleared via a setting on the human machine interface HMI Condenser Fan Control...

Page 33: ...one through four should use their respective dead bands Stages five through seven should all use Stage Down Dead Band 4 When the saturated condenser refrigerant temperature is below the target the act...

Page 34: ...ll and tube type evaporator When staging down a compressor the maximum position is reduced by 10 for one minute to prevent liquid from getting to compressors After this initial one minute delay the va...

Page 35: ...arms are classified in the following sections per the Global Chiller Protocol Standard using the Fault Problem Warning scheme When any Unit Fault Alarm is active the alarm digital output should be tur...

Page 36: ...conditions no longer exist Evaporator LWT Sensor Fault Trigger Sensor shorted or open Action Taken Normal stop all circuits Reset This alarm can be cleared manually via the keypad or BAS command but o...

Page 37: ...e keypad or BAS command when communication between main controller and the extension module is working for 5 seconds or Expansion Valve Type Thermal Unit Problem Alarms Low Ambient Lockout No longer a...

Page 38: ...reset is enabled For this alarm out of range is considered to be a signal less than 3mA or more than 21mA Action Taken Cannot use LWT reset function Reset Auto clear when LWT reset is disabled or LWT...

Page 39: ...he evaporator pressure sensor fault is active Action Taken Rapid stop circuit Reset This alarm can be cleared manually via the keypad if the evaporator pressure is above 137 9 KPA 20 PSI High Condense...

Page 40: ...s alarm can be cleared manually via the keypad or BAS command but only if the sensor is back in range Suction Temperature Sensor Fault Trigger Sensor shorted or open and Expansion Valve Type Electroni...

Page 41: ...if the circuit is no longer in the run state High Condenser Pressure Unload Trigger This event is triggered if all of the following are true circuit state Run more than one compressor is running on th...

Page 42: ...porator Pressure Unload set point for a time greater than half of the current freezestat time circuit is not currently in a low OAT start it has been at least 30 seconds since a compressor has started...

Page 43: ...m log 3 Event Log An Event Log similar to the Alarm Log stores the last 50 event occurrences Each Event Log entry includes an event description and a time and date stamp for the event occurrence plus...

Page 44: ...ins a menu title a parameter such as a value or a setpoint or a link which will have an arrow in the right of the line to a further menu The first line visible on each display includes the menu title...

Page 45: ...h can also be accessed by pressing the Menu Button The navigating wheel is the only navigating device necessary although the MENU ALARM and BACK buttons can provide shortcuts as explained later Passwo...

Page 46: ...the wheel again cause the new value to be saved and the keypad display to leave the edit mode and return to the navigation mode A parameter with an R is read only it is giving a value or description...

Page 47: ...creen the linked screen is indicated in the rightmost column Example the Enter Password screen links to screen U 2 For each screen the screen s from which you can navigate to it is also shown on the s...

Page 48: ...3 Set Up R U 14 Temperatures R U 15 Date Time Schedules R U 16 Power Conservation R U 17 LON Setup R U 18 BACnet IP Setup R U 19 BACnet MSTP Setup R U 20 Modbus Setup R U 21 AWM Setup R U 22 Configura...

Page 49: ...ervice Support Reference R R Screen U 9 From Screen U 1 Review Operation No password Operator Links to screen Alarm Active U 30 Alarm Log U 31 Unit Status Settings U 33 Circuit 1 Status Settings Cx 2...

Page 50: ...sion R R Application Version R R HMI GUID R R OBH GUID R R Screen U 13 From Screen U 4 Status Settings No password Operator Links to screen Unit Status R Next Compressor On R Next Compressor Off R Chi...

Page 51: ...elta T R Active Set Point R Start Up Temperature R Shut Down Temperature R Stage Up Temperature R Stage Down Temperature R Pulldown Rate Outside Air Temperature R Cool LWT Setpoint 1 R W Cool LWT Setp...

Page 52: ...sk R Actual Gateway R Given IP Address R W Given Mask R W Given Gateway R W Unit Support R W NC Dev 1 R W NC Dev 2 R W BACnet BSP R Screen U 20 From Screen U 4 U 11 BACnet MSTP Setup No password Opera...

Page 53: ...ssword Operator Links to screen Apply Changes Number Of Compressors Expansion Valve Type Number Of Fans Fan VFD Enable Power Configuration Comm Module 1 Type Comm Module 2 Type Comm Module 3 Type Scre...

Page 54: ...etpoint High Pressure Shutdown Setpoint Low Ambient Start Time Evaporator Water Freeze Evaporator Flow Proof Evap Recirculate Timeout Screen U 27 From Screen U 4 U 11 Calibrate Sensors No password Ope...

Page 55: ...U 38 Screen U 33 From Screen U 9 Unit Status Settings No password Operator Links to screen Actual Time Actual Date Unit Status Unit Mode Unit Capacity Evap Leaving Water Temp Evap Entering Water Temp...

Page 56: ...W Count R Last Occurrence R Screen U 37 From Screen U 32 Circuit 1 Event Log No password Operator Links to screen Event Selection R W Day Selection R W Count R Last Occurrence R Screen U 38 From Scre...

Page 57: ...mpressor Stop Compressor 3 4 Run Hours Number Of Starts Last Compressor Start Last Compressor Stop Compressor 5 6 Run Hours Number Of Starts Last Compressor Start Last Compressor Stop Condenser Number...

Page 58: ...r 5 6 Output State Liquid Line Solenoid Output State Hot Gas Bypass Output State Fan Output 1 State Fan Output 2 State Fan Output 3 State Fan Output 4 State Fan Output 5 State Fan VFD Speed Screen Cx...

Page 59: ...peed Cond Target 100 Cond Target 67 Cond Target 50 Cond Target 33 Screen Cx 7 From Screen Cx 1 EXV No password Operator Links to screen EXV State Suction Superheat Superheat Target EXV Control Mode EX...

Page 60: ...the Motor WARNING Avoid swapping any 2 of the 3 motor lead connections which will cause reversal of the motor direction In applications where reversed rotation could cause equipment damage or personne...

Page 61: ...button will return to the Frequency Reference display 3 Moves the cursor to the right Resets the drive to clear a fault situation 4 RUN Key Starts the drive in LOCAL mode 5 Up Arrow Key Scrolls up to...

Page 62: ...to the MEMOBUS Modbus CommunicationInputs of the drive OP Displayed when the frequency reference is assigned to an Option Unit of the drive RP Displayed when the frequency reference is assigned to th...

Page 63: ...an the operator is selected for Run command and frequency reference control REMOTE During run During deceleration to stop When a Run command is input and frequency reference is 0 Hz While the drive wa...

Page 64: ...i function contact outputs do not operate The drive will not operate the motor until the error has been reset Correct the settings that caused the operation error to clear the error Tuning Errors Tuni...

Page 65: ...ntactors and relays for excessive noise Check for over or undervoltage Inspect for signs of overheating such as melted or cracked insulation Replace damaged parts Optional BAS Interface The AGZ chille...

Page 66: ...ntrol band before the MicroTech III controller will stage on cooling 4 Set the Evap Delta T and the Start Delta T as a starting point 5 Put both pumpdown switches PS1 and PS2 to the ON position 6 Put...

Page 67: ...ll water strainers before placing the chiller into service Pre Startup Refrigerant Piping Checkout 1 Check all exposed brazed joints for evidence of leaks Joints may have been damaged during shipping...

Page 68: ...air handler load Note The hot gas bypass valve cannot generate a 100 false load The pressure regulating valves are a Sporlan HGBE 8 75 150 7 8 ODF on models AGZ 025 to 065 and Sporlan HGBE 8 75 150 1...

Page 69: ...reen Warning LED one time indicating the module has not communicated with the master controller for longer than 5 minutes Code 2 Reserved For Future Use Code 3 Short Cycling The module will flash the...

Page 70: ...OTE If a compressor with CoreSense Communications fails in the field the CoreSense module should remain with the failed compressor so the manufacturer s technicians can download the CoreSense data to...

Page 71: ...f cycle Power must be supplied to the heaters 8 hours before starting the compressors Evaporator Models AGZ 025D through 130D The evaporator is a compact high efficiency dual circuit brazed plate to p...

Page 72: ...8 kPa Each evaporator is designed constructed inspected and stamped according to the requirements of the ASME Boiler and Pressure Vessel Code Double thickness insulation is available as an option Phas...

Page 73: ...overy can be required strictly following Clean Air Act regulations governing refrigerant discharge to the atmosphere The Schrader purge valve is located on the vertical coil headers on both sides of t...

Page 74: ...changed or verify moisture content by performing an acid test on the compressor oil Planned Maintenance Schedule OPERATION WEEKLY MONTHLY Note 1 ANNUAL Note 2 General Complete unit log and review Not...

Page 75: ...410A with 400 psig rating Open cylinders slowly Avoid rough handling of cylinders and secure as appropriate Cap when not in use Do not overfill recovery cylinders or overcharge units Check gauge cali...

Page 76: ...with approximately 15 of the coil tubes located in a subcooler section of the coil to achieve liquid cooling to within 5 F 3 C of the outdoor air temperature when all condenser fans are operating Onc...

Page 77: ...lief is 600 650 psid Brazed connections only No StayBrite or solder connections solder should never be used with any refrigerant K or L type refrigeration tubing only Use nitrogen purge Higher R 410A...

Page 78: ...in the event of a power failure do not normally require any maintenance The solenoids can however require replacement of the solenoid coil or of the entire valve assembly The solenoid coil can be chec...

Page 79: ...recirculation 6 Clean coil 7 Correct Low Discharge Pressure 1 Refrigerant flood back 1 Correct 2 Wind blowing into coil at low ambient 2 Shield coil from direct wind Wind guards are available 3 Fault...

Page 80: ...superheat 3 Crankcase heater burnout 3 Replace crankcase heater Motor Overload Relays or Circuit Breakers Open 1 Low voltage during high load conditions 1 Check supply voltage for excessive line drop...

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Page 84: ...kin Applied equipment is sold pursuant to its standard terms and conditions of sale including Limited Product Warranty Consult your local Daikin Applied sales representative for warranty details To fi...

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