Daikin AWV008 Installation, Operation And Maintenance Manual Download

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Installation, Operation,

and Maintenance Manual

Pathfinder

Air-cooled Screw Chillers

Model AWV

100 to 565 Tons (350 to 1985 kW)

HFC-134a Refrigerant

60/50 Hz

IOM 1242-2

Group:

Chiller

Part Number:

IOM1242-2

Date:

August 2018

Summary of Contents for AWV008

Page 1: ...ion Operation and Maintenance Manual Pathfinder Air cooled Screw Chillers Model AWV 100 to 565 Tons 350 to 1985 kW HFC 134a Refrigerant 60 50 Hz IOM 1242 2 Group Chiller Part Number IOM1242 2 Date Aug...

Page 2: ...changes in design and construction at any time without notice Introduction 5 Installation and Application Considerations 7 Installation and Application Considerations Remote Evaporators 25 Dimensions...

Page 3: ...nts EXV Sensors Transducers installed and wired properly Wiring complies with National Electrical Code and local codes See Notes Remote EXV wired with shielded cable Miscellaneous Yes No N A Initials...

Page 4: ......

Page 5: ...ds when halo carbon refrigerant travels in a rubber hose A grounding strap must be used between the auxiliary refrigerant tank and the chiller s end sheet earth ground which will safely take the charg...

Page 6: ...and Handling on page 7 The standard limited warranty on this equipment covers parts that prove defective in material or workmanship Specific details of this warranty can be found in the warranty state...

Page 7: ...displace air and cause suffocation Immediately evacuate and ventilate the equipment area If the unit is damaged follow Environmental Protection Agency EPA requirements Do not expose sparks arcing equi...

Page 8: ...wer to the unit before servicing condenser fan motors or compressors Failure to do so can cause bodily injury or death Figure 2 Air Flow Clearance Requirements Sufficient clearance must be maintained...

Page 9: ...Between Wall and Unit Control Panel 4 Feet 5 Feet 6 Feet 0 0 0 2 0 4 0 6 0 8 1 0 1 2 8 12 16 20 24 Capacity Reduction Height of Wall Feet Full Load Capacity Reduction AWV008 010 4 Feet 5 Feet 6 Feet...

Page 10: ...Case 2 Full Load Capacity Reduction 4 Feet 5 Feet 6 Feet 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 8 12 16 20 24 Capacity Reduction Height of Wall Feet Full Load Capacity Reduction AWV020 024 4 Feet 5 Feet 6 F...

Page 11: ...factors for the two outside units Figure 13 Three or More Units Side by Side Figure 14 Case 3 Full Load Capacity Reduction Figure 15 Case 3 Power Increase 1 0 2 0 3 0 4 0 5 0 6 0 7 0 6 8 10 12 Power...

Page 12: ...tion and restriction and require care that sufficient air clearance is provided safety requirements are met and service access is provided A solid wall surrounding a unit is substantially a pit and th...

Page 13: ...Distance 6 ft Distance 8 ft Distance 10 ft 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 0 8 10 12 13 14 Power Increase Depth of Pit Wall Height ft Power Increase AWV016 018 Distance 6 ft Distance 8 ft Dis...

Page 14: ...evaporator inlet connection and downstream of any welded connections no welded connections between strainer and evaporator AWV models require a strainer as specified in Inlet Strainer Guidelines on pa...

Page 15: ...plings that may be used for gauges and sensors The pipe provides sufficient clearance from the evaporator for strainer basket removal inch blowdown valve Two grooved clamps The strainer is sized per T...

Page 16: ...ion to the chilled water system to provide freeze protection Freeze point should be approximately 10 F 5 6 C below minimum design ambient temperature or 10 F 5 6 C below the lowest design leaving wate...

Page 17: ...V chillers are designed to operate with leaving antifreeze solution temperatures per software range limits Consult the local Daikin Applied sales office for performance outside these temperatures Leav...

Page 18: ...n the unit start to start timer which can be set from two to sixty minutes while keeping the chiller powered by the generator until the fully synchronized Automatic Transfer Switch properly hands over...

Page 19: ...P WATER PUMP RELAY 120VAC 0 25AMP MAX 28 17 17 17 ALARM OUTPUT EVAP WATER PUMP RELAY No 1 BY OTHERS 3 PHASE POWER SOURCE POWER BLOCK OR DISCONNECT SWITCH MODE SWITCH USE DRY CONTACTS ONLY SEE NOTE 2 I...

Page 20: ...WER BLOCK OR DISCONNECT SWITCH MODE SWITCH USE DRY CONTACTS ONLY SEE NOTE 2 IF MODE SWITCH IS USED REMOVE LEAD 322 BETWEEN M5 21 AND MS 10 57 21 M5 M5 TO COMPRESSOR S AND FAN MOTORS OR CIRCUIT 1 CIRCU...

Page 21: ...R SOLENOID VALVE OPTIONAL EXPANSION VALVE WATER IN WATER OUT DX EVAPORATOR SUCTION TUBING OIL PRESS TRANSDUCER WITH SCHRADER VALVE DISCHARGE TUBING AIR FLOW AIR FLOW CONDENSER ASSEMBLY F3 F4 COMPRESSO...

Page 22: ...TER IN WATER OUT DX EVAPORATOR SUCTION TUBING OIL PRESS TRANSDUCER WITH SCHRADER VALVE DISCHARGE TUBING AIR FLOW AIR FLOW CONDENSER ASSEMBLY F3 F4 COMPRESSOR RELIEF VALVE SUCTION TEMP SENSOR SUCTION T...

Page 23: ...23 IOM 1242 2 PATHFINDER MODEL AWV CHILLERS Figure 31 Representative Refrigerant Diagram Packaged Unit With Braze Plate Evaporator Without Optional Economizer NOTE PIPING SHOWN FOR ONE SYSTEM OF UNIT...

Page 24: ...om Installation and Application Considerations Representative Refrigerant Diagram Packaged Unit With Braze Plate Evaporator With Optional Economizer PACKAGE CHILLER WITH OPTIONAL ECONOMIZER NOTE PIPIN...

Page 25: ...cation 6 When facing the unit control box the left hand compressor is circuit 1 and the right hand is circuit 2 7 The condenser cannot be used for refrigerant charge isolation for service The circuit...

Page 26: ...t of 14GA wire connected from the cable to the unit allowing up to a total distance of 100 feet When splicing is required the connections must be soldered together and individually shrink wrapped to b...

Page 27: ...PATHFINDER MODEL AWV CHILLERS Figure 33 Piping Schematic Remote Evaporator One of Two Circuits UNIT HAS TWO INDEPENDANT SYSTEMS NOTE PIPING SHOWN FOR ONE SYSTEM OF UNIT REMOTE CHILLER REMOTE CHILLER...

Page 28: ...per 5 1 8 265 75 Copper 5 1 8 65 100 Copper 3 5 8 90 100 Copper 3 5 8 115 100 Copper 4 1 8 140 100 Copper 5 1 8 165 100 Copper 5 1 8 190 100 Copper 5 1 8 215 100 Copper 5 1 8 240 100 Copper 6 1 8 265...

Page 29: ...er 6 1 8 265 175 Copper 6 1 8 65 200 Copper 4 1 8 90 200 Copper 4 1 8 115 200 Copper 4 1 8 140 200 Copper 5 1 8 165 200 Copper 5 1 8 190 200 Copper 6 1 8 215 200 Copper 6 1 8 240 200 Copper 6 1 8 265...

Page 30: ...er 6 1 8 265 250 Copper 6 1 8 65 275 Copper 4 1 8 90 275 Copper 4 1 8 115 275 Copper 4 1 8 140 275 Copper 5 1 8 165 275 Copper 5 1 8 190 275 Copper 6 1 8 215 275 Copper 6 1 8 240 275 Copper 6 1 8 265...

Page 31: ...line piping risers Maximum allowable suction line temperature loss target 5 F some selections are greater than 5 F due to minimum velocity requirements at minimum compressor speed Recommended Horizon...

Page 32: ...7 2998 1360 5164 2342 259 979 18 2 FEET MOUNTING 463 270 10 6 2123 83 6 80 3 2 33 1 3 SHRADER FITTING FOR REFRIGERANT PRESSURE 2 75 2 95 20 8 528 11 9 303 75 2 95 332532100 EVAPORATOR EV4027 EVAPORAT...

Page 33: ...4 1 1375 195 7 7 2360 92 9 64 2 5 572 22 5 42 1 6 REF 110 4 3 2935 115 6 51 2 0 40 2 0 51 1 6 10 4 12 5 ALL 25 COUPLINGS SECTION C C 18MM X 43MM SLOTS QTY 4 60 2 4 17 4 443 80 3 2 262 10 3 3283 129 3...

Page 34: ...9 2X 12 5 ALL 0 25 COUPLINGS 332945000 EVAPORATOR EV6633 2 68 68 2 68 68 54 2 13 18MM 71 X 43MM 1 69 SLOTS QTY 4 528 20 8 60 2 4 80 3 2 166 9 6 57 33 1 3 231 9 1 3282 129 2 640 25 2 18 2 MOUNTING FEE...

Page 35: ...20 BASE RAIL WIDTH TYP 100 1 CG Y CG X MINI CONTROL BOX ALL TURBOSCREW UNITS FIELD POWER ENTRY AT BOTTOM OF BOX 43 8 WATER INLET OUTLET L1 L2 L3 L4 L5 L6 10 12 14 FAN OF FANS EVAP A B Z CG X CG Y CG...

Page 36: ...TER OUTLET M3 M4 2 60 M1 M2 M7 M8 M5 M6 2 60 FIELD POWER ENTRY FROM BOTTOM FOR SMALL CONTROL BOX SHOWN FROM SIDE FOR LARGE CONTROL BOX 100 1 87 6 DOES NOT INCLUDE LIFTING LUGS 5 2 BASE RAIL WIDTH Z BA...

Page 37: ...7 EV 5039 171 1 138 2 21 2 29 9 57 8 371 7 20 EV 5027 171 1 92 9 21 2 29 9 57 8 409 6 23 135 209 320 15 80 3 160 2 238 363 EV 5039 171 1 138 2 21 2 29 9 57 8 409 6 EV 6633 175 5 111 4 21 2 26 9 60 1...

Page 38: ...installation tasks are complete then the springs should be adjusted to the vendor listed compression for the load point When securing the isolator do not overtighten the mounting bolts Overtightening...

Page 39: ...1 595 7 26 7 EV40271111 07 6 188 0 2 0 748 0 26 0 EV40271212 07 6 188 0 2 3 748 0 28 1 EV50271414 07 8 219 3 2 4 876 6 28 4 EV50271717 05 8 290 6 2 6 1171 2 30 4 EV50391212 11 8 207 8 3 0 834 8 35 7...

Page 40: ...700 800 PD ft Flow Rate gpm Evaporator EV40271111 07 0 10 20 30 0 100 200 300 400 500 600 700 800 PD ft Flow Rate gpm Evaporator EV40271212 07 0 10 20 30 0 200 400 600 800 1000 PD ft Flow Rate gpm Eva...

Page 41: ...EV66391616 09 Figure 59 Model EV66391717 07 0 10 20 30 40 50 0 200 400 600 800 1000 1200 PD ft Flow Rate gpm Evaporator EV66391414 11 0 10 20 30 40 50 0 200 400 600 800 1000 1200 1400 PD ft Flow Rate...

Page 42: ...from any interference or for the correction thereof General Description The MicroTech III control system consists of a controller and a number of extension input output I O modules which vary dependi...

Page 43: ...n on the controller itself Communication to the VFD s and EVAP EXV MODULE is required for operation in all configurations Communication to ECON EXV MODULE is required only if the chiller is configured...

Page 44: ...Fan s On DO8 Circuit 2 Fan Output 2 Fan s Off Fan s On DO9 Circuit 2 Fan Output 3 Fan s Off Fan s On DO10 Circuit 2 Fan Output 4 Fan s Off Fan s On CC Modules Circuit 1 and 2 Table 18 Analog Inputs Fo...

Page 45: ...al Inputs Description Signal Off Signal On X1 External Alarm External Device Failure External Device OK X5 Circuit 1 Switch Circuit Off Circuit On X6 Circuit 2 Switch Circuit Off Circuit On Table 28 D...

Page 46: ...to 80 Hz Dependent on type Circuit 2 Compressor Max Speed 45 Hz 45 to 60 Hz 46 to 86 Hz 46 to 80 Hz Dependent on type Compressor VFD 1 Primary RLA 100 1 to 1000 amps Compressor VFD 2 Primary RLA 100 1...

Page 47: ...Dynamic Set Point Ranges section Evaporator Flow Loss Delay 15 seconds 5 to 15 seconds Evaporator Recirculate Timeout 3 minutes 1 to 10 minutes Low OAT Lockout 0 C 32 F See Dynamic Set Point Ranges s...

Page 48: ...h March January through December Daylight Savings Time Start Week 2nd Week 1st through 5th Week Daylight Savings Time End Month November January through December Daylight Savings Time End Week 1st Wee...

Page 49: ...ction Current Current 2nd Day 3rd Day 4th Day 5th Day 6th Day 7th Day NOTE The Manual Speed value will follow the compressor speed command while Speed Control Auto When Speed Control Manual the Manual...

Page 50: ...ut Off Off On Test 75 VR Solenoid Output Off Off On Test 50 VR Solenoid Output Off Off On Test Liquid Line Solenoid Output Off Off On Test Liquid Injection Solenoid Output Off Off On Test Evaporator E...

Page 51: ...cause a normal shutdown of any running circuits When the controller is powered up the Unit Enable Set Point will be initialized to Disable if the Unit Enable Initial Set Point is set to Disable The ch...

Page 52: ...ons Enum Status Conditions 1 Auto Unit State Auto 2 Auto Sound Reduction Unit State Auto and Sound Reduction is active 3 Off Ice Mode Timer Unit State Off Unit Mode Ice and Ice Delay Active 4 Off Low...

Page 53: ...t lockout condition Circuits that are not running will enter a circuit level lockout condition when OAT drops below the lockout set point This condition will clear at the circuit level when OAT rises...

Page 54: ...ol is selected the primary standby logic above is still used When the evaporator is not in the run state the run hours of the pumps will be compared The pump with the least hours will be designated as...

Page 55: ...t Load Unload Sequence This section defines which circuit is the next one to load or unload if the logic does not call for simultaneous load or unload of both circuits The next circuit to load must me...

Page 56: ...ly If either circuit is running in manual capacity control or running with active capacity limiting events then no load balancing adjustments will be made Ice Mode Operation In Ice Mode running circui...

Page 57: ...oint Power failure lasts at least one second Unit is enabled LWT Error is at least equal to the Stage Up Delta T set point RapidRestore will end if any of the following conditions occur LWT Error is l...

Page 58: ...essure alarms and as a reference for the trigger values of the high pressure hold and unload events Chiller software is designed to calculate a dynamic maximum saturated condenser temperature High sat...

Page 59: ...n T3 Start to Run Compressor speed 19Hz for at least 30 seconds T4 Run to Pumpdown Any of the following are required Unit capacity control logic requires this circuit to stop Unit state is pumpdown A...

Page 60: ...The compressor is controlled via a digital output to give the run command to compressor VFD a modbus speed command to control compressor speed digital outputs for compressor VR solenoids to control V...

Page 61: ...3 seconds VR Solenoid Valve Control There are three solenoid valves for changing volume ratio of the compressor 50 VR solenoid valve 75 VR solenoid valve 100 VR solenoid valve The compressor should st...

Page 62: ...t 10 minutes after compressor start Minimum Target 38 C After compressor has been running 10 minutes Minimum Target Max 16 C A B Fan Stage Down DB A Saturated temperature of Evaporator Pressure 180 kP...

Page 63: ...y the active stage up deadband and active stage down deadband the fan stage will not change When saturated condenser temperature is outside of the deadbands error is accumulated and will cause a chang...

Page 64: ...er temperature to the VFD target The minimum and maximum speed are set by the VFD Min Speed and VFD Max Speed set points Stage Up Compensation In order to create a smoother transition when the fan sta...

Page 65: ...SSH target will vary based on DSH discharge superheat In some conditions EXV will be positioned to control evaporator pressure to keep all parameters within operating envelope There are five EXV cont...

Page 66: ...iguration set point is set to No then the economizer position should remain 0 Control Concept EXV will be positioned using control algorithm Maintain DSH above requirements for compressor Maximize cir...

Page 67: ...after the circuit enters the Pumpdown state or when the circuit state is Off Circuit Capacity Overrides The following conditions override automatic capacity control as described These overrides keep...

Page 68: ...d Alarms are cleared only if the conditions required to initiate the alarm no longer exist All alarms and groups of alarms can be cleared via the keypad or network via LON using nviClearAlarms and via...

Page 69: ...a trigger condition 2 If the flow loss alarm has occurred due to this trigger it is always a manual reset alarm Evaporator Water Freeze Protect Alarm Evaporator Water Freeze Protect Displayed Text Eva...

Page 70: ...put off for 1 second Action Taken Rapid shutdown all circuits and lock out unit from running Reset This alarm can be cleared manually via the keypad or via BAS command after the emergency switch input...

Page 71: ...on with the economizer EXV module has failed Specifically this means that 16 consecutive failures of read write command blocks for this address have occurred Action Taken Economizer valve command is s...

Page 72: ...essure Switch Alarm Mechanical Low Pressure Switch Displayed Text Cn MLP Switch Trigger The alarm is triggered if all of the following are true for at least 40 seconds Circuit state is Run MLP Switch...

Page 73: ...igh Trigger Compressor VFD reports motor overheat fault The fault code for this is 0020H Action Taken Rapid shutdown of circuit and lock out from running Reset This alarm can be cleared manually via t...

Page 74: ...the unit configuration Action Taken Rapid shutdown of circuit and lock out from running Reset This alarm can be cleared manually via the Unit Controller keypad or via BAS command Compressor VFD Tempe...

Page 75: ...occur after circuit state is Start or Run for at least 90 seconds Action Taken Rapid shutdown of circuit and lock out from running Reset This alarm can be cleared manually via the keypad or BAS comman...

Page 76: ...rcuit state pumpdown for time Pumpdown Time set point Action Taken Shut down circuit Reset N A Economizer Pressure Sensor Fault Alarm Economizer Pressure Sensor Fault Displayed Text Cn EconPressSenFau...

Page 77: ...03 psi above the low evaporator pressure hold value for 3 seconds It is also reset if the circuit is no longer in the Run state or the unit operating mode is changed to Ice Low Evaporator Pressure Un...

Page 78: ...onds It is also reset if the compressor is not running or the unit operating mode is changed to Ice High Motor Current Unload Trigger This event will trigger when all of the following are true for at...

Page 79: ...llowing are true for at least for 30 seconds Unit mode is Cool Compressor is running VFD Heatsink Temp Max VFD Temperature 3 C Action Taken Compressor speed reduced by 1 Hz every 10 seconds Reset This...

Page 80: ...data fields set points A line in a menu may also be a link to further menus This is often referred to as a jump line meaning pushing the navigation wheel will cause a jump to a new menu An arrow is di...

Page 81: ...tton is repeatedly pressed the display continues to revert one page back along the current navigation path until the main menu is reached When the Menu Home button is pressed the display reverts to th...

Page 82: ...IOM 1242 2 PATHFINDER MODEL AWV CHILLERS 82 www DaikinApplied com Using the Controller Figure 73 HMI Keypad Navigation...

Page 83: ...witch without first moving Q1 and Q2 to the Stop position unless it is an emergency as this will prevent the unit from going through a proper shutdown pumpdown sequence resulting in possible equipment...

Page 84: ...ers to Off position until ready to start unit 6 Open the optional compressor suction butterfly valves the liquid line shutoff valves and compressor discharge valves 7 Vent the air from the evaporator...

Page 85: ...ubricated No further lubrication is required Excessive fan motor bearing noise is an indication of a potential bearing failure POE type oil is used for compressor lubrication This type of oil is extre...

Page 86: ...ter sits tightly on the sealing spigot 3 Replace the oil filter housing cover 4 Evacuate air and non condensibles before valving refrigerant back into the compressor Electrical Terminals DANGER Electr...

Page 87: ...sential to extend the life of an epoxy coated coil and is required to maintain warranty coverage Coil cleaning shall be part of the unit s regularly scheduled maintenance procedures Failure to clean a...

Page 88: ...controller and manually select the lead circuit as circuit 1 or 2 Pump Operation It is highly recommended that the chiller unit control the chilled water pump s The integral chiller control system ha...

Page 89: ...for clear flow X Check compressor oil sight glass for correct level lubricant charge X Check filter drier pressure drop Note 6 X Perform compressor vibration test optional X Perform oil analysis test...

Page 90: ...e keypad the BAS or a 4 20 mA signal that limits the compressor loading to a designated percent of full load Frequently used to limit unit power input Load Balance Load balance is a technique that equ...

Page 91: ...y labor is available as set forth above such free labor does not include diagnostic visits inspections travel time and related expenses or unusual access time or costs required by product location 2 R...

Page 92: ...s sold pursuant to its standard terms and conditions of sale including Limited Product Warranty Consult your local Daikin Applied representative for warranty details To find your local Daikin Applied...

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