Daikin DWSC 050 Installation, Operation And Maintenance Manual Download Page 1

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Single/Dual Compressor Centrifugal Chillers
DWSC/DWDC 050, 063, 079, 087, 100, 113, 126, Cooling Only
DWCC 100, 113, 126

DHSC 050, 063, 079, 087, 100, 126, Heat Recovery

Original Instructions

Installation, Operation and Maintenance Manual

D-EIMWC00804-14EN

Summary of Contents for DWSC 050

Page 1: ...or Centrifugal Chillers DWSC DWDC 050 063 079 087 100 113 126 Cooling Only DWCC 100 113 126 DHSC 050 063 079 087 100 126 Heat Recovery Original Instructions Installation Operation and Maintenance Manu...

Page 2: ...r maintenance CAUTION This manual provides information about the features and procedures for the complete series All units are delivered from factory as complete sets which include wiring diagrams and...

Page 3: ...d regulations Note concerning electrical safety Safe use and maintenance of the unit as explained in this manual is fundamental to prevent accidents during operation and maintenance and repair work Th...

Page 4: ...mbol 6 Unit characteristics technical 3 Gas type 7 Emergency stop 4 Control panel code Compressor Control Panel Motor Terminal Box 1 Terminal box fixing 3 Electrical hazard symbol 2 Manufacturer s log...

Page 5: ...7 Remote Starter Display Wiring 29 Control Power Wiring 29 Multiple Chiller Setup 34 Prestart System Checklist 37 Operation 38 Operator Responsibilities 38 Standby Power 38 MicroTech II Control 38 Cap...

Page 6: ...804 14EN Centrifugal Chillers 7 Information and illustrations cover the Daikin products at the time of publication and we reserve the right to make changes in design and construction at anytime withou...

Page 7: ...izes of units are the 050 063 076 079 087 100 113 and 126 They provide a cooling capacity range from 80 tons to 2500 tons In this manual all references to the DWSC models will equally apply to other m...

Page 8: ...his 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...

Page 9: ...replacement if necessary The length of the vessel should be allowed at one end Doors or removable wall sections can be utilized for tube clearance Minimum clearance at all other points including the t...

Page 10: ...should this be desirable 1 1 8 28 5 mm mounting holes are provided in the unit support at the four corners Note Units are shipped with refrigerant and oil valves closed to isolate these fluids for sh...

Page 11: ...ce wait without leaving the injured person alone until the rescue operators come give all necessary information to the the rescue operators System Water Volume All chilled water systems need adequate...

Page 12: ...economizer systems Over 300 Tons Chillers over 300 tons are equipped with thermal expansion valves TXV and will start and run with entering condenser water temperatures as low as calculated by the fo...

Page 13: ...wer kW per ton the cooling tower fan motor power becomes a higher percentage of the total peak load chiller power Daikin s Energy Analyzer program can optimize the chiller tower operation for specific...

Page 14: ...and Interface Panel side so in this case the right hand condenser connections would be for the tower If the condenser connections were on the other end right hand the tower connections would be the le...

Page 15: ...24 VAC low current 16ma Flow switch wire must be in separate conduit from any high voltage conductors 115 VAC and higher Table 1 Flow Switch Flow Rates Pipe Size NOTE inch 1 1 4 1 1 2 2 2 1 2 3 4 5 6...

Page 16: ...condenser flow 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 See Figure 15 Fi...

Page 17: ...D EIMWC00804 14EN Figure 7 Heat Recovery Schematic EVAPORATOR TOWER CONDENSER RECOVERY CONDENSER AUXILIARY HEATER HEAT LOAD TC TC COOLING LOAD OPEN CIRCUIT TOWER HEAT RECOVERY CHILLER LEGEND TC TEMPER...

Page 18: ...D EIMWC00804 14EN Centrifugal Chillers 19 Field Insulation Guide Figure 8 Insulation Requirements Cooling only Units...

Page 19: ...20 Centrifugal Chillers D EIMWC00804 14EN...

Page 20: ...1 54 206 66 6 1 3285 1488 1 E2212 X 500 227 45 170 90 8 3 2877 1305 1 E2212 X 645 291 63 240 90 8 3 3550 1609 1 E2216 X 1312 595 79 301 144 13 4 4200 1903 1 E2412 X 1005 456 88 335 131 12 1 4410 1999...

Page 21: ...307 33 123 1753 795 2 C1809 X 597 271 43 162 1887 856 2 C1812 X 845 384 44 166 2050 930 2 C2009 X 728 330 47 147 1896 860 2 C2012 X 971 440 62 236 2528 1147 2 C2209 X 822 372 73 278 2596 1169 2 C2212...

Page 22: ...ter When using chilled water it is important that the water pressure drop across the evaporator is greater than the pressure drop across the oil cooler or insufficient oil cooler flow will result If t...

Page 23: ...As can be seen with cooling water in the 45 F to 65 F 7 C to 18 C range considerably less water will be used and the pressure drop will be greatly reduced When supplied with city water the oil piping...

Page 24: ...e 12 Oil Cooler Connections DWDC 100 126 16 Foot Shells Table 8 Cooling Water Connection Sizes Model DWSC DHSC 063 087 DWDC 063 087 DWSC DHSC 100 126 DWDC DWCC 100 126 Conn Size in in 1 in 1 in Oil Re...

Page 25: ...king pipe connections Whenever vent piping is installed the lines must be run in accordance with local code requirements where local codes do not apply the latest issue of ANSI ASHRAE Standard 15 code...

Page 26: ...ping Sizes Equivalent length ft 2 2 18 5 105 8 296 7 973 6 4117 4 Pipe Size inch NPT 1 1 4 1 1 2 2 2 1 2 3 4 Moody Factor 0 0209 0 0202 0 0190 0 0182 0 0173 0 0163 NOTE A 1 inch pipe is too small for...

Page 27: ...tems Materials required 1 Loctite brand safety solvent 12 oz package available as Daikin part number 350A263H72 2 3M Co Scotchfil brand electrical insulation putty available in a 60 inch roll as Daiki...

Page 28: ...e compressor controller and to the bias block both located in the compressor control panel Figure 14 Field Wiring for Optional Display Control Power Wiring The control circuit on the Daikin centrifuga...

Page 29: ...re Size AWG Maximum Length ft m Wire Size AWG 0 0 to 50 15 2 12 120 36 6 to 200 61 0 6 50 15 2 to 75 22 9 10 200 61 0 to 275 83 8 4 75 22 9 to 120 36 6 8 275 83 8 to 350 106 7 3 Notes 1 Maximum length...

Page 30: ...SWITCH stops the compressor immediately It is wired in series with the COMPRESSOR On Off switch Surge Capacitors All units except those with solid state starters or VFDs are supplied with standard su...

Page 31: ...building load 9 The condenser water pump must cycle with the unit A customer supplied 115 Vac 25 VA maximum coil rated condenser water pump relay CP1 2 is to be wired as shown 10 Optional customer su...

Page 32: ...R COOLING TOWER THIRD STAGE STARTER COOLING TOWER SECONDH STAGE STARTER COOLING TOWER FIRST STAGE STARTER COOLING TOWER BYPASS VALVE COOLING TOWER VFD ALARM RELAY NOTE 4 MICROTECH COMPRESSOR CONTROL B...

Page 33: ...ection can be designated as Chiller A The isolation board is attached to the DIN rail adjacent to the Chiller A unit controller The isolation board has a pigtail that is plugged into J10 on the contro...

Page 34: ...00 111000 000100 B 9 10 13 14 15 16 100100 010100 101100 011100 111100 000010 C 17 18 21 22 23 24 100010 010010 101010 011010 111010 000110 D 25 26 29 30 31 32 100110 010110 101110 011110 111110 00000...

Page 35: ...n sequence The Modes setpoints will do several different types of operation Normal Efficiency Standby etc as described in the operating manual The same Modes setting must be replicated on each chiller...

Page 36: ...sor ready for connection when service engineer is on hand for start up Do not connect starter or compressor terminals All interlock wiring complete between control panel and complies with specificatio...

Page 37: ...n service technician be consulted Daikin conducts training for centrifugal operators at its factory Training Center in Staunton Virginia several times a year These sessions are structured to provide b...

Page 38: ...ermination Control Power Isolation Board 110 volt Circuit Breaker 115 volt Circuit Breaker Latch Relay Heater Relay Compressor Relay Oil Pump Overload Relay Reset Button Oil Pump Contactor Oil Pump St...

Page 39: ...e piston through ports SA and SB and the vanes are held in that position Refer to Figure 22 and Figure 23 for solenoid action Note that both solenoids cannot be energized simultaneously Vane Speed Met...

Page 40: ...ure 21 Oil Sump and Compressor Controller Panel NOTE 4 way solenoid valve and vane close switches are located on the compressor suction inlet The mechanical high pressure cutout is located in the disc...

Page 41: ...ion SB De energized Section SA De energized From Oil Pump Discharge Adjustable Needle Valves Integral With Four Way Solenoid Valve HOLDING Figure 23 Vane Control Solenoid Operation Continued Drain Fro...

Page 42: ...udes the pump pump motor and lubricant heater The oil is pumped to the internal oil filter in the compressor casting and then to the internal refrigerant cooled oil cooler The other compressor sizes C...

Page 43: ...point the hot gas bypass solenoid valve is energized making hot gas bypass available for metering by the hot gas regulating valve This hot gas provides a stable refrigerant flow and keeps the chiller...

Page 44: ...D EIMWC00804 14EN Centrifugal Chillers 45 Even with tower fan control some form of water flow control such as tower bypass must be used...

Page 45: ...bstitute 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 ser...

Page 46: ...leak contaminated moist air into the refrigerant circuit thereby eliminating the need for annual oil changes An annual laboratory oil check is recommended to check overall compressor condition CE 050...

Page 47: ...he 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 co...

Page 48: ...erminal connections 5 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 poss...

Page 49: ...eated or improperly treated water 6 Remove condenser heads at least once a year to inspect the condenser tubes and clean if required Annual Startup A dangerous condition can exist if power is applied...

Page 50: ...ly shut off the compressor Use a portable condensing unit to complete the pump down condense the refrigerant and pump it into the condenser or pumpout vessel using approved procedures A pressure regul...

Page 51: ...efrigerant drum to the gauge port on the liquid line shutoff valve and purge the charging line between the refrigerant cylinder and the valve Then open the valve to the mid position 2 Turn on both the...

Page 52: ...The need to change lubricating oil and filters 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...

Page 53: ...eased until the liquid temperature reached 22 degrees F Liquid R 134a can hold approximately 470 ppm at 15 degrees F an evaporator temperature which could be encountered in ice applications Since free...

Page 54: ...1 Iron 100 1 Moisture 150 2 3 Silica 50 1 Total Acid Number TAN 19 3 Key To Action 1 Re sample after 500 hours of unit operation If content increases less than 10 change oil and filter and re sample...

Page 55: ...on System Clean Oil Cooler Strainer water X Oil Cooler Solenoid Operation O Oil Appearance clear color quantity O Oil Filter Pressure Drop O Oil Analysis Note 5 X Oil change if indicated by oil analys...

Page 56: ...ll produce a low reading In handling electrical components only fully qualified technicians must attempt service 2 Approach temperature the difference between the leaving water temperature and the sat...

Page 57: ...ffice Operator Schools Training courses for Centrifugal Maintenance and Operation are held through the year at the Training Center in Staunton Virginia The school duration is three and one half days a...

Page 58: ...aratuses under pressure The units are included in category IV of the classification according to European Directive PED 97 23 EC For chillers belonging to this category some local regulations require...

Page 59: ...arming potential The refrigerant quantity is indicated on the unit name plate Periodical inspections for refrigerant leaks may be required depending on European or local legislation Please contact you...

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Page 62: ...nt and the products and services presented therein Specification are subject to change without prior notice Refer to the data communicated at the time of the order Daikin Applied Europe S p A explicit...

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