water-cooled screw compressor chillers - daikin...
TRANSCRIPT
Installation and Maintenance Manual IMM 1157
Group: Chiller
Part Number: 331373601
Effective: March 2012
Supercedes: November, 2011
Water-Cooled Screw Compressor Chillers
WGS 130AW to WGS 190AW, Packaged Water-Cooled Chiller
WGS 130AA to WGS 190AA, Chiller with Remote Condenser
120 to 200 Tons, 420 to 700 kW
R-134A, 60 Hz
2 WGS 130A to WGS 190A IMM 1157
Table of Contents
Introduction . ......................................3 General Description. .................................... 3 Nomenclature. .............................................. 3 Inspection . ................................................... 3
Installation . ........................................4 Vibration Isolators . ...................................... 6
Water Piping . ...................................10 Flow Switch. .............................................. 12 Glycol Solutions . ....................................... 13 Condenser Water Piping ............................ 14 Water Pressure Drop. ................................. 15
Refrigerant Piping. ..........................18 Unit with Remote Condenser..................... 18 Factory-Mounted Condenser ..................... 21
Dimensional Data . ...........................22 Physical Data. ...................................25
WGS-AW, Water-Cooled........................... 25 WGS-AA Remote Condenser .................... 26
Unit Configuration . .........................27 Components . .............................................. 27
Wiring. ..............................................28 BAS Interface . ........................................... 29 Remote Operator Interface Panel............... 29
Electrical Data................................. 30 Wiring Diagrams. .......................................38 Control Panel Layout .................................46
Sequence of Operation.................... 49 Start-Up and Shutdown. ................ 50
Pre Start-up . ...............................................50 Start-up .......................................................50 Weekend or Temporary Shutdown.............51 Start-up after Temporary Shutdown...........51 Extended Shutdown. ..................................51 Start-up after Extended Shutdown. ............51
System Maintenance ....................... 52 General. ......................................................52 Electrical Terminals . ..................................53 POE Lubrication . .......................................53 Sight Glass and Moisture Indicator . ..........54 Sump Heaters. ............................................54
Maintenance Schedule .................... 55 System Service................................. 56
Troubleshooting Chart . ..............................58 Warranty Statement ....................... 59
Unit controllers are LONMARK certified with an optional LONWORKS communications module.
© 2013 Daikin Applied . Illustrations and data cover the Daikin product at the time of publication and we reserve the right to make changes in design and construction at anytime without notice. Units with remote condensers (Models AA) are not included in the scope of AHRI certification. Unit controllers are LONMARK certified with an optional LONWORKS communications module. The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; LONMARK , LonTalk and LONWORKS and the LONMARK logo are managed, granted, and used by LONMARK International under a license granted by Echelon Corporation; Modbus from Schneider Electric; FanTrol, MicroTech II, Open Choices™, and SpeedTrol from Daikin .
Manufactured in an ISO Certified Facility
IMM 1157 WGS 130A to 190A 3
Introduction
General Description Daikin Type WGS water chillers are designed for indoor installations and are available with factory-mounted water-cooled condensers (Model WGS AW), or arranged for use with remote air-cooled or evaporative condensers (Model WGS AA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing. They consist of two semi-hermetic rotary screw compressors, a two-circuit shell-and-tube evaporator, two shell-and-tube water-cooled condensers (WGS-AW), and complete refrigerant piping.
Units manufactured for use with remote condensers (Models WGS-AA) have all refrigerant specialties factory-mounted and connection points for refrigerant discharge and liquid lines.
Liquid line components are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and electronic expansion valves.
The electrical control center includes a MicroTech II microprocessor control system and equipment protection and operating controls necessary for dependable, automatic operation.
The compressor circuits are equipped with individual compressor isolation circuit breakers on single point power connection options. A unit disconnect switch is available as an option over the standard power block.
Nomenclature
W G S 130 A W
Inspection When the equipment is received, carefully check all items against the bill of lading to be sure of a complete shipment. Carefully inspect all units for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. Check the unit serial plate before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of Daikin
Note: Unit shipping and operating weights are given in the physical data tables beginning on page 25.
Water-Cooled Condensing
Global
Rotary Screw Compressor
Nominal Capacity (Tons)
W = Water-Cooled Condenser A = Unit Less Condenser
Design Vintage
4 WGS 130A to 190A IMM1157
Installation
WARNING
Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. Avoid contact with sharp edges. Personal injury can
result.
Start-up by Daikin Factory Service is included on all units sold for installation within the USA and Canada and must be performed by them to initiate the standard limited product warranty. Two-week prior notification of start-up is required. The contractor should obtain a copy of the Start-up Scheduled Request Form from the sales representative or from the nearest office of Daikin Service. Handling Every model WGS-AW water chiller with water-cooled condensers is shipped with a full refrigerant charge. For shipment, the charge is contained in the condensers and is isolated by the condenser liquid shutoff valves and the compressor discharge valves.
A nitrogen/helium holding charge is applied to remote condenser models to maintain a slight positive system pressure. After installation, the unit must be leak-tested, vacuumed, and charged with the operating charge of refrigerant. The operating charge is field-supplied and charged on remote condenser models.
WARNING
Escaping refrigerant can displace air and cause suffocation. Immediately evacuate and ventilate the equipment area. If the unit is damaged, follow Environmental Protection Agency (EPA) requirements. Do not expose sparks, arcing equipment,
open flame or other ignition source to the refrigerant.
Moving the Unit If optional factory-installed skids are not used, some means such as dollies or skids must be used to protect the unit from damage and to permit easy handling and moving. Figure 1, Lifting the Unit
Notes: 1. You must use lifting halo or "I" spreader equal to the dimensions shown.2. Each lifting cable alone must be strong enough to lift chiller.3. Perform all moving and handling with skids or dollies under the unit when possible, and do not remove
them until the unit is in the final location. (continued next page)
48.0(1219.2)
84.0(2133.6)
62.0(1574.8)
WGS 130-190 PACKAGE
108.0(2743.2)
LIFT ONLY WITH HOLESPROVIDED IN BASE
WGS LESS CONDENSER
62.0(1574.8)
48.0(1219.2)
Water-Cooled Chiller Remote Condenser Chiller
IMM 1157 WGS 130A to 190A 5
4. In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit. Do not drop the unit at the end of the roll.
5. Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers.
Table 1, Lifting Loads
AW, Package Units, lbs. (kg) AA, Less Condenser Units, lbs (kg) WGS Model RF RB LF LB
Shipping Weight
RF RB LF LB Shipping Weight
130A 2276
(1032) 1699 (770)
2213 (1003)
1651 (749)
7840 (3556) 1428 (647)
1444 (655)
1386 (629)
1402 (636)
5659 (2567)
140A 2276
(1032) 1699 (770)
2213 (1003)
1651 (749)
7840 (3556) 1428 (647)
1444 (655)
1386 (629)
1402 (636)
5659 (2567)
160A 2368
(1074) 1794 (813)
2300 (1042)
1742 (790)
8206 (3722) 1515 (687)
1543 (700)
1470 (667)
1496 (679)
6024 (2732)
170A 2471
(1096) 1813 (822)
2350 (1065)
1763 (799)
8345 (3785) 1515 (687)
1543 (700)
1470 (667)
1496 (679)
6024 (2732)
190A 2471
(1096) 1813 (822)
2350 (1065)
1763 (799)
8345 (3785) 1515 (687)
1543 (700)
1470 (667)
1496 (679)
6024 (2732)
NOTES: 1. RF=right front, RB=right back, LB=left back, LF=left front, when view from the control panel. See Figure 2 on page
6. 2. The optional sound enclosure adds 650 lbs (295 kg) to the lifting weight, evenly distributed.
Location WGS chillers are designed for indoor application and must be located in an area where the surrounding ambient temperature is 40°F to 122°F (4.4°C to 50°C).
Because of the NEMA 1 electrical control enclosures, do not expose the units to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the water chiller. If necessary, provide additional structural members to transfer the weight of the unit to the nearest beams.
Note: Unit shipping and corner weights are given in Table 1. Operating weights are in the physical data tables beginning on page 25.
Space Requirements for Connections and Servicing The chilled water piping enters and leaves the unit from the right side when looking at the front of the unit (control panel end). Left-hand connections are available as an option. Condenser water connections are located at the rear of the unit, opposite the control panel. Provide clearance of at least 4 feet (1625 mm), or more if codes require in front of the panel. Three feet (1219 mm) clearance should be provided on all other sides and ends of the unit for general servicing. The National Electric Code (NEC) may require additional clearance in front of the control panel and should be consulted. On units equipped with a water-cooled condenser (Type WGS-AW), also provide clearance for cleaning or removal of condenser tubes on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (10 feet, 3050 mm). Tube replacement requires the tube length of condenser plus one to two feet of workspace. This space can often be provided through a doorway or other aperture.
Placing the Unit The small amount of vibration normally encountered with the water chiller makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure.
6 WGS 130A to 190A IMM1157
Control Panel End
Condenser Connections
3
1
4
2
LF
RF
LB
FRB
Vibration Isolators It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration.
Figure 2, Isolator Locations
Transfer the unit as indicated under “Moving the Unit.” on page 4. In all cases, set the unit in place and level with a spirit level. When spring-type isolators are required, install springs running under the main unit supports.
The unit should be set initially on shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims, which are then removed.
Use a rubber anti-skid pad under isolators if hold-down bolts are not used.
Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining the piping and transmitting vibration and noise.
NOTE: All spring isolators have four, same color springs per housing.
Table 2, Weights & Vibration Isolators, Packaged Unit, w/o Sound Enclosure
ARRANGEMENT WGS-AW, WITH WATER-COOLED CONDENSERS, WITHOUT SOUND ENCLOSURE
CORNER WEIGHT LBS (KG)
SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGS UNIT SIZE
OPR. WT.
Lbs. (kg) 1 2 3 4 1 2 3 4 1 2 3 4
RP-4 RP-4 RP-4 RP-4 130AW
8557 (3881)
1778 (806)
2556 (1159)
1732 (786)
2491 (1130)
1D-2040Black
1D-3600Green
1D-2040 Black
1D-3600 Green Brick Red Lime Brick Red Lime
RP-4 RP-4 RP-4 RP-4 140AW
8557 (3881)
1778 (806)
2556 (1159)
1732 (786)
2491 (1130)
1D-2040Black
1D-3600Green
1D-2040 Black
1D-3600 Green Brick Red Lime Brick Red Lime
RP-4 RP-4 RP-4 RP-4 160AW
9314 (4225)
1910 (866)
2805 (1272)
1863 (845)
2736 (1241)
1D-2700Purple
1D-3600Green
1D-2700 Purple
1D-3600 Green Brick Red Lime Brick Red Lime
RP-4 RP-4 RP-4 RP-4 170AW
9505 (4311)
1959 (889)
2852 (1294)
1911 (867)
2783 (1262)
1D-2700Purple
1D-3600Green
1D-2700 Purple
1D-3600 Green Brick Red Lime Brick Red Lime
RP-4 RP-4 RP-4 RP-4 190AW
9505 (4309)
1959 (889)
2852 (1294)
1911 (867)
2783 (1262)
1D-2700Purple
1D-3600Green
1D-2700 Purple
1D-3600 Green Brick Red Lime Brick Red Lime
NOTE: ID 2040, ID 2700 and ID 3600 have four same color springs per housing.
IMM 1157 WGS 130A to 190A 7
Table 3, Weights & Vibration Isolators, Packaged Unit, w/ Sound Enclosure
ARRANGEMENT WGS-AW, WITH WATER-COOLED CONDENSERS, WITH SOUND ENCLOSURE
CORNER WEIGHT LBS (KG)
SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGS UNIT SIZE
OPR. WT. Lbs. (kg)
1 2 3 4 1 2 3 4 1 2 3 4
RP-4 RP-4 RP-4 RP-4 130AW
9205
4179
1928
875
2730
1239
1882
854
2665
1210
1D-2700
Purple
1D-3600
Green
1D-2700
Purple
1D-3600
Green Brick Red Lime Brick
Red Lime
RP-4 RP-4 RP-4 RP-4 140AW
9205
4179
1928
875
2730
1239
1882
854
2665
1210
1D-2700
Purple
1D-3600
Green
1D-2700
Purple
1D-3600
Green Brick Red Lime Brick
Red Lime
RP-4 RP-4 RP-4 RP-4 160AW
9962
4523
2060
935
2979
1352
2013
914
2910
1321
1D-2700
Purple
1D-3600
Green
1D-2700
Purple
1D-3600
Green Lime Charcoal Lime Charcoal
RP-4 RP-4 RP-4 RP-4 170AW
10153
4609
2109
957
3026
1374
2061
936
2957
1342
1D-2700
Purple
1D-3600
Green
1D-2700
Purple
1D-3600
Green Lime Charcoal Lime Charcoal
RP-4 RP-4 RP-4 RP-4 190AW
10153
4609
2109
957
3026
1374
2061
936
2957
1342
1D-2700
Purple
1D-2700
Green
1D-2700
Purple
1D-2700
Green Lime Charcoal Lime Charcoal
NOTE: ID 2700 and ID 3600 have four same-color springs per housing.
Table 4, Weights & Vibration Isolators, Remote Condenser, Without Sound Enclosure ARRANGEMENT WGS-AA, FOR REMOTE CONDENSER, WITHOUT SOUND ENCLOSURE (SEE NOTE)
CORNER WEIGHT LBS (KG) SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGSUNIT SIZE
OPR. WT. LBS. (KG) 1 2 3 4 1 2 3 4 1 2 3 4
RP-4 RP-4 RP-4 RP-4 130AA
6265 (2842)
1572 (713)
1603 (727)
1530 (694)
1560 (708)
1D-2040Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick Red
Brick Red
RP-4 RP-4 RP-4 RP-4 140AA
6265 (2842)
1572 (713)
1603 (727)
1530 (694)
1560 (708)
1D-2040Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick RedBrick Red
RP-4 RP-4 RP-4 RP-4 160AA
7022 (3185)
1752 (794)
1800 (818)
1708 (775)
1758 (797)
1D-2040Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick RedBrick Red
RP-4 RP-4 RP-4 RP-4 170AA
7022 (3185)
1752 (794)
1800 (818)
1708 (775)
1758 (797)
1D-2040Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick RedBrick Red
RP-4 RP-4 RP-4 RP-4 190AA
7022 (3185)
1752 (794)
1800 (818)
1708 (775)
1758 (797)
1D-2040Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick RedBrick Red
NOTE: ID 2040 has four same-color springs per housing.
Table 5, Weights & Vibration Isolators, Remote Condenser, With Sound Enclosure ARRANGEMENT WGS-AA, FOR REMOTE CONDENSER, WITH SOUND ENCLOSURE (SEE NOTE)
CORNER WGT LBS (KG)
SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR
MOUNTINGS UNIT SIZE
OPR. WT. LBS. (KG)
1 2 3 4 1 2 3 4 1 2 3 4 RP-4 RP-4 RP-4 RP-4
130AA 6913 3139
1722 782
1777 807
1680 763
1734787
1D-2040 Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick Red
Brick Red
RP-4 RP-4 RP-4 RP-4 140AA
6913 3139
1722 782
1777 807
1680 763
1734787
1D-2040 Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick Red
Brick Red
RP-4 RP-4 RP-4 RP-4 160AA
7666 3480
1902 864
1974 896
1858 844
1932877
1D-2040 Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick Red
Brick Red
RP-4 RP-4 RP-4 RP-4 170AA
7666 3480
1902 864
1974 896
1858 844
1932877
1D-2040 Black
1D-2040Black
1D-2040Black
1D-2040Black Brick
Red Brick Red
Brick Red
Brick Red
RP-4 RP-4 RP-4 RP-4 190AA 7666
3480 1902 864
1974 896
1858 844
1932877
1D-2040 Black
1D-2040Black
1D-2040Black
1D-2040Black
Brick Red
Brick Red
Brick Red
Brick Red
NOTE: ID 2040 has four same color springs per housing.
8 WGS 130A to 190A IMM1157
Table 6, Isolator Kit Part Numbers Model AW, w/o
Sound Enclosure WGS 130AW WGS 140AW WGS 160AW WGS 170AW WGS 190AW
Spring Part Number 332320601 332320601 332320602 332320602 332320602
R-I-S Part Number 332325601 332325601 332325601 332325601 332325601
Model AW, w Sound
Enclosure WGS 130AW WGS 140AW WGS 160AW WGS 170AW WGS 190AW
Spring Part Number 332320602 332320602 332320602 332320602 332320602
R-I-S Part Number 332325601 332325601 332325602 33232562 332325602
Model AA, w/o
Sound Enclosure WGS 130AA WGS 140AA WGS 160AA WGS 170AA WGS 190AA
Spring Part Number 332320603 332320603 332320603 332320603 332320603
R-I-S Part Number 332325603 332325603 332325603 332325603 332325603
Model AA, w/ Sound Enclosure
WGS 130AA WGS 140AA WGS 160AA WGS 170AA WGS 190AA
Spring Part Number 332320603 332320603 332320603 332320603 332320603
R-I-S Part Number 332325603 332325603 332325603 332325603 332325603
NOTE: Model AW = packaged, water-cooled, Model AA = remote condenser, air-cooled
Figure 3, CP-4, Spring Flex Mounting Figure 4, RP-4, R-I-S Mounting
NOTES:
MOUNT MATERIAL TO BE DURULENE RUBBER.1.
MOLDED STEEL AND ELASTOMER MOUNT FOR2.OUTDOOR SERVICE CONDITIONS.
3. RP-4 MOUNT VERSION WITH STUD IN PLACE.ALL DIMENSIONS ARE IN DECIMAL INCHES
DRAWING NUMBER 3314814
1.13 ± .25APPROX.
1.63
.38
DURULENEMATERIAL
RAISED GRIP RIBS
3.00
3.75
5.00
6.25
3.87.56 TYP.
4.63
R.28TYP.
R.250 TYP.
R.750 TYP.RECESSEDGRIP RIBS
ø .500-13NC-2B
R4
R4
VM
&C
VM
&C
IMM 1157 WGS 130A to 190A 9
Figure 5, WGS-AA, Remote Condenser Configuration
Discharge Connections
Liquid Return Connections
10 WGS 130A to 190A IMM1157
Water Piping
Vessel Drains at Start-up Evaporators are drained of water in the factory and shipped with an open ball valve in the drain hole. The drain is located on the bottom of the vessel. Be sure to close the valve prior to filling the vessel with fluid.
Condensers: Units are drained of water in the factory and are shipped with condenser drain plugs in the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid.
General Due to the variety of piping practices, follow the recommendations of local authorities for code compliance. They can supply the installer with the proper building and safety codes required for a proper installation.
The piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. Other piping design considerations include:
1. All piping should be installed and supported to prevent the chiller connections from bearing any strain or weight of the system piping.
2. Vibration eliminators to reduce vibration and noise transmission to the building.
3. Shutoff valves to isolate the unit from the piping system during unit servicing.
4. Manual or automatic air vent valves at the high points of the system. Drains should be placed at the lowest points in the system.
5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve).
6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of the vessels to aid in unit servicing.
7. A strainer or some means of removing foreign matter from the water before it enters the pump. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). A strainer can prolong pump life and help maintain system performance.
Important Note A cleanable 20-mesh strainer must also be placed in the water line just prior to the inlet of the evaporator. This will aid in preventing foreign material from entering the unit and decreasing the performance of the evaporator.
8. If the unit is used as a replacement chiller on a previously existing piping system, flush the system thoroughly prior to unit installation. Regular water analysis and chemical water treatment on the evaporator and condenser are recommended immediately upon equipment start-up.
9. In the event glycol is added to the water system as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance will be less, and water side pressure drop will be higher. If the percentage of glycol is large, or if propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 32°F (0°C). Reset the freezestat setting to approximately 8° to 10°F (4.4° to 5.5°C) below the leaving chilled water setpoint temperature. See the section titled “Glycol Solutions” on page 13 for additional information concerning the use of glycol.
10. Make a preliminary leak check of the water piping before filling the system.
IMM 1157 WGS 130A to 190A 11
! WARNING
This unit contains POE lubricants that must not come into contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate piping).
Note: A water flow switch or pressure differential switch must be mounted in the evaporator outlet water line to signal that there is water flow before the unit will start.
Figure 6, Typical Field Evaporator Water Piping
Vent
Drain
GateValve
WaterStrainer
VibrationEliminatorValved
PressureGauge
In
OutProtect All Field Piping
Against Freezing
Flow
VibrationEliminator
FlowSwitch
BalancingValve
GateValve
Flow
NOTE: Water piping must be supported independently from the unit.
System Water Volume All chilled water systems need adequate time to recognize a load change, respond to that load change and stabilize, without undesirable short cycling of the compressors or loss of control. In air conditioning systems, the potential for short cycling usually exists when the building load falls below the minimum chiller plant capacity or on close-coupled systems with very small water volumes.
Some of the things the designer should consider when looking at water volume are the minimum cooling load, the minimum chiller plant capacity during the low load period and the desired cycle time for the compressors.
Assuming that there are no sudden load changes and that the chiller plant has reasonable turndown, a rule of thumb of “gallons of water volume equal to two to three times the chilled water gpm flow rate” is often used.
A properly designed storage tank should be added if the system components do not provide sufficient water volume.
Variable Chilled Water Flow Reducing chilled water flow in proportion to load can reduce total system power consumption. Certain restrictions apply to the amount and rate of flow change. The rate of flow change should be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the minimum flows listed in the pressure drop data on page 16.
Chilled Water Piping The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. A 1.0 mm (16 to 20 mesh) strainer must be installed in the return water line before the inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into the evaporator inlet.
12 WGS 130A to 190A IMM1157
The return water line must be piped to the evaporator inlet connection and the supply water line must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse direction, a substantial decrease in capacity and efficiency of the unit will be experienced.
A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to prove water flow before starting the unit.
Provide drain connections at all low points in the system to permit complete drainage. Air vents should be located at the high points in the system to purge air out of the system. The evaporator is equipped with vent and drain connections.
Install pressure gauges in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator can be measured to determine water flow from the flow/pressure drop curves on page 16. Vibration eliminators are recommended in both the supply and return water lines.
Insulate chilled water piping to reduce heat loss and prevent condensation. Perform complete unit and system leak tests prior to insulating the water piping. Insulation with a vapor barrier is recommended. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility.
Flow Switch Field Installed A water flow switch must be mounted in the leaving evaporator and condenser water line to prove adequate water flow before the unit can start. This will protect against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up.
A flow switch is available from Daikin under part number 01750330. It is a “paddle” type switch and adaptable to any pipe size from 1 in. (25 mm) to 6 in. (152 mm) nominal. Certain flow rates are required to open the switch and are listed in Table 7. Switch terminals Y and R should be made to panel terminals 60 and 67 (chilled water) and 60 and 76 (condenser water). There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a “no flow” condition exists. 1. Apply pipe sealing compound to only the threads of the switch and screw unit into the
1-in. (25-mm) reducing tee. The flow arrow must be pointed in the correct direction.
2. Piping should provide a straight length before and after the flow switch of at least fivetimes the pipe diameter without any valves, elbows, or other flow restricting elements.
3. Trim the flow switch paddle if needed, to fit the pipe diameter. Make sure the paddledoes not hang up in the pipe.
! CAUTION
Make sure the arrow on the side of the switch is pointed in the direction of flow. Connect the flow switch according to the wiring diagram (see wiring diagram inside control box door). Incorrect installation will cause improper operation and possible evaporator damage.
IMM 1157 WGS 130A to 190A 13
Table 7, Flow Switch Flow Rates inch 1 1/4 1 1/2 2 2 1/2 3 4 5 6 8 Pipe Size
(NOTE !) mm 32 (2) 38 (2) 51 63 (3) 76 102 (4) 127 (4) 153 (4) 204 (5) gpm 5.8 7.5 13.7 18.0 27.5 65.0 125.0 190.0 205.0 Flow Lpm 1.3 1.7 3.1 4.1 6.2 14.8 28.4 43.2 46.6 gpm 3.7 5.0 9.5 12.5 19.0 50.0 101.0 158.0 170.0
Min. Adjst. No
Flow Lpm 0.8 1.1 2.2 2.8 4.3 11.4 22.9 35.9 38.6 gpm 13.3 19.2 29.0 34.5 53.0 128.0 245.0 375.0 415.0 Flow Lpm 3.0 4.4 6.6 7.8 12.0 29.1 55.6 85.2 94.3 gpm 12.5 18.0 27.0 32.0 50.0 122.0 235.0 360.0 400.0
Max. Adjst. No
Flow Lpm 2.8 4.1 6.1 7.3 11.4 27.7 53.4 81.8 90.8
NOTES: 1. A segmented 3-inch paddle (1, 2, and 3 inches) is furnished mounted, plus a 6-inch paddle loose. 2. Flow rates for a 2-inch paddle trimmed to fit the pipe. 3. Flow rates for a 3-inch paddle trimmed to fit the pipe. 4. Flow rates for a 3-inch paddle. 5. Flow rates for a 6-inch paddle
Optional Factory-Mounted The chiller may be equipped with the optional factory-mounted flow switch. The 24 Vac powered flow sensors are a solid state alternative to mechanical switches for sensing the acceptable flow rate of water. The flow sensors are extremely reliable with no moving parts that can become stuck or break in the flow process. These compact units are constructed of corrosion-resistant materials and 316 stainless steel parts and are factory-installed directly through a ¼ inch NPT into the flow. No field adjustments are required. The flow sensors operate on the calorimetric principle. The sensors use the cooling effect of a flowing fluid to provide reliable flow rate detection of liquids over a very wide flow range. The amount of thermal energy that is removed from the tip determines the local flow rate and when it exceeds a setpoint it changes the output-state.
Glycol Solutions When using a glycol solution, the chiller capacity, flow rate, evaporator pressure drop, and chiller power input can be calculated using the following formulas. Refer to Table 8 for ethylene glycol and Table 9 for propylene glycol. Capacity, Capacity is reduced compared to that of plain water. To find the reduced value, multiply the chiller’s capacity when using water by the capacity correction factor C to find the chiller’s capacity when using glycol. Flow, Multiply the water flow by the G correction factor to determine the glycol flow required to give the same Delta-T as water.
To determine evaporator gpm (or T) knowing T (or gpm) and capacity:
TablesFromGCorrectionFlowxT
CapacityGlycolxGPMGlycol
24
For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps) and kW:
TablesfromGCorrectionFlowxTx
kWLpsGlycol
18.4
Pressure Drop, To determine glycol pressure drop through the cooler, enter the water pressure drop graph on page 16 at the actual glycol flow. Multiply the water pressure drop found there by correction factor P to obtain corrected glycol pressure drop. Power, To determine glycol system kW, multiply the water system kW by factor K.
14 WGS 130A to 190A IMM1157
Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point found in Table 8. On glycol applications the supplier normally recommends that a minimum of 25% solution by weight be used for protection against corrosion or the use of additional inhibitors.
Note: The effect of glycol in the condenser is negligible. As glycol increases in temperature, its characteristics have a tendency to mirror those of water. Therefore, for selection purposes, there is no derate in capacity for glycol in the condenser.
Table 8, Ethylene Glycol Freeze Point % Ethylene
Glycol °F °C C Capacity K Power G Flow P Pressure Drop
10 26 -3.3 0.996 0.999 1.035 1.096 20 18 -7.8 0.986 0.998 1.060 1.219 30 7 -13.9 0.978 0.996 1.092 1.352 40 -7 -21.7 0.966 0.993 1.131 1.530 50 -28 -33.3 0.955 0.991 1.182 1.751
Table 9, Propylene Glycol Freeze Point % Percent
Glycol °F °C C Capacity K Power G Flow P Pressure Drop
10 26 -3 0.987 0.992 1.010 1.068 20 19 -7 0.975 0.985 1.028 1.147 30 9 -13 0.962 0.978 1.050 1.248 40 -5 -21 0.946 0.971 1.078 1.366 50 -27 -33 0.929 0.965 1.116 1.481
! CAUTION
Do not use automotive grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors, which cause plating on copper tubes. The type and handling of glycol used must be consistent with local codes.
Condenser Water Piping Arrange the condenser water so the water enters the condensers’ bottom connections or the single bottom manifold connection if the optional manifold has been ordered. The condenser water will discharge from the top condenser connections or the single top connection of the optional manifold. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency.
Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine flow on the pressure drop/flow curves on page 17. Vibration eliminators are recommended in both the supply and return water lines.
Water-cooled condensers can be piped for use with cooling towers or well water. Cooling tower applications should be made with consideration of freeze protection and scaling problems. Contact the cooling tower manufacturer for equipment characteristics and limitations for the specific application.
Head pressure control must be provided if the entering condenser water can fall below the curve values on page Error! Bookmark not defined.. The MicroTech II unit controller can provide this function, using entering condenser water as the control point. The control will work with or without the optional condenser manifolds. The water sensors are factory-installed.
IMM 1157 WGS 130A to 190A 15
The controller setpoints have to be adjusted for water control and certain output connections made to the tower components. See the operating manual OM WGS and the field wiring diagram in this manual for further details.
Condenser Water Sensors Packaged WGS chillers are supplied with one ECWT sensor and one LCWT sensor. The option the unit is ordered with will determine the sensor location requirements. Listed below are the two possibilities.
WGS Ordered Without the Condenser Manifold: If the unit is ordered without the condenser manifold option, the entering and leaving water sensors will have to be field-installed in their respective condenser water piping, at a common location. Since each WGS is supplied with an independent condenser vessel per refrigerant circuit, the water temperature sensors must be installed in a location prior to the water piping split on the entering water side and after the piping is rejoined on the leaving water side. The sensors ship with the chiller, temporarily attached to the condenser vessel. The sensors will be landed on the control panel end and provided with additional lead length for field installation.
WGS Ordered With the Condenser Manifold: If the unit is ordered with the condenser manifold option, both sensors will be factory-installed in the manifolds.
Water Pressure Drop The vessel flow rates must fall between the minimum and maximum values shown on the appropriate evaporator and condenser curves. Flow rates below the minimum values shown will result in laminar flow that will reduce efficiency, cause erratic operation of the electronic expansion valve and could cause low temperature cutoffs. On the other hand, flow rates exceeding the maximum values shown can cause erosion in the evaporator and condenser.
Measure the chilled water pressure drop through the evaporator at field-installed pressure taps. It is important not to include valves or strainers in these readings.
16 WGS 130A to 190A IMM1157
Figure 7, Evaporator Pressure Drop WGS 130 – WGS 190
WGS 160, 170, 190
WGS 130, 140
Minimum Flow Nominal Flow Maximum Flow
Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop WGS Model
gpm L/s Ft. kPa gpm L/s Ft. kPa gpm L/s Ft. kPa
130AW/AA 195 12.3 5.8 17.4 312 19.7 13.5 40.4 520 32.9 33.9 101.1
140AW/AA 211 13.4 6.7 20.0 338 21.4 15.6 46.6 563 35.6 39.0 116.5
160AW/AA 235 14.9 4.6 13.8 376 23.8 10.8 32.3 627 39.7 27.3 81.6
170AW/AA 254 16.1 5.3 15.9 407 25.8 12.5 37.3 678 42.9 31.6 94.2
190AW/AA 273 17.3 6.1 18.1 437 27.7 14.2 42.5 728 46.1 35.9 107.2
Note: Minimum, nominal, and maximum flows are at a 16F, 10F, and 6F chilled water temperature range respectively and at ARI tons.
IMM 1157 WGS 130A to 190A 17
Figure 8, Condenser Pressure Drop WGS 130 – WGS 190
WGS 130, 140, 160with Manifold
WGS 130, 140, 160without Manifold
WGS 170, 190with Manifold
WGS 170, 190without Manifold
Pressure Drop Without Optional Condenser Manifold
Minimum Flow Nominal Flow Maximum Flow
Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop WGS Model
gpm L/s Ft. kPa gpm L/s Ft. kPa gpm L/s Ft. kPa
130AW 304 19.2 4.1 12.2 390 24.7 6.5 19.3 650 41.1 16.0 47.9
140AW 304 19.2 4.1 12.2 422 26.7 7.4 22.2 704 44.5 18.5 55.1
160AW 304 19.2 4.1 12.2 470 29.8 9.0 26.9 784 49.6 22.4 66.8
170AW 372 23.5 4.3 12.8 509 32.2 7.9 23.7 848 53.7 19.8 59.1
190AW 372 23.5 4.3 12.8 546 34.6 9.0 26.9 911 57.6 22.5 67.1
Pressure Drop With Optional Condenser Manifold
Minimum Flow Nominal Flow Maximum Flow
Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop WGS Model
gpm L/s Ft. kPa gpm L/s Ft. kPa gpm L/s Ft. kPa
130AW 304 19.2 4.7 14.0 390 24.7 7.4 22.0 650 41.1 18.5 55.1
140AW 304 19.2 4.7 14.0 422 26.7 8.5 25.3 704 44.5 21.3 63.5
160AW 304 19.2 4.7 14.0 470 29.8 10.3 30.7 784 49.6 25.8 77.1
170AW 372 23.5 5.3 15.8 509 32.2 9.4 28.1 848 53.7 23.8 71.1
190AW 372 23.5 5.3 15.8 546 34.6 10.7 32.0 911 57.6 27.1 80.9
18 WGS 130A to 190A IMM1157
Refrigerant Piping
Unit with Remote Condenser General For remote condenser application (WGS-AA), the chillers are shipped with a nitrogen/helium holding charge of 20 psi is used to pressurize the system with a slight positive pressure to prevent contaminants from entering the unit. This holding charge should not be mistaken as a refrigerant charge, and can not be used as part of the final total refrigerant charge. After installation, the unit should be pressurized and tested for leaks, vacuumed and charged with the correct refrigerant operating charge, taking into consideration the length of refrigerant piping. The operating charge is field-supplied and charged for remote condenser models. It is important that the unit be kept tightly closed until the remote condenser is installed and piped to the unit. It is the contractor’s responsibility to install the interconnection piping, leak-test the entire system, evacuate the system, and supply the system refrigerant charge. The system should be held under vacuum until it is charged under supervision of the Daikin authorized service technician who will supervise unit commissioning. The unit operating charge (less piping and condenser) can be found on page 26.
! IMPORTANT NOTE !
Service Form SF99006 and an isometric sketch of the Remote Piping Layout showing pipe size, location of fittings, measured lengths and elevations MUST BE SUBMITTED TO Daikin Technical Response Center and reviewed before order entry. Daikin Factory Service will not perform startup without reviewed Service Form SF99006 and
drawing. Installation must match reviewed drawing.
All field piping, wiring and procedures must comply with design guidelines set forth in the product literature, and be performed in accordance with ASHRAE, EPA, local codes and industry standards and per included sizing tables. Any product failure caused, or contributed to, by failure to comply with appropriate design guidelines will not be covered by
manufacturer’s warranty.
Daikin Technical Response: Fax: 763-509-7666; Phone : 540-248-9201; e-mail: [email protected]
The following notes apply to all size units:
Maximum linear line length shall not exceed 75 feet. Maximum Total Equivalent Length (TEL) shall not exceed 180 feet. The condenser shall not be located more than 15 feet above the indoor unit. The condenser shall not be located more than 20 feet below the indoor unit. No underground piping.
It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility.
The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory-mounted as standard equipment with the water chiller.
After the equipment is properly installed, leak tested, and evacuated, it can be charged with R-134a and started under Daikin service supervision. Total operating charge will depend on the air-cooled condenser used and volume of the refrigerant piping.
Note: On the arrangement WGS-AA units (units with remote condensers), the installer must record the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate in the appropriate blocks provided for this purpose.
IMM 1157 WGS 130A to 190A 19
The following discussion is intended for use as a general guide to the piping of air-cooled and evaporative condensers.
Use the tables shown in this manual for sizing the discharge and liquid lines. Discharge lines must be designed to handle oil properly and to protect the compressor from damage that can result from condensing liquid refrigerant in the line during shutdown. Careful consideration must be given for sizing each section of piping so that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is too low, considerable oil can collect in the riser and the horizontal header, causing the compressor to lose its oil and result in damage due to lack of lubrication. When the compressor load is increased, the oil that had collected during reduced loads can be carried as a slug through the system and back to the compressor, where a sudden increase of oil concentration can cause liquid slugging and damage to the compressor.
Any horizontal run of discharge piping should be pitched away from the compressor approximately 1/8-inch per foot (10.4 mm per m) or more. This is necessary to move, by gravity, any oil lying in the header.
Any discharge line coming into a horizontal discharge header should rise above the centerline of the discharge header. This is necessary to prevent liquid refrigerant from draining from the condenser when the compressor is not operating. If the compressors are lower than the condenser, or refrigerant migration is possible, a check valve should be installed at the condenser.
A check/relief valve may be necessary in the liquid line at the condenser for applications where the liquid line is higher than the condensing unit or where refrigerant migration is an issue. The liquid line should be insulated when it is routed where the ambient exposure is higher than the condenser’s ambient temperature. A relief device may also be required in the discharge line piping.
Figure 9 illustrates a typical piping arrangement involving a remote air-cooled condenser located at a higher elevation than the compressor. This arrangement is commonly encountered when the air-cooled condenser is on a roof and the compressor is on grade level or in a basement equipment room.
Notice in Figure 9 that the discharge line is looped at the bottom and top of the vertical run. This is done to prevent oil and condensed refrigerant from flowing back into the compressor and causing damage. The highest point in the discharge line should always be above the highest point in the condenser coil. Include a purging vent at this point to extract non-condensables from the system. This method should also be employed if the air-cooled condenser is located on the same level as the compressor.
Head Pressure Control The MicroTech II circuit controllers are capable of controlling the fans of remote air-cooled condensers connected to each of the unit’s two refrigerant circuits. Control is based on condensing temperature and uses a combination of fan variable frequency drive (VFD) and fan cycling.
Recommended Refrigerant Pipe Sizes NOTES: 1. Pressure drop is in equivalent degrees F. 2. On WGS 140 and 170, the # 1 circuit is always the smallest and is closest to the control panel.
Horizontal or Downflow Discharge Line Sizes
Recommended Discharge Line Size, inch, O.D.
Up to Up to Up to Up to Up to Unit, Circuit
Nominal
Circuit
Tons
Conn.
Size
At Unit 50 Equiv.Ft 75 Equiv.Ft 100 Equiv.Ft. 125 Equiv.Ft. 150 Equiv.Ft.
WGS 130, Both Line Size 2 5/8 2 5/8 2 5/8 2 5/8 2 5/8
WGS 140, Cir #1 65 2 5/8
Press Drop, F 0.55 0.82 1.10 1.37 1.64
WGS 140, Cir #2
WGS 160, Both
WGS 170, Cir #1
80 2 5/8 Line Size
Press Drop, F2 5/8
0.80
2 5/8
1.21
2 5/8
1.61
2 5/8
2.01
3 1/8
1.04
WGS 170, Cir #2 Line Size 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8
WGS 190, Both 95 2 5/8
Press Drop, F 1.08 1.62 2.16 1.17 1.40
20 WGS 130A to 190A IMM1157
Recommended Vertical Upflow Discharge Line Sizes
Recommended Discharge Line Size, inch,
O.D.
Up to Up to Up to Unit, Circuit
Nominal
Circuit
Tons
Connection
Size, O.D.
at WGS Unit 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft.
WGS 130, Both Line Size 2 1/8 2 1/8 2 1/8
WGS 140, Cir #1 65 2 5/8
Press Drop, F 1.52 2.28 3.03
WGS 140, Cir #2
WGS 160, Both
WGS 170, Cir #1
80 2 5/8 Line Size
Press Drop, F
2 5/8
0.80
2 5/8
0.99
2 5/8
1.32
WGS 170, Cir #2 Line Size 2 5/8 2 5/8 2 5/8
WGS 190, Both 95 2 5/8
Press Drop, F 0.94 1.41 1.88
Recommended Liquid Line Size
Recommended Liquid Line Size, inch O.D.
Up to Up to Up to Up to Up to Unit, Circuit
Nominal
Circuit
Tons
Conn.
Size,
at Unit 50 Equiv.Ft 75 Equiv.Ft 100 Equiv.Ft. 125 Equiv.Ft. 150 Equiv.Ft.
WGS 130, Both Line Size 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8
WGS 140, Cir #1 65 1 3/8
Press Drop, F 0.76 1.14 1.52 1.89 2.27
WGS 140, Cir #2
WGS 160, Both
WGS 170, Cir #1
80 1 3/8 Line Size
Press Drop, F1 3/8
1.11
1 3/8
1.67
1 3/8
2.23
1 3/8
2.78
1 3/8
3.34
WGS 170, Cir #2 Line Size 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8
WGS190, Both 95 1 3/8
Press Drop, F 1.50 2.25 1.33 1.66 1.99
Figure 9, Condenser Above Compressor (One of Two Circuits Shown)
Condenser
Relief Valve
Check Valve (Preferred)
Pressure Tap
Discharge Line
Loop
P i t c h
To Evaporator
Maximum linear line length shall not exceed 75 ft.
Maximum Total Equivalent Length (TEL) shall not exceed 180 ft.
The condenser shall not be located more than 15 ft above the indoor unit.
The condenser shall not be located more than 20 ft below the indoor unit.
IMM 1157 WGS 130A to 190A 21
Factory-Mounted Condenser Units with the standard factory-mounted, water-cooled condensers are provided with complete refrigerant piping and full operating refrigerant charge at the factory.
There is a possibility on water-cooled units utilizing low temperature pond or river water as a condensing medium that if the water valves leak, the condenser and liquid line refrigerant temperature could drop below the equipment room temperature on the “off” cycle. This problem arises only during periods when cold water continues to circulate through the condenser and the unit remains off due to satisfied cooling load.
If this condition occurs:
1. Cycle the condenser pump off with the unit.
2. Check the liquid line solenoid valve for proper operation.
Relief Valve Piping The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-134a) “shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 20 feet (6.1 meters) from any window, ventilation opening or exit in any building.” The piping must be provided with a rain cap at the outside terminating point and with a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. In addition, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s).
The size of the discharge pipe from the pressure relief valve should not be less than the size of the pressure relief outlet. When two or more valves are piped together, the common header and piping to the atmosphere should not be less than the sum of the area of each of the lines connected to the header.
The locations of the unit relief valves are shown on the piping schematic drawing on page 27. There are six valves on the water-cooled units, one for each circuit on the compressor oil separator (54 lb. air/min., 350 psi), suction line (17.3 lb. air/min., 200 psi), and condenser (54 lb. air/min., 350 psi). Remote condenser models have four valves.
NOTE: Provide fittings to permit vent piping to be easily disconnected for inspection or replacement of the relief valve.
Figure 10, Relief Valve Piping
22 WGS 130A to 190A IMM1157
Dimensional Data
WGS-AW Water-Cooled
Figure 11, WGS 130AW through WGS 190AW Packaged Chiller
Without Optional Condenser Water Manifolds
330643201D010BWGS 130-190 Packaged
120.0" (3048.0)RECOMMENDED
CLEARANCE FOR
CONDENSERTUBE
SERVICING
114.8 (2915.9)
31.8(807.7)
169.9 (4315.5)
16.2(411.5)
4.0 IN. (101.6)SCH 40 PIPEVICTAULIC GROOVED.INLET AND OUTLET
WATER IN
WATER OUT
WATER OUT WATER IN
0 .88 (22.4) MOUNTING HOLES TYP. 4
VENT
DRAIN
RELIEF VALVES 1 PER CIRCUIT
RELIEFVALVES(ONE HIDDEN)
RELIEF VALVE
RELIEF VALVE
CIRC. #1 CIRC. #2
34.0(863.6)
“A”
CONTROL PANEL
EVAPORATOR
CONDENSER
FIELD POWERKNOCKOUTS
FIELD CONTROLKNOCKOUTS
20.5(520.7)
29.0(736.6)
8.3(210.8)
13.8(350.5)
LIFTING BRACKETS
REMOVABLE
LIFTING BRACKETS
REMOVABLE
“B”
“C”
“D”
“X”
“Y”
“Z”
11.75 (298.4)
14.75 (374.6)
Notes: 1. Unit water connection handing is oriented facing the control panel. 2. Unit shown with standard right-hand evaporator connections. Left-hand available as option. 3. Condenser connections available only as shown.
Dimensions
Inches (mm)
Evaporator
Victualic
Inches (mm)
Center of Gravity
Inches (mm)
Additions for Sound
Enclosure
Inches (mm)
WGS
Models
“A” “B” “C” “D” “X” “Y” “Z” Length Width Height
WGS 130AW-
140AW
74.6
(1894.8)
29.3
(744.2)
95.0
(2413.0)
6.0
(152.4)
83.9
(2131.1)
35.8
(909.3)
16.8
(426.7)
4.0
(101.6)
2.5
(63.5)
3.0
(76.2)
WGS 160AW-
190AW
76.6
(1945.6)
30.4
(772.2)
92.9
(2359.6)
8.0
(203.2)
84.0
(2133.6)
36.0
(914.4)
16.8
(426.7)
4.0
(101.6)
2.5
(63.5)
5.0
(127.0)
IMM 1157 WGS 130A to 190A 23
WGS-AW, Water-Cooled with Optional Condenser Manifolds
Figure 12 WGS 130AW through 190AW with Optional Condenser Manifolds
330643601D010BWGS 130-190 w/Manifold
114.8 (2915.9)
“C”
31.8(807.7)
“B”
35.0 (889.0)
32.0 (812.8)
“X”
169.9 (4315.5)
16.2(411.5)
4.0 IN. (101.6)SCH 40 PIPEVICTAULIC GROOVED.INLET AND OUTLET
WATER IN
WATER OUT
WATER OUT WATER IN
0 .88 (22.4) MOUNTING HOLES TYP. 4
VENT
DRAIN
RELIEF VALVES 1 PER CIRCUIT
RELIEFVALVES(ONE HIDDEN)
RELIEF VALVE RELIEF VALVE
CIRC. #1 CIRC. #2
“Y”
“Z”
34.0(863.6)
“A”
CONTROL PANEL
EVAPORATOR
CONDENSER
FIELD POWERKNOCKOUTS
FIELD CONTROLKNOCKOUTS
20.5(520.7)
29.0(736.6)0
8.3(210.8)
13.8(350.5)
REMOVABLE LIFTING
BRACKETS
REMOVABLE LIFTING
BRACKETS
“D”
Notes: 1. Unit water connection handing is oriented facing the control panel. 2. Unit shown with standard right-hand evaporator connections. Left-hand available as option. 3. Condenser connections available only as shown.
Dimensions
Inches (mm)
Evaporator
Victualic
Inches (mm)
Center of Gravity
Inches (mm)
Additions for Sound
Enclosure
Inches (mm)
WGS
Models
“A” “B” “C” “D” “X” “Y” “Z” Length Width Height
WGS 130AW-
140AW
74.6
(1894.8)
29.3
(744.2)
95.0
(2413.0)
6.0
(152.4)
83.9
(2131.1)
35.8
(909.3)
16.8
(426.7)
4.0
(101.6)
2.5
(63.5)
3.0
(76.2)
WGS 160AW-
190AW
76.6
(1945.6)
30.4
(772.2)
92.9
(2359.6)
8.0
(203.2)
84.0
(2133.6)
36.0
(914.4)
16.8
(426.7)
4.0
(101.6)
2.5
(63.5)
5.0
(127.0)
24 WGS 130A to 190A IMM1157
WGS-AA Remote Condenser
Figure 13, Dimensions, WGS 130AA through WGS 190AA Remote Condenser
330643401D010BWGS 130-190 Less Condenser
179.3 (4554.2)
“C”
12.0(304.8)
155.3 (3944.6)
6.00 SCH 40 PIPEfor WGS 130-140
8.00 SCH 40 PIPEFOR WGS 160-190
VICTAULIC GROOVEDINLET AND OUTLET
WATER INWATER OUT
18.0(457.2)
“B”
“X”
0 .88 MOUNTINGHOLES 4 PLACES
LIFTING HOLES4 PLACES
CIRC. #2
VENT
DRAIN
RELIEF VALVES(ONE HIDDEN)
RELIEF VALVERELIEF VALVE
“Z”
“Y”
34.0 (863.6)
“A”
CONTROLPANEL
FIELD POWERKNOCKOUTS
FIELD CONTROLKNOCKOUTS
19.3(490.2)
32.0 (812.8)
“F”
“E”“D”
77.8 (1976.1)85.6 (2174.2)
EVAPORATOR
0 2.625" DISCHARGE #2FIELD CONNECTION
0 2.625" DISCHARGE #1FIELD CONNECTION
0 1.375" LIQUID #1FIELD CONNECTION
0 1.375" LIQUID #2FIELD CONNECTION
CIRC. #1
REARVIEW
FRONTVIEW
Notes: 1. Unit water connection handing is oriented facing the control panel. 2. Unit shown has right hand evaporator water connections.
Dimensions Inches (mm)
Center of Gravity Inches (mm)
Additions for Sound Enclosure
Inches (mm) WGS
Models “A” “B” “C” “D” “E” “F” “X” “Y” “Z” Length Width Height
WGS 130-
140AW
60.8 (1544.3)
38.1 (967.7)
95.0 (2413.0)
33.1 (840.7)
26.1 (662.9)
19.7 (500.4)
92.3 (2344.4)
32.3 (820.4)
16.8 (426.7)
4.0 (101.6)
2.5 (63.5)
3.0 (76.2)
WGS 160-
190AW
62.8 (1595.1)
39.6 (1005.8)
92.9 (2359.7)
32.7 (830.6)
25.7 (652.8)
21.7 (551.2)
92.5 (2349.5)
32.5 (825.5)
16.7 (424.2)
4.0 (101.6)
2.5 (63.5)
5.0 (127.0)
IMM 1157 WGS 130A to 190A 25
Physical Data
WGS-AW, Water-Cooled
Table 10, WGS-130AW - WGS-190AW WGS UNIT SIZE 130AW 140AW 160AW 170AW 190AW
Unit capacity @ ARI conditions tons, (kW) (1)
130.0 (457.1) 140.7 (494.7) 156.7 (551.0) 169.6 (596.3) 182.1 (640.3)
No. Circuits 2 2 2 2 2
COMPRESSORS, Frame 3
Nominal Horsepower 65 65 65 80 80 80 80 95 95 95 Number (2) 1 1 1 1 1 1 1 1 1 1 % Minimum Capacity (Modulated) 15 13/17 15 14/16 15 Oil Charge per Compressor oz., (l) 256 (7.6) 256 (7.6) 256 (7.6) 256 (7.6) 256 (7.6)
CONDENSER
Number 2 2 2 2 2 No. Refrigerant Circuits 1 1 1 1 1 Diameter, in., (mm) 12 (305) 12 (305) 12 (305) 12 (305) 12 (305) Tube Length, in., (mm) 120 (3048) 120 (3048) 120 (3048) 120 (3048) 120 (3048)
Design W.P. psig, (kPa): Refrigerant Side 350 (2413) 350 (2413) 350 (2413) 350 (2413) 350 (2413)
Water Side 150 (1034) 150 (1034) 150 (1034) 150 (1034) 150 (1034)
No. of Passes 2 2 2 2 2 Pump-Out Capacity per Circuit, lb., (kg) (3)
330 (150) 330 (150) 330 (150) 296 (134) 296 (134)
Connections: Water In & Out, in, (mm) victaulic 4.0 (101) 4.0 (101) 4.0 (101) 4.0 (101) 4.0 (101) Relief Valve, In., (mm) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) Purge Valve, Flare In., (mm) .625 (15.9) .625 (15.9) .625 (15.9) .625 (15.9) .625 (15.9) Vent & Drain, in. (mm) FPT 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) 0.5 (12.7) Liquid Subcooling Integral Integral Integral Integral Integral
EVAPORATOR
Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons, (l) 68 (257) 68 (257) 115 (435) 115 (435) 115 (435) Refrig. Side D.W.P., psig, (kPa) 354 (2441) 354 (2441) 354 (2441) 354 (2441) 354 (2441) Water Side D.W.P., psig, (kPa) 152 (1048) 152 (1048) 152 (1048) 152 (1048) 152 (1048) Water Connections: Inlet & Outlet, in., (mm) victaulic 6.0 (152) 6.0 (152) 8.0 (203) 8.0 (203) 8.0 (203) Drain & Vent (NPT INT.) 0.5 0.5 0.5 0.5 0.5
UNIT DIMENSIONS (4)
Length In., (mm) 169.9 (4315.5) 169.9 (4315.5) 169.9 (4315.5) 169.9 (4315.5) 169.9 (4315.5) Width In., (mm) 34 (864) 34 (864) 34 (864) 34 (864) 34 (864) Height In., (mm) 74 (1880) 74 (1880) 75.5 (1918) 75.5 (1918) 75.5 (1918)
UNIT WEIGHTS (5)
Operating Weight, lb., (kg) 8557 (3881) 8557 (3881) 9314 (4225) 9505 (4311) 9505 (4311) Shipping Weight, lb., (kg) 7840 (3556) 7840 (3556) 8206 (3722) 8345 (3785) 8345 (3785) Operating Charge per Circuit, R-134a, lb., (kg)
127 (58) 127 (58) 128 (58) 124 (56) 124 (56)
Notes: 1. Certified in accordance with ARI Standard 550/590-98. 2. All units have one compressor per circuit. 3. 80% full R-134a at 90°F (32°C) per refrigerant circuit. 4. Dimensions are without the optional sound enclosure. See dimension drawings for enclosure dimensions. 5. The optional sound enclosure adds 650 lbs (295 kg) to the shipping and operating weights.
26 WGS 130A to 190A IMM1157
WGS-AA Remote Condenser Table 11, WGS-130AA - WGS-190AA
WGS UNIT SIZE 130AA 140AA 160AA 170AA 190AA
Unit capacity @ 44F LWT, 125F SDT, tons, (kW) 116.0 (407.9) 125.9 (442.7) 136.1 (478.5) 148.0 (520.4) 160.1 (562.9)
No. Circuits 2 2 2 2 2
COMPRESSORS, FRAME 3
Nominal Horsepower 65 65 65 80 80 80 80 95 95 95 Number (2) 1 1 1 1 1 1 1 1 1 1 % Minimum Capacity (Modulated) 15 13/17 15 14/16 15 Oil Charge per Compressor oz., (l) 256 (7.6) 256 (7.6) 256 (7.6) 256 (7.6) 256 (7.6)
CONDENSER (Remote)
EVAPORATOR
Number 1 1 1 1 1 No. Refrigerant Circuits 2 2 2 2 2 Water Volume, gallons, (l) 68 (257) 68 (257) 115 (435) 115 (435) 115 (435) Refrig. Side D.W.P., psig, (kPa) 354 (2441) 354 (2441) 354 (2441) 354 (2441) 354 (2441) Water Side D.W.P., psig, (kPa) 152 (1048) 152 (1048) 152 (1048) 152 (1048) 152 (1048) Water Connections: Inlet & Outlet, in., (mm) victaulic 6.0 (152) 6.0 (152) 8.0 (203) 8.0 (203) 8.0 (203) Drain & Vent (NPT INT.) 0.5 0.5 0.5 0.5 0.5
UNIT DIMENSIONS (3)
Length In., (mm) 179.3 (4554.2) 179.3 (4554.2) 179.3 (4554.2) 179.3 (4554.2) 179.3 (4554.2) Width In., (mm) 34 (864) 34 (864) 34 (864) 34 (864) 34 (864) Height In., (mm) 60 (1524) 60 (1524) 61.8 (1570) 61.8 (1570) 61.8 (1570)
UNIT WEIGHTS (4)
Operating Weight, lb., (kg) 6265 (2841) 6265 (2841) 7022 (3185) 7022 (3185) 7022 (3185) Shipping Weight, lb., (kg) 5659 (2567) 5659 (2567) 6024 (2732) 6024 (2732) 6024 (2732) Operating Charge per Circuit, lb., (kg) R-134a
35 (15.9) 35 (15.9) 36 (16.5) 36 (16.5) 36 (16.5)
Notes: 1. Certified in accordance with ARI Standard 550/590-98. 2. Dimensions are without the optional sound enclosure. See dimension drawings for enclosure dimensions. 3. The optional sound enclosure adds 650 lbs (295 kg) to the shipping and operating weights.
IMM 1157 WGS 130A to 190A 27
Unit Configuration
The chiller unit has two refrigerant circuits, each with a single semi-hermetic rotary screw compressor, a shared two-circuited shell-and-tube evaporator, a water-cooled condenser, interconnecting refrigerant piping and refrigerant specialties. A single two-section control panel contains the control and starting equipment.
Figure 14, Schematic Piping Diagram (One of Two Circuits)
DX EVAPORATOR
WATER COOLED CONDENSERWATER OUT
FIELD DISCHARGE CONNECTION.
FIELD LIQUID CONNECTION.
PACKAGE UNIT ONLY
DISCHARGE TUBING
SUCTION TUBING
LIQUIDTUBING
LESS CONDENSER UNIT ONLY
330643901 -C010AWGS REFRIGERANT PIPING
LIQUID SHUT-OFF VALVE
LIQUID FILTER DRYER
WATER OUT WATER IN
PRESSURE RELIEF VALVE CHARGING VALVE
WATER IN
ELECTRONIC EXPANSION
VALVE
LIQUID SIGHT GLASS
SCHRADER VALVE (LESS CONDENSER ONLY)
SUCTION SHUT-OFFVALVE (OPTIONAL)
CHARGING VALVE
PRESSURE RELIEF VALVE
SCHRADER VALVE
SCHRADER VALVE
SCHRADER VALVE
PRESSURE RELIEF VALVE
SCREW COMPRESSOR
DISCHARGE SHUT-OFF AND CHECK VALVE
Components
Table 12, Major Components
Compressor Size Frame 3200
Condenser Size Unit Size
System #1 System #2
Evaporator Size
System #1 System #2
130A Small Small EV40271212 C1210-101 C1210-101
140A Small Medium EV40271212 C1210-101 C1210-101
160A Medium Medium EV50271313 C1210-101 C1210-101
170A Medium Large EV50271313 C1210-121 C1210-121
190A Large Large EV50271313 C1210-121 C1210-121
28 WGS 130A to 190A IMM1157
Wiring
Field Wiring, Power The WGS “A” vintage chillers are built standard with:
Multi-point (2) power supply to a terminal block per circuit with no compressor isolation circuit breakers.
Optional power connections include:
Multi-point power connection to a non-fused disconnect switches with through-the-door handle mounted in the control box in lieu of the power block
Multi-point power connection to high interrupt rated disconnect switches with through-the-door handle
Multi-point power connection to high interrupt disconnect switches with through-the-door handle in a high short circuit current rated panel
Single point power connection to a terminal block with individual compressor isolation circuit breakers per circuit
Single point power connection to high interrupt circuit breakers with through-the-door handles and with individual compressor isolation circuit breakers per circuit
Single point power connection to a high interrupt rated disconnect switch in a high short circuit current rated panel and with individual compressor isolation circuit breakers per circuit.
A factory installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit.
Circuit breakers for backup compressor short circuit protection are standard on all units.
Wiring and conduit selections must comply with the National Electrical Code and/or local requirements.
An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 30) give specific information on recommended wire sizes.
NOTE: Use only copper conductors in main terminal block. Terminations are sized for copper only.
Field Wiring, Control A factory-mounted control transformer is provided to supply the correct control circuit voltage.
The transformer power leads are connected to the power block PB1 or disconnect switch DS1.
Interlock Wiring, Condenser Pump Starter or Air-Cooled Condenser Fan Starter The MicroTech II controller can interlock a condenser pump starter, and tower fans, and control a tower bypass valve on water-cooled units. Up to six air-cooled condenser fan contactors per circuit can be controlled by the MicroTech II unit controller on remote condenser applications. Pressure switches supplied with the condenser can also control condenser fan operation. Coil voltage must be 115 volts with a maximum of 20 VA.
An evaporator and condenser (water-cooled units only) flow switch is necessary on all units. It is also advisable to wire a chilled water pump interlock in series with the flow switch for additional evaporator freeze protection.
IMM 1157 WGS 130A to 190A 29
Ambient Air Sensor Units with a remote air-cooled condenser will have an outdoor air sensor furnished with the unit inside the control panel and wired to the correct terminals. It must be installed outdoors in a location that will give the true outdoor temperature that the condenser coils will see. Splicing of the sensor lead may be required. The sensor must be installed for the unit to operate.
BAS Interface Connection to the chiller for all building automation systems (BAS) protocols is at the unit controller. An optional interface module, depending on the protocol being used, may have been factory-installed in the unit controller (or it can be field installed).
Protocols Supported Table 13, Standard Protocol Data
Protocol Physical Layer Data Rate Controller Other
BACnet/IP or BACnet/Ethernet
Ethernet 10 Base-T 10 Megabits/sec MicroTech II Reference ED 15062
BACnet MSTP RS-485 9600, 19200 or 38400 bits/sec MicroTech II Reference ED 15062
LONWORKS FTT-10A 78kbits/sec MicroTech II Reference ED 15062
Modbus RTU RS-485 or RS-232 9600 or 19200
bits/sec MicroTech II Reference ED 15063
The interface kits on the MicroTech II controller are as follows:
BACnet Kit P/N 350147404: BACnet/IP, BACnet MS/TP, or BACnet Ethernet LONWORKS
Units equipped with a pCo2 (with DIP switches) for CP1 require Kit P/N350147401.
Units equipped with a pCo3 (no DIP switches) for CP1 require Kit P/N 350147409. Modbus: Modbus RTU
Optional Open Choices™ BAS interfaces. The locations and interconnection requirements for the various standard protocols are found in their respective installation manuals.
Modbus IM 743-2 LONWORKS IM 735-2 BACnet IM 736-2
Referenced documents may be obtained from the local Daikin sales office, from the local Daikin Service office, or from the Daikin Technical Response Center, located in Staunton, Virginia (540-248-0711).
These documents can also be found on www.DaikinApplied.com under Product Information > (chiller type) > Control Integration.
The following are trademarks or registered trademarks of their respective companies: BACnet from the American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., LonTalk, LONMARK and LONWORKS from Echelon Corporation, and Modbus and Modbus RTU from Schneider Electric.
Remote Operator Interface Panel The box containing the optional remote interface panel will have installation instructions, IOM MT II Remote, shipped with it. The manual is also available for downloading from www.DaikinApplied.com .
30 WGS 130A to 190A IMM1157
Electrical Data
Table 14, Electrical Data, Water-cooled, Single-Point Connection
POWER SUPPLY FIELD WIRE
FIELD FUSE SIZE or BREAKER SIZE WGS
UNIT SIZE
VOLTS
MINIMUM CIRCUIT
AMPACITY (MCA) QTY
MIN. WIRE GAUGE
RECOM- MENDED
MAXIMUM
208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 243 3 250 300 350 460 201 3 4/0 225 250
130AW
575 162 3 2/0 200 225 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 253 3 250 300 350 460 209 3 4/0 250 300
140AW
575 169 3 2/0 200 225 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 261 3 300 300 350 460 216 3 4/0 250 300
160AW
575 174 3 2/0 200 250 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 276 3 300 350 400 460 228 3 4/0 300 300
170AW
575 182 3 3/0 225 250 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 288 3 350 350 400 460 237 3 250 300 300
190AW
575 189 3 3/0 225 250 Notes 1. Table based on 75°C field wire. 2. Complete notes are on page 40.
IMM 1157 WGS 130A to 190A 31
Table 15, Electrical Data, Water-cooled, Multiple-Point Connection
ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT 2 (COMP 2)
FIELD FUSING FIELD FUSING POWER SUPPLY FIELD WIRE
POWER SUPPLYFIELD WIRE
WGS UNIT SIZE
VOLTS MINIMUM CIRCUIT
AMPS (MCA) QTY
MIN. WIRE GAUGE
REC FUSESIZE
MAX FUSE SIZE
MINIMUMCIRCUIT
AMPS (MCA) QTY
MIN.WIREGAUGE
REC FUSE SIZE
MAX FUSE SIZE
208 247 3 250 300 400 247 3 250 300 400
230 223 3 4/0 300 400 223 3 4/0 300 400
380 135 3 1/0 175 225 135 3 1/0 175 225
460 112 3 2 150 200 112 3 2 150 200
130AW
575 90 3 3 110 150 90 3 3 110 150
208 247 3 250 300 400 267 3 300 350 450
230 223 3 4/0 300 400 240 3 250 300 400
380 135 3 1/0 175 225 145 3 1/0 175 250
460 112 3 2 150 200 120 3 1 150 200
140AW
575 90 3 3 110 150 97 3 3 125 150
208 267 3 300 350 450 267 3 300 350 450
230 240 3 250 300 400 240 3 250 300 400
380 145 3 1/0 175 250 145 3 1/0 175 250
460 120 3 1 150 200 120 3 1 150 200
160AW
575 97 3 3 125 150 97 3 3 125 150
208 267 3 300 350 450 292 3 350 350 500
230 240 3 250 300 400 263 3 300 350 450
380 145 3 1/0 175 250 160 3 2/0 200 250
460 120 3 1 150 200 132 3 1/0 175 225
170AW
575 97 3 3 125 150 105 3 2 150 175
208 292 3 350 350 500 292 3 350 350 500
230 263 3 300 350 450 263 3 300 350 450
380 160 3 2/0 200 250 160 3 2/0 200 250
460 132 3 1/0 175 225 132 3 1/0 175 225
190AW
575 105 3 2 150 175 105 3 2 150 175
NOTES: 1. Table based on 75°C field wire. 2. Complete notes are on page 40. 3. 3/0 wire is required for the disconnect switch option, 2/0 may be used for power block connection.
32 WGS 130A to 190A IMM1157
Table 16, Electrical Data, Remote Condenser, Single-Point Connection POWER SUPPLY
FIELD WIRE FIELD FUSE SIZE or
BREAKER SIZE WGS UNIT SIZE
VOLTS
MINIMUM CIRCUIT
AMPACITY (MCA) QTY
MIN. WIRE GAUGE
RECOM- MENDED
MAXIMUM
208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 n/a n/a n/a n/a n/a 460 252 3 250 MCM 300 350
130AA
575 192 3 3/0 AWG 225 250 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 n/a n/a n/a n/a n/a 460 265 3 300 MCM 300 350
140AA
575 203 3 4/0 AWG 250 250 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 n/a n/a n/a n/a n/a 460 275 3 300 MCM 350 350
160AA
575 212 3 4/0 AWG 250 300 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 n/a n/a n/a n/a n/a 460 299 3 350 MCM 350 400
170AA
575 236 3 250 MCM 300 300 208 n/a n/a n/a n/a n/a 230 n/a n/a n/a n/a n/a 380 n/a n/a n/a n/a n/a 460 318 3 (2) 250 MCM 400 450
190AA
575 255 3 250 MCM 300 350 Notes 1. Table based on 75°C field wire. 2. Complete notes are on page 40.
IMM 1157 WGS 130A to 190A 33
Table 17, Electrical Data, Remote Condenser, Multiple-Point Connection
ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT 2 (COMP 2)
POWER SUPPLY FIELD FUSING POWER SUPPLY FIELD FUSING
FIELD WIRE FIELD WIRE
WGS UNIT SIZE
VOLTS MINIMUM CIRCUIT
AMPS (MCA) QTY
MIN.WIREGAUGE
REC. FUSE SIZE
MAX FUSESIZE
MINIMUMCIRCUIT
AMPS (MCA) QTY
MIN. WIREGAUGE
REC. FUSE SIZE
MAX FUSE SIZE
208 290 3 350 350 500 290 3 350 350 500
230 263 3 300 350 450 263 3 300 350 450
380 160 3 2/0 200 250 160 3 2/0 200 250
460 140 3 1/0 175 250 140 3 1/0 175 250
130AA
575 107 3 2 150 175 107 3 2 150 175
208 290 3 350 350 500 334 3 400 450 600
230 263 3 300 350 450 300 3 350 400 500
380 160 3 2/0 200 250 182 3 3/0 225 300
460 140 3 1/0 175 250 153 3 2/0 200 250
140AA
575 107 3 2 150 175 118 3 1 150 200
208 334 3 2-250 450 600 334 3 2-250 450 600
230 300 3 350 400 500 300 3 350 400 500
380 182 3 3/0 225 300 182 3 3/0 225 300
460 153 3 2/0 200 250 153 3 2/0 200 250
160AA
575 118 3 1 150 200 118 3 1 150 200
208 334 3 2-250 450 600 390 6 2-250 500 700
230 300 3 350 400 500 353 3 2-250 450 600
380 182 3 3/0 225 300 223 3 4/0 300 400
460 153 3 2/0 200 250 177 3 3/0 225 300
170AA
575 118 3 1 150 200 142 3 1/0 175 250
208 390 6 2-250 500 700 390 6 2-250 500 700
230 353 3 2-250 450 600 353 3 2-250 450 600
380 223 3 4/0 300 400 223 3 4/0 300 400
460 177 3 3/0 225 300 177 3 3/0 225 300
190AA
575 142 3 1/0 175 250 142 3 1/0 175 250
NOTES: 1. Table based on 75°C field wire. 2. Complete notes are on page 40. 3. 3/0 wire is required for the disconnect switch option, 2/0 may be used for power block connection.
34 WGS 130A to 190A IMM1157
Table 18, Water-cooled, Compressor Amp Draw
RATED LOAD AMPS WGS UNIT SIZE
VOLTS CIRCUIT #1 CIRCUIT #2
208 197 197 230 178 178 380 108 108 460 89 89
130AW
575 72 72 208 197 213 230 178 192 380 108 116 460 89 96
140AW
575 72 77 208 213 213 230 192 192 380 116 116 460 96 96
160AW
575 77 77 208 213 233 230 192 210 380 116 128 460 96 105
170AW
575 77 84 208 233 233 230 210 210 380 128 128 460 105 105
190AW
575 84 84
Table 19, Remote Condenser, Compressor Amp Draw
RATED LOAD AMPS WGS UNIT SIZE
VOLTSCIRCUIT #1 CIRCUIT #2
208 232 232 230 210 210 380 128 128 460 112 112
130AA
575 85 85 208 232 267 230 210 240 380 128 145 460 112 122
140AA
575 85 94 208 267 267 230 240 240 380 145 145 460 122 122
160AA
575 94 94 208 267 312 230 240 282 380 145 178 460 122 141
170AA
575 94 113 208 312 312 230 282 282 380 178 178 460 141 141
190AA
575 113 113
IMM 1157 WGS 130A to 190A 35
Table 20, Water-cooled, Field Wiring Information with Single-Point Power
WIRING TO STANDARD UNIT POWER BLOCK WIRING TO OPTIONAL NONFUSED
DISCONNECT SWITCH IN UNIT WGS UNIT SIZE
VOLTS TERMINAL SIZE
AMPS
CONNECTOR LUG RANGE PER PHASE
(COPPER WIRE ONLY)
SIZE AMPS
CONNECTOR LUG RANGE PER PHASE
(COPPER WIRE ONLY) 208 n/a n/a n/a n/a 230 n/a n/a n/a n/a 380 400 #6-350 400 3/0-500 460 400 #6-350 250 #6-350
130AW
575 400 #6-350 250 #6-350 208 n/a n/a n/a n/a 230 n/a n/a n/a n/a 380 400 #6-350 400 3/0-500 460 400 #6-350 250 #6-350
140AW
575 400 #6-350 250 #6-350 208 n/a n/a n/a n/a 230 n/a n/a n/a n/a 380 400 #6-350 400 3/0-500 460 400 #6-350 250 #6-350
160AW
575 400 #6-350 250 #6-350 208 n/a n/a n/a n/a 230 n/a n/a n/a n/a 380 400 #6-350 400 3/0-500 460 400 #6-350 250 #6-350
170AW
575 400 #6-350 250 #6-350 208 n/a n/a n/a n/a 230 n/a n/a n/a n/a 380 400 #6-350 400 3/0-500 460 400 #6-350 250 #6-350
190AW
575 400 #6-350 250 #6-350
Table 21, Remote Condenser, Field Wiring Information with Single-Point Power
WIRING TO STANDARD UNIT POWER BLOCK WIRING TO OPTIONAL NONFUSED
DISCONNECT SWITCH IN UNIT WGS UNIT SIZE
VOLTS TERMINAL SIZE
AMPS
CONNECTOR LUG RANGE PER PHASE
(COPPER WIRE ONLY)
SIZE AMPS
CONNECTOR LUG RANGE PER PHASE
(COPPER WIRE ONLY) 208 n/a n/a n/a n/a
230 n/a n/a n/a n/a 380 n/a n/a n/a n/a
460 400 #6-350 400 3/0-500
130AA
575 400 #6-350 250 #6-350
208 n/a n/a n/a n/a
230 n/a n/a n/a n/a 380 n/a n/a n/a n/a
460 400 #6-350 400 3/0-500
140AA
575 400 #6-350 250 #6-350
208 n/a n/a n/a n/a
230 n/a n/a n/a n/a 380 n/a n/a n/a n/a
460 400 #6-350 400 3/0-500
160AA
575 400 #6-350 250 #6-350
208 n/a n/a n/a n/a
230 n/a n/a n/a n/a 380 n/a n/a n/a n/a
460 400 #6-350 400 3/0-500
170AA
575 400 #6-350 250 #6-350
208 n/a n/a n/a n/a
230 n/a n/a n/a n/a 380 n/a n/a n/a n/a
460 400 #6-350 400 3/0-500
190AA
575 400 #6-350 400 3/0-500
36 WGS 130A to 190A IMM1157
Table 22, Water-cooled, Field Wiring to Multiple-Point Power Block WIRING TO UNIT POWER BLOCK
TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER
PHASE (COPPER WIRE ONLY)
WGS UNIT SIZE
VOLTS
CKT 1 CKT 2 CKT 1 CKT 2
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
130AW
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
140AW
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
160AW
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
170AW
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
190AW
460 400 400 #6-350 #6-350 575 400 400 #6-350 #6-350
Table 23, Remote Condenser, Field Wiring to Multiple-Point Power Block WIRING TO UNIT POWER BLOCK
TERMINAL SIZE (AMPS) CONNECTOR WIRE RANGE PER
PHASE (COPPER WIRE ONLY)
WGS UNIT SIZE
VOLTS
CKT 1 CKT 2 CKT 1 CKT 2
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
130AA
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
140AA
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
160AA
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
170AA
575 400 400 #6-350 #6-350
208 400 400 #6-350 #6-350
230 400 400 #6-350 #6-350 380 400 400 #6-350 #6-350
460 400 400 #6-350 #6-350
190AA
575 400 400 #6-350 #6-350
IMM 1157 WGS 130A to 190A 37
Table 24, Water-cooled , Field Wiring to Multiple-Point Disconnect Switc WIRING TO UNIT DISCONNECT SWITCH
TERMINAL SIZE (AMPS)
CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY)
WGS UNIT SIZE
VOLTS
CKT 1 CKT 2 CKT 1 CKT 2
208 250 250 #6-350 #6-350 230 250 250 #6-350 #6-350 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
130AW
575 250 250 #6-350 #6-350 208 250 400 #6-350 3/0-500 230 250 250 #6-350 #6-350 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
140AW
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 250 250 #6-350 #6-350 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
160AW
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 250 400 #6-350 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
170AW
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 400 400 3/0-500 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
190AW
575 250 250 #6-350 #6-350
Table 25, Remote Condenser, Field Wiring to Multiple-Point Disconnect Switch WIRING TO UNIT DISCONNECT SWITCH
TERMINAL SIZE (AMPS)
CONNECTOR WIRE RANGE PER PHASE (COPPER WIRE ONLY)
WGS UNIT SIZE
VOLTS
CKT 1 CKT 2 CKT 1 CKT 2
208 400 400 3/0-500 3/0-500 230 400 400 3/0-500 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
130AA
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 400 400 3/0-500 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
140AA
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 400 400 3/0-500 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
160AA
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 400 400 3/0-500 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
170AA
575 250 250 #6-350 #6-350 208 400 400 3/0-500 3/0-500 230 400 400 3/0-500 3/0-500 380 250 250 #6-350 #6-350 460 250 250 #6-350 #6-350
190AA
575 250 250 #6-350 #6-350
38 WGS 130A to 190A IMM1157
Wiring Diagrams
Figure 15, WGS 130AW – 190AW Field Wiring Diagram
DWG. 330588201 REV. 0B
TO COMPRESSOR(S)
DISCONNECT(BY OTHERS)
3 PHASE
POWER
SUPPLY
GND LUG
UNIT MAINTERMINAL BLOCK
FUSED CONTROLCIRCUIT TRANSFORMER
120 VAC
NOTE: ALL FIELD WIRING TO BEINSTALLED AS NEC CLASS 1WIRING SYSTEM WITH CONDUCTORRATED 600 VOLTS
TB1(115 VAC)
TB1-2
1
82
2EVAP. PUMP RELAY #1
(BY OTHERS)120 VAC 1.0 AMP MAX
N
120 VAC
81
75
24 VAC
ALARM BELL RELAY
FACTORY SUPPLIED ALARMFIELD WIRED
ALARM BELLOPTION
TB1(24 VAC OR 30 VDC)
72
IF REMOTE STOP CONTROLIS USED, REMOVE LEAD 897FROM TERM. 40 TO 53.
89760
66
AUTO
ON
OFF
MANUAL
60
68
AUTO
ON
OFF
MANUAL
REMOTE STOPSWITCH
(BY OTHERS)
ICE MODESWITCH
(BY OTHERS)
TIMECLOCK
71
4-20MA FOREVAP. WATER RESET
(BY OTHERS)
4-20MA FORDEMAND LIMIT(BY OTHERS)
-
-
GND
FU4 FU5
FU7
CHWR
ABR
85
2EVAP. PUMP RELAY #2
(BY OTHERS)120 VAC 1.0 AMP MAX
N
120 VACCHWR
86
2COND. PUMP RELAY #1
(BY OTHERS)120 VAC 1.0 AMP MAX
N
120 VAC
CWR
87
2N
120 VAC
CWR
88
2TOWER FAN #1(BY OTHERS)
120 VAC 1.0 AMP MAX
N120 VAC
M11
89
2N
120 VACM12
78
77N
80
79
0-10VDC
COND. PUMP RELAY #2(BY OTHERS)
120 VAC 1.0 AMP MAX
TOWER FAN #2(BY OTHERS)
120 VAC 1.0 AMP MAX
(BY OTHERS)
60
76
NOR. OPEN PUMP AUX.CONTACTS (OPTIONAL)
COND. FLOWSWITCH
(BY OTHERS)
60
67
NOR. OPEN PUMP AUX.CONTACTS (OPTIONAL)
EVAP. FLOWSWITCH
(BY OTHERS)
70
70
COOLING TOWER BYPASS(BY OTHERS)
N
0-10VDC
+
+
2
ALARM BELLRELAY
ALARM BELL OPTION
BELL
1 2
COM NO
*MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED
*MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED
IMM 1157 WGS 130A to 190A 39
Figure 16, WGS 130AA – 190AA Field Wiring Diagram (Remote Condenser)
DWG. 330588101 REV. 0C
TO COMPRESSOR(S)
DISCONNECT(BY OTHERS)
3 PHASE
POWER
SUPPLY
GND LUG
UNIT MAINTERMINAL BLOCK
FUSED CONTROLCIRCUIT TRANSFORMER
120 VACNOTE: ALL FIELD WIRING TO BEINSTALLED AS NEC CLASS 1WIRING SYSTEM WITH CONDUCTORRATED 600 VOLTS
TB1(115 VAC)
TB1-2
1
82
2EVAP. PUMP RELAY #1
(BY OTHERS)120 VAC 1.0 AMP MAX
N
120 VAC
81
75
24 VAC
TB1(24 VAC)
72
IF REMOTE STOP CONTROLIS USED, REMOVE LEAD 897FROM TERM. 40 TO 53.
89760
66
AUTO
ON
OFF
MANUAL
60
68
AUTO
ON
OFF
MANUAL
REMOTE STOPSWITCH
(BY OTHERS)
ICE MODESWITCH
(BY OTHERS)
TIMECLOCK
71
4-20MA FOREVAP. WATER RESET
(BY OTHERS)
4-20MA FORDEMAND LIMIT(BY OTHERS)
-
-
GND
FU4 FU5
FU7
CHWR
85
2EVAP. PUMP RELAY #2
(BY OTHERS)120 VAC 1.0 AMP MAX
N
120 VACCHWR
60
67
NOR. OPEN PUMP AUX.CONTACTS (OPTIONAL)
EVAP. FLOWSWITCH
(BY OTHERS)
70
70
+
+
ALARM BELL RELAY
FACTORY SUPPLIED ALARMFIELD WIRED
ALARM BELLOPTION ABR
NO1
2N
120 VAC
NO2
2N
120 VAC
NO3
2N
120 VAC
NO4
2N
120 VAC
M14
NO5
2N
NO6
2N
M11
M12
M13
120 VAC
120 VAC
M15
M16
(LOCATED ONCIRCUIT
CONTROLLER)
J13
C
C
CIRCUIT #1
J12
(LOCATED ONCIRCUIT
CONTROLLER)
CONDENSER FANCONTACTOR COIL #1
CONDENSER FANCONTACTOR COIL #2
CONDENSER FANCONTACTOR COIL #3
CONDENSER FANCONTACTOR COIL #4
CONDENSER FANCONTACTOR COIL #5
CONDENSER FANCONTACTOR COIL #6
TB692
98144
145
146
14598
93
148
14598
94
150
14598
95
152
14598
96
154
14598
97
NO1
2N
120 VAC
NO2
2N
120 VAC
NO3
2N
120 VAC
NO4
2N
120 VAC
M24
NO5
2N
NO6
2N
M21
M22
M23
120 VAC
120 VAC
M25
M26
(LOCATED ONCIRCUIT
CONTROLLER)
J13
C
C
CIRCUIT #2
J12
(LOCATED ONCIRCUIT
CONTROLLER)
CONDENSER FANCONTACTOR COIL #1
CONDENSER FANCONTACTOR COIL #2
CONDENSER FANCONTACTOR COIL #3
CONDENSER FANCONTACTOR COIL #4
CONDENSER FANCONTACTOR COIL #5
CONDENSER FANCONTACTOR COIL #6
TB792
98244
245
246
24598
93
248
24598
94
250
24598
95
252
24598
96
254
24598
97
2
ALARM BELLRELAY
ALARM BELL OPTION
BELL
1 2
COM NO
*MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED.
See notes on page 40.
40 WGS 130A to 190A IMM1157
Notes for “Electrical Data Single/Multiple Point” Power: 1. Wire sizing amps is 10 amps if a separate 115V power supply is used.
2. Unit wire size ampacity is equal to 125% of the largest compressor motor, plus 100% ofthe RLA of all other loads in the circuit, including the control transformer.
3. Recommended power lead wire sizes for 3 conductors per conduit are based on 100%conductor ampacity in accordance with NEC. Voltage drop has not been included.Therefore, power leads should be kept short. All terminal block connections must bemade with copper (type THW) wire.
4. The recommended power lead wire sizes are based on an ambient temperature of 86°F(30°C). Ampacity correction factors must be applied for other ambient temperatures.Refer to the National Electrical Code Handbook.
5. The recommended fuse size or HACR circuit breaker size is equal to 150% of thelargest compressor motor RLA plus 100% of the remaining compressor RLA.
6. The maximum fuse size or HACR circuit breaker size is equal to 225% of the largestcompressor motor RLA plus 100% of the remaining compressor RLA.
7. Must be electrically grounded according to national and local electrical codes.
Power Limitations: 1. Voltage within 10 percent of nameplate rating.
2. Voltage unbalance not to exceed 2% with a resultant current unbalance of 6 to 10 timesthe voltage unbalance per NEMA MG-1, 1998 Standard. This is an importantrequirement and must be adhered to.
Notes for “Electrical Data” 1. Requires a disconnect switch per circuit to supply electrical power to the unit. If field
supplied, this power supply must either be fused or use an HACR type circuit breaker.
2. Use copper wiring to unit power block or optional non-fused disconnect switch.
3. All field wire size values given in table apply to 75°C rated wire per NEC.
Notes for Wiring Diagram Remote Condenser Units On remote condenser units, head pressure control by cycling fans can be accomplished several ways. The MicroTech II controller in the unit can be used. It senses discharge pressure and will stage up to 6 condenser fans when wired in accordance with Figure 16 on page 39. If the condenser has more than 6 fans, 2 can be operated on a step. For example, a condenser with 10 fans would have 2 fans on steps #1 through #4 and one fan each on steps #5 and #6. Condensers with less than 6 fans would use the appropriate MicroTech II steps beginning with #1.
Wire so that the first-on, last-off fan stage has one fan on it.
The Daikin ACD condensers have unit-mounted and wired single fan motor VFD combined with fan cycling by pressure switches for the balance of the fans available as an option. They can be used for staging fans instead of the WGS MicroTech II controller.
See Ambient Air Sensor note on page 29.
Circuit Breakers The circuit breaker used in the High Short Circuit panel option may have a higher trip rating than the unit Maximum Overload Protection (MOP) value shown on the unit nameplate. The circuit breaker is installed as a service disconnect switch and does not function as branch circuit protection, mainly that the protection device must be installed at the point of origin of the power wiring. The breaker (disconnect switch) is oversized to avoid nuisance trips at high ambient temperature conditions.
IMM 1157 WGS 130A to 190A 41
Figure 17, Schematic Diagram Legend
Designation Description Standard
Location Designation Description
Standard
Location
ABR Alarm Bell Relay Field Mounted M12 Tower Fan 1 Field Mounted
BB Bias Block Outer Panel PB1 / 2 Power Block Inner Panel
CB1 / 2 Circuit Breaker Inner Panel REC 115V Outlet (Optional) Outer Panel
CB11 / 211 Circuit Controller
Output Breaker Output Panel RS1 Remote Stop Switch Field Mounted
CB12 / 22 Circuit Controller
Compr. Heater Output Panel S1 System Shut-Off Switch Outer Panel
CHW1 Chilled Water Flow
Switch Field Mounted S01 Suction Pressure Compressor
CHWR Chilled Water Relay Field Mounted S02 Discharge Pressure Compressor
CWR Cond. Water Relay Field Mounted S03 Liquid Pressure Liquid Line
CWI Cond. Water Flow
Switch Field Mounted S04 Suction Temperature Compressor
Cir. Contr. 1 /
2 Circuit Controller Outer Panel S05 Discharge Temperature Compressor
Compr 1 / 2 Compressors Behind Control
Box S06 Liquid Temperature Liquid Line
DS ½ Disconnect Switch Inner Panel S07 Outside Ambient
Temperature
Behind Control
Box
FU4 T1 Primary Fuse Inner Panel S08 Leaving Water Sensor Leaving Water
Nozzle
FU5 T1 Primary Fuse Inner Panel S09 Entering Water
Temperature
Entering Water
Nozzle
FU6 T1 Secondary Fuse Inner Panel S10 Demand Limit Reset Field Mounted
FU7 T1 Secondary Fuse Inner Panel S11 Leaving Water Reset Field Mounted
F3 115v Outlet Fuse
(Optional)
Cir. #2 Outer
Panel CS Circuit System Switch Outer Panel
GRD Ground Inner Panel Load/Unload Load/Unload Solenoid Compressor
Htr-Compr Compressor Heater Compressor T1 Control Transformer Inner Panel
MHP High Pressure Switch Compressor T2 Unit Contr. 24V
Transformer Outer Panel
MHPR Mechanical High
Pressure Relay Outer Panel T13 / T23
Circuit Contr. 24V
Transformer Outer Panel
MS1 Mode Switch Field Mounted T14 / T24 Comp. Load/Unload 24V
Transformer Outer Panel
SSS ½ Comp. Solid State
Starter Inner Panel T15 / T25
EXV Driver 24V
Transformer Outer Panel
MJ Mechanical Jumper Control Box TB1 – TB2 Terminal Blocks Outer Panel
M11 Tower Fan 2 Field Mounted WJ Wire Jumper Control Box
42 WGS 130A to 190A IMM1157
Figure 18, WGS 130 - 190, Circuit Controller Schematic Wiring Diagram
IDC1
1
1
3
3
(SEE LINE 693)TO T15
J1
J2
122
121
MJ
J3
EVAP PRESS TRANSDUCER (S01)
CONDENSER PRESS TRANSDUCER (S02)
SHIELD
40
40
CIRCUIT SWITCH
J5
ID1
ID2
ID3
ID4
ID5
ID6
ID7
ID8
128CS
127
DIG
ITA
L O
UT
PU
TS
A+
GND
B-J11
J12
C1
NO1
NO2
NO3
C1
J13
C4
NO4
NO5
NO6
C4
WJ
123
J14
C7
C7
NO8
C8
NC8
J15
NO7
GOG
B4BC4
B5BC5
COMPRESSORSSS CONTACT
J4
J6
B6
B7
B8
GND
J3
J5
J4
J2
J1RED
WHTBLK
REDWHTBLK
0-5 VDC
0-5 VDC
MJ
20120
T13120V
24V
114 113
137
138
BLKRED
25
26DC GROUND
21 VDC1
2
SLIDE LOADINDICATOR
SUCTION TEMP. (S04)
DISCHARGE TEMP. (S05)BLKRED
VG
VGD
Y3
Y4
Y1
Y2
124
125
126EXV DRIVER(SEE DETAIL 1)
ID9
ID10
ID11
ID12
IDC9
J7
129
131
21WHT
DPS
C 1
BLKDIFFERENTIAL PRESSURE SWITCH
GRNPE
130MECHANICAL HIGH PRESSURE FAULT
132
133
134
244-20MA3
SLIDE LOAD
INDICATOR
135
136
3
1
OLS220
GREENPE
J16
C9
NO9
NO10
NO11
C9
J17
NO12
NC12
NO13
C13
NC13
J18
C12
PE
120
OHMS
MJ
116
1
5
2
6
ID13H
ID13
IDC13
ID14
ID14H
J8
(LOWER LEVEL)
CONTROLLER
40
882
883
BIAS 5
BIAS 6
BLKCONDENSER LEAVING WATER TEMP. (S12)
RED
NOTES: 1) * - REPRESENTS CIRCUIT
2) ONE HUNDRED SERIES FOR CIRCUIT #13) TWO HUNDRED SERIES FOR CIRCUIT #2
MJ
22
139 (SEE LINE 687)
OIL SEP. HEATER
0-10VDC
MHPR
2 4
GND
A+
B-
D3 SA-
SB+
SCOM
SHLD
165
TB1-7
164STARTER FAULT
TB1-6
FLT
BLACK
WHITE
GREEN
DETAIL 2 - THERMISTOR CARD
1 2
MOTORGUARDISTOR
J3-1
170 171J3-2
LP*
REMOTE EVAP. ONLY.
IN SERIES WITH 170
188
IMM 1157 WGS 130A to 190A 43
Schematic Wiring Diagram (Continued)
-601
-602
-603
-604
-605
-606
-607
-608
-609
-610
-611
-612
-613
-614
-615
-616
-617
-618
-619
-620
-621
-622
-623
-624
-625
-626
-627
-628
-629
-630
-631
-632
-633
-634
-635
-636
-637
-638
-639
-640
-641
-642
-643
-644
-645
-646
-647
-648
-649
-650-651
-652
-653
-654
-655
-656
-657
-658
-659
-660
-661
-662
-663
-664
-665
-666
-667
-668
-669
-670
-671
-672
-673
-674
-675
-676
-677
-678
-679
-680
-681
-682
-683
-684
-685
-686
-687
-688
-689
-690
-691
-692
-693
-694
-695
-696
-697
-698
-699
-700
TB1
1
1
2
2
3
4
20
20
21
22
24
25
TERMINAL BLOCKAND LEAD NUMBERS
LINENO.
BLACK
WHITE
GROUND
(p LAN) TO OTHER CIRCUIT CONTROLLERS AND UNIT CONTROLLER
(RESISTOR USED ONLY AT END OF DAISY CHAIN)
1
184
3
105T1
115V
103 NB2
180
CB11
18141
MHPR
0 1
1831 2
MHP
SSS RUN
187
162
1601
5
2
6
T14
120V
24V
161
163
(SEE LINE 690)
1
21
2
GRNPE
LOAD SOLENOID
1
21
GRNPE
2 50
UNLOAD SOLENOID
SV
SV
SCHEM. 330588401 REV. 0B
191
185
PUMPDOWN
DETAIL 1EXV
DRIVER
ANALOG OUTPUT J4-Y3 126
TB1-40 139
+
-PID
GREEN
WHITE
RED
BLACK
+
-
195
196117TO: TB1-2
116TO: TB1-1T15120V
1 5
2 6
24V AC
24V AC
EXV
MOTOR
1
HEATER
2
HTR-OIL SEP.
PUMPDOWN
(TERMINATE AT EACH CONTROLLER)
182
K1
102 101
26
40
40
50
105, 114, 116, 160
180
101, 113, 117,183
177
161, 187
181, MHP-1
182, 184, MHP-2
122, 124
127, BLK, 130, 2-OIL
WHT, 129
3-OIL, 135
1-SLIDE, 137
2-SLIDE, 138
123, 125
40 132, 134, RED
RED, 1-OIL, 136, 139
3-SLIDE, 133
163, 2-LOAD, 2-UNLOAD, 190
27
28
186
192
27
28
172, 1-LOAD
173, 1-UNLOADMJ
185
172
173
PE
PE
PE
PE
GRN - OIL
GRN - DPS
GRN - LOAD
GRN - UNLOAD
197
117(SEE LINE 694)
175
CB12
176
150
152
154
M*1
M*2
M*3
144
146
148
M*4
M*5
M*6REMOTE COND.
2
9892
93
94
95
96
97
92
93
95
94
91
96 152
150
148
146
144
171
30177
FU7
2 1
30 176, 177
90 170
97 154
INT
SV50
19018949
49 188, 189
44 WGS 130A to 190A IMM1157
Figure 19, WGS 130 - 190, Unit Controller Schematic Wiring Diagram
J15
J14
J11
J1
J2
812
801
MJ
J3
BLKRED
804
OUTSIDE AIR TEMP or COND. ENTERING WATER TEMP. (S07)
EVAP. LEAVING WATER TEMP (S08)
EVAP. ENTERING WATER TEMP (S09)
BLK
RED
BLK
RED
75
4-20MADEMAND LIMIT (S10)
UNIT SWITCH
J4
J5
ID1
ID2
ID3
ID4
ID5
ID6
ID7
ID8
808
809
810
811
807
897
RS1
REMOTE SWITCH
EVAP. FLOW SWITCHCHWI
MODE SWITCH
DIG
ITA
L O
UT
PU
TS
CONTROLLER
A+
GND
B-
813
J12
C1
NO1
NO2
NO3
C1
J13
C4
NO4
NO5
NO6
C4
802
C7
C7
NO8
C8
NC8
NO7
GO
G
B1
B2
B3
GND
+VDC
B4
BC4
B5
BC5
EVAP. WATER TEMP. RESET (S11)
PE
4-20MA
SHIELDPE
SHIELDPE
815CWI
COND. FLOW SWITCH
NOTE: J2-B1 OUTSIDE AIR TEMP. IS FOR TGS UNITS ONLY AND CONDENSER ENTERING WATER TEMP. IS FOR WGS UNITS ONLY.
Y4
Y3
Y2
Y1
VG0
VG
S1
884
885
COOLING TOWER BYPASS
COOLING TOWER VFD
887
889
(0-10VDC)
(0-10VDC)
886
888
MJ71
72
70
70
73
77
79
78
80
805806
814
60
60
67
66
68
76
MS1
60
60
67
76
BLU
BLU
WHT
WHT
BRN
BRN
75
75
IDC1800
FACTORY
INSTALLED
FLOW
SWITCHES
IMM 1157 WGS 130A to 190A 45
WGS 130 - 190, Unit Controller Schematic Wiring Diagram (Continued)
-301
-302
-303
-304
-305
-306
-307
-308
-309
-310
-311
-312
-313
-314
-315
-316
-317
-318
-319
-320
-321
-322
-323
-324
-325
-326
-327
-328
-329
-330
-331
-332
-333
-334
-335
-336
-337
-338
-339
-340
-341
-342
-343
-344
-345
-346
-347
-348
-349
-350
-351
-352
-353
-354
-355
-356
-357
-358
-359
-360
-361
-362
-363
-364
-365
BLACK
WHITE
GROUND
(p LAN) TO CIRCUIT CONTROL BOXES
(TERMINATE AT EACH CONTROLLER)
LOAD 2LOAD 1
LINE 21
5
2
624V
T2
120V821LINE 1820
1
822
829
823
824
SEE LINE 301
120V
120V
WJ
LINENO.
CONTACTLOCATION
TERMINAL BLOCKAND LEAD NUMBERS
85
82
81
1
UNIT ALARM
EVAPORATOR PUMP 1
EVAPORATOR PUMP 2
COND. PUMP 1
83060
2
SEE LINE 307
SEE
LINE 306
G
-
+
5
BIAS
BLOCK
880
881
882
883
TO UNIT CONTROLLER B-
TO UNIT CONTROLLER A+
TO CIRCUIT CONTROLLER J4
TO CIRCUIT CONTROLLER J4
86825
120VCWR
COND. PUMP 2 87826
120VCWR
TOWER FAN 1 88827
120VM11
TOWER FAN 2 89828
120VM12
CHWR
CHWR
ABR
SCHEM. 330588301 REV. 0B
TB1
NOTE:
TB1-75 THRU
TB1-89 ARE
FIELD
WIRING
TERMINALS.
820, 822, 8901
2
60
60
60
75
75
75
821, 891
801, 807, 884
800, 885
802, 886
813, 888
897, 830
812
2
2
2
75
897, 809
810
811
806
804
805
814
815
886
887
888
889
829
823
824
825
826
827
828
66
67
68
70
71
72
73
76
77
78
79
80
81
82
85
86
87
88
89
60
60
75
70
2
G
WB
115V OUTLET
890FU12
1 2
891PE
REC
MJ
MJ
83
84
46 WGS 130A to 190A IMM1157
Control Panel Layout
Figure 20, Outer (Microprocessor) Panel
NOTES: 1. Transformers T2 through T25 are class 100, 120V to 12V. 2. Switches for MHPR 11 and 12 (Mechanical High Pressure Switches) are located on the compressors. 3. Mechanical High Pressure Switches Open at 310 psi, Close at 250 psi
T2, Unit Controller
T13, Circ#1 Controller
T14, Circ#1 Load Solenoid
T15, Circ#1 EXV Power
T25, Circ#2 EXV Power
T24, Circ#2 Load Solenoid
T23, Circ#2 Controller
Unit Controller
MHPR11 &12, Mechanical High Pressure Relay
Circ#1 Controller
Circuit Breaker & Switch Panel
Circ#1 & 2 EXV Drivers
External Disconnect Handle
Circ#2 Controller
TB3, Circ#2 Controller Terminal Board
TB2Circ#1 Controller Terminal Board
TB1 Unit Controller Terminal Board
IMM 1157 WGS 130A to 190A 47
Figure 21, Inner (Power) Panel
Circ#1 Solid State Starter
Circ#2 Solid State Starter
SSS1 Bypass Contactor
SSS2 Bypass Contactor
Secondary Fuses
Circ#1 Circuit Breaker
Circ#2 Circuit Breaker
Unit Disconnect Switch W/ External Handle
External Disconnect Handle
T1, Supply Voltage to 120V Transformer
Primary Fuses
Outside (Microprocessor) Panel
48 WGS 130A to 190A IMM1157
Figure 22, Circuit Breaker/Fuse Panel
Figure 23, Inner and Outer Panel Diagrams
CB11
CB22
FU7
UNITCONTROLLER
CIRCUIT CONTROLLER#1
TB1
EXV.DRIVER
#2
CONVERTER BOARD
T13T2 T14 T15 T23 T24 T25
CIRCUIT CONTROLLER#2
MODBUS CARD
EXV.DRIVER
#1
S1
SP
CS1CS2
CB12
SP
CB21
SP
F3
TB11 TB21
OUTER PANEL INNER PANEL
SSS #1 SSS #2
BYPASSCONTACTOR
D3CONTR.
BRD.
THERM-ISTORCARD
CT3
CT2
CT1
BYPASSCONTACTOR
D3CONTR.
BRD.
THERM-ISTORCARD
CT3
CT2
CT1
FU6
T1
CB1
CB2
DS1 GND
FU4
FU5
SINGLEPOINT
OR
CIR. #1
DSHANDLE
(MULTI-
POINT)
CIR. #2
DSHANDLE
(MULTI-
POINT)
MHPR1
MHPR2
RECOPTION
(DS1 DS2MULTIPOINT
POWER)
330589001 REV. 00 - Legend
S1 Main Unit On-Off Switch
Open Location
CS1, Circuit#1 On-Off Switch
CS2, Circuit#2 On-Off Switch
CB11 Circ#1 Circuit Breaker
CB12, Circ#1 Sump Heater
Open Location
CB21, Circ#2 Circuit
CB22, Circ#2 Sump Heater
Open Locations
Location for Optional 115V Receptacle
IMM 1157 WGS 130A to 190A 49
Sequence of Operation Compressor Heaters With the control power on, 120V power is applied through the control circuit Fuse FU7 to the compressor oil separator heater(HTR-OIL SEP).
Startup/Compressor Staging During cool mode the following must be true to start a circuit operating. The evaporator and condenser pump outputs must be energized and flow must be established for a period of time defined by the evaporator recirculate setpoint. Established flow will be detected by evaporator and condenser water flow switches. The water temperature leaving the evaporator must be greater than the Active Leaving Water Temperature setpoint, plus the Startup Delta-T, before a circuit will start. The first circuit to start is determined by sequence number. The lowest sequence numbered circuit will start first. If all sequence numbers are the same (default), then the circuit with the fewest number of starts will start first. During operation the slides for load and unload will be pulsed such that the active leaving water temperature setpoint is maintained. The second circuit start will occur once the first circuit has loaded to 75% slide capacity or is in Capacity Limit and the water temperature leaving the evaporator is greater than the active leaving water temperature Setpoint plus Stage Delta-T. The circuits will load or unload simultaneously through a continuous capacity control to maintain the evaporator leaving water temperature. If all sequence numbers are the same, the circuit with the most run hours will be shutdown first. The circuit with the most run hours will stop when the water temperature leaving the evaporator is less than the Active Leaving Water Temperature Setpoint minus Stage Delta-T. The last remaining circuit will shutdown when the water temperature leaving the evaporator is greater than the Active Leaving Water Temperature Setpoint minus the Stop Delta-T.
Automatic Pumpdown The WGS has separate refrigerant circuits so the refrigerant charge is stored in the condenser when the circuit is off. Pumpdown to the condenser helps keep refrigerant from migrating to the compressor. It also helps establish a pressure differential on start for oil flow. In a normal shutdown, each circuit will close its expansion valve, causing the evaporator pressure to reach a low-pressure setpoint. Once this setpoint is reached, or a specified amount of time has elapsed, the running circuit will be shut down.
Chilled Water and Condenser Water Pumps The chiller’s MicroTech II controller has a total of four pump outputs, two for the evaporator and two for the condenser. There is a manual setting in the software for the user to select either pump output 1 or 2. It is recommended that the chiller’s outputs control the water pumps, as this will offer the most protection for the unit.
Cooling Tower Control The MicroTech II controller can control the cooling tower fans and/or a tower bypass valve. This provides a simple and direct method to control the unit’s discharge pressure. Programming directions and the sequence of operation can be found in the MicroTech II manual. Some means of discharge pressure control must be installed if the condenser water temperature can fall below the values shown on page Error! Bookmark not defined..
Condenser Fan Control The MicroTech II controller can be programmed to cycle on and off condenser fans based on the discharge pressure. Details are in the MicroTech II manual.
50 WGS 130A to 190A IMM1157
Start-Up and Shutdown
Pre Start-up 1. Flush and clean the chilled-water system. Proper water treatment is required to prevent
corrosion and organic growth.
2. With the main disconnect open, check all electrical connections in control panel andstarter to be sure they are tight and provide good electrical contact. Althoughconnections are tightened at the factory, they can loosen enough in shipment to cause amalfunction.
3. Check and inspect all water piping. Make sure flow direction is correct and piping ismade to correct connection on evaporator and condenser.
4. Open all water flow valves to the condenser and evaporator.
5. Flush the cooling tower and system piping to be sure the system is clean. Startevaporator pump and manually start condenser pump and cooling tower. Check allpiping for leaks. Vent the air from the evaporator and condenser water circuit, as well asfrom the entire water system. The cooler circuit should contain clean, treated, non-corrosive water.
6. Check to see that the evaporator water temperature sensor is securely installed.
7. Make sure the unit control switch S1 is open (off) and the circuit switches CS1 and CS2are open. Place the main power disconnect switch to “on.” This will energize thecompressor sump heaters. Wait a minimum of 12 hours before starting the unit.
8. Measure the water pressure drop across the evaporator and condenser, and check thatwater flow is correct (on pages 16 and 17) per the design flow rates.
9. Check the actual line voltage to the unit to make sure it is the same as called for on thecompressor nameplate, within + 10%, and that phase voltage unbalance does not exceed2%. Verify that adequate power supply and capacity is available to handle load.
10. Make sure all wiring and fuses are of the proper size. Also make sure that all interlock wiring is completed per Daikin diagrams.
11. Verify that all mechanical and electrical inspections by code authorities have beencompleted.
12. Make sure all auxiliary load and control equipment is operative and that an adequatecooling load is available for initial start-up.
Start-up 1. Open the compressor discharge shutoff valves until backseated. Always replace valve
seal caps.
2. Open the two manual liquid line shutoff valves (king valves).
3. Verify that the compressor sump heaters have operated for at least 12 hours prior tostart-up. Crankcase should be warm to the touch.
4. Check that the MicroTech II controller is set to the desired chilled water temperature.
5. Start the system auxiliary equipment for the installation by turning on the time clock,ambient thermostat and/or remote on/off switch and water pumps.
6. Switch on the unit circuit breakers.
7. Set circuit switches CS1 and CS2 to ON for normal operation.
8. Start the system by setting the unit system switch S1 to ON.
9. After running the unit for a short time, check the oil level in each compressor, rotationof condenser fans (if any), and check for flashing in the refrigerant sight glass.
IMM 1157 WGS 130A to 190A 51
Weekend or Temporary Shutdown Move circuit switches CS1 and CS2 to the off pumpdown position. After the compressors have shut off, turn off the chilled water pump if not on automatic control from the chiller controller or building automation system (BAS). With the unit in this condition, it will not restart until these switches are turned back on.
Power to the unit (disconnect closed) so that the sump heaters will remain energized.
Start-up after Temporary Shutdown 1. Start the water pumps. 2. Check compressor sump heaters. Compressors should be warm to the touch. 3. With the unit switch S1 in the “ON” position, move the circuit switches CS1 and CS2 to
the ON position. 4. Observe the unit operation for a short time, noting unusual sounds or possible cycling of
compressors.
Extended Shutdown 1. Close the manual liquid line shutoff valves. 2. After the compressors have shut down, turn off the water pumps. 3. Turn off all power to the unit. 4. Move the unit control switch S1 to the “OFF” position. 5. Close the discharge shutoff valves. 6. Tag all opened disconnect switches to warn against start-up before opening the
compressor suction and discharge valves. 7. Drain all water from the unit evaporator, condenser and chilled water piping if the unit
is to be shut down during the winter and exposed to below-freezing temperatures. Do not leave the vessels or piping open to the atmosphere over the shutdown period to help prevent excessive corrosion.
Start-up after Extended Shutdown 1. Inspect all equipment to see that it is in satisfactory operating condition. 2. Remove all debris that has collected on the surface of the condenser coils (remote
condenser models) or check the cooling tower, if present. 3. Open the compressor discharge valves until backseated. Always replace valve seal caps. 4. Open the manual liquid line shutoff valves. 5. Check circuit breakers. They must be in the “OFF” position. 6. Check to see that the circuit switches CS1 and CS2 and the unit control switch S1 are in
the “OFF” position. 7. Close the main power disconnect switch. The circuit disconnects switches should be off. 8. Allow the sump heaters to operate for at least 12 hours prior to start-up. 9. Start the chilled water pump and purge the water piping as well as the evaporator in the
unit. 10. Start the system auxiliary equipment for the installation by turning on the time clock,
ambient thermostat and/or remote on/off switch. 11. Check that the MicroTech II controller is set to the desired chilled water temperature. 12. Switch the unit circuit breakers to “ON.” 13. Start the system by setting the system switch S1 and the circuit switches to “ON”.
! CAUTION
52 WGS 130A to 190A IMM1157
Most relays and terminals in the control center are powered when S1 is closed and the control circuit disconnect is on. Therefore, do not close S1 until ready for start-up or serious equipment damage can occur.
14. After running the unit for a short time, check the oil level in the compressor oil sight
glass and check the liquid line sight glass for bubbles.
System Maintenance
General To provide smooth operation at peak capacity and to avoid damage to package components, set and follow a program of periodic inspections. The following items are intended as a guide to be used during inspection and must be combined with sound refrigeration and electrical practices to help provide trouble-free performance.
The liquid line sight glass/moisture indicator on all circuits must be checked to be sure that the glass is full and clear and that the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed.
Water supplies in some areas can foul the water-cooled condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high condenser approach temperature (saturated discharge temperature minus leaving condenser water temperature) and can result in nuisance trip-outs. To clean the condenser, mechanical cleaning or a chemical descaling solution should be used according to the manufacturer’s directions.
Systems with remote air-cooled condensers require periodic cleaning of the finned surface of the condenser coil. Cleaning can be accomplished by using a cold water spray, brushing, vacuuming, or high-pressure air. Do not use tools that could damage the coil tubes or fins.
The compressor oil level must be checked periodically to be sure that the level is near the center of the oil sight glass located on the compressor (see Figure 24). Low oil level can cause inadequate lubrication and if oil must be added, use oils referred to in the following “Compressor Lubrication” section.
A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid valve but before the expansion valve. An accurate subcooled liquid pressure and temperature can be taken here. The pressure read here could also provide an indication of excessive pressure drop through the filter-drier and solenoid valve due to a clogging filter-drier. Note: A normal pressure drop through the solenoid valve is approximately 3 psig (20.7 kPa) at full load conditions.
! CAUTION
A blown fuse or tripped protector indicates a short ground or overload. Correct the problem before replacing fuses or restarting compressor. The control panel must be serviced by a trained and qualified technician. Improper service can damage equipment.
IMM 1157 WGS 130A to 190A 53
! CAUTION
The panel is always energized, even when the system switch is off. Pull the main unit disconnect to de-energize the panel and crankcase heaters. Failure to do so can result in severe personal injury or death. If motor or compressor damage is suspected, do not restart until qualified service personnel have checked the unit.
Electrical Terminals ! DANGER
To avoid severe injury or death from electric shock, turn off all power and lockout and tag-out electric source before continuing with the following service. Note unit might be powered from multiple sources.
POE Lubrication ! WARNING
This unit contains POE lubricants that must be handled carefully and the proper protective equipment (gloves, eye protection, etc.) must be used when handling POE lubricant. POE must not come into contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate piping).
No routine lubrication is required on WGS units.
Compressor oil must be ICI RL68HB, Daikin Part Number 735030446 in a 1-gallon container. This is synthetic polyolester oil with anti-wear additives and is highly hygroscopic. Care must be taken to minimize exposure of the oil to air when charging oil into the system.
Figure 24, Compressor Oil Filter
The Lub Control measures the pressure drop across the lubricant filter and shuts off the compressor if the differential pressure becomes too high. It is reset through the circuit controller. Change oil when pressure drop exceeds 15 psig.
Compressor Oil Filter
Oil Level Sight Glass
Lub Control
54 WGS 130A to 190A IMM1157
Sight Glass and Moisture Indicator The refrigerant sight glasses should be observed periodically. A monthly observation should be adequate. A clear glass of liquid indicates that there is adequate refrigerant charge in the system to provide proper feed through the expansion valve. The sight glass should be clear when the ambient temperature is above 75F (23C) and all fans on a circuit are running, when air cooled.
Bubbling refrigerant in the sight glass may occur at other conditions and may indicate that the system is short of refrigerant charge. Refrigerant gas flashing in the sight glass could also indicate an excessive pressure drop in the line, possibly due to a clogged filter-drier or a restriction elsewhere in the system. An element inside the sight glass indicates what moisture condition corresponds to a given element color. If the sight glass does not indicate a dry condition after about 12 hours of operation, the unit should be pumped down and the filter-driers changed.
If the system is suspected of being short of refrigerant, a qualified service technician with EPA certification should be contacted to thoroughly check out the unit and add refrigerant if necessary.
Sump Heaters The compressors are equipped with sump lubricant heaters. The function of the heater is to keep the temperature in the crankcase high enough to prevent refrigerant from migrating to the crankcase and condensing in the lubricant during the off-cycle. When a system is to be started up initially, the power to the heaters should be turned on for at least 12 hours before the compressors are started. The sump should be up to about 80°F (26.7°C) before the system is started up (warm to the touch), to minimize lubrication problems or liquid slugging of compressor on start-up.
If the crankcase is cool (below 80°F) (26.7°C) and the oil level in the sight glass is full to top, allow more time for oil to warm before starting the compressor.
The crankcase heaters are on whenever power is supplied to the unit and the compressor is not running.
IMM 1157 WGS 130A to 190A 55
Maintenance Schedule
I. Compressor A. Performance Evaluation (Log & Analysis) * O B. Motor Meg. Windings X
Ampere Balance (within 10%) X
Terminal Check (tight connections, porcelain clean) X
Motor Cooling (check temperature) X
C. Lubrication System Oil Level O X
Oil Appearance (clear color, quantity) O
Oil change if indicated by oil analysis X
II. Controls A. Operating Controls Check Settings and Operation X
B. Protective Controls Test Operation of: Alarm Relay X Pump Interlocks X High and Low Pressure Cutouts X III. Condenser B. Test Water Quality X C. Clean Condenser Tubes (or as required) X D. Eddy current Test - Tube Wall Thickness X E. Seasonal Protection X IV. Evaporator B. Test Water Quality X C. Clean Evaporator Tubes (or as required) X D. Eddy current Test - Tube Wall thickness (or as required) X E. Seasonal Protection X V. Expansion Valves A. Performance Evaluation (Superheat Control) X VI. Compressor - Chiller Unit A. Performance Evaluation O B. Leak Test: Compressor Fittings and Terminal X Piping Fittings X Vessel Relief Valves X C. Vibration Isolation Test X D. General Appearance: Paint X Insulation X
VII. Starter(s) A. Examine Contactors (hardware and operation) X B. Verify Overload Setting and Trip X C. Test Electrical Connections X
Key: O = Performed by in-house personnel X = Performed by service personnel
56 WGS 130A to 190A IMM1157
System Service
! DANGER
Service on this equipment must be performed by trained, experienced technicians. Causes for repeated tripping of equipment protection controls must be investigated and corrected. Disconnect all power (there may be multiple sources) before doing any service inside the unit or severe personal injury or death can occur.
NOTE: Anyone servicing this equipment must comply with the requirements set forth by the EPA concerning refrigerant reclamation and venting.
Filter-Driers
Figure 25, FIlter-Drier Assembly
There is a filter-drier assembly for each circuit located in the liquid line. The cartridges should be changed when the pressure drop across them exceeds the values shown in Table 26 below, when measured at the Schrader fittings before and after the housing. To change the filter:
1. Shut off the circuit. This will close the expansion valve.
2. Shut off the condenser liquid shutoff valve, isolating the filter-drier.
3. Remove any remaining refrigerant from one of the Schrader valves using approved EPA procedures.
4. Remove the housing cover, after checking that there is no positive pressure in the filter-drier.
5. Replace the filters, reinstall the cover, evacuate, and open the liquid line valve.
Table 26, Liquid Line Filter-Drier Pressure Drop PERCENT CIRCUIT MAXIMUM RECOMMENDED PRESSURE
100% 7 (48.3)
75% 5 (34.5)
50% 3 (20.7)
25% 3 (20.7)
Evaporator
Condenser
Schrader Fitting
Schrader Fitting
Sensor
ExpansionValve
Filter-Drier
SightGlass
Liquid LineValve
ExpansionValve
IMM 1157 WGS 130A to 190A 57
Electronic Expansion Valve The electronic expansion valve is located in the liquid line entering the evaporator.
The expansion valve meters the amount of refrigerant entering the evaporator to match the cooling load. It does this by maintaining constant condenser subcooling. (Subcooling is the difference between the actual refrigerant temperature of the liquid as it leaves the condenser and the saturation temperature corresponding to the condenser pressure.) All WGS chillers are factory set at 20F subcooling at 100% slide position and 10F (12.2C) subcooling at minimum slide position. These settings can be offset by discharge superheat.
When the control panel is first powered, the microprocessor will automatically step the valve to the fully closed (shut) position and the indicator light on the EXV will show closed position. The valve can also be heard closing as it goes through the steps. The valve will take approximately 30 seconds to go from a full open position to a full closed position.
The position of the valve can be viewed at any time by using the MicroTech II controller keypad through the View Refrigerant menus. There are 6386 steps between closed and full open. There is also a sight glass on the EXV to observe valve movement.
If the problem can be traced to the power element only, it can be unscrewed from the valve body without removing the valve, but only after pumping the unit down.
Evaporator The evaporator is a shell-and-tube unit. Normally no service work is required on the evaporator.
Water-cooled Condenser The condensers are of the shell-and-tube type with water flowing through the tubes and refrigerant in the shell. External finned copper tubes are rolled into steel tube sheets. Integral subcoolers are incorporated on all units. All condensers are equipped with 350 psig (2413 kPa) relief valves. Normal tube cleaning procedures can be followed.
58 WGS 130A to 190A IMM1157
Troubleshooting Chart PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
Compressor Will Not Run
1. Main switch, circuit breakers open. 2. Fuse blown. 3. Thermal overloads tripped or fuses
blown. 4. Defective contactor or coil. 5. System shut down by equipment
protection devices. 6. No cooling required. 7. Liquid line solenoid will not open. 8. Motor electrical trouble. 9. Loose wiring.
1. Close switch 2. Check electrical circuits and motor
winding for shorts or grounds. Investigate for possible overloading. Replace fuse or reset breakers after fault is corrected.
3. Overloads are auto reset. Check unit closely when unit comes back on line.
4. Repair or replace. 5. Determine type and cause of shutdown
and correct it before resetting protection switch.
6. None. Wait until unit calls for cooling. 7. Repair or replace coil. 8. Check motor for opens, short circuit, or
burnout. 9. Check all wire junctions. Tighten all
terminal screws.
Compressor Noisy or Vibrating
1. Flooding of refrigerant into compressor. 2. Improper piping support on suction or
liquid line. 3. Worn compressor.
1. Check superheat setting of expansion valve.
2. Relocate, add or remove hangers. 3. Replace.
High Discharge Pressure
1. Condenser water insufficient or temperature too high.
2. Fouled condenser tubes (water-cooled condenser). Clogged spray nozzles (evaporative condenser). Dirty tube and fin surface (air cooled condenser).
3. Noncondensables in system. 4. System overcharge with refrigerant. 5. Discharge shutoff valve partially closed. 6. Condenser undersized (air-cooled). 7. High ambient conditions (air-cooled).
1. Readjust temperature control or water regulating valve. Investigate ways to increase water supply.
2. Clean.
3. EPA purge the noncondensables. 4. Remove excess refrigerant. 5. Open valve. 6. Check condenser rating tables against
the operation. 7. Check condenser rating tables against
the operation.
Low Discharge Pressure
1. Faulty condenser temp. regulation. 2. Insufficient refrigerant in system. 3. Low suction pressure. 4. Condenser too large. 5. Low ambient conditions (air-cooled)
1. Check condenser control operation. 2. Check for leaks. Repair and add charge. 3. See corrective steps for low suction
pressure below. 4. Check condenser rating table against the
operation. 5. Check condenser rating tables against
the operation.
High Suction Pressure
1. Excessive load. 2. Expansion valve overfeeding.
1. Reduce load or add additional equipment.
2. Check remote bulb. Regulate superheat.
Low Suction Pressure
1. Lack of refrigerant. 2. Evaporator dirty. 3. Clogged liquid line filter-drier. 4. Expansion valve malfunctioning. 5. Condensing temperature too low. 6. Compressor will not unload. 7. Insufficient water flow.
1. Check for leaks. Repair and add charge. 2. Clean chemically. 3. Replace cartridge(s). 4. Check and reset for proper superheat.
Replace if necessary. 5. Check means for regulating condensing
temperature. 6. See corrective steps for failure of
compressor to unload. 7. Adjust flow.
Little or No Oil Pressure
1. Clogged suction oil strainer. 2. Excessive liquid in crankcase. 3. Low oil level. 4. Flooding of refrigerant into crankcase.
1. Clean. 2. Check sump heater. Reset expansion
valve for higher superheat. Check liquid line solenoid valve operation.
3. Add oil. 4. Adjust expansion valve.
IMM 1157 WGS 130A to 190A 59
PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
Compressor Loses Oil
1. Lack of refrigerant.
2. Velocity in risers too low (A-C only).3. Oil trapped in line.
1. Check for leaks and repair. Addrefrigerant.
2. Check riser sizes.3. Check pitch of lines and refrigerant
velocities.
Motor Overload Relays or Circuit Breakers Open
1. Low voltage during high load conditions.
2. Defective or grounded wiring in motor orpower circuits.
3. Loose power wiring.4. High condensing temperature.
5. Power line fault causing unbalancedvoltage.
6. High ambient temperature around theoverload relay
1. Check supply voltage for excessive linedrop.
2. Replace compressor-motor.
3. Check all connections and tighten.4. See corrective steps for high discharge
pressure.5. Check Supply voltage. Notify power
company. Do not start until fault iscorrected.
6. Provide ventilation to reduce heat.
Compressor Thermal Switch Open
1. Operating beyond design conditions.
2. Discharge valve partially shut.
1. Add facilities so that conditions are withinallowable limits.
2. Open valve.
Freeze Protection Opens
1. Thermostat set too low.2. Low water flow.3. Low suction pressure.
1. Reset to 42°F (6°C) or above.2. Adjust flow.3. See “Low Suction Pressure.”
Warranty Statement
Limited Warranty
Daikin International’s written Limited Product Warranty and any other expressly purchased Extended Warranty are the only warranties applicable. Consult your local Daikin Representative for warranty details. Refer to Form 933-430285Y. To find your local Daikin Representative, go to www.DaikinApplied.com .
60 WGS 130A to 190A IMM1157
(800) 432-1342 www.DaikinApplied.com IMM 1157 (3/12)
Daikin Training and Development
Now that you have made an investment in modern, efficient Daikin equipment, its care should be a high priority. For training information on all Daikin HVAC products, please visit us at www.DaikinApplied.com and click on training, or call 540-248-9646 to speak to the Training Department.
Warranty
All Daikin equipment is sold pursuant to Daikin’s Standard Terms and Conditions of Sale and Limited Product Warranty. Consult your local Daikin Representative for warranty details. Refer to form 933-430285Y. To find your local representative, go to www.DaikinApplied.com
This document contains the most current product information as of this printing. For the most up-to-date product information, please go to www.DaikinApplied.com .