Operating and Maintenance Manual OMM 1130-2 Group: Chiller Part Number: OMM1130-2 Date: March 2014 Water-Cooled Scroll Compressor Chillers WGZ030DW to WGZ200DW, Packaged Water-Cooled Chiller WGZ030DA to WGZ200DA, Chiller with Remote Condenser 30 to 200 Tons, 105 to 700 kW R-410a 50-60 Hertz
Table of Contents Introduction ....................................... 3 Using the Controller........................ 51 General Description .............................. 3 Nomenclature ........................................ 3 Water Pressure Drop ............................. 3 Components .......................................... 6 Menu Screens ...................................... 52 Menu Descriptions .............................. 53 Unit Configuration ............................
Introduction General Description Daikin Type WGZ water chillers are designed for indoor installations Equipment room temperature for operating and standby conditions is 40°F to 122°F (4.4°C to 50°C). They are available with water-cooled condensers (Model DW), or arranged for use with remote air-cooled or evaporative condensers (Model DA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing.
Figure 1, Evaporator Pressure Drop, WGZ030D – WGZ200D Minimum Flow & Pr. Drop Nominal Flow & Pr. Drop Maximum Flow & Pr. Drop Inch-Pound Inch-Pound Inch-Pound S.I. S.I. S.I. GPM Ft L/S kPa GPM Ft L/S kPa GPM Ft L/S kPa Model Curve Ref WGZ030D A 56.3 2.6 3.5 7.7 90.0 6.3 5.6 18.8 WGZ035D B 64.9 3.6 4.1 10.8 103.8 8.8 6.5 WGZ040D C 76.3 2.9 4.8 8.6 122.1 7.0 7.6 WGZ045D D 85.3 3.9 5.3 11.6 136.5 9.5 WGZ050D E 96.4 3.0 6.0 9.1 154.2 WGZ055D F 105.8 4.1 6.
Pressure Drop (ft of water) Figure 2, Condenser Pressure Drop, WGZ030D – WGZ200D Flow Rate (GPM) Unit Model Min. Flow & PD Ref # IP Nom. Flow & PD SI IP SI IP SI GPM Ft. L/S WGZ030D A 56.1 2.4 3.5 WGZ035D B 64.9 3.4 4.1 WGZ040D C 76.3 2.7 4.8 WGZ045D D 85.3 3.6 5.4 WGZ050D E 96.4 2.9 6.1 8.7 WGZ055D F 105.8 3.8 6.7 11.4 169.2 WGZ060D G 113.4 4.5 7.2 13.5 181.5 WGZ070D H 132.8 4.1 8.4 12.3 212.4 WGZ080D I 146.8 3.7 9.3 11.1 WGZ090D J 165.
Components Figure 3, Compressor Locations 4 2 Circuit 2 3 1 Circuit 1 Evaporator Evaporator and Condenser Connections Control Panel NOTE: Models WGZ150 to WGZ200 add a #5 compressor to circuit #1 and a #6 compressor to circuit #2.
Unit Configuration The chiller units have two refrigerant circuits, Models WGZ 030 to WGZ 130 have two tandem scroll compressors (total of four), a single two-circuited brazed plate evaporator, a single two-circuited watercooled condenser, interconnecting refrigerant piping and a control panel with associated sensors and transducers.
Field Wiring Diagrams Figure 5, WGZ030DW – WGZ200DW Field Wiring Diagram (Packaged Unit) 8 WGZ030D through WGZ200D OMM 1130-2
Figure 6, WGZ030DA – WGZ200DA Field Wiring Diagram (Remote Condenser) OMM 1130-2 9
Control Panel Layout Table 1, Typical Control Panel, 4-Compressor Unit (3) 120V/24V Transformers Microtech Controller LineV/120V Control Transformer (2) Circuit Mechanical Hi-Pressure Switch Relays Control Transformer Fuses, Primary Control Transformer Fuse, Secondary (4) Compressor Circuit Breakers Optional Disconnect Switch (4) Compressor Contactors Location for Optional External Overloads Grounding Lug NOTES: 1.
Start-Up and Shutdown Pre Start-up 1. The chilled-water system should be flushed and cleaned. Proper water treatment is required to prevent corrosion and organic growth. 2. With main disconnect open, check all electrical connections in control panel and starter to be sure they are tight and provide good electrical contact. Although connections are tightened at the factory, they can loosen enough in shipment to cause a malfunction. 3. Check and inspect all water piping.
. Start the system by setting the system switch S1 to on. 13. After running the unit for a short time, check the oil level in each compressor crankcase, rotation of condenser fans (if any), and check for flashing in the refrigerant sight glass. 14. After system performance has stabilized, it is necessary that the “Compressorized Equipment Warranty Form” (Form No. 206036A) be completed to establish commencement of the warranty period. Be sure to list the pressure drop across both vessels.
11. 12. 13. 14. Check that the MicroTech II controller is set to the desired chilled water temperature. Check resets of all equipment protection controls. Switch the unit circuit breakers to “on.” Start the system by setting the system switch S1 to “on.” ! CAUTION 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. 15.
Start Up Temp is the LWT at which the first compressor starts. The start up temperature equals the stage up temperature plus the Start Delta temperature. A high Start Delta will keep the unit off longer and reduce unit cycling at low loads. However, this high Start Delta will cause a larger excursion from the LWT setpoint before the unit starts. Stated another way, the Start Delta is the number of degrees above the Evap LWT setpoint, plus ½ the Dead Band, that determines when the first compressor starts.
When staging down, one compressor on each circuit will be left on until each circuit has only one compressor running. In other words, the compressor, on either circuit, with the most run-hours will stop first. The compressor with the most run-hours on the other circuit will stop next. One compressor on each circuit will be running. The third compressor off will be the one, on either circuit, with the most run-hours. The remaining compressor will be the last off. See the following description of pumpdown.
directions and the sequence of operation can be found on page 65. Some means of discharge pressure control must be installed if the condenser water temperature can fall below 60°F (16°C). Condenser Fan Control Model AC chillers equipped with air-cooled or evaporative-cooled condensers usually require some form of discharge pressure control. The MicroTech II controller can be programmed to provide this function by cycling condenser fans based on the unit discharge pressure.
MicroTech II Controller Controller Software Version This manual is based on software version WGZD20102F. The “02F” is the version descriptor. The version installed in a unit can be viewed by pressing the MENU and ENTER keys simultaneously, then pressing MENU to return to the regular menu screen. General Description The MicroTech II controller’s state-of-the-art design will not only permit the chiller to run more efficiently but will also simplify troubleshooting if a system failure occurs.
Keypad/Display A 4-line by 20-character/line liquid crystal display and 6-key keypad is mounted on the unit controller. Its layout is shown below. Figure 8, Keypad and Display in MENU Mode Key to Screen Pathway Menu Key Air Conditioning < ALARM VIEW < SET < Arrow Keys "Enter" Key The four arrow keys (UP, DOWN, LEFT, RIGHT) have three modes of use. Scroll between data screens as indicated by the arrows (default mode).
Table 4, Analog Outputs # Output Signal Range 1 Cooling Tower Bypass Valve Position Description 0 to 10 VDC 0 to 100% Open 2 Cooling Tower VFD Speed 0 to 10 VDC 0 to 100% 3 Circuit #1 Electronic Expansion Valve 0 to 10 VDC 0 to 100% 4 Circuit #2 Electronic Expansion Valve 0 to 10 VDC 0 to 100% NOTE: Analog outputs 3 & 4 are for R410A and R134a units only. Table 5, Digital Inputs The following parameters are digital inputs to this controller.
Table 6, Continued # Type Load Output OFF Output ON 5 Motor Control Relay #3 = Compr#3 Description C1 Starter Compressor OFF Compressor ON *6 Condenser Fan #3– Water Cooled =N /Tower Fan #2-Water Cooled=Y C1 / UT Fan Contactor Fan OFF Fan ON *6 Motor Control Relay #5 = Compr#5 (R134a,R410a) C1 Starter Compressor OFF Compressor ON 7 Liquid Line #1 C1 Solenoid Cooling OFF Cooling ON 8 Condenser Fan #2 – Water Cooled =N /Tower Fan #1-Water Cooled=Y C2 / UT Fan Contactor Fan OF
Setpoints The following parameters are remembered during power off, are factory set to the Default value, and can be adjusted to any value in the Range column. The PW (password) column indicates the password level that must be active in order to change the setpoint.
Table 7, Continued Description Expansion Valve Type Circuit 1 EXV Control Circuit 1 EXV Position Circuit 2 EXV Control Circuit 2 EXV Position MaxOpPress SuperheatTarg Alarms Low Evap Pressure-Hold Low Evap Pressure-Unload Default Range PW Electronic Auto N/A Auto N/A 156 10 Thermal, Electronic Auto, Manual 0-100% Auto, Manual 0-100% 142 – 170 psig 8-12°F M M M M M M M See following section; Automatic Adjusted Limits Evap. Freeze 38.0 °F Cond.
Automatic Adjusted Limits The following are set points that will be limited based on the option selected.
Dynamic Defaults Some set points will have a particular default value loaded when another setting is changed.
When the alarm occurs due to this trigger, it can auto reset the first two times each day, with the third occurrence being manual reset. For the auto-reset occurrences, the alarm will reset automatically when the evaporator state is Run again. This means the alarm stays active while the unit waits for flow, then it goes through the recirculation process after flow is detected. Once the recirculation is complete, the evaporator goes to the Run state which will clear the alarm.
When the evaporator pressure goes below the Low Evaporator Pressure Unload set point, a timer starts. If this timer exceeds the freeze time, then a ‘Evap Press Low Cir N’ alarm trip occurs. If the evaporator pressure rises to the unload set point or higher, and the freeze time has not been exceeded, the timer will reset. Action Taken: Rapid stop circuit Reset: This alarm can be cleared manually via the keypad if the evaporator pressure is above the absolute low-pressure limit.
Action Taken: Normal stop all circuits Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range. Suction Temperature Sensor Fault Alarm description (as shown on screen): SuctT Sensor Fail N Trigger: Sensor shorted or open AND Expansion Valve Type = Electronic Action Taken: Rapid stop circuit Reset: This alarm can be cleared manually via the keypad, but only if the sensor is back in range.
Alarm Log An alarm log stores the last 25 alarms and/or events to occur. When an alarm or event occurs, it is put into the first slot in the alarm log and all others are moved down one, dropping the last entry. In the alarm log, the date and time the alarm occurred are stored, as well as a list of other parameters. These parameters include compressor states, evaporator pressure, condenser pressure, number of fans on, OAT, and evaporator LWT.
High Condenser Pressure - Unload Event description (as shown on screen): CondPressHighUnloadN Trigger: This event is triggered if all of the following are true: • circuit state = Run • more than one compressor is running on the circuit • condenser pressure > High Condenser Pressure – Unload set point Action Taken: Stage off one compressor on the circuit every 10 seconds, except the last one.
Liquid Line Temperature Sensor Fail (TGZ unit only) Event description (as shown on screen): Low Source Temp Trigger: Sensor shorted or open. Action Taken: None. Reset: N/A Low Source Water Temperature (TGZ unit in ‘heat’ mode only) Event description (as shown on screen): LiqL Sensor Fail N Trigger: Unit is in heat mode and the leaving evaporator water temperature drops below the Low Source Temperature set point.
Controller Operation Calculations The Control Band defines the temperatures around the Controlling Leaving Water Temperature set point where compressors will be staged on or off. In cool mode, the controlling leaving water temperature set point will be Evap LWT. In heat mode, the controlling leaving water temperature set point will be Heat LWT. In cooling mode, the Control Band is calculated as follows: Control Band = Evap Delta Temperature Set Point * 0.
The Stage Down temperature is calculated as: Stage Down Temperature = Heat LWT + (Control Band/2) The Heat Start up and Shutdown temperatures are calculated from the Control Band. The Start Up temperature determines when the first compressor on the unit will start. The Start Up temperature calculation is shown below: Start Up Temperature = Stage Up Temperature - Start Up Delta Temperature The Shutdown temperature defines when the last running compressor will shutdown.
Parameters used: 1. Heating Leaving Water Temperature set point (Heat LWT) 2. Heating Maximum Reset set point (Htg MaxRes) 3. LWT Reset signal 4-20mA Reset is 0ºF and the active leaving water set point is equal to the Heat LWT set point if the reset signal is less than or equal to 4 mA. Reset is equal to the Max Reset set point and the active leaving water set point is equal to the Heat LWT minus Max Reset set points if the reset signal equals or exceeds 20 mA.
Heating Mode Return Reset Heat LWT set point (140ºF) ‘Active’ Heat LWT Set Point Htg MaxRes set point (range of reset action) (10ºF) Heat LWT (–) Htg MaxRes (130ºF) 0ºF Htg StrtResDT setpoint Condenser Delta Temperature The active heating leaving water set point is reset using the following parameters: 1. Heating Leaving Water Temperature set point (Heat LWT) 2. Heating Maximum Reset set point (Htg MaxRes) 3. Heating Start Reset Delta Temperature (Htg StrtResDT) 4.
Evaporator Saturated Temperature Evaporator saturated temperature is calculated from the evaporator pressure for each circuit. R410a Evaporator Saturated Temperatures When R410a refrigerant is selected the refrigerant pressure will be fitted to a curve made up of 24 straight-line segments. The accuracy of calculated saturated temperatures are less than +/- 0.5°F when compared to standard look up tables for R410a.
Changing the Unit Enable Set Point is accomplished according to the following table. NOTE: An “x” indicates that the value is ignored.
Power Up Start Delay After powering up the unit, the motor protector modules may not reset for up to 150 seconds. After the control is powered up, no compressor can start for 150 seconds. Motor protect inputs are ignored during this time so as to avoid tripping a false alarm. Ice Mode Start Delay An adjustable start to start ice delay timer will limit the frequency with which the chiller may start in Ice mode. The timer starts when the first compressor starts while the unit is in ice mode.
Unit State Diagram Off Power On T3 Pumpdown T1 T4 Auto T2 Evaporator Water Pump State Control (Evap State) The state-transition diagram shown below controls operation of the evaporator pump.
Primary/Standby Pump Staging The pump designated as primary will start first. If the evaporator state is start for a time greater than the recirculate timeout set point and there is no flow, then the primary pump will shut off and the standby pump will start. When the evaporator is in the run state, if flow is lost for more than half of the flow proof set point value, the primary pump will shut off and the standby pump will start.
8-Fan Remote Condenser, R22, R407C Stage Fans Operating on Circuit 1 Fans Operating on Circuit 2 1 Fan 1 Fan 2 2 Fans 1, 3 Fans 2, 4 3 Fans 1, 3, 5 Fans 2, 6, 8 4 Fans 1, 3, 5, 7 Fans 2, 4, 6, 8 8-Fan Remote Condenser, R410A Stage Fans Operating on Circuit 1 1 Fan 1 Fans Operating on Circuit 2 Fan 2 2 Fans 1, 3 Fans 2, 4 3 Fans 1, 5, 7 Fans 2, 6, 8 4 Fans 1, 3, 5, 7 Fans 2, 4, 6, 8 10 Fan Remote Condenser, R410A Stage Fans Operating on Circuit 1 1 Fan 1 Fans Operating on Cir
When stage down occurs or the saturated temperature rises back within the Stage Down dead band the Stage Down Error Accumulator is reset to zero. Forced Fan Stage at Start Fans may be started simultaneously with the compressor based on outdoor ambient temperature. When the compressor starts, and after compressor operation is verified by either a 1 psi drop in evaporator or 1 psi rise in condenser pressures, a Fantrol stage is forced based on the following table.
Auto – The primary pump is the one with the least run hours, the other is used as a backup. #1 Primary – Pump 1 is used normally, with pump 2 as a backup. #2 Primary – Pump 2 is used normally, with pump 1 as a backup. Primary/Standby Pump Staging The pump designated as primary will start first. If the condenser state is start for a time greater than the re-circulate timeout set point and there is no flow, then the primary pump will shut off and the standby pump will start.
Additional stages can turn on (up to the number specified by the Tower Stages set point) when above conditions are met for the next stage plus the following condition: VFD Speed is > the Stage Up @ set point (only if Valve/VFD Control set point = VFD Stage OR Valve SP/VFD Stage) Down staging shall occur when the following conditions are met: The stage down timer completes The ECWT is < Stage #X ON (Temp) set point – Stage Differential (Temp) set point Bypass valve position is < the Stage Down @ set point (o
Valve Stage Mode This mode is only operational when the Valve/VFD Control set point is set to Valve Stage. In this mode the valve output is controlled as for Valve Set Point mode (above) except that the active set point for the controlled parameter is selected according to the following table.
Stage Down Now The Stage Down Now flag is set based on the following tests: If Unit Mode = Cool AND LWT error < -0.5 * Control band AND More than one compressor running AND Stage down timer expired THEN Stage Down Now = True If Unit Mode = Cool AND LWT error < (-0.
compressor will shutdown if the evaporator pressure gets down to 5.0 psi. For R410a, the absolute limit for low evaporator pressure is 20.0 psi. When the Low OAT Start Timer has expired, if the evaporator pressure is greater than or equal to the Low Evaporator Pressure Unload set point, the start is considered successful and normal alarm and event logic is reinstated.
Hold Clear Reset Value = High Pressure Unload set point – [“Initial Offset” + [“Step-Increase” x [“number of occurrence”-1]]] Initial Offset & Step Increase Condenser Configuration No. of Compressors R410A R22, R407C R134a Step Increase 4 40 psi 30 psi 30 psi 10 psi 6 32 psi N/A 20 psi 10 psi 4 100 psi 70 psi N/A 15 psi 6 80 psi N/A N/A 15 psi Water-Cooled Air-Cooled Example of Operation: Assume a packaged water-cooled WGZ unit with 4 compressors using R410A as the refrigerant.
Network Limit The maximum unit capacity can be limited by a network signal. This function is only enabled if the unit control source is set to network. The maximum unit capacity stage is based on the network limit value received from the BAS, and is determined as shown in the following graph. Network Limit vs. Max Stage (with 4 compressors) Network Limit vs. Max Stage (with 6 compressors) 4 6 5 3 Max Stage Max Stage 2 4 3 2 1 1 0 0 0 25.0 50.0 75.0 100.0 0 Network Limit (%) 16.7 33.3 50.
• • A normal stage down occurs, and only one compressor on the circuit is running Unit mode = Ice AND the ice set point is reached Pump Down Procedure • • • • If both compressors are running, shut off the appropriate compressor based on sequencing logic With one compressor left running, turn off hot gas output and liquid line output Keep running until evaporator pressure reaches the pump down pressure, then stop compressor If evaporator pressure does not reach pump down pressure within two minutes, stop
Manual EXV Control The EXV position can be set manually. Manual control can only be selected when the circuit is in the run state. At any other time, the EXV control set point is forced to auto. When EXV control is set to auto, the manual EXV position setting follows the auto control position. When EXV control is set to manual, the EXV position is equal to the manual EXV position setting.
Using the Controller Getting Started There are two basic procedures to learn in order to utilize the MicroTech II controller: • Navigating through the menu matrix to reach a desired menu screen and knowing where a particular screen is located. • Knowing what is contained in a menu screen and how to read that information or how to change a setpoint contained in the menu screen. Navigating Through the Menus The menus are arranged in a matrix of screens across a top horizontal row.
Figure 9, Display in the Shortcut (SCROLL) Mode and Keypad Layout MENU Key Air Conditioning VIEW UNIT STATUS Unit = COOL Compr. #1/#2=OFF/OFF Evap Pump = RUN ENTER Key ARROW ENTER Key Pressing the ENTER key changes the function of the ARROW keys to the editing function as shown below: LEFT key Default, changes a value to the factory-set default value. RIGHT key Cancel, cancels any change made to a value and returns to the original setting.
Figure 10, Menu Matrix “MENU” “VIEW” MENUS UNIT CIRCUITS VIEW UNIT VIEW UNIT VIEW FANS EVENTS VIEW VIEW REFRIGERANT VIEW VIEW VIEW EVENT (1) STATUS TEMP CIRC #1 CIRC #2 REFRIGERANT REFRIGERANT FAN/TOWER (1) (1) STATUS STATUS CIRCUIT #1 CIRCUIT #2 (1) (1) (1) (1) (1) VIEW VIEW VIEW EVAP VIEW EVAP VIEW (2) (2) FAN/TOWER VIEW UNIT VIEW UNIT STATUS TEMP COMP #1 CIRC #2 (5) (2) STATUS STATUS (3) (3) VIEW EVENT (n) (n) ⇐ Continued ⇐ (Right side of matrix continued
VIEW menu: VIEW < COMPRESSOR < UNIT < EVAPORATOR < FANS/TOWER VIEW UNIT menu: VIEW < TEMP UNIT < STATUS < REFRIGERANT SET menu: SET < ALARM LIMITS < UNIT SPs < COMPRESSOR SPs < FANS/TOWER SPs Screen Definitions – VIEW View Unit Status VIEW UNIT STATUS (1) Auto Cooling Stage = 0 Evap Pump = RUN Unit states can be OFF, COOL, GYLCOL, ICE, or ALARM as determined from the Unit Mode setpoint, the Unit Enable, and the presence of an alarm. Circuit states can be OFF/OFF, ON/OFF, OFF/ON, and ON/ON.
This menu gives the status of digital inputs (D.I.), 1=ON, 0=OFF. Numbers are 1 through 18. See Table 5 on page 19 for number reference. VIEW UNIT STATUS (6) Analog Output (volts x 100) 1 = 000.0 2 = 000.0 VIEW UNIT STATUS (7) Analog Output (volts x 100) 3 = 000.0 4 = 000.0 VIEW UNIT STATUS (8) EXB1 Online D.O. 1 2 3 4 0 0 0 0 View Unit Tempertures Water Cooled = Y TGZ in Cool Mode Water Cooled = N VIEW UNIT TEMP (1) Evap LWT = XX.X°F Cond EWT = XXX.X°F LWT Target = XX.
VIEW UNIT TEMP (3) Control Temps Start Up XX.X°F Stage Up XX.X°F VIEW UNIT TEMP (4) Control Temps Stage Down XX.X°F Shut Down XX.X°F TGZ Unit Only in Cool Mode TGZ Unit Only in Heat Mode VIEW UNIT TEMP (5) Cond LWT XX.X°F Evap EWT XX.X°F VIEW UNIT TEMP (5) Cond LWT XX.X°F Evap EWT XX.
VIEW CIRCUIT#2 Comp 4 = OFF Hours = XXXXX Starts = XXXXX (3) If # of Compresors = 6 Only f or R410A or R134a VIEW CIRCUIT 1 Comp6=Off Hours = XXXXX Starts = XXXXX (4) View Refrigerant VIEW REFRG Cir 1 (1) Evap Press XXX.X psi Cond Press XXX.X psi R 134a, R22, R410A VIEW REFRG Cir 1 (2) Sat Evap XXX.X °F Sat Cond XXX.X °F i R407C VIEW REFRG Cir 1 (2) Evap Dew XXX.X °F Cond. Mid XXX.X °F VIEW REFRG Cir 1 (3) SuctionTemp=XXX.X°F Surperheat = XXX.X°F EvapApproach= XX.
VIEW REFRG Cir 2 (1) Evap Press XXX.X psi Cond Press XXX.X psi R 134a, R22, R410A VIEW REFRG Cir 2 (2) Sat Evap XXX.X °F Sat Cond XXX.X °F i R407C VIEW REFRG Cir 2 (2) Evap Dew XXX.X °F Cond. Mid XXX.X °F VIEW REFRG Cir 2 (3) SuctionTemp=XXX.X°F Surperheat = XXX.X°F EvapApproach= XX.X°F TGZ Only (R134a) VIEW REFRG Cir 2 (4) LiqLineTemp=XXX.X°F Subcooling = XXX.X°F CondApproach= XX.X°F Units with EEV only VIEW REFRG Cir 2 (5) EXV Ctrl = XXX EXV Pos = XXX.X% SH Target = XX.
Water Cooled = Y Only or TGZ Unit (R134a) VIEW TOWER (2) Bypass Valve = XXX% VFD Speed = XXX% The Bypass Valve value shall be “None” (in place of XXX%) if the Valve/VFD Control setpoint = None or VFD Stage. The VFD Speed value shall be “None” if the Valve/VFD Control setpoint = None, Valve Setpoint, or Valve Stage. Water Cooled = N Only VIEW FANS (1) Fans On Circuit#1 =XX Fans On Circuit#2 =XX This screen shows the number of air-cooled condenser fans “on” for each circuit.
Screen Definitions – EVENT LOG EVENT LOG (X) Event Description Time Date Screen Definitions – SET Set Unit Setpoints SET UNIT SPs (1) Unit Enable = OFF Unit Mode = COOL Source = KEYPAD Unit Enable settings can be OFF and ON as determined from the Unit Enable setpoint. Unit Enable is an external signal or a keypad setting that keeps the unit off when the setting is OFF and allows it to run if there is a call for cooling when the setting is ON.
SET UNIT SPs (4) Start Delta= XX.X°F Stop Delta= XX.X°F Demand Limit = ON See page 13 for an explanation of compressor staging. WGZ Units Only SET UNIT SPs (5) Max Pulldn=X.X°F/min Evap Recirc= XXX sec Evap Pump = #1 Only TGZ Units Only (R134a) SET UNIT SPs (5) Max Pulldn=X.X°F/min Evap Recirc= XXX sec Evap Pump = #1 Only Evap Pump choices are; #1 Only, #2 Only, Auto, #1 Primary, #2 Primary.
SET UNIT SPs (9) SET UNIT SPs (9) Units = °F/psi Units = °F/psi Lang = ENGLISH Lang = ENGLISH Refrig = R410A Refrig = R134a Refrigerant type is factory-set. SET UNIT SPs (10) Protocol = Modbus Ident Number=001 Baud Rate=9600 BAS interface settings, available mid-2003. SET UNIT SPs (11) Evap Press Sensor Cir 1 Offset XX.X psi Cir 2 Offset XX.X psi The pressure offsets on menus 11 and 12 and the temperature offsets on menus 10, 11 and 12 correct the controller's display of the parameters.
WGZ Unit (R22,R407C,R410A) SET UNIT SPs (17) ENTER PASSWORD: XXXX Active Password Level: None TGZ Unit (Refrig = 134a) SET UNIT SPs (17) Clg ResType = X Clg MaxRes = XX.X ºF Clg StrtRes = XX.X ºF TGZ Unit in Cooling Mode . SET UNIT SPs (17) ENTER PASSWORD: XXXX Active Password Level: None TGZ Unit in Heat Mode. SET UNIT SPs (17) Htg ResType = X Htg MaxRes = XX.X ºF Htg StrtRes = XX.X ºF TGZ Unit Heat Mode.
# of Compressors = 4 # of Compressors = 6 SET COMP SPs (3) Comp 1 = Enable Comp 3 = Enable # of Compressors = 4 SET COMP Comp 1 = Comp 3 = Comp 5 = SPs (3) Enable Enable Enable # of Compressors = 6 SET COMP SPs (4) Comp 2 = Enable Comp 4 = Enable SET COMP Comp 2 = Comp 4 = Comp 6 = SPs (4) Enable Enable Enable Enable screens #3 and #4 require the manager password to change.
The last action to take place is the shutoff of all compressors running when the LowEvPrStop setting is reached (default is 58 psi). Reducing these time intervals will increase detrimental compressor cycling. It is recommended that these settings not be changed. SET ALARM LMTS (2) High Cond Pressure Unload= XX.X°F Stop=XXXsec Unload is a limit alarm that unloads the unit at 370 psi in an attempt to prevent total shutdown from the HighCondPr at 380 psi. The stage down is set at 370 psi.
Set Air-Cooled Condenser Fans Water-cooled = Off SET FANS SPs Fan Stages=X Speedtrol=Yes/No (1) Water-cooled = Off SET FANS SPs (2) Stage ON Deadband (°F) Stg2 Stg3 Stg4 XXX XXX XXX Water-cooled = Off SET FANS SPs (3) Stage Off Deadband (°F) Stg2 Stg3 Stg4 XXX XXX XXX The SET FANS SP screens 2 through 5 establish the temperature that will stage the condenser fans on and off. These screens apply only to units set up for use with air-cooled condensers (WaterCooled=No).
Bypass valve position is > the Stage Up @ setpoint (only if Valve/VFD Control setpoint = Valve Stage) Additional stages can turn on (up to the number specified by the Tower Stages setpoint) when above conditions are met for the next stage plus the following condition: VFD Speed is > the Stage Up @ setpoint (only if Valve/VFD Control setpoint = VFD Stage OR Valve SP/VFD Stage) Down staging shall occur when the following conditions are met: The stage down timer completes The ECWT is < Stage #X ON (Temp) setpo
Water-cooled = Y SET TOWER SPs (4) Valve/VFD Control= ValveSP/VFDStage Valve Type=NC to Twr Valve/VFD Control settings are None, Valve Setpoint, Valve Stage, VFD Stage, or ValveSP/VFDStage. Default is None which results in no control of the tower from the MicroTech II controller. Valve Setpoint, the valve will control (bypass tower) to hold the minimum temperature as established by the Set Tower SPs in screen (5) below.
Figure 11, Initial Valve Position Initial Valve Position Max Position @ Setpoint (90°F) (values are examples only) Min Position @ Setpoint (60°F) Min Start Position Setpoint (10%) Max Start Position Setpoint (90%) Operation After Start When the condenser pump is in the RUN state, the valve output shall be controlled in one of two modes as specified by the Valve/VFD Control setpoint. The controlled parameter shall be the condenser entering water temperature.
TEST The test screens are only available when the unit is in TEST mode. Using these screens, any digital output can be controlled manually.
SET UNIT SPs (X) (data) (data) (data)
BAS Interface The BAS interface will use the supervisor port on the controller as a connection point. Protocols Supported The following building automation system (BAS) protocols are supported. It is possible to change the building automation interface without loading different software. BACnet® When protocol is set to BACnet, the baud rate and ident set points are not accessible. The ident setting is locked at 1 for BACnet, and the baud rate is locked to 19200.
Table continued Type Index I/O Description LONworks BACnet I 11 O Active alarms 11 x x Modbus x I 12 O Active alarms 12 x x x I 13 O Active alarms 13 x x x I 14 O Active alarms 14 x x x I 15 O Active alarms 15 x x x I 16 O Active alarms 16 x x x I 17 I Network chiller mode set point x x x I 18 O LON Chiller run mode x I 19 O Active chiller mode x I 20 I Network demand limit default set point x I 21 I Network chiller mode default set po
Chiller Mode Applies to Integer 17 and Integer 19. Network Chiller Mode Set Point and Active Chiller Mode use the same numbering scheme to represent ice mode or cool mode. The output representing the mode is shown below for each protocol. Mode LONworks BACnet Modbus Heat Cool Ice 1 3 11 3 2 1 3 2 1 Any time the chiller is not in Ice mode, Cool mode will be assumed. LON Chiller Run Mode Applies to Integer 18.
setting is checked. If this is set low, then the defaults for BAS cool set point, network limit, unit enable, and unit mode will be loaded. If the setting is set high, then no defaults are loaded and the status of the BAS enable set point is restored to the original value.
Compressor Motor protection Module The 20, 26, and 30 HP compressors are equipped with an module that provides protection against: • High motor temperature • High scroll temperature • Phase missing • Phase reversal • Low control circuit voltage The module also has a LED display in the upper righthand corner that gives information on compressor operation. The module is accessible by removing the compressor motor cover.
longer than 6 hours. Once the module has locked out the compressor, a power cycle or Modbus reset command will be required to clear the lockout. Code 3 – Short Cycling: The module will flash the red Alert LED three times indicating the compressor is locked out due to short cycling. A Code 3 Alert will open the M2-M1 contacts.
Optional Controls Phase/Voltage Monitor (Optional) The phase/voltage monitor is a device that provides protection against three-phase electrical motor loss due to power failure conditions, phase loss, and phase reversal. Whenever any of these conditions occur, an input relay is deactivated, disconnecting power to the thermostatic control circuit. The compressor does a rapid shutdown including a pump down cycle. The input relay remains deactivated until power line conditions return to an acceptable level.
System Maintenance General To provide smooth operation at peak capacity and to avoid damage to package components, a program of periodic inspections should be set up and followed. The following items are intended as a guide to be used during inspection and must be combined with sound refrigeration and electrical practices to provide trouble-free performance.
POE Lubrication POE type oil is used for compressor lubrication. This type of oil is extremely hygroscopic, which means it will quickly absorb moisture if exposed to air and may form acids that can be harmful to the chiller. Avoid prolonged exposure of POE oil to the atmosphere to prevent this problem. For more details on acceptable oil types, contact your Daikin Applied service representative. ! CAUTION POE oil must be handled carefully using proper protective equipment (gloves, eye protection, etc.
Maintenance Schedule I. Compressor A. Performance Evaluation (Log & Analysis) * B. Motor • Meg. Windings • Ampere Balance (within 10%) • Terminal Check (tight connections, porcelain clean) • Motor Cooling (check temperature) C. Lubrication System • Oil Level • Oil Appearance (clear color, quantity) • Oil change if indicated by oil analysis II. Controls A. Operating Controls • Check Settings and Operation B.
System Service ! DANGER Service on this equipment is to be performed only by qualified refrigeration personnel. Causes for repeated tripping of equipment protection controls must be investigated and corrected. Disconnect all power before doing any service inside the unit or serious 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.
Table 8, Thermostatic Expansion Valve ! CAUTION Adjustment of expansion valve should only be performed by a qualified service technician. Failure to do so can result in improper unit operation. Note: Superheat will vary with compressor unloading, but should be approximately as follows: between 8°F and 12°F (4.4°C and 6.7°C) at full load; between 6°F and 10°F at part load.
Troubleshooting Chart PROBLEM 1. 2. 3. Compressor Will Not Run Compressor Noisy or Vibrating High Discharge Pressure POSSIBLE CAUSES Main switch, circuit breakers open. Fuse blown. Thermal overloads tripped or fuses blown. Defective contactor or coil. System shut down by equipment protection devices. 3. 6. 7. 8. No cooling required. Liquid line solenoid will not open. Motor electrical trouble. 6. 7. 8. 9. Loose wiring. 9. 1. Flooding of refrigerant into crankcase. 5.
PROBLEM 8. Compressor Loses Oil Motor Overload Relays or Circuit Breakers Open Compressor Thermal Switch Open Freeze Protection Opens OM 1130-2 POSSIBLE CAUSES Lack of refrigerant. 1. 9. Velocity in risers too low (A-C only). 10. Oil trapped in line. 2. 3. 1. Low voltage during high load conditions. 1. 2. Defective or grounded wiring in motor or power circuits. Loose power wiring. High condensing temperature. 2. 5. Power line fault causing unbalanced voltage. 5. 6. 6. 1.
Daikin Applied Training and Development Now that you have made an investment in modern, efficient Daikin Applied equipment, its care should be a high priority. For training information on all Daikin Applied HVAC products, please visit us at www.DaikinApplied.com and click on training, or call 540-248-9646 and ask for the Training Department. Warranty All Daikin Applied equipment is sold pursuant to Daikin Applied standard terms and conditions of sale, including Limited Product Warranty.
