Daikin AGZ030EH Unit installation

Installation, Operation, and Maintenance Manual
Air-Cooled Scroll Compressor Chiller
IOM 1206-1
Group: Chillers
Part Number: IOM1206-1
Date: May, 2014
AGZ030EH - AGZ070EH, Packaged Chillers
R-410A, 50/60 Hz
© 2014 Daikin Applied
.
Contents
Installation and Application Information . . . . . . . . 3
Lifting and Mounting Weights . . . . . . . . . . . . . . . . 10
Physical Data - Packaged Units . . . . . . . . . . . . . . 14
Pressure Drop Data . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Unit Controller Operation . . . . . . . . . . . . . . . . . . . 23
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Contents
Using the Controller . . . . . . . . . . . . . . . . . . . . . . .
Optional Low Ambient Fan VFD. . . . . . . . . . . . . .
Start-up and Shut-down Procedures. . . . . . . . . .
Component Operation . . . . . . . . . . . . . . . . . . . . .
Unit Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . .
Warranty Registration Form (Scroll) . . . . . . . . . .
49
53
59
61
64
71
73
Hazard Identification
DANGER
Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.
WARNING
Warnings indicate potentially hazardous situations which can result in property damage, severe personal injury, or death if not
avoided.
CAUTION
Cautions indicate potentially hazardous situations which can result in personal injury or equipment damage if not avoided.
Modbus
©2014 Daikin Applied. Illustrations and data cover the Daikin Applied product at the time of publication and we reserve the right to make changes in design and
construction at anytime without notice.
2
IOM 1206-1
Installation and Application Information
Installation and Application Information
Chiller Nomenclature
A G Z XXX E H
Air-Cooled
Application
H = Standard Packaged
Global Design
Scroll Compressor
Nominal Tons
Design Vintage
WARNING
Installation is to be performed by qualified personnel who are familiar with local codes and regulations.
CAUTION
Sharp edges on unit and coil surfaces are a potential hazard to personal safety. Avoid contact with them.
General Description
Figure 1: Suggested Pushing Arrangment
Blocking is required
across full width
Daikin air-cooled water chillers are complete, self-contained,
automatic chiller units designed for outdoor installation.
Packaged units are completely assembled, factory wired,
charged, and tested.
The electrical control center includes all equipment protection
and operating controls necessary for dependable automatic
operation.
Additional Manual
This manual covers the installation, of dual circuit, AGZ-EH
packaged, scroll compressor chillers using R-410A.
Information for units with either the pump package or remote
evaporator options can be found at www.DaikinApplied.com.
Inspection
Figure 2: Required Lifting Arrangement
S preader bars
require d
(use caution)
Number of fans may vary
fro m this d iagram. The lifting
me thod will remain the sam e.
Check all items carefully against the bill of lading. Inspect all
units for damage upon arrival. Report shipping damage and
file a claim with the carrier. Check the unit nameplate before
unloading, making certain it agrees with the power supply
available. Daikin Applied is not responsible for physical
damage after the unit leaves the factory.
Handling
Be careful to avoid rough handling of the unit. Do not push or
pull the unit from anything other than the base. Block the
pushing vehicle away from the unit to prevent damage to the
sheet metal cabinet and end frame (see Figure 1).
To lift the unit, 2-1/2" (64mm) diameter lifting eyes are
provided on the base of the unit. Arrange spreader bars and
cables to prevent damage to the condenser coils or cabinet (see
Figure 2).
All rigg ing l ocations
mu st be used.
CAUTION
All lifting locations must be used to prevent damage to unit.
DANGER
Do not stand beneath the unit while it is being lifted or installed.
IOM 1206-1
3
Installation and Application Information
Operating and Standby Limits
Table 1: Operating Limits
Maximum standby ambient temperature
131°F (55°C)
Maximum operating ambient temperature
104°F (40°C)
-with optional high ambient package (see information under High Ambient Operation‚ page 9
Minimum operating ambient temperature (standard control)
125°F (52°C)
32°F (0°C)
Minimum operating ambient temperature (with optional low-ambient control)
-10°F (-23°C)
Leaving chilled water temperature
Leaving chilled fluid temperatures (with anti-freeze) - Note that in cases of high ambient
temperature, the lowest leaving water temperature settings may be outside of the chiller operating
envelope; consult Daikin tools to ensure chiller is capable of the required lift.
Operating chilled water delta-T range
40°F to 65°F (2°C to 18°C)
15°F to 65°F (-9°C to 18°C)
6°F to 16°F (3.3°C to 8.9°C)
Maximum evaporator operating inlet fluid temperature
81°F (27°C)
Maximum evaporator non-operating inlet fluid temperature
100°F (38°C)
Unit Placement
Air Clearance
AGZ units are for outdoor applications and can be mounted
either on a roof or at ground level. For roof mounted
applications, install the unit on a steel channel or I-beam frame
to support the unit above the roof. For ground level
applications, install the unit on a substantial base that will not
settle. Use a one-piece concrete slab with footings extended
below the frost line. Be sure the foundation is level within 0.5”
(13mm) over its length and width. The foundation must be
strong enough to support the weights listed in the Physical
Data Tables beginning on page 15.
The Daikin Applied advanced “W” coil design and open airpassage ends allow very close unit spacing and a small
installation footprint. The AGZ-E fans are canted inward and
reduce recirculation by directing discharge air to the center of
the unit, reducing the tendency to flow outward and spill over
into the coil inlet.
Service Clearance
Sides: Minimum of 4 feet (1.22 m)
Control panel end: Minimum of 4 feet
Opposite control panel:
• Minimum 4 feet on models 030 to 70;
4
Sufficient clearance must be maintained between the unit and
adjacent walls or other units to allow the required unit air flow
to reach the coils. Failure to do so will result in a capacity
reduction and an increase in power consumption. No
obstructions are allowed above the unit at any height.
Spacing Requirements
In general, with a small performance penalty in some cases,
AGZ-E units can be spaced at four feet from other units or a
wall. Curves on the following pages give the minimum
clearance for different types of installations and also capacity
reduction and power increase if closer spacing is used.
IOM 1206-1
Installation and Application Information
Case 1: Open Screening Walls
Case 2: Pit Installation
Decorative screening walls are often used to help conceal a
unit either on grade or on a rooftop. Design these walls such
that the combination of their open area and distance from the
unit do not require performance adjustment. It is assumed that
the wall height is equal to or less than the unit height when
mounted on its base support. If the wall height is greater than
the unit height, see Case 2 for Pit Installation. The distance
from the sides of the unit to the side walls must be sufficient
for service, such as opening control panel doors. For uneven
wall spacing, the distance from the unit to each wall can be
averaged providing no distance is less than 4 feet. Values are
based on walls on all four-sides.
Pit installations can cause operating problems resulting from
air recirculation and restriction, and require care that sufficient
air clearance is provided, safety requirements are met and
service access is provided. Pit covers must have abundant open
area at least equal to the chiller footprint. A solid wall
surrounding a unit is substantially a pit and this data should be
used.
6
Steel grating is sometimes used to cover a pit to prevent
accidental falls or trips into the pit. The grating material and
installation design must be strong enough to prevent such
accidents, yet provide abundant open area to avoid
recirculation problems. Have any pit installation reviewed by
the Daikin Applied sales representative prior to installation to
ensure it has sufficient air-flow characteristics and approved
by the installation design engineer to avoid risk of accident.
5
Figure 4: Case 2 - Pit Installation
Figure 3: Case 1 Adjustment Factor
Wall Free Area vs. Distance
4
Distance
from
Wall to
Unit (ft)
3
2
1
0
0
10
20
30
40
50
% Open Wall Area
AGZ030-070
Figure 5: Case 2 Adjustment Factors (AGZ030E-070E)
Full Load Capacity Reduction (AGZ030-070)
6.0
5.0
4.0
% Capacity
Reduction
3.0
2.0
1.0
0.0
0
8
10
12
13
14
Depth of Pit (ft)
Distance = 4 ft
Distance = 5 ft
Distance = 6 ft
Power Increase (AGZ030-070)
9.0
8.0
7.0
6.0
5.0
% Pow e r
Incre as e 4.0
3.0
2.0
1.0
0.0
0
8
Distance = 4 ft
IOM 1206-1
10
12
De pth of Pit (ft)
Distance = 5 ft
13
14
Distance = 6 ft
5
Installation and Application Information
POE Lubricants
!
WARNING
Thus 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).
Chilled Water Piping
IMPORTANT: Piping design must be provided by a qualified
Architect or Systems HVAC Design Engineer familiar with
piping design, as well as local codes and regulations. The
manufacturer recommendations provided here are to be used
as a general guide, but do not replace system design by a
qualified professional.
Install a cleanable perforated basket strainer with 0.062-inch
perforations and 40% open area for models 030 to 070 in the
water line just prior to the inlet of the evaporator. An optional
strainer kit is available for factory installation or field
mounting.
Design the water piping so the chilled water circulating pump
discharges into the evaporator inlet. Connect the return water
line to the evaporator inlet connection. Connect the supply
water line to the evaporator outlet connection. If not already
factory installed, install a flow switch in the horizontal piping
of the supply (evaporator outlet) water line.
Provide drain connections at low points in the system to permit
complete drainage of the system. Locate air vents at the high
points in the system to purge air out of the system. A vent
connection on top of the evaporator vessel allows air to be
purged out of the evaporator. Purge air from the water system
before unit start-up to provide adequate flow through the
evaporator.
exposed to outdoor temperature against freezing. Wrap the
lines with a heater cable and add proper amount of glycol to
the system to further protect the system.
Optional Inlet Strainer
An inlet water strainer kit is available to be field-installed,
sized per Table 2 and with the pressure drop show in Figure 6.
This pressure drop must be accounted for in the total system
pressure drop. The kit consists of:
• (1) Y-type 40% open area strainer with 304 stainless
steel perforated basket, Victaulic pipe connections and
strainer cap.
• (1) Extension pipe with (2) Schrader fittings that can be
used for a pressure gauge and thermal dispersion flow
switch. The pipe provides sufficient clearance from the
evaporator for strainer basket removal.
• (1) ½-inch blowdown valve.
• (2) Victaulic clamps.
Figure 6: Strainer Pressure Drop
Units with brazed-plate evaporators (030-070) must have a
drain connection provided in the bottom of the lower
connection pipe and a vent on the top of the upper connection
pipe. These evaporators do not have drain or vent connections
due to their construction.
Install pressure gauges in the inlet and outlet water lines to the
evaporator. Measure pressure drop through the evaporator and
compare to flow as shown on page 18. Vibration eliminators
are recommended in both the supply and return water lines.
Insulate chilled water piping to reduce heat loss and prevent
condensation. Chillers not running in the winter should have
their water systems thoroughly drained to protect against
freezing. If the chiller operates year-round, or if the system is
not drained for the winter, protect the chilled water piping
6
Table 2: Strainer Data
AGZ Model
030-055
060-070
Strainer Size Strainer Plus Pipe
(in.)
Length (in.)
2.5
16.75
3.0
17.75
Strainer
Weight (lbs)
14
20
IOM 1206-1
Installation and Application Information
Water Flow Limitations
Variable Evaporator Flow
Constant Evaporator Flow
Reducing evaporator flow in proportion to load can reduce
system power consumption. The rate of flow change should be
a maximum of 10 percent of the flow per minute. For example,
if the maximum design flow is 200 gpm and it will be reduced
to a flow of 140 gpm, the change in flow is 60 gpm. Ten
percent of 200 gpm equals 20 gpm change per minute or a
minimum of three minutes to go from maximum to minimum.
Do not reduce flow lower than the minimum flows listed in the
evaporator pressure drop section, page 18. The water flow
through the evaporator must remain between the minimum and
maximum values listed. If flow drops below the minimum
allowable, large reductions in heat transfer can occur. If the
flow exceeds the maximum rate, excessive pressure drop and
tube erosion can occur.
The evaporator flow rates and pressure drops shown on
page 18 are for full load design purposes. The maximum flow
rate and pressure drop are based on a 6°F temperature drop.
Avoid higher flow rates with lower temperature drops to
prevent potential control problems resulting from a very small
control band and limited start up/shut off temperature changes.
The minimum flow and pressure drop is based on a full load
evaporator temperature drop of 16°F. Evaporator flow rates
below the minimum values can result in laminar flow causing
freeze-up problems, scaling and poor control. Flow rates above
the maximum values will result in unacceptable pressure drops
and can cause excessive erosion, potentially leading to failure.
Figure 7: Typical Piping, Brazed-Plate Evaporator (models AGZ030E-070E)
Install piping with minimum bends and changes in elevation to
minimize pressure drop. The following issues should be
considered when designing and installing water piping:
1 Vibration eliminators to reduce vibration and noise
transmission to the building.
2 Shutoff valves are required to isolate the unit from the
piping during unit servicing.
3 Manual or automatic air vent valves at the high points of
the system. Drains must be installed at the lowest points
in the system.
4 Adequate water pressure must be maintained (expansion
tank or regulating valve).
5 Temperature and pressure indicators located at the unit
are required to aid in unit servicing.
6 Chilled water piping and strainer must be supported
independently from the unit.
7 Flush the system water piping thoroughly before making
connections to the unit evaporator. Design the water
piping so the chilled water circulating pump discharges
into the evaporator inlet.
8 The unit's evaporator has a thermostat and heater to
prevent freeze-up down to -20 F ( 29 C). The heating
cable can be wired to a separate 115 V supply circuit. As
shipped from the factory, the heating cable is wired to the
IOM 1206-1
control circuit. All water piping to the unit must also be
protected to prevent freezing.
9 If the unit is used as a replacement chiller, flush the
system thoroughly before unit installation. Regular water
analysis and chemical water treatment for the evaporator
loop is recommended immediately at equipment start-up.
10 The total water volume in the system should be sufficient
to prevent frequent "on-off" cycling. Turnover rate
should not be less than 4 minutes for normal variable
cooling loads.
11 When glycol is added to the water system for freeze
protection, the refrigerant suction pressure will be lower,
cooling performance less, and water side pressure drop
greater. If the percentage of glycol is high, or if
propylene is used instead of ethylene glycol, the added
pressure drop and loss of performance could be
substantial. When Glycol or Ice are selected as Unit
Mode, the MicroTech III control will automatically reset
the available range for the Leaving Water Temperature,
Freezestat and Evaporator Pressure settings.
12 Reset the freezestat setting to 6 degrees F (3.3 degrees C)
below the leaving chilled water setpoint temperature
after the glycol percentage is verified safe for the
application. See the section titled "Glycol Solutions" on
page 9 for additional information concerning glycol.
7
Installation and Application Information
13 Perform a preliminary leak check before insulating the
piping and filling the system.
14 Piping insulation should include a vapor barrier to
prevent condensation and possible damage to the
building structure.
Water Connections
Bring water piping to the evaporator through the side between
the vertical supports. Provide taps for the connection of
pressure gauges and thermometers in the inlet and outlet lines.
Check the inlet and outlet labels on the unit against the
certified drawings supplied on the job and be sure the water
piping is hooked up correctly. Contact the Daikin Applied
sales office if any discrepancies exist.
System Water Volume Considerations
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 storage tank
may have to be added to the system.
BAS should enable chiller only when there is a cooling
demand.
Evaporator Freeze Protection
Evaporator freeze-up can be a concern in the application of aircooled water chillers. To protect against freeze-up, insulation
and electric heaters are furnished with the unit; models 030
through 070 have an external plate heater and thermostat. They
protect the evaporator down to -20° F (-29° C) ambient air
temperature. Although the evaporator is equipped with freeze
protection, it does not protect water piping external to the unit
or the evaporator itself if there is a power failure or heater
cable burnout, or if the chiller is unable to control the chilled
water pumps. Use one of the following recommendations for
additional protection:
1 If the unit will not be operated during the winter, drain
evaporator and chilled water piping and flush with
glycol.
2 Add a glycol solution to the chilled water system to
provide freeze protection. Freeze point should be
8
approximately ten degrees (F) below minimum design
ambient temperature.
3 The addition of thermostatically controlled heat and
insulation to exposed piping.
The evaporator heater cable is factory wired to the 115 volt
circuit in the control box. This power should be supplied from
a separate source, but it can be supplied from the control
circuit. Operation of the heaters is automatic through the
ambient sensing thermostat that energizes the evaporator
heaters for protection against freeze-up. Unless the evaporator
is drained in the winter or contains an adequate concentration
of anti-freeze, the disconnect switch to the evaporator heater
must not be open.
Chilled Water Pump
It is important that the chilled water pumps be wired to, and
controlled by, the chiller's microprocessor. When equipped
with optional dual pump output, the chiller controller has the
capability to selectively send the signal to a pump relay (by
others) to start pump A or B or automatically alternate pump
selection and also has standby operation capability. The
controller will energize the pump whenever at least one circuit
on the chiller is enabled to run, whether there is a call for
cooling or not. This helps ensure proper unit start-up sequence.
The pump will also be turned on when the water temperature
reaches 1°F below the Freeze Setpoint to help prevent
evaporator freeze-up. Connection points are shown in the Field
Wiring Diagram on page 20.
CAUTION
Adding glycol or draining the system is the recommended method of
freeze protection. If the chiller does not have the ability to control the
pumps and the water system is not drained in temperatures below
freezing, catastrophic evaporator failure may occur.
Failure to allow pump control by the chiller may cause the
following problems:
1 If any device other than the chiller attempts to start the
chiller without first starting the pump, the chiller will
lock out on the No Flow alarm and require manual reset.
2 If the chiller evaporator water temperature drops below
the “Freeze setpoint” the chiller will attempt to start the
water pumps to avoid evaporator freeze. If the chiller
does not have the ability to start the pumps, the chiller
will alarm due to lack of water flow.
3 If the chiller does not have the ability to control the
pumps and the water system is not to be drained in
temperatures below freezing, the chiller may be subject
to catastrophic evaporator failure due to freezing. The
freeze rating of the evaporator is based on the immersion
heater and pump operation. The immersion heater itself
may not be able to properly protect the evaporator from
freezing without circulation of water.
IOM 1206-1
Installation and Application Information
Low Ambient Operation
Compressor staging is adaptively determined by system load,
ambient air temperature, and other inputs to the MicroTech III
control. A low ambient option with fan VFD allows operation
down to -10° F (-23° C). The minimum ambient temperature is
based on still conditions where the wind is not greater than
five mph. Greater wind velocities will result in reduced
discharge pressure, increasing the minimum operating ambient
temperature. Field installed hail/wind guards are available to
allow the chiller to operate effectively down to the ambient
temperature for which it was designed.
High Ambient Operation
AGZ-E units for high ambient operation (104ºF to 125ºF,
40ºC to 52ºC) require the addition of the optional high ambient
package that includes a small fan with a filter in the air intake
to cool the control panel.
There is also a set of normally closed contacts on the switch
that can be used for an indicator light or an alarm to indicate
when a "no flow" condition exists. Freeze protect any flow
switch that is installed outdoors. Differential pressure switches
are not recommended for outdoor installation. They can freeze
and not indicate a no-flow conditions.
Glycol Solutions
The use of a glycol/water mixture in the evaporator to prevent
freezing will reduce system capacity and efficiency, as well as
increase pressure drop. The system capacity, required glycol
solution flow rate, and pressure drop with glycol may be
calculated using the following formulas and tables.
Glycol Flow (gpm) =
CapacityTo ns
0 .00429 × Delta − T
× Flow Correction Factor
1 Capacity - Multiply the capacity based on water by the
Capacity correction factor from Table 3 or Table 4.
All units with the optional VFD low ambient fan control
automatically include the high ambient option.
2 Flow - Multiply the water evaporator flow by the Flow
correction factor from Table 3 or Table 4 to determine
the increased evaporator flow due to glycol. If the flow is
unknown, it can be calculated from the following
equation:
Flow Switch
All chillers require a chilled water flow switch to check that
there is adequate water flow through the evaporator ant to shut
the unit down if there isn't. There are two options for meeting
this requirement.
3 Pressure drop - Multiply the water pressure drop from
Table 15, page 18 by Pressure Drop correction factor
from Table 3 or Table 4. High concentrations of
propylene glycol at low temperatures may cause
unacceptably high pressure drops.
1 A factory-mounted thermal dispersion flow switch.
2 A "paddle" type flow switch is available from Daikin
Applied (part number 017503300) for field mounting
and wiring. Wire from switch terminals Y and R to the
unit control panel terminals shown on the field wiring
diagrams, page 21 and page 22. Mount the flow switch in
the leaving water line to shut down the unit when water
flow is interrupted. A flow switch is an equipment
protection control and should never be used to cycle a
unit.
Installation should be per manufacturer's instructions included
with the switch. Flow switches should be calibrated to shut off
the unit when operated below the minimum listed flow rate for
the unit as listed on page 18.
4 Power - Multiply the water system power by Power
correction factor from Table 3 or Table 4.
Test coolant with a clean, accurate glycol solution hydrometer
(similar to that found in service stations) or refractto determine
the freezing point. Obtain percent glycol from the freezing
point table below. It is recommended that a minimum of 25%
solution by weight be used for protection against corrosion or
that additional compatible inhibitors be added. Concentrations
above 35% do not provide any additional burst protection and
should be carefully considered before using.
CAUTION
Do not use an automotive-grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors
which will cause plating on the copper tubes within the chiller evaporator. The type and handling of glycol used must be
consistent with local codes.
Table 3: Ethylene Glycol Factors
% E.G.
Freeze Point
Table 4: Propylene Glycol Factors
Capacity
Power
Flow
PD
% P.G.
-3.3
0.998
0.998
1.036
1.097
-7.8
0.993
0.997
1.060
1.226
7
-13.9
0.987
0.995
1.092
40
-7
-21.7
0.980
0.992
50
-28
-33.3
0.973
0.991
oF
oC
10
26
20
18
30
IOM 1206-1
Freeze Point
Capacity
Power
Flow
PD
-3.3
0.995
0.997
1.016
1.100
-7.2
0.987
0.995
1.032
1.211
9
-12.8
0.978
0.992
1.057
1.380
40
-5
-20.6
0.964
0.987
1.092
1.703
50
-27
-32.8
0.952
0.983
1.140
2.251
oF
oC
10
26
20
19
1.369
30
1.132
1.557
1.182
1.791
9
Lifting and Mounting Weights
Lifting and Mounting Weights
Figure 8: Lifting Locations
Approximate Lifting Locations
See Dimension Drawing for exact location
L1
L4
L2
CONTROL PANEL
L3
Figure 9: Mounting Locations
2
4
1
3
CONTROL
PANEL END
Table 5: Lifting and Mounting Weights - Packaged Chillers with Microchannel Coils
P A C KA G E UN IT S WIT H M IC R O C H A N N E L C O ILS
UN IT
M OD EL
A GZ 030E
A GZ 035E
A GZ 040E
A GZ 045E
A GZ 050E
A GZ 055E
A GZ 060E
A GZ 065E
A GZ 070E
10
S H IP P IN G O P E R A T IN G LIF T IN G C O R N E R WE IG H T LB S ( KG )
B A S E D O N S H IP P IN G WE IG H T
WE IG H T
WE IG H T
M O UN T IN G WE IG H T LB S ( KG )
B A S E D O N O P E R A T IN G WE IG H T
LB S ( KG )
LB S ( KG )
L1
L2
L3
L4
M1
M2
M3
M4
2947
(1337)
2873
(1303)
2948
(1337)
3094
(1403)
3093
(1403)
3106
(1409)
3130
(1420)
3130
(1420)
3472
(1575)
2960
(1343)
2887
(1310)
2964
(1344)
3112
(1412)
3114
(1412)
3128
(1419)
3155
(1431)
3155
(1431)
3497
(1586)
1011
(459)
1051
(477)
1067
(484)
1051
(477)
1049
(476)
1052
(477)
1059
(480)
1059
(480)
1180
(535)
799
(362)
861
(391)
881
(400)
832
(377)
837
(380)
840
(381)
851
(386)
851
(386)
847
(384)
635
(288)
528
(240)
548
(249)
676
(307)
671
(304)
675
(306)
676
(307)
676
(307)
842
(382)
502
(228)
433
(196)
453
(205)
535
(243)
536
(243)
539
(244)
543
(246)
543
(246)
604
(274)
980
(445)
1005
(456)
1022
(464)
1021
(463)
1020
(463)
1023
(464)
1031
(468)
1031
(468)
1157
(525)
775
(352)
824
(374)
844
(383)
809
(367)
814
(369)
817
(371)
828
(376)
828
(376)
830
(377)
673
(305)
581
(264)
601
(273)
715
(324)
712
(323)
716
(325)
718
(326)
718
(326)
880
(399)
532
(241)
476
(216)
496
(225)
567
(257)
568
(258)
572
(259)
577
(262)
577
(262)
631
(286)
IOM 1206-1
Lifting and Mounting Weights
Table 6: Lifing and Mounting Weights - Packaged Chillers with Copper Tubes and Aluminum Fin Coils
P A C KA G E UN IT S WIT H C O P P E R T UB E A N D A LUM IN UM F IN C O ILS
UN IT
M OD EL
A GZ 030E
A GZ 035E
A GZ 040E
A GZ 045E
A GZ 050E
A GZ 055E
A GZ 060E
A GZ 065E
A GZ 070E
IOM 1206-1
S H IP P IN G O P E R A T IN G LIF T IN G C O R N E R WE IG H T LB S ( KG )
B A S E D O N S H IP P IN G WE IG H T
WE IG H T
WE IG H T
M O UN T IN G WE IG H T LB S ( KG )
B A S E D O N O P E R A T IN G WE IG H T
LB S ( KG )
LB S ( KG )
L1
L2
L3
L4
M1
M2
M3
M4
3044
(1381)
2978
(1351)
3030
(1374)
3292
(1493)
3317
(1505)
3334
(1512)
3359
(1524)
3364
(1526)
3709
(1682)
3057
(1387)
2992
(1357)
3046
(1382)
3310
(1501)
3338
(1514)
3356
(1522)
3384
(1535)
3389
(1537)
3734
(1674)
1032
(468)
1075
(488)
1083
(491)
1093
(496)
1098
(498)
1102
(500)
1110
(503)
1110
(503)
1232
(559)
822
(373)
887
(402)
898
(407)
877
(398)
886
(402)
891
(404)
902
(409)
903
(410)
898
(407)
662
(300)
556
(252)
574
(260)
733
(332)
737
(334)
742
(337)
743
(337)
745
(338)
914
(415)
527
(259)
459
(208)
476
(216)
588
(267)
595
(270)
600
(272)
604
(275)
606
(275)
667
(303)
1002
(454)
1030
(467)
1039
(471)
1065
(483)
1071
(486)
1075
(488)
1083
(491)
1084
(492)
1210
(549)
798
(362)
850
(386)
862
(391)
854
(387)
864
(392)
869
(394)
880
(399)
881
(400)
882
(400)
700
(318)
609
(276)
626
(284)
772
(350)
776
(352)
781
(354)
784
(356)
786
(357)
950
(431)
558
(253)
502
(228)
519
(235)
619
(281)
627
(284)
631
(286)
637
(289)
639
(290)
692
(314)
11
Lifting and Mounting Weights
Figure 10: Spring and RIS Isolators
RP-4 Rubber-in-Shear (RIS)
CP-2 Spring Isolator
6.25
5.00
3.75
3.00
ø .500-13NC-2B
R4
4.63
.56 TYP.
V M& C
VM & C
3.87
R.28
TYP.
R4
R.250 TYP.
RECESSED
GR IP RIBS
DURULENE
MAT ERIAL
R.750 TYP.
1.13 ± .25
APPR OX.
1.63
.38
RAISED GR IP RIBS
N OT ES :
1.
MO U N T MA TE R IA L T O BE D U R U LE N E R U B BE R .
2.
MO LD E D S TE E L A N D E LA S TOM E R M OU N T F OR
OU T D OOR S ER V I C E C ON D I TI ON S .
3.
R P -4 M OU N T V ER SI ON W I TH ST U D I N P LA C E .
DRAWING NUMBER 3314814
A LL D IM EN S ION S A RE I N D E CI MA L I N CH E S
Table 7: Isolator Kit Numbers
Spring Isolator Kit Numbers
12
R-I-S Isolator Kit Numbers
Packaged Unit
Packaged Unit
Copper Fins
AGZ-E
Model
Alum inum Fins
Copper Fins
332320102
332320132
030
332325101
332325101
332320102
332320132
035
332325101
332325101
332320102
332320132
040
332325101
332325101
AGZ-E
Model
Alum inum Fins
030
035
040
045
332320132
332320132
045
332325101
332325101
050
332320132
332320132
050
332325101
332325101
055
332320132
332320132
055
332325101
332325101
060
332320132
332320132
060
332325101
332325101
065
332320132
332320109
065
332325101
332325101
070
332320132
332320109
070
332325101
332325101
IOM 1206-1
Lifting and Mounting Weights
Table 8: Isolator Locations (Microchannel and Aluminum Fins/Copper Tubes)
AGZ-E
Model
030
035
040
045
050
055
060
065
070
Rubber-In-Shear (RIS) Mounts
M1
M2
M3
M4
RP -4
RP -4
RP -4
B ro wn
B ro wn
RP -4
RP -4
B ro wn
B ro wn
M5
M6
Spring Isolator Mountings
M7
M8
M1
M2
M3
M4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
Dk Grn
Dk P rpl
B lack
B lack
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
Dk Grn
Dk P rpl
B lack
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
B lack
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
Dk P rpl
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
Dk P rpl
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
Dk P rpl
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
Dk P rpl
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
Dk P rpl
B lack
RP -4
RP -4
RP -4
RP -4
CP -2
CP -2
CP -2
CP -2
B ro wn
B ro wn
B ro wn
B ro wn
Dk Grn
Dk P rpl
Dk P rpl
B lack
M1
M2
M3
M4
M5
M6
M7
M8
Table 9: Isolator Locations (Copper Fins)
AGZ-E
Model
030
035
040
045
050
055
060
065
070
Rubber-In-Shear (RIS) Mounts
M5
M6
Spring Isolator Mountings
M1
M2
M3
M4
M7
M8
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dk Purple
Dk Purple
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dark Grn
Dark Grn
Black
RP-4
RP-4
RP-4
RP-4
CP-2
CP-2
CP-2
CP-2
Brown
Brown
Brown
Brown
Dark Grn
Dark Grn
Dark Grn
Black
IOM 1206-1
M5
M6
M7
M8
13
Lifting and Mounting Weights
Table 10: Seismic Isolator Kit Numbers
Figure 11: Seismic Neoprene Isolation Pads
8.00
203.2
Pack age d Unit - Alum inum Fins
AGZ-E
M ode l
Ne opre ne Pads
Spring Is olators
030
334549001
334548801
035
334549001
334548801
040
334549001
334548801
045
334549001
334548801
050
334549001
334548801
055
334549001
334548801
060
334549001
334548801
065
334549001
334548801
070
334549001
334548802
4.00
101.6
2.00
50.8
.875
22.2
THRU
ALL
4.00
101.6
Figure 12: Seismic Spring Isolators
1 1/8
8
13/16DIAHOLEFOR
ATTACHMENT TO
CONCRETE (6 TYP)
(BASEPLATE)
3/4DIAHOLEFOR
ATTACHMENTTO
STEEL (4TYP)
(VIEWCUTAWAYFORCLARITY)
21/4
61/4
27/8
27/8
7/
1 1/2
5 1/8
7 1/4
5 3/4
3/4REMOVABLE
ADJUSTING BOLT
STEELSHIM
(REMOVEAFTER
SPRINGADJUSTMENT)
3/4STD.WASHER
(BY OTHERS)
3/8GAP
1/2
1/4-3/8
61/8
FREE &
OPERATING
HEIGHT
ELASTOMERIC
SNUBBER
LIMIT STOPS
(NOT SHOWN
IN TOP VIEW
FOR CLARITY)
SHIPPING SPACER
ASSY STRAP
(NOT SHOWN
IN OTHER VIEWS
FOR CLARITY)
3/8
10 1/4
8
Table 11: Seismic Isolator Locations
Neoprene Pads
AGZ-E
Model
M1
M2
M3
M4
030
Brown
Brown
Brown
035
Brown
Brown
040
Brown
Brown
045
Brown
050
14
M5
Spring Isolators
M6
M7
M8
M1
M2
M3
M4
Brown
Pink
Pink
Tan
Tan
Brown
Brown
Pink
Pink
Tan
Tan
Brown
Brown
Pink
Pink
Tan
Tan
Brown
Brown
Brown
Pink
Pink
Tan
Tan
Brown
Brown
Brown
Brown
Pink
Pink
Tan
Tan
055
Brown
Brown
Brown
Brown
Pink
Pink
Tan
Tan
060
Brown
Brown
Brown
Brown
Pink
Pink
Tan
Tan
065
Brown
Brown
Brown
Brown
Pink
Pink
Tan
Tan
070
Brown
Brown
Brown
Brown
Pink
Pink
Pink
Tan
M5
M6
M7
M8
IOM 1206-1
Physical Data - Packaged Units
Table 12: Physical Data - AGZ030E - AGZ040E
Physical Data - Packaged Units
Physical Data
AGZ030E
CIRCUIT 1
AGZ-E (Microchannel Packaged Chiller)
AGZ035E
CIRCUIT 2
BASIC DATA
28.1 (98.8)
Unit Cap. @ AHRI tons (kW) - See Note 1
Unit Operating Charge lbs (kg) - Sealed Filter Drier
14 (6.4)
14 (6.4)
- Replaceable Core Filter Drier
16 (7.3)
16 (7.3)
94.4 x 88 x 100.4
Unit Dim ens ions
(2398 x 2235 x 2550)
L x W x H, in. (m m )
2960 (1343)
Package Unit Operating Weight, lbs . (kg)
2947 (1337)
Package Unit Shipping Weight, lbs (kg)
N/A
Weight-Add for (Upper) Louvered Panels , lbs (kg)
144 (65)
Weight-Add for (Lower) Louvered Panels , lbs (kg)
COMPRESSORS, SCROLL, HERMETIC
Nom inal HP
7.5 / 7.5
7.5 / 7.5
Oil charge per Com pres s or , oz (g)
85 (2410)
85 (2410)
Staging, 4 Stages (If Circuit is in Lead)
0-25-50-75-100 0-25-50-75-100
MICROCHANNEL CONDENSER
Coil Inlet Face Area, s q. ft. (s q. m .)
24.9 (2.3)
24.9 (2.3)
Rows Deep/Fins Per Inch
1 / 21
1 / 21
CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE
# of Fans per Circuit - Fan Diam eter in (m m )
4 - 30 (762)
4 - 30 (762)
1.5 (1.1)
Fan Motor, hp (kW)
Fan & Motor RPM
1140
Fan Tip Speed, fpm (m /s )
8950 (45)
Airflow, cfm (l/s )
EVAPORATOR, BRAZED PLATE
Evaporator, Model (1 Evaporator / 2 Circuits )
Dry Weight lbs (kg)
Water Volum e, gallons (liters )
Victaulic inlet/outlet conn. in. (m m )
Max. Water Pres s ure, ps i (kPa)
Max. Refrigerant Pres s ., ps i (kPa)
Note
Note
Note
Note
1:
2:
3:
4:
CIRCUIT 1
CIRCUIT 2
34.9 (122.7)
14 (6.4)
14 (6.4)
16 (7.3)
16 (7.3)
94.4 x 88 x 100.4
(2398 x 2235 x 2550)
2887 (1310)
2873 (1303)
N/A
144 (65)
AGZ040E
CIRCUIT 1
CIRCUIT 2
39.2 (137.9)
19 (8.6)
19 (8.6)
21 (9.5)
21 (9.5)
94.4 x 88 x 100.4
(2398 x 2235 x 2550)
2964 (1344)
2948 (1337)
167 (76)
144 (65)
9.0 / 9.0
85 (2410)
10.0 / 10.0
85 (2410)
10.0 / 10.0
85 (2410)
10.0 / 10.0
85 (2410)
0-23-50-73-100
0-27-50-77-100
0-25-50-75-100
0-25-50-75-100
24.9 (2.3)
1 / 21
24.9 (2.3)
1 / 21
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
4 - 30 (762)
4 - 30 (762)
1.5 (1.1)
1140
8950 (45)
4 - 30 (762)
4 - 30 (762)
1.5 (1.1)
1140
8950 (45)
34,000 (16047)
34,000 (16047)
40,400 (19,067)
ACH-230DQ-78H
84 (38.1)
2.0 (7.6)
2.5 (65)
653 (4502)
653 (4502)
ACH-230DQ-86H
91 (41.3)
2.2 (8.4)
2.5 (65)
653 (4502)
653 (4502)
ACH-230DQ-94H
98 (44.5)
2.4 (9.2)
2.5 (65)
653 (4502)
653 (4502)
Nominal capacity based on 95° F ambient air and 54° F/44° F water range.
For all 380V/60 & 575V/60 models, HP = 2.0.
Water connection shown is nominal pipe size.
Brazed plate evaporators do not have drain or vent connections integral to the heat exchanger. The connections must be installed in the field inlet and
outlet piping as shown in Piping Section of IM 1100, available on www.DaikinApplied.com.
IOM 1206-1
15
Physical Data - Packaged Units
Table 13: Physical Data - AGZ045E - AGZ055E
Physical Data
AGZ045E
CIRCUIT 1
AGZ-E (Microchannel Packaged Chiller)
AGZ050E
CIRCUIT 2
BASIC DATA
Unit Cap. @ AHRI tons (kW) - See Note 1
42.6 (149.8)
Unit Operating Charge lbs (kg) - Sealed Filter Drier
19 (8.6)
19 (8.6)
- Replaceable Core Filter Drier
21 (9.5)
21 (9.5)
Unit Dim ens ions
94.4 x 88 x 100.4
L x W x H, in. (m m )
(2398 x 2235 x 2550)
Package Unit Operating Weight, lbs . (kg)
3112 (1412)
Package Unit Shipping Weight, lbs (kg)
3094 (1403)
Weight-Add for (Upper) Louvered Panels , lbs (kg)
167 (76)
Weight-Add for (Lower) Louvered Panels , lbs (kg)
144 (65)
COMPRESSORS, SCROLL, HERMETIC
Nom inal HP
12.0 / 12.0
12.0 / 12.0
Oil charge per Com pres s or , oz (g)
110 (3119)
110 (3119)
Staging, 4 Stages (If Circuit is in Lead)
0-25-50-75-100 0-25-50-75-100
MICROCHANNEL CONDENSER
Coil Inlet Face Area, s q. ft. (s q. m .)
49.8 (4.6)
49.8 (4.6)
Rows Deep/Fins Per Inch
1 / 21
1 / 21
CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE
# of Fans per Circuit - Fan Diam eter in (m m )
4 - 30 (762)
4 - 30 (762)
Fan Motor, hp (kW)
1.5 (1.1)
Fan & Motor RPM
1140
Fan Tip Speed, fpm (m /s )
8950 (45)
Airflow, cfm (l/s )
EVAPORATOR, BRAZED PLATE
Evaporator, Model (1 Evaporator / 2 Circuits )
Dry Weight lbs (kg)
Water Volum e, gallons (liters )
Victaulic inlet/outlet conn. in. (m m )
Max. Water Pres s ure, ps i (kPa)
Max. Refrigerant Pres s ., ps i (kPa)
Note
Note
Note
Note
16
1:
2:
3:
4:
CIRCUIT 1
CIRCUIT 2
48.3 (169.8)
19 (8.6)
19 (8.6)
21 (9.5)
21 (9.5)
94.4 x 88 x 100.4
(2398 x 2235 x 2550)
3114 (1412)
3093 (1403)
167 (76)
144 (65)
AGZ055E
CIRCUIT 1
CIRCUIT 2
51.8 (182.1)
19 (8.6)
19 (8.6)
21 (9.5)
21 (9.5)
94.4 x 88 x 100.4
(2398 x 2235 x 2550)
3128 (1419)
3106 (1409)
167 (76)
144 (65)
13.0 / 13.0
110 (3119)
13.0 / 13.0
110 (3119)
13.0 / 13.0
110 (3119)
15.0 / 15.0
110 (3119)
0-25-50-75-100
0-25-50-75-100
0-23-50-73-100
0-27-50-77-100
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
4 - 30 (762)
4 - 30 (762)
1.5 (1.1)
1140
8950 (45)
4 - 30 (762)
4 - 30 (762)
1.5 (1.1)
1140
8950 (45)
40,400 (19,067)
40,400 (19,067)
40,400 (19,067)
ACH-230DQ-110H
112 (50.1)
2.3 (8.7)
2.5 (65)
653 (4502)
653 (4502)
ACH-230DQ-126H
126 (57.2)
2.6 (9.8)
2.5 (65)
653 (4502)
653 (4502)
ACH-230DQ-134H
133 (60.3)
2.8 (10.6)
2.5 (65)
653 (4502)
653 (4502)
Nominal capacity based on 95° F ambient air and 54° F/44° F water range.
For all 380V/60 & 575V/60 models, HP = 2.0.
Water connection shown is nominal pipe size.
Brazed plate evaporators do not have drain or vent connections integral to the heat exchanger. The connections must be installed in the field inlet and
outlet piping as shown in Piping Section beginning on of IM 1100, available on www.DaikinApplied.com.
IOM 1206-1
Physical Data - Packaged Units
Table 14: Physical Data - AGZ060E - AGZ070E
Physical Data
AGZ-E (Microchannel Packaged Chiller)
AGZ060E
AGZ065E
AGZ070E
CIRCUIT 1
CIRCUIT 2
CIRCUIT 1
CIRCUIT 2
CIRCUIT 1
CIRCUIT 2
BASIC DATA
Unit Cap. @ AHRI tons (kW) - See Note 1
57.0 (200.5)
Unit Operating Charge lbs (kg) - Sealed Filter Drier
19 (8.6)
19 (8.6)
- Replaceable Core Filter Drier
21 (9.5)
21 (9.5)
Unit Dim ens ions
94.4 x 88 x 100.4
L x W x H, in. (m m )
(2398 x 2235 x 2550)
Package Unit Operating Weight, lbs . (kg)
3155 (1431)
Package Unit Shipping Weight, lbs (kg)
3130 (1420)
Weight-Add for (Upper) Louvered Panels , lbs (kg)
167 (76)
Weight-Add for (Lower) Louvered Panels , lbs (kg)
144 (65)
COMPRESSORS, SCROLL, HERMETIC
Nom inal HP
15.0 / 15.0
15.0 / 15.0
Oil charge per Com pres s or , oz (g)
110 (3119)
110 (3119)
Staging, 4 Stages (If Circuit is in Lead)
0-25-50-75-100 0-25-50-75-100
MICROCHANNEL CONDENSER
Coil Inlet Face Area, s q. ft. (s q. m .)
49.8 (4.6)
49.8 (4.6)
Rows Deep/Fins Per Inch
1 / 21
1 / 21
CONDENSER FANS, DIRECT DRIVE PROPELLER TYPE
# of Fans per Circuit - Fan Diam eter in (m m )
4 - 30 (762)
4 - 30 (762)
Fan Motor, hp (kW)
1.5 (1.1)
Fan & Motor RPM
1140
Fan Tip Speed, fpm (m /s )
8950 (45)
Airflow, cfm (l/s )
40,400 (19,067)
EVAPORATOR, BRAZED PLATE
Evaporator, Model (1 Evaporator / 2 Circuits )
ACH-230DQ-154H
Dry Weight lbs (kg)
150 (68.1)
Water Volum e, gallons (liters )
2.8 (10.6)
Victaulic inlet/outlet conn. in. (m m )
2.5 (65)
Max. Water Pres s ure, ps i (kPa)
653 (4502)
653 (4502)
Max. Refrigerant Pres s ., ps i (kPa)
Note
Note
Note
Note
1:
2:
3:
4:
58.7 (206.4)
19 (8.6)
19 (8.6)
21 (9.5)
21 (9.5)
94.4 x 88 x 100.4
(2398 x 2235 x 2550)
3155 (1431)
3130 (1420)
167 (76)
144 (65)
65.1 (228.9)
20 (9.1)
20 (9.1)
22 (10.0)
22 (10.0)
94.4 x 88 x 100.4
(2398 x 2235 x 2550)
3497 (1586)
3472 (1575)
167 (76)
144 (65)
15.0 / 15.0
110 (3119)
15.0 / 15.0
110 (3119)
15.0 / 20.0
110 (3119)
152 (4309)
15.0 / 20.0
110 (3119)
152 (4309)
0-25-50-75-100
0-25-50-75-100
0-21-50-71-100
0-28-50-78-100
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
49.8 (4.6)
1 / 21
4 - 30 (762)
4 - 30 (762)
2.0 (1.5)
1140
8950 (45)
48,000 (22654)
4 - 30 (762)
4 - 30 (762)
2.0 (1.5)
1140
8950 (45)
48,000 (22654)
ACH-230DQ-154H
150 (68.1)
2.8 (10.6)
2.5 (65)
653 (4502)
653 (4502)
ACH-230DQ-154H
150 (68.1)
2.8 (10.6)
2.5 (65)
653 (4502)
653 (4502)
Nominal capacity based on 95° F ambient air and 54° F/44° F water range.
For all 380V/60 & 575V/60 models, HP = 2.0.
Water connection shown is nominal pipe size.
Brazed plate evaporators do not have drain or vent connections integral to the heat exchanger. The connections must be installed in the field inlet and
outlet piping as shown in Piping Section beginning on of IM 1100, available on www.DaikinApplied.com.
IOM 1206-1
17
Pressure Drop Data
Figure 13: Pressure Drop Curves
Pressure Drop Data
100
A
B
C
D
E
BC
F
E
D F GH
I
G
A
H
I
B CD
D p (ft)
10
E
FGH
I
A
BC
E
H
D FG
I
A
1
10
100
Flow R ate (g pm )
1000
Table 15: Pressure Drop Data
Variable Flow System Only
Minim um Flow Rate
Curve
Ref.
Model
A
18
IP
Fixed Flow System Only
Minim um Flow Rate
SI
IP
Fixed and Variable Flow System s
Nom inal Flow Rate
Maxim um Flow Rate
SI
IP
SI
IP
SI
GPM
DP ft.
lps
DP kpa
GPM
DP ft.
lps
DP kpa
GPM
DP ft.
lps
DP kpa
GPM
DP ft.
lps
30E
27.0
1.7
1.7
5.1
42.2
4.0
2.7
12.0
67.4
9.8
4.3
29.4
112.4
26.0
7.1
DP kpa
77.7
B
35E
33.5
2.4
2.1
7.1
52.4
5.6
3.3
16.7
83.8
13.7
5.3
40.9
139.6
36.4
8.8
108.7
C
40E
37.1
2.5
2.3
7.4
57.9
5.8
3.7
17.3
92.6
14.2
5.8
42.5
154.4
37.7
9.7
112.6
D
45E
40.9
2.3
2.6
6.8
63.9
5.3
4.0
15.8
102.2
13.2
6.5
39.4
170.4
34.4
10.8
102.7
E
50E
46.4
2.7
2.9
7.9
72.5
6.2
4.6
18.5
115.9
15.2
7.3
45.3
193.2
40.0
12.2
119.6
F
55E
G
60E
49.7
54.0
2.3
2.3
3.1
3.4
7.0
6.9
77.7
84.3
5.5
5.4
4.9
5.3
16.3
16.1
124.3
134.9
13.4
13.1
7.8
8.5
40.0
39.3
207.2
224.8
35.6
34.7
13.1
14.2
106.2
103.6
H
65E
I
70E
55.5
61.5
2.4
3.0
3.5
3.9
7.3
8.8
86.7
96.2
5.7
6.9
5.5
6.1
17.0
20.6
138.7
153.8
13.9
16.9
8.8
9.7
41.4
50.4
231.2
256.4
36.6
44.5
14.6
16.2
109.3
133.0
IOM 1206-1
Electrical Data
Electrical Data Notes
Electrical Data
Notes for Unit Amp Draw:
1 Compressor RLA values are for wire sizing purposes
only. Normal operating current draw at rated capacity
may be less than the RLA value.
Notes for Electrical Data Single- and Multi-Point
1 Unit wire size ampacity (MCA) is equal to 125% of the
largest compressor-motor RLA plus 100% of RLA of all
other loads in the circuit.
2 The control transformer is furnished and no separate
115V power is required. For both single- and multi-point
power connections, the control transformer is in circuit
#1 with control power wired from there to circuit #2. In
multi-point power, disconnecting power to circuit #1
disconnects control power to the unit.
3 Wire sizing amps is 15 amps if a separate 115V power
supply is used for the control circuit.
4 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. It is recommended that power leads be kept
short. All terminal block connections must be made with
copper (type THW) wire and aluminum wire.
5 Recommended Fuse Sizes are selected at approximately
175% of the largest compressor RLA, plus 100% of all
other loads in the circuit.
6 Maximum Fuse or breaker size is equal to 225% of the
largest compressor RLA, plus 100% of all other loads.
7 The recommended power 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 NEC Handbook.
8 Must be electrically grounded according to national and
local electrical codes.
Notes for Wiring Data
1 Single-point power supply requires a single disconnect to
supply electrical power to the unit. This power supply
must either be fused or use a circuit breaker.
2 Power wiring connections to the chiller may be done
with either copper or aluminum wiring. Wire should be
sized per NEC and/or local codes. Wire sizing and wire
count must fit in the power connection lug sizing starting
on page 22.
3 Aluminum wire shall be installed in accordance with
NECA/AA 104-2012, Standard for Installing Aluminum
Building Wire and Cable (ANSI).
4 All field wire size values given in table apply to 75°C
rated wire per NEC.
Voltage Limitations:
1 Within 10 percent of nameplate rating.
2 Voltage unbalance not to exceed 2% with a resultant
current unbalance of 6 to 10 times the voltage unbalance
per NEMA MG-1, 2009 Standard Rev. 1-2010.
IOM 1206-1
Table 16: HSCCR Panel Rating
AGZ-E Model Size
208V-230V
380V-460V
575V
030-070
65kA
65kA
25kA
Table 17: Standard Panel Rating
AGZ-E Model Size
208V
230V
380V
460V
575V
030-070
5kA
5kA
5kA
5kA
5kA
Circuit Breakers
Factory installed compressor circuit breakers are standard on
units with single point power supply only. This option provides
compressor short circuit protection and makes servicing easier
Electrical Control Center
Operating and equipment protection controls and motor
starting components are separately housed in a centrally
located, weather resistant control panel with hinged and toollocked doors. In addition to the MicroTech III controller
described in the next sections, the following components are
housed in the panel:
•
•
•
•
•
•
•
•
•
•
Power terminal blocks, multi-point connection standard
Control, input, and output terminal block
Control transformer
Optional disconnect switch (through-the-door handle)
Compressor motor inherent thermal and overload protection is standard
Optional phase voltage monitor with under/over voltage
and phase reversal protection
Fan contactors with short circuit protective devices.
Optional ground fault protection
FanTrol fan staging head pressure control system
Power connections are per the following table
Power Connections
Table 18: Power Connection Availability
Power Connection
Power
Block
Disc. Swt.
Comp Circuit
Breakers
Panel
HSCCR
AGZ030E-070E
Optional Single Point
Std
Opt.
Std
Opt
AGZ030E-070E
Standard Multi-Point
Std
Opt.
Not Avail.
Opt.
Definitions:
1 Power Block: An electrical device to directly accept field
wiring without any disconnecting means.
2 Disconnect Switch: A molded case switch that accepts
field wiring and disconnects main power to the entire
unit or each main power supply if the multi-point power
supply option is selected. This option does not provide
overcurrent protection.
3 Compressor Circuit Breakers: A manually reset circuit
breaker for each compressor, providing compressor only
short circuit protection and located ahead of contactor.
4 Control Panel High Short Circuit Current Rating:
(Previously "withstand rating"). The entire control panel
is designed for short circuit current rating in Table 16. In
the event of a short circuit, the damage is contained
within the control panel enclosure.
19
Field Wiring Diagram
Figure 14: Typical Field Wiring Diagram (Single-point connection)
Field Wiring Diagram
FIELD WIRING DIAGRAM
WITH MICROTECH CONTROLLER
PANEL
DISCONNECT SWITCH
OR
POWER BLOCK
DISCONNECT
(BY OTHERS)
3 PHASE
POWER
SOURCE
L1
T1
L2
T2
L3
T3
TO
COMPRESSOR(S)
AND FAN MOTORS
FU4
FU5
T1
TB1
CHW1
PUMP NO.1 RELAY
(BY OTHERS)
120VAC @ 1.0AMP MAX
35
120 VAC
301
FU6
CONTROL CIRCUIT
FUSE
SEE NOTE 1
TB1
33
N
301A
299
120
VAC
TB1
1A
TB1
CHW2
PUMP NO.2 RELAY
(BY OTHERS)
120VAC @ 1.0AMP MAX
P2+ 120 VAC
ALARM BELL
RELAY
N
FU
15A for 1.5 KVA
30A for 3.0KVA
(BY OTHERS)
120 VAC
FIELD
SUPPLIED
OPTION
Notes:
1.) IF FIELD SUPPLIED, CONTROL
POWER USER MUST REMOVE
FU6, AND WIRE NUMBERS 299, 301A
INSIDE CONTROL PANEL
TB1
31
DISCONNECT
(BY OTHERS)
TB1 22
N
(FACTORY WIRING)
TB1
34
120 VAC
ABR
ALARM
BELL OPTION
TB1
32A
TIME
CLOCK
TB2
52
IF REMOTE STOP
CONTROL IS USED
585 REMOVE LEAD 585
FROM TERM
TB2
TB2-52 TO TB2-72
72
AUTO
REMOTE
STOP SWITCH
(BY OTHERS)
ON
MANUAL
OFF
TIME
CLOCK
ON
COM NO
ABR
1
BELL
ALARM BELL
OPTION
2
TB2
74
MANUAL
CHW FLOW SWITCH
-MANDATORY(BY OTHERS)
43
83
54
ALARM BELL
RELAY
TB2
TB2
TB2
AUTO
ICE MODE
SWITCH
(BY OTHERS)
GND
(317)
OFF
TB2
45
NOR. OPEN PUMP
AUX. CONTACTS
(OPTIONAL)
TB2
TB2
EXTERNAL
ALARM/
EVENT
67
44
TB2
61
TB2
+
4-20MA FOR
EVAP. WATER RESET
(BY OTHERS)
_
68
TB2
69
TB2
4-20MA FOR
DEMAND LIMIT
(BY OTHERS)
+
70
TB2
_
71
TB2
91
LIQUID LINE #1
SOLENOID
24VAC 1.5 AMP MAX
TB2
93A
LESS
EVAPORATOR
ONLY
24 VAC
N
SV1
TB2
92
LIQUID LINE #2
SOLENOID
24VAC 1.5 AMP MAX
24 VAC
TB2
93A
N
SV2
20
IOM 1206-1
Field Wiring Diagram
Figure 15: Typical Field Wiring Diagram (Multi-point connection)
FIELD WIRING DIAGRAM
WITH MICROTECH CONTROLLER
PANEL
DISCONNECT SWITCH
OR
POWER BLOCK
DISCONNECT
(BY OTHERS)
3 PHASE
POWER
SOURCE
L1
T1
L2
T2
L3
T3
TO
COMPRESSOR(S)
AND FAN MOTORS
FU4
FU5
T1
TB1
CHW1
PUMP NO.1 RELAY
(BY OTHERS)
120VAC @ 1.0AMP MAX
35
120 VAC
301
FU6
CONTROL CIRCUIT
FUSE
SEE NOTE 1
TB1
33
N
301A
299
120
VAC
TB1 22
TB1
1A
TB1
CHW2
PUMP NO.2 RELAY
(BY OTHERS)
120VAC @ 1.0AMP MAX
P2+ 120 VAC
ALARM BELL
RELAY
N
FU
15A for 1.5 KVA
30A for 3.0KVA
(BY OTHERS)
120 VAC
FIELD
SUPPLIED
OPTION
Notes:
1.) IF FIELD SUPPLIED, CONTROL
POWER USER MUST REMOVE
FU6, AND WIRE NUMBERS 299, 301A
INSIDE CONTROL PANEL
TB1
31
DISCONNECT
(BY OTHERS)
N
(FACTORY WIRING)
TB1
34
120 VAC
ABR
ALARM
BELL OPTION
TB1
32A
OFF
TIME
CLOCK
TB2
52
IF REMOTE STOP
CONTROL IS USED
585 REMOVE LEAD 585
FROM TERM
TB2
TB2-52 TO TB2-72
72
AUTO
REMOTE
STOP SWITCH
(BY OTHERS)
ON
MANUAL
OFF
TIME
CLOCK
ON
COM NO
ABR
1
BELL
ALARM BELL
OPTION
2
TB2
74
MANUAL
CHW FLOW SWITCH
-MANDATORY(BY OTHERS)
43
83
54
ALARM BELL
RELAY
TB2
TB2
TB2
AUTO
ICE MODE
SWITCH
(BY OTHERS)
GND
(317)
TB2
45
NOR. OPEN PUMP
AUX. CONTACTS
(OPTIONAL)
TB2
TB2
EXTERNAL
ALARM/
EVENT
67
44
TB2
61
TB2
+
4-20MA FOR
EVAP. WATER RESET
(BY OTHERS)
_
68
TB2
69
TB2
4-20MA FOR
DEMAND LIMIT
(BY OTHERS)
+
70
TB2
_
71
TB2
91
LIQUID LINE #1
SOLENOID
24VAC 1.5 AMP MAX
TB2
93A
LESS
EVAPORATOR
ONLY
24 VAC
N
SV1
TB2
92
LIQUID LINE #2
SOLENOID
24VAC 1.5 AMP MAX
24 VAC
TB2
93A
N
SV2
IOM 1206-1
21
Electrical Data
Electrical Data
Table 19: Electrical Data - Single Point (50/60 Hz)
Sin g le Po in t Fie ld Data
M ode l
Siz e
030E
035E
040E
045E
050E
055E
060E
065E
070E
L u g Ran g e
Ratin g s
V o ltag e
M CA
RFS
M FS
Po w e r Blo ck
Dis co n n e ct
(1) 6-350MCM
208V /60
149
175
175
(1) 14-2/0
230V /60
149
175
175
(1) 14-2/0
(1) 6-350MCM
380V /60
87
100
100
(1) 14-2/0
(1) 12-1/0
460V /60
74
80
80
(1) 14-2/0
(1) 12-1/0
575V /60
64
70
70
(1) 14-2/0
(1) 12-1/0
(1) 12-1/0
400V /50
77
90
90
(1) 14-2/0
208V /60
163
175
175
(1) 14-2/0
(1) 6-350MCM
230V /60
163
175
175
(1) 14-2/0
(1) 6-350MCM
380V /60
96
110
110
(1) 14-2/0
(1) 4-300MCM
460V /60
77
90
90
(1) 14-2/0
(1) 12-1/0
575V /60
64
70
70
(1) 14-2/0
(1) 12-1/0
400V /50
80
90
90
(1) 14-2/0
(1) 12-1/0
208V /60
168
200
200
(1) 14-2/0
(1) 6-350MCM
230V /60
168
200
200
(1) 14-2/0
(1) 6-350MCM
380V /60
107
125
125
(1) 14-2/0
(1) 4-300MCM
460V /60
80
90
90
(1) 14-2/0
(1) 12-1/0
575V /60
67
80
80
(1) 14-2/0
(1) 12-1/0
400V /50
83
100
100
(1) 14-2/0
(1) 12-1/0
208V /60
228
250
250
(1) 2-600MCM
(1) 6-350MCM
230V /60
228
250
250
(1) 2-600MCM
(1) 6-350MCM
380V /60
117
125
125
(1) 14-2/0
(1) 4-300MCM
460V /60
90
100
100
(1) 14-2/0
(1) 12-1/0
575V /60
75
90
90
(1) 14-2/0
(1) 12-1/0
400V /50
94
110
110
(1) 14-2/0
(1) 4-300MCM
208V /60
241
250
250
(1) 2-600MCM
(2) 3/0-500MCM
230V /60
241
250
250
(1) 2-600MCM
(2) 3/0-500MCM
380V /60
131
150
150
(1) 14-2/0
(1) 4-300MCM
460V /60
109
125
125
(1) 14-2/0
(1) 4-300MCM
575V /60
97
110
110
(1) 14-2/0
(1) 4-300MCM
400V /50
107
125
125
(1) 14-2/0
(1) 4-300MCM
208V /60
251
300
300
(1) 2-600MCM
(2) 3/0-500MCM
230V /60
251
300
300
(1) 2-600MCM
(2) 3/0-500MCM
380V /60
147
175
175
(1) 14-2/0
(1) 6-350MCM
460V /60
118
125
125
(1) 14-2/0
(1) 4-300MCM
575V /60
105
125
125
(1) 14-2/0
(1) 4-300MCM
400V /50
114
125
125
(1) 14-2/0
(1) 4-300MCM
208V /60
260
300
300
(1) 2-600MCM
(2) 3/0-500MCM
230V /60
260
300
300
(1) 2-600MCM
(2) 3/0-500MCM
380V /60
161
175
175
(1) 14-2/0
(1) 6-350MCM
460V /60
126
150
150
(1) 14-2/0
(1) 4-300MCM
575V /60
113
125
125
(1) 14-2/0
(1) 4-300MCM
400V /50
121
125
125
(1) 14-2/0
(1) 4-300MCM
208V /60
268
300
300
(1) 2-600MCM
(2) 3/0-500MCM
230V /60
268
300
300
(1) 2-600MCM
(2) 3/0-500MCM
380V /60
161
175
175
(1) 14-2/0
(1) 6-350MCM
460V /60
129
150
150
(1) 14-2/0
(1) 4-300MCM
575V /60
113
125
125
(1) 14-2/0
(1) 4-300MCM
400V /50
121
125
125
(1) 14-2/0
(1) 4-300MCM
208V /60
306
350
350
(1) 2-600MCM
(2) 3/0-500MCM
230V /60
306
350
350
(1) 2-600MCM
(2) 3/0-500MCM
380V /60
164
200
200
(1) 14-2/0
(1) 6-350MCM
460V /60
138
150
150
(1) 14-2/0
(1) 4-300MCM
575V /60
116
125
125
(1) 14-2/0
(1) 4-300MCM
400V /50
134
150
150
(1) 14-2/0
(1) 4-300MCM
Note: 1.For RFS, if the operating ambient is going to be above 105F, then MFS must be used.
2.Power wiring connections to the chiller may be done with either copper or aluminum wiring. Wire should be sized per NEC
and/or local codes. Wire sizing and wire count must fit in the power connection lug sizing shown in the above table.
22
IOM 1206-1
Electrical Data
Table 20: Electrical Data - Mutli-point (50/60 Hz)
M u ltip le Po in t Fie ld Data - C ir cu it #1
M ode l
Siz e
030E
035E
040E
045E
050E
055E
060E
065E
070E
V o ltag e
M u ltip le Po in t Fie ld Data - C ir cu it #2
L u g Ran g e
Ratin g s
L u g Ran g e
Ratin g s
M CA
RFS
M FS
Po w e r Blo ck
Dis c. Sw itch
M CA
RFS
M FS
Po w e r Blo ck
Dis c. Sw itch
208V /60
78
100
100
(1) 14-2/0
(1) 12-1/0
78
100
100
(1) 14-2/0
(1) 4-300MCM
230V /60
78
100
100
(1) 14-2/0
(1) 12-1/0
78
100
100
(1) 14-2/0
(1) 4-300MCM
380V /60
46
60
60
(1) 14-2/0
(1) 12-1/0
46
60
60
(1) 14-2/0
(1) 12-1/0
460V /60
39
50
50
(1) 14-2/0
(1) 12-1/0
39
50
50
(1) 14-2/0
(1) 12-1/0
575V /60
34
40
45
(1) 14-2/0
(1) 12-1/0
34
40
45
(1) 14-2/0
(1) 12-1/0
400V /50
40
50
50
(1) 14-2/0
(1) 12-1/0
40
50
50
(1) 14-2/0
(1) 12-1/0
208V /60
82
100
110
(1) 14-2/0
(1) 4-300MCM
88
110
110
(1) 14-2/0
(1) 4-300MCM
230V /60
82
100
110
(1) 14-2/0
(1) 4-300MCM
88
110
110
(1) 14-2/0
(1) 4-300MCM
380V /60
44
60
60
(1) 14-2/0
(1) 12-1/0
56
70
70
(1) 14-2/0
(1) 12-1/0
460V /60
39
50
50
(1) 14-2/0
(1) 12-1/0
42
50
50
(1) 14-2/0
(1) 12-1/0
575V /60
32
40
40
(1) 14-2/0
(1) 12-1/0
35
45
45
(1) 14-2/0
(1) 12-1/0
400V /50
40
50
50
(1) 14-2/0
(1) 12-1/0
44
60
60
(1) 14-2/0
(1) 12-1/0
208V /60
88
110
110
(1) 14-2/0
(1) 4-300MCM
88
110
110
(1) 14-2/0
(1) 4-300MCM
230V /60
88
110
110
(1) 14-2/0
(1) 4-300MCM
88
110
110
(1) 14-2/0
(1) 4-300MCM
380V /60
56
70
70
(1) 14-2/0
(1) 12-1/0
56
70
70
(1) 14-2/0
(1) 12-1/0
460V /60
42
50
50
(1) 14-2/0
(1) 12-1/0
42
50
50
(1) 14-2/0
(1) 12-1/0
575V /60
35
45
45
(1) 14-2/0
(1) 12-1/0
35
45
45
(1) 14-2/0
(1) 12-1/0
400V /50
44
60
60
(1) 14-2/0
(1) 12-1/0
44
60
60
(1) 14-2/0
(1) 12-1/0
208V /60
120
150
150
(1) 14-2/0
(1) 4-300MCM
120
150
150
(1) 14-2/0
(1) 6-350MCM
230V /60
120
150
150
(1) 14-2/0
(1) 4-300MCM
120
150
150
(1) 14-2/0
(1) 6-350MCM
380V /60
62
80
80
(1) 14-2/0
(1) 12-1/0
62
80
80
(1) 14-2/0
(1) 12-1/0
460V /60
48
60
60
(1) 14-2/0
(1) 12-1/0
48
60
60
(1) 14-2/0
(1) 12-1/0
575V /60
39
50
50
(1) 14-2/0
(1) 12-1/0
39
50
50
(1) 14-2/0
(1) 12-1/0
400V /50
49
60
60
(1) 14-2/0
(1) 12-1/0
49
60
60
(1) 14-2/0
(1) 12-1/0
208V /60
127
150
175
(1) 14-2/0
(1) 6-350MCM
127
150
175
(1) 14-2/0
(1) 6-350MCM
230V /60
127
150
175
(1) 14-2/0
(1) 6-350MCM
127
150
175
(1) 14-2/0
(1) 6-350MCM
380V /60
69
90
90
(1) 14-2/0
(1) 12-1/0
69
90
90
(1) 14-2/0
(1) 12-1/0
460V /60
58
70
80
(1) 14-2/0
(1) 12-1/0
58
70
80
(1) 14-2/0
(1) 12-1/0
575V /60
51
60
70
(1) 14-2/0
(1) 12-1/0
51
60
70
(1) 14-2/0
(1) 12-1/0
400V /50
56
70
70
(1) 14-2/0
(1) 12-1/0
56
70
70
(1) 14-2/0
(1) 12-1/0
208V /60
127
150
175
(1) 14-2/0
(1) 6-350MCM
137
175
175
(1) 14-2/0
(1) 6-350MCM
230V /60
127
150
175
(1) 14-2/0
(1) 6-350MCM
137
175
175
(1) 14-2/0
(1) 6-350MCM
380V /60
69
90
90
(1) 14-2/0
(1) 12-1/0
85
110
110
(1) 14-2/0
(1) 4-300MCM
460V /60
58
70
80
(1) 14-2/0
(1) 12-1/0
66
80
90
(1) 14-2/0
(1) 12-1/0
575V /60
51
60
70
(1) 14-2/0
(1) 12-1/0
59
70
80
(1) 14-2/0
(1) 12-1/0
400V /50
56
70
70
(1) 14-2/0
(1) 12-1/0
64
80
80
(1) 14-2/0
(1) 12-1/0
208V /60
137
175
175
(1) 14-2/0
(1) 6-350MCM
137
175
175
(1) 14-2/0
(1) 6-350MCM
230V /60
137
175
175
(1) 14-2/0
(1) 6-350MCM
137
175
175
(1) 14-2/0
(1) 6-350MCM
380V /60
85
110
110
(1) 14-2/0
(1) 4-300MCM
85
110
110
(1) 14-2/0
(1) 4-300MCM
460V /60
66
80
90
(1) 14-2/0
(1) 12-1/0
66
80
90
(1) 14-2/0
(1) 12-1/0
575V /60
59
70
80
(1) 14-2/0
(1) 12-1/0
59
70
80
(1) 14-2/0
(1) 12-1/0
400V /50
64
80
80
(1) 14-2/0
(1) 12-1/0
64
80
80
(1) 14-2/0
(1) 12-1/0
208V /60
230V /60
141
141
175
175
175
175
175
175
175
175
85
110
110
(1) 6-350MCM
(1) 6-350MCM
(1) 4-300MCM
141
141
380V /60
(1) 14-2/0
(1) 14-2/0
(1) 14-2/0
85
110
110
(1) 14-2/0
(1) 14-2/0
(1) 14-2/0
(1) 6-350MCM
(1) 6-350MCM
(1) 4-300MCM
460V /60
68
80
90
(1) 14-2/0
(1) 12-1/0
68
80
90
(1) 14-2/0
(1) 12-1/0
575V /60
59
70
80
(1) 14-2/0
(1) 12-1/0
59
70
80
(1) 14-2/0
(1) 12-1/0
400V /50
64
80
80
(1) 14-2/0
(1) 12-1/0
64
80
80
(1) 14-2/0
(1) 12-1/0
208V /60
162
200
225
(1) 14-2/0
(1) 6-350MCM
162
200
225
(1) 14-2/0
(1) 6-350MCM
230V /60
162
200
225
(1) 14-2/0
(1) 6-350MCM
162
200
225
(1) 14-2/0
(1) 6-350MCM
380V /60
86
110
110
(1) 14-2/0
(1) 4-300MCM
86
110
110
(1) 14-2/0
(1) 4-300MCM
460V /60
73
90
100
(1) 14-2/0
(1) 12-1/0
73
90
100
(1) 14-2/0
(1) 4-300MCM
575V /60
61
80
80
(1) 14-2/0
(1) 12-1/0
61
80
80
(1) 14-2/0
(1) 12-1/0
400V /50
71
90
100
(1) 14-2/0
(1) 12-1/0
71
90
100
(1) 14-2/0
(1) 4-300MCM
Note: 1.For RFS, if the operating ambient is going to be above 105F, then MFS must be used.
2.Power wiring connections to the chiller may be done with either copper or aluminum wiring. Wire should be sized per NEC
and/or local codes. Wire sizing and wire count must fit in the power connection lug sizing shown in the above table.
IOM 1206-1
23
Unit Controller Operation
Unit Controller Operation
Unit Controller Operation
1 current unit status
2 control parameters
Overview
3 alarms. Security protection prevents unauthorized
The MicroTech® III controller’s state-of-the-art design not
only permits the chiller to run more efficiently, but also can
simplify troubleshooting if a system failure occurs. Every
MicroTech IIII controller is programmed and tested prior to
shipment to facilitate start-up.
changing of the setpoints and control parameters.
MicroTech III control continuously performs self-diagnostic
checks, monitoring system temperatures, pressures and
protection devices, and will automatically shut down a
compressor or the entire unit should a fault occur. The cause
of the shutdown will be retained in memory and can be easily
displayed in plain English for operator review. The MicroTech
III chiller controller will also retain and display the date/time
the fault occurred. In addition to displaying alarm diagnostics,
the MicroTech III chiller controller also provides the operator
with a warning of limit (pre-alarm) conditions.
The controller menu structure is separated into three distinct
categories that provide the operator or service technician with
a full description of :
Controller Inputs and Outputs
Main Controller
Table 21: Analog Inputs
#
AI1
AI2
AI3
X1
X4
Description
Evaporator EWT
Evaporator LWT
Outside Ambient
Temperature
Demand Limit
LWT Reset
Type
NTC 10k
NTC 10k
Expected Range
340 to 300k Ω
340 to 300k Ω
NTC 10k
340 to 300k Ω
4-20 mA
4-20 mA
1 to 23 mA
1 to 23 mA
Output Type
Voltage
Voltage
Range
0 to 10 volts
0 to 10 volts
Table 22: Analog Outputs
#
X5
X6
Description
Circuit 1 Fan VFD Speed
Circuit 2 Fan VFD Speed
Table 23: Digital Inputs
Description
DI1 External Alarm/Event
DI2 Evaporator Flow Switch
Double Set Point/ Mode
DI3
Switch
DI4 Remote Switch
DI5 Unit Switch
Signal Off
Signal On
External Fault
No External Fault
No Flow
Flow
See sections on Unit Mode Selection and LWT
Target
Remote Disable
Remote Enable
Unit Disable
Unit Enable
Table 24: Digital Outputs
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
DO9
DO10
24
Description
Evaporator Water Pump 1
Alarm Indicator
Circuit 1 Fan Output 1
Circuit 1 Fan Output 2
Circuit 1 Fan Output 3
Circuit 1 Fan Output 4
Circuit 2 Fan Output 1
Circuit 2 Fan Output 2
Circuit 2 Fan Output 3
Circuit 2 Fan Output 4
Output Off
Pump Off
Alarm Not Active
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Fan(s) Off
Output On
Pump On
Alarm Active
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
Fan(s) On
IOM 1206-1
Unit Controller Operation
Compressor Module 1
Table 25: Analog Inputs
X1
X2
X4
Description
Circuit 1 Suction Temperature
Circuit 1 Evaporator Pressure
Circuit 1 Condenser Pressure
Signal Type
NTC 10k
Voltage
Voltage
Expected Range
340 to 300k Ω
0.4 to 4.6 volts
0.4 to 4.6 volts
Signal Off
Circuit Disable
Fault
Fault
Fault
Signal On
Circuit Enable
No fault
No fault
No fault
Table 26: Digital Inputs
X6
X7
X8
DI1
Description
Circuit 1 Switch
Circuit 1 MHP Switch
Circuit 1 Motor Protection
Circuit 1 (or Unit) PVM/GFP
Note: The Motor Protection and MHP input signal are wired in
series. If Motor Protection input is open, MHP Switch
input will also be open.
Table 27: Digital Outputs
DO1
DO2
DO3
DO4
DO5
DO6
Description
Compressor #1
Compressor #3
Compressor #5
Evaporator Water Pump 2
Circuit 1 Hot Gas Bypass SV
Circuit 1 Liquid Line SV
Output Off
Compressor Off
Compressor Off
Compressor Off
Pump Off
Solenoid Closed
Solenoid Closed
Output On
Compressor On
Compressor On
Compressor On
Pump On
Solenoid Open
Solenoid Open
Compressor Module 2
Table 28: Analog Inputs
X1
X2
X4
Description
Circuit 2 Suction Temperature
Circuit 2 Evaporator Pressure
Circuit 2 Condenser Pressure
Signal Type
NTC 10k
Voltage
Voltage
Expected Range
340 to 300k Ω
0.4 to 4.6 volts
0.4 to 4.6 volts
Table 29: Digital Inputs
X6
X7
X8
DI1
Description
Circuit 2 Switch
Circuit 2 MHP Switch
Circuit 2 Motor Protection
Circuit 2 PVM/GFP
Signal Off
Circuit Disable
Fault
Fault
Fault
Signal On
Circuit Enable
No fault
No fault
No fault
Note: The Motor Protection and MHP input signal are wired in
series. If Motor Protection input is open, MHP Switch
input will also be open.
Table 30: Digital Outputs
DO1
DO2
DO3
DO5
DO6
Description
Compressor #2
Compressor #4
Compressor #6
Circuit 2 Hot Gas Bypass SV
Circuit 2 Liquid Line SV
IOM 1206-1
Output Off
Compressor Off
Compressor Off
Compressor Off
Solenoid Closed
Solenoid Closed
Output On
Compressor On
Compressor On
Compressor On
Solenoid Open
Solenoid Open
25
Unit Controller Operation
EXV Module 1 and 2
These modules will be used only when the expansion
valve type is electronic.
Table 31: Digital Outputs
DO1
Description
Circuit 1 Fan Output 5
Output Off
Fan(s) Off
Output On
Fan(s) On
Table 32: Stepper Motor Output
Description
EXV Stepper Coil 1
EXV Stepper Coil 2
M1+, M1M2+, M2-
RapidRestore®
This module will be used only when the unit is equipped with
the RapidRestore option.
Table 33: Digital Inputs
Description
Signal Off
DI1
RapidRestore Enable
Disable RapidRestore
Signal On
Allow RapidRestore
Enabling
DI2
Backup Chiller
Designation
Not Backup Chiller
Backup Chiller
Sensor Information
Temperature
Pressure
All temperature sensors will be Daikin part number 1934146.
Pressure inputs will be read using 0 to 5 volt ratiometric
sensors. Nominal voltage range will be 0.5 to 4.5 volts.
Pressure on the low side will be measured using Daikin part
number 331764501.
Pressure on the high side will be measured using Daikin part
number 331764601.
26
IOM 1206-1
Unit Controller Operation
Setpoints
SetPoint Tables
Setpoints are stored in permanent memory.
Setpoints are initially set to the values in the Default
column, and can be adjusted to any value in the Range
column.
Unit Level Setpoints:
Description
Mode/Enabling
Default
Range
Unit Enable
Network Unit Enable
Control source
Available Modes
Network Mode Command
Enable
Disable
Local
Cool
Cool
Disable, Enable
Disable, Enable
Local, Network
Cool, Cool w/Glycol, Cool/Ice w/Glycol, Ice, Test
Cool, Ice
7°C (44.6°F)
7°C (44.6°F)
4.4°C (39.9°F)
7°C (44.6°F)
4.4°C (39.9°F)
5.6°C (10.1°F)
0.3°C (0.5°F)
0.6°C/min (1.1°F/min)
5.6 °C (10.1°F)
Off
100%
Off
See Auto Adjusted Ranges
See Auto Adjusted Ranges
-9.5 to 4.4 °C (14.9 to 39.9 °F)
See Auto Adjusted Ranges
-9.5 to 4.4 °C (14.9 to 39.9 °F)
0.6 to 8.3 °C (1.1 to 14.9 °F)
0.3 to 1.7 °C (0.5 to 3.1 °F)
0.1 to 2.7 °C/min (0.2 to 4.9 °F/min)
3.3 to 8.9 °C (5.9 to 16 °F)
Off, On
0 to 100%
Off, On
Single Point
Staging and Capacity Control
Cool LWT 1
Cool LWT 2
Ice LWT
Network Cool Set Point
Network Ice Set Point
Startup Delta T
Shut Down Delta T
Max Pulldown
Nominal Evap Delta T
Demand Limit Enable
Network Capacity Limit
LWT Reset Enable
Configuration
Power Input
Evap Control
#1 Only
Number of Compressors
Expansion Valve Type
Fan VFD enable
Number of fans
4
Thermal
No
4
Single Point, Multi Point
#1 Only, #2 Only, Auto,
#1 Primary, #2 Primary
4,6
Thermal, Electronic
No, Yes
4,6,8,10,12,14
30
240 sec
30 sec
No
15 min
5 min
No
12
No
15 to 300 seconds
120 to 480 sec
20 to 60 sec
No, Yes
10-60 minutes
3-20 minutes
No, yes
1-23 hours
No,Yes
0°C (0°F)
0°C (0°F)
0°C (0°F)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
689.5 KPA(100 PSI)
696.4 KPA(101 PSI)
4240 KPA(615 PSI)
4137 KPA(600 PSI)
5 sec
2.2°C (36°F)
165 sec
0°C (32°F)
Event
Off
Off
See Auto Adjusted Ranges
See Auto Adjusted Ranges
3310 to 4275 KPA (480 to 620 PSI)
3241 to 4137 KPA (470 to 600 PSI)
5 to 15 sec
See Auto Adjusted Ranges
150 to 240 sec
See Auto Adjusted Ranges
Event, Alarm
Off, On
Off, On
Timers
Evap Recirc Timer
Stage Up Delay
Stage Down Delay
Stage Delay Clear
Start-start timer
Stop-start timer
Clear Cycle Timers
Ice Time Delay
Clear Ice Timer
Sensor Offsets
Evap LWT sensor offset
Evap EWT sensor offset
OAT sensor offset
Alarm Settings
Low Evap Pressure Unload
Low Evap Pressure Hold
High Condenser Pressure
High Condenser Pressure Unload
Evaporator Flow Proof
Evaporator Water Freeze
Low OAT Start Time
Low Ambient Lockout
External Alarm Configuration
Clear Alarms
Network Clear Alarms
IOM 1206-1
27
Unit Controller Operation
Circuit Setpoints
(exist individually for each circuit):
Description
Mode/Enabling
Circuit mode
Compressor 1 Enable
Compressor 2 Enable
Compressor 3 Enable
Network Compressor 1 Enable
Network Compressor 2 Enable
Network Compressor 3 Enable
EXV control
EXV position
Suction SH Target
Max Evap Pressure
Default
Range
Enable
Enable
Enable
Enable
Enable
Enable
Enable
Auto
5.56°C (10°F)
1076 KPA(156.1 PSI)
Disable, Enable, Test
Enable, Disable
Enable, Disable
Enable, Disable
Enable, Disable
Enable, Disable
Enable, Disable
Auto, manual
0% to 100%
4.44 to 6.67 °C (8 to 12 °F)
979 to 1172 KPA (142 to 170 PSI)
37.8°C (100°F)
32.2°C (90°F)
32.2°C (90°F)
29.4°C (85°F)
32.22 to 48.9 °C (90 to 120 °F)
32.22 to 48.9 °C (90 to 120 °F)
29.44 to 43.3 °C (85 to 110 °F)
29.44 to 43.3 °C (85 to 110 °F)
VFD Max Speed
VFD Min Speed
Fan Stage Up Deadband 1
Fan Stage Up Deadband 2
Fan Stage Up Deadband 3
Fan Stage Up Deadband 4
Fan Stage Down Deadband 1
Fan Stage Down Deadband 2
Fan Stage Down Deadband 3
Fan Stage Down Deadband 4
100%
25%
8.33°C (15°F)
5.56°C (10°F)
5.56°C (10°F)
5.56°C (10°F)
11.11°C (20°F)
11.11°C (20°F)
8.33 °C (15 °F)
5.56 °C (10 °F)
90 to 110%
25 to 60%
8.33 to 13.89 °C (15 to 25 °F)
5.56 to 8.33 °C (10 to 15 °F)
5.56 to 8.33 °C (10 to 15 °F)
5.56 to 8.33 °C (10 to 15 °F)
8.33 to11.11 °C (15 to 20 °F)
8.33 to11.11 °C (15 to 20 °F)
5.56 to 8.33 °C (10 to 15 °F)
3.33 to 5.56 °C (6 to 10 °F)
Sensor Offsets
Evap pressure offset
Cond pressure offset
Suction temp offset
0 KPA (0 PSI)
0 KPA (0 PSI)
0°C (0°F)
-100 to 100 KPA (-14.5 to 14.5 PSI)
-100 to 100 KPA (-14.5 to 14.5 PSI)
-5.0 to 5.0 °C (-9.0 to 9.0 °F)
Condenser
Condenser Target
Condenser Target
Condenser Target
Condenser Target
100%
67%
50%
33%
See Special Setpoints
Note: Condenser Target 50% will be available only when Number of Compressors is 4.
28
IOM 1206-1
Unit Controller Operation
Auto Adjusted Ranges
Some settings have different ranges of adjustment based on
other settings:
Cool LWT 1, Cool LWT 2, and Network Cool Set Point
Available Mode Selection
Range
Without Glycol
4.4 to 18.3 °C (39.9 to 65°F)
With Glycol
-9.5 to 18.3 °C (14.9 to 65 °F)
Evaporator Water Freeze
Available Mode Selection
Without Glycol
With Glycol
Range
2.2 to 5.6 °C (36 to 42.1 °F)
-10.8 to 5.6 °C (12.6 to 42.1 °F)
Low Evaporator Pressure Hold and Unload
Available Mode Selection
Range
Without Glycol
669 to 793 KPA (97 to 115 PSI)
With Glycol
407 to 793 KPA (59 to 115 PSI)
Low Ambient Lockout
Fan VFD
= no for all circuits
= yes on any circuit
Range
0 to 18.3 °C (32 to 65 °F)
-23.3 to 18.3 °C (-9.9 to 65 °F)
Special Set Point Operations
Security
The following setpoints are not changeable unless the unit
switch is off:
All setpoints are protected using passwords. A four-digit
password provides operator access to changeable parameters.
Service level passwords are reserved for authorized service
personnel.
• Available Modes
• Number of Compressors
• Expansion Valve Type
• Number of Fans
• Fan VFD Enable
The Circuit Mode setpoints should not be changeable unless
the corresponding circuit switch is off.
The Compressor Enable setpoints should not be changeable
unless the corresponding compressor is not running.
EXV Position set point on each circuit follows the actual EXV
position while EXV Control = Auto. When EXV Control =
Manual, the position set point should be changeable.
The Clear Alarms and Network Clear Alarms settings are
automatically set back to Off after being On for 1 second.
IOM 1206-1
Operator password: 2526
Entering Passwords
Passwords are entered on the first screen on the unit controller,
If the wrong password is entered, a message will temporarily
appear stating this. If no valid password is active the active
password level displays “none.”
Editing Setpoints
After a valid password has been entered at the unit controller,
setpoints may be changed. If the operator attempts to edit a
setpoint for which the necessary password level is not active,
no action will be taken.
Once a password has been entered, it remains valid for 10
minutes after the last key-press on the unit controller.
29
Unit Controller Operation
Unit Functions
Definitions
The calculations in this section are used in unit level and
circuit control logic.
LWT Slope
LWT slope is calculated such that the slope represents the
estimated change in LWT over a time frame of one minute.
Pulldown Rate
The slope value calculated above will be a negative value as
the water temperature is dropping. A pulldown rate is
calculated by inverting the slope value and limiting to a
minimum value of 0°C/min.
LWT Error
LWT error is calculated as:
LWT – LWT target
Unit Capacity
For applying unit capacity limits, an estimate of total unit
capacity is needed. Unit capacity will be based on the
estimated circuit capacities.
The unit capacity is the number of compressors running (on
circuits that are not pumping down) divided by the number of
compressors on the unit.
Control Band
The Control Band defines the band in which unit capacity will
not be increased or decreased.
The Control Band is calculated as follows for constant
evaporator flow:
• Four compressor units: Control Band = Nominal Evap
Delta T Set Point * 0.3
• Six compressor units: Control Band = Nominal Evap
Delta T Set Point * 0.2
When Variable Evaporator Flow is required, the control band
increases as capacity decreases to account for the decrease in
flow. It is assumed that the flow will vary to maintain the full
capacity evaporator temperature delta at part load conditions.
The control band is limited at each capacity step to a
maximum value that corresponds to the minimum flow for that
capacity step.
Since evaporator flow is represented by the set point Full
Capacity Evaporator Delta T, the calculations of the control
band for variable flow applications are explained in terms of
delta T also. The term ‘Effective Full Capacity Delta T’ means
the approximate temperature delta that would be observed with
30
the unit running at full capacity for the given flow. ‘Nominal
flow’ means the flow that is needed for a 5.56°C (10°F) delta
T at full unit capacity.
Table 34: Minimum Flows and Corresponding Maximum
Effective Full Capacity Delta T:
Minimum
Max Effective
Number of
Unit
Flow
Full Capacity
Compressors Capacity
(nominal %)
DT
4
100%
75%
50%
25%
62.5%
55%
47.5%
40%
8.9 °C (16 °F)
10.1 °C (18.2 °F)
11.7 °C (21.1 °F)
13.9 °C (25 °F)
For variable evaporator flow, the Control Band is calculated as
follows:
1 Effective Full Capacity Delta T = (Full Capacity Evap
Delta T* 100) /Unit Capacity
2 If above value is more than the Max Effective Full
Capacity dT listed in the table above for the
corresponding unit capacity, it is set equal to the value in
the table.
3 Effective Full Capacity Delta T with the limit applied is
then multiplied by 0.35 for units with four compressors.
This gives the total control band for the unit
configuration and actual unit capacity.
Staging Temperatures
If the unit is configured for use without glycol:
When the LWT target is more than half the Control Band
above 3.9°C (39.0°F)
• Stage Up Temperature = LWT target + (Control Band/2)
• Stage Down Temperature = LWT target – (Control Band/
2)
If the LWT target is less than half the Control Band above
3.9°C (39.0°F)
• Stage Down Temperature = LWT target – (LWT target 3.9°C)
• Stage Up temperature = LWT target + Control Band –
(LWT target – 3.9°C)
If the unit is configured for use with glycol, the compressor
staging temperatures are calculated as shown below:
• Stage Up Temperature = LWT target + (Control Band/2)
• Stage Down Temperature = LWT target – (Control Band/
2)
The Start up and Shutdown temperatures are referenced from
the Control Band:
• Start Up Temperature = Stage Up Temperature + Start
Up Delta set point
• Shutdown Temperature = Stage Down Temperature –
Shutdown Delta set point
IOM 1206-1
Unit Controller Operation
Unit Enable
Enabling and disabling the chiller is accomplished using
setpoints and inputs to the chiller. The unit switch, remote
switch input, and Unit Enable Set Point all are required to be
‘on’ for the unit to be enabled when the control source is set to
‘local.’ The same is true if the control source is set to
Unit
Switch
Off
Control
Source
Set Point
Remote
Switch
Input
Unit
Enable
Set Point
BAS
Enable
Set Point
Off
On
On
Local
Network
Network
Off
On
On
On
On
Off
On
Unit Mode Selection
The operating mode of the unit is determined by setpoints and
inputs to the chiller. The Available Modes Set Point
determines what modes of operation can be used. This set
point also determines whether the unit is configured for glycol
use. The Control Source Set Point determines where a
command to change modes will come from. A digital input
switches between cool mode and ice mode if they are available
Control Source
Set Point
Local
Local
Network
Network
Mode
Input
BAS
Request
Off
On
Cool
Ice
Available Modes
Set Point
Cool
Cool w/Glycol
Cool/Ice w/Glycol
Cool/Ice w/Glycol
Cool/Ice w/Glycol
Cool/Ice w/Glycol
Ice w/Glycol
Test
‘network,’ with the additional requirement that the building
automation system (BAS) Enable set point must be ‘on’. The
BAS should enable the chiller only when there is a demand for
cooling.
Unit is enabled according to the following table:
Unit Enable
Off
Off
Off
On
Off
On
and the control source is set to ‘local.’ The BAS mode request
switches between cool mode and ice mode if they are both
available and the control source is set to ‘network.’
The Available Modes Set Point should only be changeable
when the unit switch is off. This is to avoid changing modes
of operation inadvertently while the chiller is running.
Unit Mode is set according to the following table:
Unit Mode
Cool
Cool
Cool
Ice
Cool
Ice
Ice
Test
Glycol Configuration
If the Available Modes Set Point is set to an option ‘w/Glycol,’
then glycol operation should be enabled for the unit. Glycol
operation should only be disabled when the Available Modes
Set Point is set to ‘Cool.’
IOM 1206-1
31
Unit Controller Operation
Unit States
The unit will always be in one of three states:
Off – Unit is not enabled to run
Auto – Unit is enabled to run
Pumpdown – Unit is doing a normal shutdown
Transitions between these states are shown in the following
diagram.
T3 - Pumpdown to Off
Any of the following are required:
• Unit rapid stop alarm active
• All circuits complete pumpdown
• Unit Switch open
T4 - Auto to Off
Any of the following are required:
• Unit rapid stop alarm active
POWER
ON
• No circuit enabled and no compressors running
OFF
• Unit Switch open
Power Up Start Delay
T3
T1
T4
PUMPDOWN
T2
AUTO
Diagram explanation on following page.
T1 - Off to Auto
All of the following are required:
• Unit Enable = On
• No Unit Alarm
• A circuit is enabled to start
• If Unit Mode = Ice then Ice Delay not active
After powering up the unit, the motor protectors may not be
engaged for up to 150 seconds. Therefore, after the control is
powered up, no compressor can start for 150 seconds. In
addition, the 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. While this timer is active, the chiller cannot restart
in Ice mode. The time delay is adjustable via the Ice Time
Delay set point.
The ice delay timer may be manually cleared to force a restart
in ice mode. A set point specifically for clearing the ice mode
delay is available. In addition, cycling the power to the
controller should clear the ice delay timer.
Low Ambient Lockout
T2 - Auto to Pumpdown
Any of the following are required:
• Unit Enable = Off and Unit Switch is closed
• Unit Mode = Ice AND LWT target is reached
• Unit Pumpdown Alarm active
32
When the OAT drops below the low ambient lockout set point
and the OAT sensor fault is not active, low ambient lockout is
triggered. The unit should go into the pumpdown state if any
circuits are running. If no circuits are running the unit should
go into the off state. This condition should clear when OAT
rises to the lockout set point plus 2.5°C (4.5°F).
IOM 1206-1
Unit Controller Operation
Unit Status
The displayed unit status should be determined by the
conditions in the following table:
#
1
2
3
4
5
6
7
8
9
10
11
Status
Auto
Auto: Motor Prot Delay
Off: Ice Mode Timer
Off: OAT Lockout
Off: All Cir Disabled
Off: Unit Alarm
Off: Keypad Disable
Off: Remote Switch
Off: BAS Disable
Off: Unit Switch
Off: Test Mode
12
Auto: Wait for load
13
14
15
16
17
18
Auto: Evap Recirc
Auto: Wait for flow
Auto: Pumpdown
Auto: Max Pulldown
Auto: Unit Cap Limit
Auto: High Ambient Limit
19
Config Changed, Reboot Required
Conditions
Unit State = Auto
Unit State = Auto and MP start up delay is active
Unit State = Off, Unit Mode = Ice, and Ice Delay = Active
Unit State = Off and Low OAT Lockout is active
Unit State = Off and both circuits unavailable
Unit State = Off and Unit Alarm active
Unit State = Off and Unit Enable Set Point = Disable
Unit State = Off and Remote Switch is open
Unit State = Off, Control Source = Network, and BAS Enable = false
Unit State = Off and Unit Switch = Disable
Unit State = Off and Unit Mode = Test
Unit State = Auto, no circuits running, and LWT is less than the active set point +
startup delta
Unit State = Auto and Evaporator State = Start
Unit State = Auto, Evaporator State = Start, and Flow Switch is open
Unit State = Pumpdown
Unit State = Auto, max pulldown rate has been met or exceeded
Unit State = Auto, unit capacity limit has been met or exceeded
Unit State = Auto and high ambient capacity limit is active
A configuration change requiring a reboot has occurred but controller has not been
rebooted yet.
Evaporator Pump Control
T1 – Off to Start
Requires any of the following
For control of the evaporator pumps, three evaporator pump
control states should be used:
Off - No pump on.
Start – Pump is on, water loop is being recirculated.
Run – Pump is on, water loop has been recirculated and circuits can start if needed.
Transitions between these states are shown in the following
diagram.
POWER
ON
• Unit state = Auto
• LWT is less than the Evap Freeze set point – 0.6°C
(1.1°F) and LWT sensor fault isn’t active
T2 – Start to Run
Requires the following
• Flow ok for time longer than evaporator recirculate time
set point
T3 – Run to Off
Requires all of the following
• Unit state is Off
OFF
• LWT is higher than the Evap Freeze set point or LWT
sensor fault is active
T3
T1
T4
T4 – Start to Off
Requires all of the following
• Unit state is Off
• LWT is higher than the Evap Freeze set point or LWT
sensor fault is active
RUN
IOM 1206-1
T2
T5
START
T5 – Run to Start
This transition should occur per the requirements for pump
staging and evaporator flow loss alarm.
33
Unit Controller Operation
Freeze Protection
• #1 Primary – Pump 1 is used normally, with pump 2 as a
backup
To protect the evaporator from freezing, the evaporator pump
will start if all of the following are true:
• LWT equal to or less than the Evap Freeze set point for
at least three seconds
• #2 Primary – Pump 2 is used normally, with pump 1 as a
backup
Primary/Standby Pump Staging
• LWT sensor fault isn’t active
• manual reset flow loss alarm is not active
Freeze protection will end when any of the following are true:
• LWT is at least 1.11°C (2°F) above the Evap Freeze set
point and pump has been in run state for at least as long
as the evaporator recirculation time
• LWT sensor fault is active
• manual reset flow loss alarm is active
Pump Selection
The pump output used will be determined by the Evap Pump
Control set point. This setting allows the following
configurations:
• #1 only – Pump 1 will always be used
• #2 only – Pump 2 will always be used
• Auto – The primary pump is the one with the least run
hours, the other is used as a backup
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. Once the standby pump is
started, the flow loss alarm logic will apply if flow cannot be
established in the evaporator start state, or if flow is lost in the
evaporator run state.
Auto Control
If auto pump control is selected, the primary/standby logic
above is still used. When the evaporator is not in the run state,
the run hours of the pumps will be compared. The pump with
the least hours will be designated as the primary at this time.
LWT Target
The LWT Target varies based on settings and inputs.
The base LWT Target is selected as follows:
Control Source
Set Point
Local
Local
Network
Local
Local
Network
Local
Local
Network
Network
Local
Network
Mode Input
BAS
Request
OFF
ON
OFF
ON
OFF
ON
COOL
ICE
Available Modes
Set Point
Base LWT Target
COOL
COOL
COOL
COOL w/Glycol
COOL w/Glycol
COOL w/Glycol
COOL/ICE w/Glycol
COOL/ICE w/Glycol
COOL/ICE w/Glycol
COOL/ICE w/Glycol
ICE w/Glycol
ICE w/Glycol
Cool Set Point 1
Cool Set Point 2
BAS Cool Set Point
Cool Set Point 1
Cool Set Point 2
BAS Cool Set Point
Cool Set Point 1
Ice Set Point
BAS Cool Set Point
BAS Ice Set Point
Ice Set Point
BAS Ice Set Point
Leaving Water Temperature (LWT) Reset
The base LWT target may be reset if the unit is in Cool mode
and LWT reset is enabled via the set point.
The reset amount is adjusted based on the 4 to 20 mA reset
input. Reset is 0° if the reset signal is less than or equal to 4
mA. Reset is 5.56°C (10.0°F) if the reset signal equals or
exceeds 20 mA. The amount of reset will vary linearly
between these extremes if the reset signal is between 4 mA and
20 mA.
When the reset amount increases, the Active LWT Target is
changed at a rate of 0.1°C every 10 seconds. When the active
reset decreases, the Active LWT Target is changed all at once.
34
After the reset is applied, the LWT target can never exceed a
value of 15.56°C (60°F).
Unit Capacity Control
Unit capacity control will be performed as described in this
section. All unit capacity limits described in following
sections must be applied as described.
Compressor Staging in Cool Mode
The first compressor on the unit should be started when
evaporator LWT is higher than the Startup Temperature.
IOM 1206-1
Unit Controller Operation
Additional compressors can be started when Evaporator LWT
is higher than the Stage Up Temperature and the Stage Up
Delay is not active.
When multiple compressors are running, one should shut down
if evaporator LWT is lower than the Stage Down Temperature
and the Stage Down Delay is not active.
All running compressors should shut down when the
evaporator LWT is lower than the Shut Down Temperature.
Stage Up Delay
A minimum amount of time, defined by the Stage Up Delay
set point, should pass between increases in the capacity stage.
This delay should only apply when at least one compressor is
running. If the first compressor starts and quickly shuts off for
some reason, another compressor may start without this
minimum time passing.
Stage Down Delay
compressor on each circuit shall be left on until each circuit
has only one compressor running.
Next To Start
If both circuits have an equal number of compressors running
or a circuit has no compressors available to start:
• the available compressor with the least starts will be next to
start
• if starts are equal, the one with the least run hours will be
next to start
• if run hours are equal, the lowest numbered one will be next
to start
If the circuits have an unequal number of compressors
running, the next compressor to start will be on the circuit with
the least compressors running if it has at least one compressor
available to start. Within that circuit:
• the available compressor with the least starts will be next to
start
A minimum amount of time, defined by the Stage Down Delay
set point, should pass between decreases in the capacity stage.
This delay should not apply when the LWT drops below the
Shut Down Temperature (unit should immediately shut down).
• if starts are equal, the one with the least run hours will be
next to start
Compressor Staging in Ice Mode
• if run hours are equal, the lowest numbered one will be next
to start
The first compressor on the unit should be started when
evaporator LWT is higher than the Startup Temperature.
Next to Stop
Additional compressors should be started as quickly as
possible with respect to the Stage Up Delay.
• the running compressor with the most run hours will be next
to stop
The unit should shut down when evaporator LWT is less than
the LWT target.
• if run hours are equal, the one with the least starts will be
next to stop
Stage Up Delay
• if starts are equal, the lowest numbered one will be next to
stop
A fixed stage up delay of one minute between compressor
starts should be used in this mode.
Staging Sequence
If both circuits have an equal number of compressors running:
If the circuits have an unequal number of compressors
running, the next compressor to stop will be on the circuit with
the most compressors running. Within that circuit:
This section defines which compressor is the next one to start
or stop. In general, compressors with fewer starts will
normally start first, and compressors with more run hours will
normally stop first.
• the running compressor with the most run hours will be next
to stop
If possible circuits will be balanced in stage. If a circuit is
unavailable for any reason, the other circuit shall be allowed to
stage all compressors on. When staging down, one
• if starts are equal, the lowest numbered one will be next to
stop
IOM 1206-1
• if run hours are equal, the one with the least starts will be
next to stop
35
Unit Controller Operation
Unit Capacity Overrides
Unit capacity limits can be used to limit total unit capacity in
Cool mode only. Multiple limits may be active at any time, and
the lowest limit is always used in the unit capacity control.
Demand Limit
The maximum unit capacity can be limited by a 4 to 20 mA
signal on the Demand Limit analog input. This function is
only enabled if the Demand Limit set point is set to ON. The
maximum unit capacity stage is determined as shown in the
following tables:
Table 35: Four Compressors:
Demand Limit
Signal (%)
Limit ≥ 75%
75% > Limit ≥ 50%
50% > Limit ≥ 25%
25% > Limit
Limit ≥ 16 mA
16 mA > Limit ≥ 12 mA
12 mA > Limit ≥ 8 mA
8 mA > Limit
Stage
Limit
1
2
3
4
RapidRestore is an option that can be added to AGZ chillers.
The general purpose of the option is to allow the capability to
restart more quickly and to load faster than normal.
The RapidRestore option shall be enabled via the
RapidRestore set point. Doing so will require the following to
be true:
• RapidRestore module is present at address 22
• DI1 on the RapidRestore module has a signal
If the DI1 input loses the signal or the RapidRestore module is
not longer communicating, then the option will be disabled in
the chiller.
Network Limit
The maximum unit capacity can be limited by a network
signal. This function is only enabled if the 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 tables:
Operation Following Power Cycle
The chiller will enter RapidRestore upon powering up when
the following conditions are met:
• RapidRestore is enabled
• Power failure lasts less than the value of the Max Power
Failure Time set point
Table 36: Four compressors:
Stage Limit
4
3
2
1
Maximum LWT Pulldown Rate
The maximum drop rate for the leaving water temperature
shall be limited by the Maximum Pulldown Rate set point only
when the unit mode is Cool.
If the rate exceeds the set point, no more compressors can be
started until the pulldown rate is less than the set point.
Running compressors will not be stopped as a result of
exceeding the maximum pulldown rate.
High Ambient Limit
On units configured with single point power connections, the
maximum load amps could be exceeded at high ambient
temperatures. If all compressors are running on circuit 1 or all
but one compressor on circuit 1, power connection is single
point, and the outdoor air temperature OAT is greater than
46.6°C (115.9°F), circuit 2 is limited to running all but one
36
RapidRestore® Option
Enabling
Demand Limit (mA)
Network Limit
Limit ≥ 100%
100% > Limit ≥ 75%
75% > Limit ≥ 50%
50% > Limit
compressor. This limit will allow the unit to operate at higher
temperatures than 46.6°C (115.9°F) up to 51.6°C (125°F).
When the limit is active, the unit is allowed to run all but one
compressor. So it will inhibit the unit fromloading if all but one
compressor is on, and it will shut down a compressor if all
compressors are running.
• Power failure lasts at least one second (shorter power
loss may result in unpredictable operation)
• Unit is enabled
When RapidRestore is triggered, the time value used for the
evaporator recirculation time will be limited to 110 seconds or
less. The evaporator recirculation time set point will not be
changed. Only the value used in the evaporator state logic will
be limited, and only if the set point exceeds the 110 second
limit.
This action will ensure that the chiller is ready to start after the
motor protection module delay has expired.
Time to Start
The manufacturer requires a minimum two minute delay after
power on until a compressor should be started, which is to
ensure proper operation of the motor protection modules. Unit
controller boot time is about 10 seconds, so a delay of 110
seconds will start upon completing boot up. After this delay,
the two minute manufacturer requirement will be satisfied.
After the 110 second delay, the first circuit to start will enter
the preopen state, which takes five seconds. The end result is
that the first compressor should start approximately 125
seconds after power is restored to the chiller.
IOM 1206-1
Unit Controller Operation
Current software has a delay of 150 seconds after bootup is
complete before the first circuit can start. The software will be
changed to use the 110 second delay discussed above only
when the chiller is performing the RapidRestore operation.
within each circuit. Assuming both circuits are able to run, the
effective unit stage up delay will be 30 to 35 seconds, so it will
load about four times faster during RapidRestore than the
fastest it possibly can during normal operation.
Fast Loading
Max Pulldown Rate
Fast loading will be performed when the following conditions
are met after the unit power up:
• Chiller enters RapidRestore operation
Max pulldown rate will be ignored during fast loading to avoid
having it interfere in the chiller getting loaded up as fast as
possible.
• Current LWT > Start Up Temperature
Backup Chiller Operation
For reference, Start Up Temperature is Stage Up Temperature
+ Start Up Delta T. Stage Up Temperature is calculated based
on the Full Capacity Evaporator Delta T set point and the
number of compressors on the chiller.
Fast loading should end if any of the following conditions
occur:
• LWT < Stage Up Temperature
• Unit capacity = 100%
• All circuits become disabled for any reason
• Unit becomes disabled for any reason
• 10 minutes have passed since unit powered up
When fast loading ends, the RapidRestore operation is
considered complete.
Capacity Changes
Normally the delay between compressors staging on is
determined by the Stage Up Delay setting. That setting
defaults to 240 seconds and has a range of 120 to 480 seconds.
During fast loading, a delay of 60 seconds between
compressor starts within a circuit should be used. In addition, a
delay of 30 seconds between compressor starts on different
circuits should be used.
This change during RapidRestore operation will allow for a
faster time to full capacity while maintaining stable operation
IOM 1206-1
If DI2 on the RapidRestore module has a signal and the unit
has RapidRestore enabled, then the chiller is considered a
‘backup chiller’. When a ‘backup chiller’ is enabled, it will
use an evaporator recirculation time of 13 seconds regardless
of what the evaporator recirculation time set point is. Then,
fast loading will be used as outlined above in the fast loading
section.
This backup chiller sequence is safe for the unit if it has had
power applied for the minimum time stated in the operation
manual. Since this sequence does not have to wait on the
compressor motor protection module delay, the unit can
achieve full capacity even faster than during a power loss
scenario.
Compressor Starts Per Hour
Since the compressor cycle timers are not maintained through
power cycling, a limitation on the number of starts per hour
will be added. Each compressor will be allowed six starts in an
hour.
If a compressor start is being delayed due to this limitation, it
can be cleared by using the existing Clear Cycle Timers
setting.
The following charts show the approximate best case scenario
for start time and loading time with the RapidRestore
operation.
37
Unit Controller Operation
Figure 16: Four Compressor Units – Power Lost and Restored
38
IOM 1206-1
Unit Controller Operation
Figure 17: Four Compressor Units - Backup Chiller, Constant Power
IOM 1206-1
39
Unit Controller Operation
Circuit Functions
Circuit Control Logic
Definitions
Circuit Enabling
Refrigerant Saturated Temperature
A circuit should be enabled to start if the following conditions
are true:
Refrigerant saturated temperature shall be calculated from the
pressure sensor readings for each circuit.
Evaporator Approach
The evaporator approach shall be calculated for each circuit.
The equation is as follows:
Evaporator Approach = LWT – Evaporator
Saturated Temperature
Condenser Approach
The condenser approach shall be calculated for each circuit.
The equation is as follows:
Condenser Approach = Condenser Saturated
Temperature - OAT
Suction Superheat
Suction superheat shall be calculated for each circuit using the
following equation:
Suction superheat = Suction Temperature –
Evaporator Saturated Temperature
Pumpdown Pressure
The pressure to which a circuit will pumpdown is based on the
Low Evaporator Pressure Unload set point. The equation is as
follows:
Pumpdown pressure = Low Evap Pressure Unload
set point – 103KPA (15 PSI)
• Circuit switch is closed
• No circuit alarms are active
• Circuit Mode set point is set to Enable
• At least one compressor is enabled to start (according to
enable setpoints)
Compressor Availability
A compressor is considered available to start if all the
following are true:
The corresponding circuit is enabled
• The corresponding circuit is not in pumpdown
• No cycle timers are active for the compressor
• No limit events are active for the corresponding circuit
• The compressor is enabled via the enable setpoints
• The compressor is not already running
Circuit States
The circuit will always be in one of four states:
Off – Circuit is not running
Preopen – Circuit is preparing to start
Run – Circuit is running
Pumpdown – Circuit is doing a normal shutdown
Transitions between these states are shown in the following
diagram.
POWER
ON
OFF
T1
T6
PREOPEN
T4
T5
T2
PUMPDOWN
T3
RUN
T1 – Off to Preopen
• No compressors are running and any compressor on circuit
is commanded to start (see unit capacity control)
T2 – Preopen to Run
• 5 seconds has passed
40
IOM 1206-1
Unit Controller Operation
Pumpdown Procedure
T3 – Run to Pumpdown
Any of the following are required:
• Last compressor on circuit is commanded to stop
• Unit State = Pumpdown
• Circuit switch is open
• Circuit mode is disable
• Circuit Pumpdown alarm is active
T4 – Pumpdown to Off
Any of the following are required:
• Evaporator Pressure < Pumpdown Pressure Value
• Unit State = Off
• Circuit Rapid Stop alarm is active
T5 – Run to Off
Any of the following are required:
• Unit State = Off
• Circuit Rapid Stop alarm is active
• A low ambient start attempt failed
T6 – Preopen to Off
Any of the following are required:
• Unit State = Off
• Unit State = Pumpdown
• Circuit switch is open
• Circuit mode is disable
• Circuit Rapid Stop alarm is active
• Circuit Pumpdown alarm is active
IOM 1206-1
Pumpdown is performed as follows:
• If multiple compressors are running, shut off the appropriate
compressors based on sequencing logic and leave only one
running
• Turn off hot gas output and liquid line output
• Keep running until evaporator pressure reaches the
pumpdown pressure, then stop compressor
• If evaporator pressure does not reach pumpdown pressure
within two minutes, stop compressor
Low Ambient Starts
A low OAT start is initiated if the condenser refrigerant
saturated temperature is less than 29.5°C (85.1° F) when the
first compressor starts. Once the compressor starts the circuit
is in a low OAT start state for a time equal to the Low OAT
Start Time set point. During Low OAT Starts, the freezestat
logic for the low evaporator pressure alarm as well as the low
evaporator pressure hold and unload alarms are disabled. The
absolute limit for low evaporator pressure is enforced and the
low evaporator pressure alarm should trigger if the evaporator
pressure drops below that limit.
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. If the
evaporator pressure is less than the Low Evaporator Pressure
Unload set point when the Low OAT Start Timer expires, the
start is unsuccessful and the compressor will shutdown.
Multiple Low Ambient Start attempts are allowed. On the third
failed Low Ambient Start attempt, the Restart Alarm is
triggered and the circuit will not attempt to restart until the
Restart alarm has been cleared.
The restart counter should be reset when either a startup is
successful, the Low OAT Restart alarm is triggered, or the unit
time clock shows that a new day has started.
41
Unit Controller Operation
Circuit Status
The displayed circuit status should be determined by the
conditions in the following table:
#
1
Status
Off:Ready
2
Off:Cycle Timers
3
Off:All Comp Disable
4
5
6
7
8
9
10
11
12
Off:Keypad Disable
Off:Circuit Switch
Off:Alarm
Off:Test Mode
Preopen
Run:Pumpdown
Run:Normal
Run:Evap Press Low
Run:Cond Press High
13
Run:High OAT Limit
Conditions
Circuit is ready to start when needed.
Circuit is off and cannot start due to active cycle timer on all
compressors.
Circuit is off and cannot start due to all compressors being
disabled.
Circuit is off and cannot start due to circuit enable set point.
Circuit is off and circuit switch is off.
Circuit is off and cannot start due to active circuit alarm.
Circuit is in test mode.
Circuit is in preopen state.
Circuit is in pumpdown state.
Circuit is in run state and running normally.
Circuit is running and cannot load due to low evaporator pressure.
Circuit is running and cannot load due to high condenser pressure.
Circuit is running and cannot add more compressors due to the
high ambient limit on unit capacity. Applies only to circuit 2.
Compressor Control
Condenser Fan Control
Compressors should run only when the circuit is in a run or
pumpdown state. They should not be running when the circuit
is in any other state.
Condenser fan control should stage fans as needed any time
compressors are running on the circuit. All running fans
should turn off when the circuit goes to the off state.
Starting a Compressor
Fan Staging
A compressor should start if it receives a start command from
the unit capacity control logic.
Fan staging shall accommodate anywhere from 2 to 7 fans on a
circuit using up to 5 outputs for control. The total number of
fans on shall be adjusted with changes of one fan at a time.
The tables below show the outputs energized for each stage.
Stopping a Compressor
A compressor should be turned off if any of the following
occur:
• Unit capacity control logic commands it off
• An unload alarm occurs and the sequencing requires this
compressor to be next off
• Circuit state is pumpdown and sequencing requires this
compressor to be next off
Stage
1
2
3
4
2 Through 4 Fans
Fan Outputs On
1
1,2
1,2,3
1,2,3,4
Cycle Timers
Condenser Target
A minimum time between starts of the compressor and a
minimum time between shutdown and start of the compressor
shall be enforced. The time values are determined by the
Start-start Timer and Stop-start Timer setpoints.
A condenser target should be selected from the setpoints based
on the number of compressors on the unit and the number of
compressors running. Each stage of capacity on a circuit will
use a different condensing target set point.
These cycle timers should not be enforced through cycling of
power to the chiller. This means that if power is cycled, the
cycle timers should not be active.
A minimum condenser target should be enforced. This
minimum will be calculated based on the evaporator LWT. As
the LWT varies from 7.2°C (45°F) to 32.2°C (90°F), the
minimum condenser target will vary from 23.9°C (75°F) to
48.9°C (120°F).
These timers may be cleared via a setting on the controller.
Staging Up
The first fan should turn on when the saturated condenser
temperature exceeds the condenser target. After this, the four
stage up dead bands shall be used. Stages one through four
42
IOM 1206-1
Unit Controller Operation
should use their respective dead bands. Stages five through six
should all use the Stage Up Dead Band 4.
When the fan stage is greater than 0, the VFD speed signal
should be enabled and control the speed as needed.
When the saturated condenser temperature is above the target
+ the active deadband, a stage up error is accumulated.
Stage Up Compensation
Stage Up Error Step = Saturated Condenser Temperature –
(Target + Stage Up dead band)
The Stage Up Error Step is added to Stage Up Accumulator
once every 5 seconds, only if the Saturated Condenser
Refrigerant Temperature is not falling. When Stage Up Error
Accumulator is greater than 11°C (19.8°F) another stage is
added.
When a stage up occurs or the saturated condenser temperature
falls back within the stage up dead band the Stage Up
Accumulator is reset to zero.
Staging Down
Four stage down dead bands shall be used. Stages one
through four should use their respective dead bands. Stages
five through seven should all use Stage Down Dead Band 4.
When the saturated condenser refrigerant temperature is below
the target – the active deadband, a stage down error is
accumulated.
Stage Down Error Step = (Target - Stage Down dead band) Saturated Condenser Temperature
The Stage Down Error Step is added to Stage Down
Accumulator once every 5 seconds. When the Stage Down
Error Accumulator is greater than 2.8°C (5°F) another stage of
condenser fans is removed.
When a stage down occurs or the saturated temperature rises
back within the Stage Down dead band the Stage Down Error
Accumulator is reset to zero.
VFD
Condenser pressure trim control is accomplished using an
optional VFD on the first fan. This VFD control should vary
the fan speed to drive the saturated condenser temperature to a
target value. The target value is normally the same as the
saturated condenser temperature target.
The speed should be controlled between the minimum and
maximum speed setpoints.
In order to create a smoother transition when another fan is
staged on, the VFD compensates by slowing down initially.
This is accomplished by adding the new fan stage up deadband
to the VFD target. The higher target causes the VFD logic to
decrease fan speed. Then, every 2 seconds, 0.1°C (0.18°F) is
subtracted from the VFD target until it is equal to the saturated
condenser temperature target set point.
High IPLV Mode
When the High IPLV Mode setting is ‘On’ and one compressor
is running on the unit, the condenser target setting for the
running circuit may be overridden. In this case, rather than use
the condenser target setting for 33% or 50% (depending on
total number of compressors), the condenser target will be
forced to 21.11°C (70°F).
In addition, when high IPLV mode is active the calculation for
the minimum allowed condenser target (based on LWT) will
be changed. The minimum value will be changed from 23.9°C
(75°F) to 21.11°C (70°F). No other changes to the operation
are made when High IPLV mode is on.
Special Operation For MicroChannel Coil
For units configured with MicroChannel condenser coils, the
fan staging is the same as for a standard coil except there are
two additional conditions which may cause the fan stage to
increase:
• If the second compressor on a circuit starts, one of the two
condenser fans is running, and the condenser saturated
temperature is higher than the target for 100% capacity, then
the second condenser fan will start immediately.
• If one of the two condenser fans is running and the saturated
condenser temperature exceeds 56.67°C (134°F) then the
second condenser fan will start immediately.
Both of these additions are in place to deal with temporarily
higher condenser pressure resulting from the lower volume of
the MicroChannel coils. Note that this software version
supports E vintage chillers only up through the AGZ070E at
this time, so all E vintage models supported have four
compressors and four fans.
VFD State
The VFD speed signal should always be 0 when the fan stage
is 0.
IOM 1206-1
43
Unit Controller Operation
EXV Control
Auto Control
Any time the circuit is not in the run state, the EXV position
should be 0. The EXV control state should display that the
EXV state is closed when this is the case.
When the circuit is in the Pre-open state, the EXV should go
into superheat control.
While a circuit is in the run state, the EXV should go into
superheat control. While in superheat control, the EXV
controls suction superheat. The suction superheat target is set
by a set point. A PID function will be used to control the
superheat to the target value. The EXV response should be
faster when the SSH is lower than 1.67oC (3oF) or higher than
the SSH Target + 1.67oC (3oF) .
The EXV should also prevent the evaporator pressure from
exceeding the Maximum Evaporator Pressure set point. This
is done by using another PID function to control evaporator
pressure to the maximum evaporator pressure.
The EXV position should be lesser position output from the
two PID functions.
Position Commands
In order to improve the reliability of the EXV positioning, the
position commands that are issued to the stepper driver are
limited in two ways:
The expansion valve maximum position may be increased if
after two minutes both the suction superheat is greater than
7.2°C (13°F) and the expansion valve has been within 5% of its
current maximum position. The maximum should increase at a
rate of 0.1% every six seconds up to a total of an additional
10%. This offset to the maximum position should be reset
when the EXV is no longer in the Superheat Control state or a
compressor on the circuit stages.
Manual 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 manual, the EXV position is equal
to the manual EXV position setting. If set to manual when the
circuit state transitions from run to another state, the control
setting is automatically set back to auto. When in manual
control, the EXV control state displayed should reflect that it is
manual control.
Liquid Line Solenoid Valve
The liquid line solenoid output should be on when the circuit
state is either Pre-open or Run. This output should be off at all
other times.
Hot Gas Bypass Solenoid Valve
First, position commands are filtered so that the minimum
change in position is 0.3%. Changes of less than this are
ignored. This avoids unnecessary movement of the EXV and
lowers the chances of losing steps as a result.
This output shall be on when circuit state is Run and one
compressor on the circuit is running. The output should be off
at all other times.
Second, the position commands are issued once per program
cycle with a maximum change of 0.7% each time. This allows
the stepper to move the valve to the commanded position
before the next position command is issued. Issuing commands
in this way may also lower the chances of losing steps.
Capacity Overrides – Limits of
Operation
EXV Position Range
The following table shows the EXV range based on the
number of compressors running and the total number of fans
on the unit.
Num Fans = 4
44
EXV Min
EXV Max
Compressors Running
1
2
3
8%
8%
50%
100%
-
The following conditions shall override automatic capacity
control as described. These overrides keep the circuit from
entering a condition in which it is not designed to run.
Low Evaporator Pressure
If the Low Evaporator Pressure Hold or Low Evaporator
Pressure Unload alarms are triggered, the circuit capacity may
be limited or reduced. See the Circuit Events section for
details on triggering, reset, and actions taken.
High Condenser Pressure
If the High Condenser Pressure Unload alarm is triggered, the
circuit capacity may be limited or reduced. See the Circuit
Events section for details on triggering, reset, and actions
taken.
IOM 1206-1
Alarms
Alarms
Situations may arise that require some action from the chiller
or that should be logged for future reference. Alarms are
classified in the following sections using the Fault/Problem/
Warning scheme.
When any Unit Fault Alarm is active, the alarm digital output
should be turned on continuously. If both circuits have a
Circuit Fault Alarm active, the alarm digital output should be
turned on continuously. If no Unit Fault Alarm is active and
only one circuit has a Circuit Fault Alarm is active, the alarm
digital output should alternate five seconds on and five
seconds off continuously.
All alarms appear in the active alarm list while active. All
alarms are added to the alarm log when triggered and when
cleared. Entries in the log representing the occurrence of an
alarm will be preceded by ‘+’ while entries representing the
clearing of an alarm will be preceded by ‘-‘.
Unit Fault Alarms
PVM/GFP Fault
Trigger: Power Configuration = Single Point and PVM/
GFP Input #1 is open.
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. After three occurrences,
the count of occurrences is reset and the cycle starts over if the
manual reset flow loss alarm is cleared.
If active via trigger condition 2:
If the flow loss alarm has occurred due to this trigger, it is
always a manual reset alarm.
Evaporator Water Freeze Protect
Trigger: Evaporator LWT drops below evaporator freeze
protect set point and LWT sensor fault is not active.
Action Taken: Rapid stop all circuits
Reset: This alarm can be cleared manually via the
keypad, but only if the alarm trigger conditions no longer
exist.
Evaporator LWT Sensor Fault
Action Taken: Rapid stop all circuits
Trigger: Sensor shorted or open
Reset: Auto reset when input is closed for at least 5
seconds or if Power Configuration = Multi Point.
Action Taken: Normal stop all circuits
Evaporator Flow Loss
Trigger:
1: Evaporator Pump State = Run AND Evaporator Flow
Digital Input = No Flow for time > Flow Proof Set Point
AND at least one compressor running
2: Evaporator Pump State = Start for time greater than
Recirc Timeout Set Point and all pumps have been tried
and Evaporator Flow Digital Input = No Flow
Action Taken: Rapid stop all circuits
Reset: This alarm can be cleared manually via the
keypad or BAS command, but only if the sensor is back
in range.
Outdoor Air Temperature Sensor Fault
Trigger: Sensor shorted or open
Action Taken: Normal stop of all circuits.
Reset: This alarm can be cleared manually via the
keypad or via BAS command if the sensor is back in
range.
External Alarm
Reset:
This alarm can be cleared at any time manually via the keypad
or via the BAS clear alarm command.
Trigger: External Alarm/Event opens for at least 5
seconds and external fault input is configured as an
alarm.
If active via trigger condition 1:
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.
IOM 1206-1
Action Taken: Rapid stop of all circuits.
Reset: Auto clear when digital input is closed.
45
Alarms
Compressor Module 1 Comm Failure
Evaporator Pump #1 Failure
Trigger: Communication with the I/O extension module
has failed.
Trigger: Unit is configured with primary and backup
pumps, pump #1 is running, and the pump control logic
switches to pump #2.
Action Taken: Backup pump is used.
Action Taken: Rapid stop of circuit 1.
Reset: This alarm can be cleared manually via the
keypad or BAS command when communication between
main controller and the extension module is working for
5 seconds.
Compressor Module 2 Comm Failure
Trigger: Communication with I/O extension module
failed.
Reset: This alarm can be cleared manually via the
keypad or BAS command.
Evaporator Pump #2 Failure
Trigger: Unit is configured with primary and backup
pumps, pump #2 is running, and the pump control logic
switches to pump #1.
Action Taken: Backup pump is used.
Action Taken: Rapid stop of circuit 2.
Reset: This alarm can be cleared manually via the
keypad or BAS command when communication between
main controller and the extension module is working for
5 seconds.
EXV Module 1 Comm Failure
Trigger: Expansion Valve Type = Electronic and
communication with the I/O extension module has failed.
Action Taken: Rapid stop of circuit 1.
Reset: This alarm can be cleared manually via the
keypad or BAS command when communication between
main controller and the extension module is working for
5 seconds or Expansion Valve Type = Thermal.
EXV Module 2 Comm Failure
Reset: This alarm can be cleared manually via the
keypad or BAS command.
Unit Warning Alarms
External Event
Trigger: External Alarm/Event input is open for at least
5 seconds and external fault is configured as an event.
Action Taken: None.
Reset: Auto clear when digital input is closed.
Bad Demand Limit Input
Trigger: Demand limit input out of range and demand
limit is enabled. For this alarm out of range is considered
to be a signal less than 3mA or more than 21mA.
Trigger: Expansion Valve Type = Electronic and
communication with the I/O extension module has failed.
Action Taken: Cannot use demand limit function.
Action Taken: Rapid stop of circuit 2.
Reset: Auto clear when demand limit disabled or
demand limit input back in range for 5 seconds.
Reset: This alarm can be cleared manually via the
keypad or BAS command when communication between
main controller and the extension module is working for
5 seconds or Expansion Valve Type = Thermal.
Bad LWT Reset Input
Unit Problem Alarms
Action Taken: Cannot use LWT reset function.
Trigger: LWT reset input out of range and LWT reset is
enabled. For this alarm out of range is considered to be a
signal less than 3mA or more than 21mA.
Reset: Auto clear when LWT reset is disabled or LWT
reset input back in range for 5 seconds.
46
IOM 1206-1
Alarms
Evaporator EWT Sensor Fault
Trigger: Sensor shorted or open
Action Taken: None.
point or higher, and the freeze time has not been
exceeded, the timer will reset.
The alarm cannot trigger if the evaporator pressure sensor fault
is active.
Reset: Auto clear when the sensor is back in range.
Action Taken: Rapid stop circuit.
Circuit Fault Alarms
PVM/GFP Fault
Trigger: Power Configuration = Multi Point and circuit
PVM/GFP input is open.
Reset: This alarm can be cleared manually via the
keypad if the evaporator pressure is above 137.9 KPA (20
PSI).
High Condenser Pressure
Action Taken: Rapid stop circuit.
Trigger: Condenser Pressure > High Condenser Pressure
set point .
Reset: Auto reset when input is closed for at least 5
seconds or if Power Configuration = Single Point.
Action Taken: Rapid stop circuit.
Low Evaporator Pressure
Trigger:
Reset: This alarm can be cleared manually via the
controller keypad.
This alarm should trigger when Freeze time is exceeded,
Low Ambient Start is not active, and Circuit State = Run.
It should also trigger if Evaporator Press < 137.9 KPA
(20 psi) and Circuit State = Run for longer than 1 second.
Mechanical High Pressure Switch
Freezestat logic allows the circuit to run for varying
times at low pressures. The lower the pressure, the
shorter the time the compressor can run. This time is
calculated as follows:
Action Taken: Rapid stop circuit.
Freeze error = Low Evaporator Pressure Unload –
Evaporator Pressure
Freeze time =
For units equipped with 10 or more condenser fans
(shell and tube type evaporator):
80 – freeze error, limited to a range of 40 to 80 seconds
For all other configurations (plate to plate type evaporator):
60 – freeze error, limited to a range of 20 to 60 seconds
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 freezestat trip
occurs. If the evaporator pressure rises to the unload set
IOM 1206-1
Trigger: Mechanical High Pressure switch input is open,
Motor Protection input is closed, and power up start
delay is not active.
Reset: This alarm can be cleared manually via the
controller keypad if the MHP switch input is closed.
Motor Protection Fault
Trigger: Motor Protection input is open and power up
start delay is not active.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the
controller keypad if the input is closed.
Low OAT Restart Fault
Trigger: Circuit has failed three low OAT start attempts.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the
keypad or via BAS command.
47
Alarms
No Pressure Change After Start
Unit Power Restore
Trigger: After start of compressor, at least a 7 KPA (1
PSI) drop in evaporator pressure OR 35 KPA (5.1 PSI)
increase in condenser pressure has not occurred after 30
seconds. The actual alarm will not be triggered until the
second occurrence.
Trigger: Unit controller is powered up.
Action Taken: Rapid stop circuit.
Circuit Events
Reset: This alarm can be cleared manually via the
keypad or via BAS command.
Low Evaporator Pressure - Hold
Evaporator Pressure Sensor Fault
Trigger: Sensor shorted or open.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the
keypad or BAS command, but only if the sensor is back
in range.
Condenser Pressure Sensor Fault
Trigger: Sensor shorted or open.
Action Taken: Rapid stop circuit.
Reset: This alarm can be cleared manually via the
keypad or BAS command, but only if the sensor is back
in range.
Suction Temperature Sensor Fault
Trigger: Sensor shorted or open and Expansion Valve
Type = Electronic.
Action Taken: Normal shutdown of circuit.
Reset: This alarm can be cleared manually via the
keypad or BAS command, but only if the sensor is back
in range.
Events
Situations may arise that require some action from the chiller
or that should be logged for future reference, but aren’t severe
enough to track as alarms. These events are stored in a log
separate from alarms. This log shows the time and date of the
latest occurrence, the count of occurrences for the current day,
and the count of occurrences for each of the previous 7 days.
Unit Events
48
Action Taken: None
Reset: None
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• evaporator pressure <= Low Evaporator Pressure - Hold
set point
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a compressor has
started on the circuit.
Action Taken: Inhibit starting of additional compressors
on the circuit.
Reset: While still running, the event will be reset if
evaporator pressure > Low Evaporator Pressure Hold SP
+ 90 KPA(13 PSI). The event is also reset if the circuit is
no longer in the run state.
Low Evaporator Pressure - Unload
Trigger:
This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the circuit
• evaporator pressure <= Low Evaporator Pressure Unload set point for a time greater than half of the current freezestat time
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a compressor has
started on the circuit.
On units equipped with 6 compressors, electronic
expansion valves, and 10 or more fans, when each
compressors starts, there should be a 2 minute window
during which the evaporator pressure must drop an
additional 27 KPA (3.9 PSI) to trigger the alarm. After
this 2 minute window, the trigger point should return to
normal.
Action Taken: Stage off one compressor on the circuit
every 10 seconds, except the last one.
IOM 1206-1
Alarms
Reset: While still running, the event will be reset if
evaporator pressure > Low Evaporator Pressure Hold SP
+ 90 KPA(13 PSI). The event is also reset if the circuit is
no longer in the run state.
High Condenser Pressure - Unload
Trigger:
This event is triggered if all of the following are true:
· circuit state = Run
· more than one compressor is running on the
circuit
· condenser pressure > High Condenser Pressure –
Unload set point
Action Taken: Stage off one compressor on the circuit
every 10 seconds while condenser pressure is higher than
the unload set point, except the last one. Inhibit staging
more compressors on until the condition resets.
Reset: While still running, the event will be reset if
condenser pressure <= High Condenser Pressure Unload
SP – 862 KPA(125 PSI). The event is also reset if the
circuit is no longer in the run state.
Circuit Warning Alarms
Failed Pumpdown
Trigger: Circuit state = pumpdown for longer than 2
minutes.
Action Taken: Rapid stop circuit.
Reset: N/A.
Alarm Logs
NOTE: refer to Figure 18 for controller components.
Press the alarm button on the controller to go to the alarm
section. Three alarm sub-sections will appear. Turn the
navigating wheel to highlight among them and press the
wheel to select.
1. Active Alarms
When an alarm or event occurs, it appears in the active
alarm list. The active alarm list holds a record of all
active alarms not yet cleared and includes the date and
time each occurred. When cleared, the alarm transfers to
the Alarm Log that contains an alarm history with time/
date stamp. A (+) before an alarm indicates that it is
active, a (-) indicates a cleared alarm. The Active Alarm
IOM 1206-1
list is only limited by the number of alarms since any
given alarm cannot appear twice.
2. Alarm Log
An alarm log stores the last 50 occurrences or resets that
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. The date and time the alarm
occurred are stored in the alarm log.
3. Event Log
An Event Log similar to the Alarm Log stores the last 50
event occurrences. Each Event Log entry includes an
event description and a time and date stamp for the event
occurrence plus the count of the event occurrences on the
current day and for each of the last seven days. Events do
not appear in the Active Alarm list.
Clearing Alarms
Active alarms can be cleared through the keypad/display
or a BAS network. Alarms are automatically cleared
when controller power is cycled. Alarms are cleared only
if the conditions required to initiate the alarm no longer
exist. All alarms and groups of alarms can be cleared via
the keypad or network via LON using nviClearAlarms
and via BACnet using the ClearAlarms object.
To use the keypad, follow the Alarm links to the Alarms
screen, which will show Active Alarms and Alarm Log.
Select Active Alarm and press the wheel to view the
Alarm List (list of current active alarms). They are in
order of occurrence with the most recent on top. The
second line on the screen shows Alm Cnt (number of
alarms currently active) and the status of the alarm clear
function. Off indicates that the Clear function is off and
the alarm is not cleared. Press the wheel to go to the edit
mode. The Alm Clr (alarm clear) parameter will be
highlighted with OFF showing. To clear all alarms, rotate
the wheel to select ON and enter it by pressing the wheel.
An active password is not necessary to clear alarms.
If the problem(s) causing the alarm have been corrected,
the alarms will be cleared, disappear from the Active
Alarm list and be posted in the Alarm Log. If not
corrected, the On will immediately change back to OFF
and the unit will remain in the alarm condition.
49
Using the Controller
Using the Controller
Figure 18: Schematic of Unit Controller
The keypad/display consists of a 5-line by 22-character
display, three buttons (keys) and a “push and roll” navigation
wheel. There is an Alarm Button, Menu (Home) Button and a
Back Button. The wheel is used to navigate between lines on a
screen (page) and to increase and decrease changeable values
when editing. Pushing the wheel acts as an Enter Button and
will jump from a link to the next set of parameters.
3
>
>
>
>
Generally, each line on the display contains a menu title, a
parameter (such as a value or a setpoint), or a link (which will
have an arrow in the right of the line) to a further menu.
The first line visible on each display includes the menu title
and the line number to which the cursor is currently
“pointing.” In the above case 3, Temperature is highlighted.
The left most position of the title line includes an “up” arrow
▲ to indicate there are lines (parameters) “above” the
currently displayed line; and/or a “down” arrow ▼ to indicate
there are lines (parameters) “below” the currently displayed
items or an “up/down” arrow ♦ to indicate there are lines
“above and below” the currently displayed line. The selected
line is highlighted.
50
When the cursor is on a line the highlights will look like this:
If line contains a changeable value-
Evaporator Delta T= 10.0F
If the line contains status-only information-
Figure 19: Typical Screen
♦6 View/Set Unit
Status/Settings
Set Up
Temperature
Date/Time/Schedule
Each line on a screen can contain status-only information or
include changeable data fields (setpoints).
Unit Status=
Run
Or a line in a menu may be a link to further menus. This is
often referred to as a jump line, meaning pushing the
navigation wheel will cause a “jump” to a new menu. An
arrow (>)is displayed to the far right of the line to indicate it is
a “jump” line and the entire line is highlighted when the cursor
is on that line.
NOTE - Only menus and items that are applicable to the
specific unit configuration are displayed.
This manual includes information relative to the operator level
of parameters; data and setpoints necessary for the every day
operation of the chiller. There are more extensive menus
available for the use of service technicians.
Navigating
When power is applied to the control circuit, the controller
screen will be active and display the Home screen, which can
also be accessed by pressing the Menu Button The navigating
wheel is the only navigating device necessary, although the
IOM 1206-1
Using the Controller
MENU, ALARM, and BACK buttons can provide shortcuts as
explained later.
Passwords
Enter passwords from the Main Menu:
• Enter Password links to the Entry screen which is an
editable screen. So pressing the wheel goes to the edit
mode where the password (5321) can be entered. The
first (*) will be highlighted, rotate the wheel clockwise
to the first number and set it by pressing the wheel.
Repeat for the remaining three numbers. The password
will time out after 10 minutes and is cancelled if a new
password is entered or the control powers down.
•Not entering a password allows access to a limited number of parameters (with asterisks) as shown in Figure 22.
• Menu title, displayed in the first line as in Figure 21.
• Link (also called Jump) having an arrow ( > ) in the right
of the line and used to link to the next menu.
• Parameters with a value or adjustable setpoint.
For example, “Time Until Restart” jumps from level 1 to level
2 and stops there.
When the Back Button is pressed the display reverts back to
the previously displayed page. If the Back button is repeatedly
pressed the display continues to revert one page back along the
current navigation path until the “main menu” is reached.
When the Menu (Home) Button is pressed the display reverts
to the “main page.”
When the Alarm Button is depressed, the Alarm Lists menu is
displayed.
Figure 20: Password Menu
Main Menu
1/3
Enter Password
>
Unit Status
Off: Unit Sw
ACTIVE SETPT 44.6°F
Edit Mode
Figure 21: Password Entry Page
Enter Password
Enter PW
****
Three types of lines exist:
1/1
Entering an invalid password has the same effect as not
entering a password.
Once a valid password has been entered, the controller allows
further changes and access without requiring the user to enter a
password until either the password timer expires or a different
password is entered. The default value for this password timer
is 10 minutes.
Navigation Mode
When the navigation wheel is turned clockwise, the cursor
moves to the next line (down) on the page. When the wheel is
turned counter-clockwise the cursor moves to the previous line
(up) on the page. The faster the wheel is turned the faster the
cursor moves. Pushing the wheel acts as an “Enter” button.
The Editing Mode is entered by pressing the navigation wheel
while the cursor is pointing to a line containing an editable
field. Once in the edit mode pressing the wheel again causes
the editable field to be highlighted. Turning the wheel
clockwise while the editable field is highlighted causes the
value to be increased. Turning the wheel counter-clockwise
while the editable field is highlighted causes the value to be
decreased. The faster the wheel is turned the faster the value is
increased or decreased. Pressing the wheel again cause the new
value to be saved and the keypad/display to leave the edit
mode and return to the navigation mode.
A parameter with an “R” is read only; it is giving a value or
description of a condition. An “R/W“ indicates a read and/or
write opportunity; a value can be read or changed (providing
the proper password has been entered).
Example 1: Check Status, for example -is the unit being
controlled locally or by an external network? We are looking
for the Unit Control Source Since this a unit status parameter,
start at Main Menu and select View/Set Unit and press the
wheel to jump to the next set of menus. There will be an arrow
at the right side of the box which indicates a jump to the next
level is required. Press the wheel to execute the jump.
You will arrive at the Status/ Settings link. There is an arrow
indicating that this line is a link to a further menu. Press the
wheel again to jump to the next menu, Unit Status/Settings.
Rotate the wheel to scroll down to Control Source and read the
result.
IOM 1206-1
51
Using the Controller
Example 2: Change a Setpoint, the chilled water setpoint for
example. This parameter is designated as Cool LWT 1 setpoint
and is a unit parameter. From the Main Menu select View/Set
Unit. The arrow indicated that this is link to a further menu.
Press the wheel and jump to the next menu View/Set Unit and
use the wheel to scroll down to Temperatures. This again has
an arrow and is a link to a further menu. Press the wheel and
jump to the Temperatures menu, which contains temperatures
values and setpoints. The first line is Evap LWT, rotate wheel
until Cool LWT 1 is highlighted. Press the wheel to enter edit
52
mode. Rotate wheel until new setpoint is reached, then press
wheel to accept the new value and exit edit mode.
Example 3: Clear an Alarm, from the Main Menu scroll down
to the Alarms line. Note the arrow indicating this line is a link.
Press the wheel to jump to the next menu Alarms There are
two lines here; Alarm Active and Alarm Log. Alarms are
cleared from the Active Alarm link. Press the wheel to jump to
the next screen. With the first line highlighted, press the wheel
to enter edit mode. Rotate wheel until AlmClr is set to On,
then press wheel to clear the alarms.
IOM 1206-1
Using the Controller
Figure 22: Controller Keypad Navigation
Visable (w/o Password)
Menu Level 1
Enter Password
Unit Status
Active Setpoint
Evap Leaving W ater Temp
Unit Capacity
Unit Mode
Menu Level 2
Menu Level 3
Enter Password
R
R
R
R
R
Alarms
Scheduled Maintenance
About This C hiller
Enter PW
R/W
Alarms
Alarm Active
Alarm Log
Next Maintenance
Next Maintenance Month/Year
Service Support Reference
About This Chiller
Model Number
G. O. Number
Unit Serial Number
Starter Model Number(s)
Starter Serial Number(s)
BSP Version
Application Version
HMI GU ID
OBH GUID
View/Set Circuit
R
R
R
R
R
R
R
R
R
Alarm Active
Active Alarm/W arning 1
R
…
R
Active Alarm/W arning n
R
Acknowledge All
R/W
Alarm Log
Alarm Entry 1
…
Alarm Entry 25
R
R
R
Starter Model Numbers
Circuit #1
Circuit #2
Circuit #3
Circuit #4
R/W
R/W
R/W
R/W
Starter Serial Numbers
Circuit #1
Circuit #2
Circuit #3
Circuit #4
R/W
R/W
R/W
R/W
View/Set Circuit
Unit Status
R
Active Setpoint
Evap Leaving W ater Temp
R
R
Evap Entering Water Temp
R
Unit Mode
R
Circuit #1
Circuit #2
View/Set Cir1
Data
Circuit #3
Status/Settings
Circuit #4
Compressor
Condenser
EXV
Configuration
Calibrate Sensors
Menu Level 4
Cir1 Status
Circuit Status
Circuit Mode
Circuit Capacity
Service Pumpdown
IOM 1206-1
Menu Level 5
R
R/W
R
R/W
Circuit Status
Circuit #1 Status
Circuit #2 Status
Circuit #3 Status
Circuit #4 Status
R
R
R
R
53
Optional Low Ambient Fan VFD
Optional Low Ambient Fan VFD
The optional VFD fan control is used for unit operation below
32°F (0°C) down to a minimum of -10°F (-23°C). The control
looks at the saturated discharge temperature and varies the fan
speed to hold the temperature (pressure) at the “target”
temperature.
Low ambient air temperature control is accomplished by using
the Optional Low Ambient VFD to control the speed of the
first fan on each circuit. This VFD control uses a proportional
integral function to drive the saturated condenser temperature
to a target value by changing the fan speed. The target value is
normally the same as the saturated condenser temperature
target setpoint.
The fan VFD always starts when the saturated condenser
temperature rises higher than the target.
What is an Inverter?
The term inverter and variable-frequency drive are related and
somewhat interchangeable. An electronic motor drive, for an
AC motor, controls the motor’s speed by varying the
frequency of the power sent to the motor.
In general, an inverter is a device that converts DC power to
AC power. The figure below shows how the variablefrequency drive employs an internal inverter. The drive first
converts incoming AC power to DC through a rectifier bridge,
creating an internal DC bus voltage. Then the inverter circuit
converts the DC back to AC again to power the motor. The
special inverter can vary its output frequency and voltage
according to the desired motor speed.
Inverter Output to the Motor
!
WARNING
Avoid swapping any 2 of the 3 motor lead connections
which will cause reversal of the motor direction. In
applications where reversed rotation could cause
equipment damage or personnel injury, be sure to verify
direction of rotation before attempting full-speed
operation. For safety to personnel, the motor chassis
ground must be connected to the ground connection at
the bottom of the inverter housing.
The AC motor must be
connected only to the
inverter’s output terminals.
The output terminals are
uniquely labeled (to
differentiate them from the
input terminals) with the
designations U/T1, V/T2,
and W/T3. This corresponds
to typical motor lead
connection designations T1, T2, and T3. The consequence of
swapping any two of the three connections is the reversal of
the motor direction. This must not be done. In applications
where reversed rotation could cause equipment damage or
personnel injury, be sure to verify direction of rotation before
attempting full-speed operation. For safety to personnel, the
motor chassis ground must be connected to the ground
connection at the bottom of the inverter housing.
Notice the three connections to the motor do not include one
marked “Neutral” or “Return.” The motor represents a
balanced “Y” impedance to the inverter, so there is no need for
a separate return. In other words, each of the three “Hot”
connections serves also as a return for the other connections
because of their phase relationship.
Do not to switch off power to the inverter while the motor is
running (unless it is an emergency stop) to avoid equipment
damage. Also, do not install or use disconnect switches in the
wiring from the inverter to the motor (except thermal
disconnect).
54
IOM 1206-1
Optional Low Ambient Fan VFD
VFD Interface
The VFD controller is located in the lower left-hand
corner of the unit control panel. It is used to view data
including fault and alarm information. No operator
intervention on this control is required for normal unit
operation.
Table 37: Display Key Functions
No.
Display
Name
Function
1
Function
Key(F1, F2)
The functions assigned to F1 and F2 vary depending on the currently displayed menu.
The name of each function appears in the lower half of the display window.
23
ESC Key
RESET Key
• Returns to the previous display.
• Moves the cursor one space to the left.
• Pressing and holding this button will return to the Frequency Reference display.
• Moves the cursor to the right.
• Resets the drive to clear a fault situation.
3
4
RUN Key
5
Up Arrow Key
6
Down Arrow
Key
7
STOP Key
8
ENTER Key
9
LO/RE
Selection Key
10
RUN Light
11
LO/RE Light
12
ALM LED Light
Starts the drive in LOCAL mode.
Scrolls up to display the next item, select parameter numbers, and increment setting
values.
Scrolls down to display the next item, select parameter numbers, and increment setting
values.
Stops drive operation.
• Enters parameter values and settings.
• Selects a menu item to move between displays
Switches drive control between the operator (LOCAL) and an external source
(REMOTE)for the Run command and frequency reference.
Lit while the drive is operating the motor.
Lit while the operator is selected to run the drive (LOCAL mode).
Refer to ALARM (ALM) LED Displays in Table 39
Table 14, Display Key Functions
IOM 1206-1
55
Optional Low Ambient Fan VFD
Figure 23: LCD Display
Table 38: Display Data
No
1
2
3
4
5
6
Name
Operation
Mode Menus
DriveWorksEZ
Function
Selection
Mode Display
Area
Ready
Data Display
FrequencyRef
erence
Assignment
<1>
Display
MODE
MONITR
Displayed when in Mode Selection.
Displayed when in Monitor Mode.
VERIFY
PRMSET
A.TUNE
Indicates the Verify Menu
Displayed when in Parameter Setting Mode.
Displayed during Auto-Tuning.
SETUP
Displayed when in Setup Mode.
DWEZ
Displayed when DriveWorksEZ is set to enable. (A1-07 = 1 or 2)
DRV
PRG
Rdy
—
Displayed when in Drive Mode.
Displayed when in Programming Mode
Indicates the drive is ready to run.
Displays specific data and operation data.
OPR
Displayed when the frequency reference is assigned to the LCD Operator Option.
AI
COM
OP
7
LO/RE Display
<2>
8
Function Key
1(F1)
9
FWD/REV
10
Function Key 2
(F2)
RP
RSEQ
LSEQ
RREF
LREF
JOG
HELP
←
HOME
ESC
FWD
REV
FWD/REV
DATA
RESET
56
Content
Displayed when the frequency reference is assigned to the Analog Input of the
drive
Displayed when the frequency reference is assigned to the MEMOBUS/Modbus
CommunicationInputs of the drive
Displayed when the frequency reference is assigned to an Option Unit of the
drive.
Displayed when the frequency reference is assigned to the Pulse Train Input of
Displayed when the run command is supplied from a remote source.
Displayed when the run command is supplied from the operator keypad.
Displayed when the run command is supplied from a remote source.
Displayed when the run command is supplied from the operator keypad
Pressing [F1} executes the Jog function.
Pressing [F1] displays the Help menu.
Pressing [F1] scrolls the cursor to the left.
Pressing [F1] returns to the top menu (Frequency Reference).
Pressing [F1] returns to the previous display
Indicates forward motor operation.
Indicates reverse motor operation.
Pressing [F2] switches between forward and reverse
Pressing [F2] scrolls to the next display
Pressing [F2] scrolls the cursor to the right
Pressing [F2] resets the existing drive fault error
IOM 1206-1
Optional Low Ambient Fan VFD
Table 39: Alarm Content
State
Illuminated
Content
Display
When the drive detects an alarm or error
When an alarm occurs
Flashing
When an oPE is detected
When a fault or error occurs during Auto-Tuning
Off
Normal operation (no fault or alarm)
Table 40: LO/RE LED and RUN LED Indictors
LED
Lit
When the operator
is selected for Run
command and
frequency
reference control
(LOCAL)
Flashing Slowly
Flashing Quickly
--
--
·While the drive was set to
Off
When a device other
than the operator is
selected for Run
command and
frequency reference
control (REMOTE)
LOCAL, a Run
command was entered
to the input terminals
then the drive was
switched to REMOTE.
·A Run command was
·During
deceleration
to stop
During run
·When a Run
command is
input and
frequency
reference is
0 Hz
entered via the input
terminals while the
drive was not in the
Drive Mode.
·During deceleration when
a Fast Stop command
was entered.
During stop
·The drive output is shut of
by the Safe Disable
function.
·The STOP key was
pressed while drive
was running in
REMOTE.
·The drive was powered up
with b1-17 = 0 (default)
while the Run
command was active.
Examples
IOM 1206-1
57
Optional Low Ambient Fan VFD
Table 41: Types of Alarms, Faults, and Errors
Type
Faults
Drive Response
When the drive detects a fault:
• The digital operator displays text indicating the specific fault and the ALM indicator LED remains lit until the fault is
reset.
• The fault interrupts drive output and the motor coasts to a stop. • Some faults allow the user to select the stopping method
when the fault occurs.
• Fault output terminals MA-MC will close, and MB-MC will open.
The drive will remain inoperable until the fault is cleared.
When the drive detects an alarm or a minor fault:
Minor Faults
and
Alarms
• The digital operator displays text indicating the specific alarm or minor fault, and the ALM indicator LED flashes.
• The drive continues running the motor, although some alarms allow the user to select a stopping method when the alarm
occurs.
• A multi-function contact output set to be tripped by a minor fault (H2-  = 10) closes. If the output is set to be tripped
by an alarm, the contact will not close.
• The digital operator displays text indicating a specific alarm and the ALM indicator LED flashes.
Remove the cause of the problem to reset a minor fault or alarm.
Operation
Errors
Tuning
Errors
An operation error occurs when parameter settings conflict or do not match hardware settings (such as with an option
card).When the drive detects an operation error:
• The digital operator displays text indicating the specific error. • Multi-function contact outputs do not operate.
The drive will not operate the motor until the error has been reset. Correct the settings that caused the operation error to
clear the error.
Tuning errors occur while performing Auto-Tuning. When the drive detects a tuning error:
• The digital operator displays text indicating the specific error. • Multi-function contact outputs do not operate.
• Motor coasts to stop.
Remove the cause of the error and repeat the Auto-Tuning process.
Copy
Function
Errors
Copy Function Errors occur when using the digital operator or the USB Copy Unit to copy, read, or verify parameter
settings.
• The digital operator displays text indicating the specific error.
• Multi-function contact outputs do not operate.
Pressing any key on the digital operator will clear the fault. Investigate the cause of the problem (such as model
incompatibility)and try again.
Table 42: Fault Reset Methods
NOTE: When a fault occurs, the cause of the fault must be
removed and the drive must be restarted. The following tables
list the various ways to restart the drive. Remove the Run
command before attempting to clear a fault. If the Run
command is present, the control will disregard any attempt to
reset the fault.
After the Fault Occurs
Fix the cause of the fault, restart
the drive, and reset the fault
Resetting via Fault Reset Digital
Input S4
Procedure
Press
on the controller.
Close then open the fault signal
digital input via terminal S4. S4 is
set for “Fault Reset” as default
(H1-04 = 14)
Turn off the main power supply if the above methods do not reset the
fault. Reapply power after the controller display has turned off.
58
IOM 1206-1
Optional Low Ambient Fan VFD
Recommended Periodic Inspection
!
WARNING
Electrical Shock Hazard. Before servicing or inspecting the equipment, disconnect power to the unit.The internal
capacitor remains charged after power is turned off. Wait at least the amount of time specified on the drive before
touching any components.
Table 43: Periodic Inspection Checklist
Inspection Area
General
Relays and Contactors
Inspection Points
Inspect equipment including wiring, terminals,
resistors, capacitors, diode and IGBT for
discoloration from overheating or deterioration.
Inspect for dirt or foreign particles
Inspect contactors and relays for excessive
noise.
Inspect for signs of overheating such as melted
or cracked insulation
Corrective Action
Replace damaged components.
Use dry air to clear away.
Check for over or undervoltage
Replace damaged parts.
Optional BAS Interface
The AGZ chiller controller is configured for stand-alone
operation or integration with BAS through an optional
communication module.
• IM 966-1, BACnet® IP Communication Module
The following installation manuals for optional BAS
interface modules are shipped with the chiller. They can
• IM 969-2, Modbus® Communication Module
also be found and downloaded from www.DaikinApplied.com.
• IM 967-1, BACnet® Communication Module (MS/TP)
• IM 968-1, LONWORKS Communication Module
• ED 15120, Protocol Information for MicroTech III
chiller, BACnet and LONWORKS
• ED 15121, Protocol Information for MicroTech III
chiller, Modbus
IOM 1206-1
59
Start-up and Shut-down Procedures
Pre Start-up
3 Put System Switch (S1) to the Emergency Stop position.
Inspected the chiller to ensure no components became loose or
damaged during shipping or installation including leak test and
wiring check.
4 Put both circuit #1 & #2 switches to the Pumpdown and
Start-up and Shut-down Procedures
Pre-Startup Water Piping Checkout
1 Check the pump operation and vent all air from the
system.
2 Circulate evaporator water, checking for proper system
pressure and evaporator pressure drop. Compare the
pressure drop to the evaporator water pressure drop
curve.
3 Flush System and clean all water strainers before placing
the chiller into service.
4 Check water treatment and proper glycol percent.
Pre-Startup Refrigerant Piping Checkout
1 Check all exposed brazed joints for evidence of leaks.
Joints may have been damaged during shipping or when
the unit was installed.
2 Check that all refrigerant valves are either opened or
closed as required for proper operation of the chiller.
3 A thorough leak test must be done using an approved
electronic leak detector. Check all valve stem packing for
leaks. Replace all refrigerant valve caps and tighten.
4 Check all refrigerant lines to insure that they will not
vibrate against each other or against other chiller
components and are properly supported.
5 Check all connections and all refrigerant threaded
connectors.
6 Look for any signs of refrigerant leaks around the
condenser coils and for damage during shipping or
installation.
7 Connect refrigerant service gauges to each refrigerant
circuit before starting unit.
Pre-Startup Electrical Check Out
WARNING
Electrical power must be applied to the compressor crankcase
heaters 8 hours before starting unit to eliminate refrigerant
from the oil.
1 Open all electrical disconnects and check all power
wiring connections. Start at the power block and check
all connections through all components to and including
the compressor terminals. These should be checked
again after 3 months of operation and at least yearly
thereafter.
2 Check all control wiring by pulling on the wire at the
spade connections and tighten all screw connections.
Check plug-in relays for proper seating and to insure
retaining clips are installed.
60
Stop position.
5 Apply power to the unit. The panel Alarm Light will stay
on until S1 is closed. Ignore the Alarm Light for the
check out period. If you have the optional Alarm Bell,
you may wish to disconnect it.
6 Check at the power block or disconnect for the proper
voltage and proper voltage between phases. Check
power for proper phasing using a phase sequence meter
before starting unit.
7 Check for 120 Vac at the optional control transformer
and at TB-2 terminal #1 and the neutral block (NB).
8 Check between TB-2 terminal #7 and NB for 120 Vac
supply for transformer #2.
9 Check between TB-2 terminal #2 and NB for 120 Vac
control voltage. This supplies the compressor crank case
heaters.
10 Check between TB-3 terminal #17 and #27 for 24 Vac
control voltage.
Start-Up
Refer to the MicroTech III Controller information on page 24
to become familiar with unit operation before starting the
chiller.
There should be adequate building load (at least 50 percent of
the unit full load capacity) to properly check the operation of
the chiller refrigerant circuits.
Be prepared to record all operating parameters required by the
"Compressorized Equipment Warranty Form". Return this
information within 10 working days to Daikin Applied as
instructed on the form to obtain full warranty benefits.
Start-Up Steps
• Verify chilled water flow.
• Verify remote start / stop or time clock (if installed) has
requested the chiller to start.
• Set the chilled water setpoint to the required temperature.
(The system water temperature must be greater than the total
of the leaving water temperature setpoint plus one-half the
control band plus the start-up delta-T before the MicroTech
III controller will stage on cooling.)
• Set the Evap Delta T based on a percent of unit nominal flow
indicated in Table 12 and the Start Delta T as a starting
point. Delta-T=Tons x 24 / gpm
• Check the controller setpoints to be sure that factory defaults
are appropriate.
• Put both pumpdown switches (PS1 and PS2) to the ON
position.
• Put system switch (S1) to ON position.
IOM 1206-1
Start-up and Shut-down Procedures
Table 44: Pumpdown and System Switch Positions
Switch
PS1, PS2,
Pumpdown
Switches
S1, System
Switch
Switch Position
ON
OFF
Circuits will
Circuit will go
operate in the
through the normal
pumpdown cycle
normal,
and shut off.
automatic mode
Unit will shut off
Unit will operate
immediately without
in the normal
pumping down
automatic mode
(emergency stop)
Post Start-up
After the chiller has been operating for a period of time and
has become stable, check the following:
• Compressor oil level. (Some scroll compressors do not have
oil sight glasses).
3 Turn off chilled water pump. Chilled water pump to
operate while compressors are pumping down.
4 To start the chiller after a temporary shutdown, follow
the start-up instructions.
Extended Shutdown
1 Front seat both condenser liquid line service valves.
2 Put both circuit switches to the OFF position
(Pumpdown and Stop position).
3 After the compressors have stopped, put System Switch
(S1) to the OFF position (emergency stop).
4 Front seat both refrigerant circuit discharge valves (if
applicable).
5 If chilled water system is not drained, maintain power to
the evaporator heater to prevent freezing. Maintain heat
tracing on the chilled water lines.
• Refrigerant sight glass for flashing.
6 Drain evaporator and water piping to prevent freezing.
• Rotation of condenser fans.
7 If electrical power to the unit is on, the compressor
• Complete the "Compressorized Equipment Warranty Form."
Shutdown
Temporary Shutdown
1 Put both circuit switches to the OFF position
(Pumpdown and Stop).
2 After compressors have stopped, put System Switch (S1)
to OFF (emergency stop).
crankcase heaters will keep the liquid refrigerant out of
the compressor oil. This will minimize start-up time
when putting the unit back into service. The evaporator
heater will be able to function.
8 If electrical power is off, make provisions to power the
evaporator heater (if chilled water system is not drained
or is filled with suitable glycol). Tag all opened electrical
disconnect switches to warn against start-up before the
refrigerant valves are in the correct operating position.
To start the chiller after an extended shutdown, follow the
prestart-up and start-up instructions.
IOM 1206-1
61
Component Operation
Component Operation
Hot Gas Bypass (Optional)
Compressor Communications
This option allows the system to operate at lower loads without
excessive on/off compressor cycling. The hot gas bypass
option is required to be on both refrigerant circuits because of
the lead / lag feature of the controller.
The communication module, installed in the 20 to 40 ton
compressor electrical box, provides advanced diagnostics,
protection, and communications that enhance compressor
performance and reliability.
This option allows passage of discharge gas into the
evaporator inlet (between the TX valve and the evaporator)
which generates a false load to supplement the actual chilled
water or air handler load.
Features include motor temperature protection, scroll
temperature protection, missing phase protection, reverse
phase protection, low control circuit voltage protection, short
cycling detection and alert, modbus communication to system
controller, operational and fault history storage, and LED
status display.
Note: The hot gas bypass valve will not generate a 100% false
load.
The pressure regulating valve is factory set to begin opening at
102 psig with R-410a and can be changed by changing the
pressure setting. The adjustment range is 75 to 150 psig. To
raise the pressure setting, remove the cap on the bulb and turn
the adjustment screw clockwise. To lower the setting, turn the
screw counterclockwise. Do not force the adjustment beyond
the range it is designed for as this will damage the adjustment
assembly. The regulating valve opening point can be
determined by slowly reducing the system load while
observing the suction pressure. When the bypass valve starts to
open, the refrigerant line on the evaporator side of the valve
will begin to feel warm to the touch.
A solenoid valve is located ahead of the bypass valve and is
controlled by the MicroTech III controller. It is active when the
first stage of cooling on a circuit is active.
WARNING
The hot gas line may become hot enough to cause injury. Be
careful during valve checkout.
VFD Low Ambient Control (Optional)
The optional VFD fan control is used for unit operation below
32oF (0oC) down to a minimum of -10oF (-23.3oC). The control
looks at the saturated discharge temperature and varies
(pressure) at the "target" temperature. This temperature is
established as an input to a setpoint screen labeled "Sat
Condenser Temp Target."
Operation
Warnings and Alerts
A solid green LED indicates the module is powered and
operation is normal.
A solid red LED indicates an internal problem with the
module.
A flashing green LED communicates Warning codes.
Warning codes do not result in a trip or lockout condition.
A flashing red LED communicates Alert codes. Alert codes
will result in a trip condition and possibly a lockout condition
Warning Codes (Flashing Green LED )
Code 1 – Loss of Communication: The module will flash the
green Warning LED one time indicating the module has not
communicated with the master controller for longer than 5
minutes.
Code 2 – Reserved For Future Use
Code 3 – Short Cycling: The module will flash the green
Warning LED three times indicating the compressor has short
cycled more than 48 times in 24 hours.
Code 4 – Open/Shorted Scroll Thermistor: The module will
flash the green Warning LED four times indicating an open/
shorted
62
IOM 1206-1
Component Operation
Alert/Lockout Codes (Flashing Red LED)
Filter-Driers
Code 1 – Motor High Temperature: The module will flash the
red Alert LED one time indicating the motor is onerheating .
A code 1 Alert will open the M2-M1 contacts. The Alert will
reset after 30 minutes. Five consecutive Code 1 Alerts will
lockout the compressor. Once the module has locked out the
compressor, a power cycle or Modbus reset command will be
required for the lockout to be cleared.
For units with optional replaceable core filter driers, each
refrigerant circuit is furnished with a replaceable core type
filter-drier. The core assembly of the replaceable core drier
consists of a filter core held tightly in the shell in a manner that
allows full flow without bypass. Pressure drop across the filter
drier must not exceed the following values.
Code 2 – Open/Shorted Motor Thermistor: The module will
flash the red Alert LED two times indicating the motor PTC
thermistor circuit has an open/shorted thermistor chain (see
Table 2). A Code 2 Alert will open the M2-M1 contacts. The
Alert will reset after 30 minutes and the M2-M1 contacts will
close if the resistance of the motor PTC circuit is back in the
normal range. The module will lockout the compressor and 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. Once locked out the compressor, a power cycle
or Modbus reset command will be required to clear the
lockout.
Code 4 – Scroll High Temperature: The module will flash the
red Alert LED four times indicating the over-temperature
condition. A Code 4 Alert will open the M2-M1 contacts.The
Alert will reset after 30 minutes. Once the module has locked
out the compressor, a power cycle or Modbus reset command
will be required to clear the lockout.
Code 5 – Reserved for Future Use
Code 6 – Missing Phase: The module will flash the red Alert
LED six times indicating a missing phase. The Alert will reset
after 5 minutes and the module will lockout the compressor
after 10 consecutive Code 6 Alerts. Once locked out, a power
cycle or Modbus reset is required.
Code 7 – Reverse Phase: The module will flash the red Alert
LED seven times indicating a reverse phase in two of the three
compressor leads. The modules will lockout the compressor
after one Code 7 Alert. A power cycle or Modbus reset
command will be required to clear the lockout.
Code 8 – Reserved For Future Use
Code 9 – Module Low Voltage: The module will flash the red
Alert LED nine times indicating low module voltage for more
than 5 seconds. The Alert will reset after 5 minutes and the
M2-M1 contacts will close if the T2-T1 voltage is above the
reset value.
Note: If a compressor with CoreSense Communications fails in
the field, the CoreSense module should remain with the
failed compressor so the manufacturer’s technicians can
download the CoreSense data to assist with determining
the root cause of compressor failure.
IOM 1206-1
PERCENT CIRCUIT
LOADING (%)
100%
75%
50%
25%
DROP ACROSS
PSI (KPA)
10 (69)
8 (55.2)
5 (34.5)
4 (27.6)
A condenser liquid line service valve is provided for isolating
the charge in the condenser, but also serves as the point from
which the liquid line can be pumped out. With the line free of
refrigerant, the filter-drier core(s) can be easily replaced.
System Adjustment
To maintain peak performance at full load operation, the
system superheat and liquid subcooling may require
adjustment. Read the following subsections closely to
determine if adjustment is required.
Liquid Line Sight Glass
The color of the moisture indicator is an indication of the
dryness of the system and is extremely important when the
system has been serviced. Immediately after the system has
been opened for service, the element may indicate a wet
condition. It is recommended that the equipment operate for
approximately 12 hours to allow the system to reach
equilibrium before deciding if the system requires a change of
drier cores.
Bubbles in the sight glass at constant full load indicates a
shortage of refrigerant, a plugged filter-drier, or a restriction in
the liquid line. However, it is not unusual to see bubbles in the
sight glass during changing load conditions.
Refrigerant Charging
Liquid line subcooling at the liquid shut-off valve should be
between 15 and 20 degrees F at full load. If the unit is at
steady full load operation and bubbles are visible in the sight
glass, then check liquid subcooling.
Expansion Valve
The expansion valve's function is to keep the evaporator
supplied with the proper amount of refrigerant to satisfy the
load conditions.
Before adjusting superheat, check that unit charge is correct
and liquid line sight glass is full with no bubbles and that the
circuit is operating under stable, full load conditions.
The suction superheat for the suction leaving the evaporator is
set at the factory for 10 to 12 degrees F at full load. To have
63
Component Operation
full rated unit performance, the superheat must be about 8
degrees F at 95°F outdoor ambient temperature.
Crankcase Heaters
The scroll compressors are equipped with externally mounted
band heaters located at the oil sump level. 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 oil during off-cycle.
Power must be supplied to the heaters 8 hours before starting
the compressors.
Evaporator
The evaporator is protected with an electric resistance heater
and insulated with 3/4" (19mm) thick closed-cell polyurethane
insulation. This combination provides freeze protection down
to -20°F (-29°C) ambient air temperature. The water side
working pressure of the brazed plate type of evaporator is 653
psig (4502 kPa). Evaporators are designed and constructed
according to, and listed by, Underwriters Laboratories (UL).
Phase Voltage Monitor (Optional)
Factory settings are as follows:
• Trip Delay Time: 2 seconds.
• Voltage Setting: set at nameplate voltage.
• Restart Delay Time: 60 seconds.
On models AGZ-030E through 070E, the evaporator is a
compact, high efficiency, dual circuit, brazed plate-to-plate
type heat exchanger consisting of parallel stainless steel plates.
64
IOM 1206-1
Unit Maintenance
Unit Maintenance
General
On initial start-up and periodically during operation, it will be
necessary to perform certain routine service checks. Among
these are checking the liquid line sight glasses, taking
condensing and suction pressure readings, and checking to see
that the unit has normal superheat and subcooling readings. A
recommended maintenance schedule is located at the end of
this section.
efficiency heat transfer from the refrigerant to the airstream.
In the unlikely occurence of a coil leak, contact Daikin
Applied to receive a replacement coil module.
Figure 24: Micro-Channel Coil Cross Section
Compressor Maintenance
The scroll compressors are fully hermetic and require no
maintenance other than checking oil level.
Lubrication
No routine lubrication is required on AGZ units. The fan
motor bearings are permanently lubricated and no further
lubrication is required. Excessive fan motor bearing noise is an
indication of a potential bearing failure.
POE type oil is used for compressor lubrication. ARNING
WARNING
POE oil must be handled carefully using proper protective
equipment (gloves, eye protection, etc.) The oil must not come
in contact with certain polymers (e.g. PVC), as it may absorb
moisture from this material. Also, do not use oil or refrigerant
additives in the system.
Further details are listed in the Unit Service section starting on
page 69.
Electrical Terminals
!
DANGER
Electric shock hazard. Turn off all power before
continuing with following service.
All-Aluminum Condenser Coils
The condenser coils are an all-aluminum design including the
connections, micro-channels, fins (an oven brazing process
brazes the fins to the micro-channel flat tube), and headers
(Figure 24), which eliminates the possibility of corrosion
normally found between dissimilar metals of standard coils.
Connecting the Condenser Coil to Copper
Tubing
Figure 25 shows the aluminum condenser coil connection to
the copper tubing in the unit. Because of the low melting point
of aluminum (1220°F compared to 1984°F for copper), this
brazed joint is performed with a low temperature brazing
process.
!
CAUTION
Potential equipment damage. If a standard copper
brazing process is performed at this joint, the process will
damage the aluminum connection. If a condenser coil
ever needs to be replaced, the copper aluminum joint
repair should be done with a ProBraze™ repair kit
manufactured by OmniTechnologies Corporation. A
non-corrosive flux must also be used. The brazing
temperature should be between 850°F–900°F. If a coil
needs replacing, contact Daikin Applied for a coil and
copper connection assembly.
During the condensing process, refrigerant in the coil passes
through the micro-channel flat tubes, resulting in higher
IOM 1206-1
65
Unit Maintenance
Figure 25: Aluminum/Copper Connection
exceed 130ºF) will reduce surface tension, increasing the ability
to remove chlorides and dirt. Pressure washer PSI must not
exceed 900 psig and the nozzel should remain at leat 1 foot from
the coil to avoid damaging fin edges.
Routine Quarterly Cleaning of ElectroFin Coated
Coil Surfaces
Quarterly cleaning is essential to extend the life of an
ElectroFin Coated Coil and is required to maintain warranty
coverage. Coil cleaning shall be part of the unit’s regularly
scheduled maintenance procedures. Failure to clean an
ElectroFin Coated Coil will void the warranty and may result
in reduced efficiency and durability in the environment.
Cleaning Micro-Channel Aluminum Coils
Maintenance consists primarily of the routine removal of dirt
and debris from the outside surface of the fins and repairing
any fin damage.
Cleaning ElectroFin® Coated Coils
The following cleaning procedures are recommended as part
of the routine maintenance activities for ElectroFin Coated
Coils. Documented routine cleaning of ElectroFin Coated
Coils is required to maintain warranty coverage. The cleaning
procedure can be downloaded from the ElectroFin web site
www.luvata.com/electrofin, click on Procedures for Cleaning.
!
WARNING
Prior to cleaning the unit, turn off and lock out the main
power switch to the unit and open all access panels.
Remove Surface Loaded Fibers
Surface loaded fibers or dirt should be removed prior to water
rinse to prevent further restriction of airflow. If unable to back
wash the side of the coil opposite that of the coils entering air
side, then surface loaded fibers or dirt should be removed with
a vacuum cleaner. If a vacuum cleaner is not available, a soft
non-metallic bristle brush may be used. In either case, the tool
should be applied in the direction of the fins. Coil surfaces can
be easily damaged (fin edges bent over) if the tool is applied
across the fins.
Note: Use of a water stream, such as a garden hose, against a
surface loaded coil will drive the fibers and dirt into the
coil. This will make cleaning efforts more difficult.
Surface loaded fibers must be completely removed prior
to using low velocity clean water rinse.
Periodic Clean Water Rinse
A monthly clean water rinse is recommended for coils that are
applied in coastal or industrial environments to help to remove
chlorides, dirt and debris. An elevated water temperature (not to
66
For routine quarterly cleaning, first clean the coil with the
below approved coil cleaner (see approved products list in
Table 45). After cleaning the coils with the approved cleaning
agent, use the approved chloride remover (under the
Recommended Chloride Remover section) to remove soluble
salts and revitalize the unit.
Recommended Coil Cleaner
The following cleaning agent, assuming it is used in
accordance with the manufacturer’s directions on the container
for proper mixing and cleaning, has been approved for use on
ElectroFin Coated Coils to remove mold, mildew, dust, soot,
greasy residue, lint and other particulate:
Table 45: ElectroFin Coated Coil Recommended Cleaning
Agents
Cleaning Agent
Enviro-Coil Concentrate
Enviro-Coil Concentrate
Reseller
Hydro-Balance Corp
P.O. Box 730
Prosper, TX 75078
800-527-5166
Home Depot
Part Number
H-EC01
H-EC01
Chlor*Rid Int’l, Inc.
Chloride Remover
P.O. Box 908
Chandler, AZ 85244
Chlor*Rid DTS
800-422-3217
CHLOR*RID DTS™ should be used to remove soluble salts
from the ElectroFin Coated Coil, but the directions must be
followed closely. This product is not intended for use as a
degreaser. Any grease or oil film should first be removed with
the approved cleaning agent.
1 Remove Barrier - Soluble salts adhere themselves to the
substrate. For the effective use of this product, the
product must be able to come in contact with the salts.
These salts may be beneath any soils, grease or dirt;
therefore, these barriers must be removed prior to
application of this product. As in all surface preparation,
the best work yields the best results.
2 Apply CHLOR*RID DTS - Apply CHLOR*RID DTS
directly onto the substrate. Sufficient product must be
applied uniformly across the substrate to thoroughly wet
IOM 1206-1
Unit Maintenance
out surface with no areas missed. This may be
accomplished by use of a pump-up sprayer or
conventional spray gun. The method does not matter, as
long as the entire area to be cleaned is wetted. After the
substrate has been thoroughly wetted, the salts will be
soluble and is now only necessary to rinse them off.
3 Rinse - It is highly recommended that a hose be used as a
pressure washer will damage the fins. The water to be
used for the rinse is recommended to be of potable
quality, though a lesser quality of water may be used if a
small amount of CHLOR*RID DTS is added. Check
with CHLOR*RID International, Inc. for
recommendations on lesser quality rinse water.
Optional High Ambient Control Panel
Consists of exhaust fan with rain hood, two inlet screens with
filters, necessary controls and wiring to allow operation to
125°F (52°C). The option can be factory or field installed as a
kit.
• It must be supplied on units operating at ambient
temperatures of 105°F (40.6°C) and above.
• It is automatically included on units with fan VFD (low
ambient option).
• Check inlet filters periodically and clean as required. Verify
that the fan is operational.
Cautions
Liquid Line Sight Glass
Harsh Chemical and Acid Cleaners
The refrigerant sight glasses should be observed periodically
(a weekly observation should be adequate). A clear glass of
liquid indicates that there is subcooled refrigerant charge in the
system. Bubbling refrigerant in the sight glass, during stable
run conditions, indicates that the system can be short of
refrigerant charge. Refrigerant gas flashing in the sight glass
could also indicate an excessive pressure drop in the liquid
line, possibly due to a clogged filter-drier or a restriction
elsewhere in the liquid line.
Harsh chemicals, household bleach or acid cleaners should not
be used to clean outdoor or indoor ElectroFin Coated Coils.
These cleaners can be very difficult to rinse out of the coil and
can accelerate corrosion and attack the ElectroFin coating. If
there is dirt below the surface of the coil, use the
recommended coil cleaners as described above.
High Velocity Water or Compressed Air
High velocity water from a pressure washer or compressed air
should only be used at a very low pressure to prevent fin and/
or coil damages. The force of the water or air jet may bend the
fin edges and increase airside pressure drop. Reduced unit
performance or nuisance unit shutdowns may occur.
See Table 22, Filter-Drier Pressure Drop on page 78 for
maximum allowable pressure drops. If subcooling is low, add
charge to clear the sight glass. If subcooling is normal (15 to
20 degrees F) and flashing is visible in the sight glass, check
the pressure drop across the filter-drier. Subcooling should be
checked at full load with 70°F (21.1°C) ambient temperature,
stable conditions, and all fans running.
An element inside the sight glass indicates the moisture
condition corresponding to a given element color. If the sight
glass does not indicate a dry condition after about 12 hours of
operation, the circuit should be pumped down and the filterdrier changed or verify moisture content by performing an acid
test on the compressor oil.
IOM 1206-1
67
Unit Maintenance
Planned Maintenance Schedule
OPERATION
General
Complete unit log and review (Note 3)
Visually inspect unit for loose or damaged components
Inspect thermal insulation for integrity
Clean and paint as required
WEEKLY
Condenser (air-cooled)
Clean condenser coils (Note 4)
Check fan blades for tightness on shaft (Note 5)
Check fans for loose rivets and cracks
Check coil fins for damage
Notes:
1 Monthly operations include all weekly operations.
2 Annual (or spring start-up) operations includes all
weekly and monthly operations.
3 Log readings can be taken daily for a higher level of unit
ANNUAL
(Note 2)
X
X
X
X
Electrical
Check terminals for tightness, tighten as necessary
Clean control panel interior
Visually inspect components for signs of overheating
Verify compressor heater operation
Test and calibrate equipment protection and operating
controls
Megger compressor motor *
Refrigeration
Leak test
Check sight glasses for clear flow
Check filter-drier pressure drop (see manual for spec)
Perform compressor vibration test
Acid test oil sample
MONTHLY
(Note 1)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
4 Coil cleaning can be required more frequently in areas
with a high level of airborne particles.
5 Be sure fan motors are electrically locked out.
* Never Megger motors while they are in a vacuum to avoid
damage to the motor.
observation.
68
IOM 1206-1
Unit Maintenance
Unit Service
R-410A
Refrigerant Terminology
Bubble Point: The temperature/pressure where bubbles first
appear when heat is added to a liquid refrigerant. Used to
measure sub-cooling.
Dew Point: The temperature/pressure where droplets first
appear when heat is removed from a refrigerant gas. Used to
measure superheat.
Fractionalization: A change in refrigerant composition due to
the tendency of the higher pressure refrigerant to leak at a
faster rate, should a system have leakage from a static twophase region.
Glide: The total difference of Dew and Bubble Point at a
specific condition. Mid-Point or Mean: Measurement half way
between Dew and Bubble Points.
Wear protective clothing. Impervious gloves and splash
goggles should be worn.
Avoid contact with liquid refrigerant (R-410A -60.8°F @
atms.) due to corrosion and freezing hazards.
Avoid exposure to vapors. 1000 ppm/8 hr.
Evacuate areas in cases of large releases. R-410A is heavier
than air and can cause asphyxiation, narcotic and cardiac
sensation effects.
Evacuate systems and break vacuum (0 psig) with nitrogen
before welding or brazing.
Always ventilate work areas before using open flames.
Exposure to open flames or glowing metal will form toxic
hydrofluoric acid & carbonyl fluoride. No smoking!
Make sure all tools, equipment, and replacement components
are rated for the refrigerant used.
POE Lubricants
Miscibility: The ability of a refrigerant and oil to mix and flow
together.
Solubility: The effect of refrigerant on the viscosity of a
lubricant.
Safety
Comparable to R-22; ANSI/ASHRAE safety group A1.
Always carry and be familiar with MSDS information for R410a.
Store refrigerant in clean, dry area out of direct sunlight.
Never heat or store cylinders above 125° F. Note vehicle
precautions!
Never tamper with cylinder valves or pressure relief valves.
(Typical relief for R-410A is 525 psig).
Never refill disposable cylinders.
Verify cylinder hook-up.
Verify cylinder label and color code match. R-410A is rose/
light maroon. Must be DOT approved, R-410A with 400 psig
rating. Open cylinders slowly.
Avoid rough handling of cylinders and secure as appropriate.
Cap when not in use.
Do not overfill recovery cylinders or overcharge units.
!
WARNING
POE oil must be handled carefully using proper
protective equipment (gloves, eye protection, etc.)
The oil must not come in contact with certain
polymers (e.g. PVC), as it may absorb moisture from
this material. Also, do not use oil or refrigerant
additives in the system.
POE type oil is used for compressor lubrication. This
type of oil is extremely hydroscopic 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.
It is important that only the manufacturer’s
recommended oils be used. Acceptable POE oil types
are:
· CPI/Lubrizol Emkarate RL32-3 MAF
· Exxon/Mobil EAL Arctic 22 CC*
· Hatcol 22CC*
· Everest 22CC*
· Copeland Ultra 32-3 MAF
Check gauge calibration before every use and manifold set for
leaks regularly.
· Parker Emkarate RL32-3MAF
Be aware of pneumatic and possible hydrostatic pressure
potentials.
· Nu Calgon 4314-66
Never pressurize systems with oxygen or ref/air mix. R-410A,
R-407C, R-134A, & R-22 are flammable with low air mix.
IOM 1206-1
· Virginia LE323MAF
Note - * These types of oils can only be used as “Top
Off” oils. This is defined as adding less than 50% of the
total amount of oil in the unit.
69
Unit Maintenance
Pump the lubricant into the unit through a closed transfer
system. Avoid overcharging the unit.
Use only new sealed metal containers of oil to insure
quality.
Buy smaller containers to prevent waste and
contamination.
Use only filter driers designed for POE and check
pressure drops frequently.
Test for acid and color at least annually. Change filter
driers if acid or high moisture (> 200 ppm) is indicated (<
100 ppm typical).
Evacuate to 500 microns and hold test to insure systems are
dry.
Control and Alarm Settings
The software that controls the operation of the unit is factoryset for operation with R-410A taking into account that the
pressure/temperature relationship differs from R-22. The
software functionality is the same for either refrigerant.
Refrigerant Charging
The AGZ units have a condenser coil design with
approximately 15% of the coil tubes located in a subcooler
section of the coil to achieve liquid cooling to within 5°F (3°C)
of the outdoor air temperature when all condenser fans are
operating.
Once the subcooler is filled, extra charge will not lower the
liquid temperature and does not help system capacity or
efficiency.
If a unit is low on refrigerant, you must first determine the
cause before attempting to recharge the unit. Locate and repair
any refrigerant leaks. Soap works well to show bubbles at
medium size leaks but electronic leak detectors are needed to
locate small leaks.
Charging or check valves should always be used on charging
hoses to limit refrigerant loss and prevent frostbite. Ball valve
type recommended.
Charge to 80-85% of normal charge before starting the
compressors.
Charging procedure
The units are factory-charged with R-410A. Use the following
procedure if recharging in the field is necessary:
To prevent fractionalization, liquid must be charged from the
refrigerant cylinder, unless charging the entire cylinder
contents.
The charge can be added at any load condition between 25 to
100 percent load per circuit, but at least two fans per
refrigerant circuit should be operating if possible.
70
Start the system and observe operation.
Trim the charge to the recommended liquid line sub-cooling
(approximately 14-20 degrees F typical).
Verify the suction superheat (10 degrees F for EEVs and 10 –
12 degrees F for TXVs) at full load conditions.
Use standard charging procedures (liquid only) to top off the
charge.
Check the sight glass to be sure there is no refrigerant flashing.
With outdoor temperatures above 60°F (15.6°C), all condenser
fans should be operating and the liquid line temperature should
be within 5°F to 10°F (2.8°C to 5.6°C) of the outdoor air
temperature. At 25-50% load, the liquid line temperature
should be within 5°F (2.8°C) of outdoor air temperature with
all fans on. At 75-100% load the liquid line temperature should
be within 10°F (5.6°C) of outdoor air temperature with all fans
on.
It may be necessary to add refrigerant through the compressor
suction. Because the refrigerant leaving the cylinder must be a
liquid, exercise care to avoid damage to the compressor by
using a flow restrictor. A sight glass can be connected between
the charging hose and the compressor. It can be adjusted to
have liquid leave the cylinder and vapor enter the compressor.
Overcharging of refrigerant will raise the compressor
discharge pressure due to filling of the condenser tubes with
excess refrigerant.
Service
With R-410A, fractionalization, if due to leaks and recharge
has a minimal effect on performance or operation.
Special tools will be required due to higher refrigerant
pressures with R-410A. Oil-less/hp recovery units, hp recovery
cylinders (DOT approved w/525# relief), gauge manifold 30”250 psi low/0-800 psi high, hoses w/800 psi working & 4,000
psi burst.
All filter driers and replacement components must be rated
POE oils and for the refrigerant pressure (R-410A 600psig
typical).
R-410A compressor internal relief is 600-650 psid.
Brazed connections only. No StayBrite or solder connections
(solder should never be used with any refrigerant). K or L type
refrigeration tubing only. Use nitrogen purge. Higher R-410A
pressures and smaller molecule size make workmanship more
critical.
R-410A must be charged from cylinder as a liquid unless
entire cylinder is used. Use a Refrigerant flow restrictor if
charging liquid to suction or to a system at pressure below a
saturated temperature of 32° F.
EPA recovery and handling requirements for R-410A are the
same as R-22.
IOM 1206-1
Unit Maintenance
Cooling the recovery cylinder will speed recovery and lessen
stress on recovery equipment.
!
WARNING
Service on this equipment is to be performed by qualified
refrigeration personnel familiar with equipment operation,
maintenance, correct servicing procedures, and the safety
hazards inherent in this work. Causes for repeated tripping of
equipment protection controls must be investigated and
corrected.
Disconnect all power before doing any service
inside the unit.
Servicing this equipment must comply with the
requirements set forth by the EPA in regards to
refrigerant reclamation and venting.
Filter-Driers
Replace the filter-drier any time excessive pressure drop
is read across the filter-drier
and/or when bubbles occur in the sight glass with normal
subcooling. The maximum recommended pressure drops
across the filter-drier are shown below.
Table 22, Filter-Drier Pressure Drop
PERCENT CIRCUIT
LOADING (%)
100%
75%
50%
25%
MAXIMUM RECOMMENDED
PRESSUREDROP ACROSS
FILTER DRIER PSIG (KPA)
10 (69)
8 (55.2)
5 (34.5)
4 (27.6)
The filter-drier should also be changed if the moisture
indicating liquid line sight glass indicates excess
moisture in the system.
During the first few months of operation the filter-drier
replacement can be necessary if the pressure drop across
the filter-drier exceeds the values listed in the paragraph
above. Any residual particles from the condenser tubing,
compressor and miscellaneous components are swept by
the refrigerant into the liquid line and are caught by the
filter-drier.
IOM 1206-1
Battery
The microprocessor has a battery located behind the clear
plastic bezel. It is a BR2032 with a minimum life of 2
years unpowered. It would be prudent to replace it on a 2year cycle. There is no indication of an eminent failure.
Liquid Line Solenoid Valve
The liquid line solenoid valves that shut off refrigerant
flow in the event of a power failure do not normally
require any maintenance. The solenoids can, however,
require replacement of the solenoid coil or of the entire
valve assembly.
The solenoid coil can be checked to see that the stem is
magnetized when energized by touching a screwdriver to
the top of the stem. If there is no magnetization, either the
coil is bad or there is no power to the coil.
The solenoid coil can be removed from the valve body
without opening the refrigerant piping after pumpdown.
For personal safety, shut off and lock out the unit power.
The coil can then be removed from the valve body by
simply removing a nut or snap-ring located at the top of
the coil. The coil can then be slipped off its mounting
stud for replacement.
To replace the entire solenoid valve follow the steps
involved when changing a filter-drier.
Evaporator
The evaporators on AGZ-E models 030 - 070 are brazed
plate type. Other than cleaning and testing, no service
work should be required on the evaporator.
71
Troubleshooting Chart
Troubleshooting Chart
PROBLEM
POSSIBLE CAUSES
POSSIBLE CORRECTIVE STEPS
1. Main switch.
1. Close switch.
2. Check electrical circuits and motor windings for shorts or
grounds. Investigate for possible overloading. Replace
2. Fuse blown. circuit breakers open
fuse or reset breakers after fault is corrected. Check for
loose or corroded connections.
3. Overloads are auto-reset. Check unit closely when unit
3. Thermal overloads tripped
comes back on line. Allow time for auto-reset.
Compressor Will
4. Defective contactor or coil.
4. Repair or replace
Not Run
5. System shutdown by equipment protection
5. Determine type and cause of shutdown and correct it
devices
before resetting equipment protection switch.
6. No cooling required
6. None. Wait until unit calls for cooling.
7. Liquid line solenoid will not open
7. Repair or replace solenoid coil. Check wiring.
8. Motor electrical trouble
8. Check motor for opens, shorts, or burnout.
9. Loose wiring
9. Check all wire junctions. Tighten all terminal screws.
1. Low or no refrigerant charge
1. Repair and recharge
2. Compressor running in reverse
2. Check unit and compressor for correct phasing
Compressor Noisy
3. Improper piping support on suction or discharge 3. Relocate, add, or remove hangers
Or Vibrating
4. Worn compressor isolator bushing
4. Replace
5. Worn Compressor
5. Replace
1. Noncondensables in system
1. Extract the noncondensables with approved procedures.
2. System overcharged with refrigerant
2. Remove excess, check liquid subcooling.
3. Optional discharge shutoff valve partially closed 3. Open valve.
High Discharge
4. FanTrol wiring not correct
4. Check FanTrol wiring.
Pressure
5. Fan not running
5. Check electrical circuit, Check fan motor.
6. Dirty condenser coil
6. Clean coil.
7. Air recirculation
7. Correct.
1. Refrigerant flood back
1. Correct.
2. Wind blowing into coil at low ambient
2. Shield coil from direct wind, Wind guards are available.
3. Faulty condenser temperature regulation
3. Check condenser control operation.
Low Discharge
4. Insufficient refrigerant in system
4. Check for leaks. Repair and add charge.
Pressure
5. Low suction pressure
5. See corrective steps for Low Suction Pressure.
6. Only one compressor operating
6. See corrective steps for Compressor Will Not Stage Up.
1. Excessive water temperature
1. Check control settings.
2. Excessive load
2. Reduce load or add additional equipment.
High Suction
3. Expansion valve overfeeding
3. Check remote bulb. Regulate superheat.
Pressure
4. Compressors running in reverse
4. Check for proper phasing.
1. Rapid load swings
1. Stabilize load.
2. Check for leaks, repair, add charge. Check liquid sight
2. Lack of refrigerant
glass.
3. Clogged liquid line filter drier
3. Check pressure drop across filter drier. Replace.
4. Expansion valve malfunctioning
4. Check and reset for proper superheat.
5. Condensing temperature too low
5. Check means for regulating condenser temperature.
Low Suction
6. See corrective steps for Compressor Staging Intervals Too
6. Compressor will not unload
Pressure
Low.
7. Insufficient water flow
7. Adjust flow.
8. Take pressure drop across vessel and contact factory to
8. Evaporator head ring gasket slippage
obtain design pressure drop for that vessel.
9. Evaporator dirty
9. Clean chemically.
10. Rapid load swings
10. Stabilize load.
1. Defective capacity control
1. Replace.
Compressor Will
2. Faulty thermostat stage or broken wire
2. Replace.
Not Stage Up
3. Stages not set for application
3. Reset thermostat setting for application.
1. Thermostat control band not set properly
1. Set control band wider.
Compressor
2. Faulty water temperature sensor
2. Replace.
Staging Intervals
3. Insufficient water flow
3. Adjust flow.
Too Short
4. Rapid load swings
4. Stabilize load.
72
IOM 1206-1
Troubleshooting Chart
POSSIBLE CAUSES
1. Oil hang-up in piping
2. Low oil level
3. Loose fitting on oil line
Compressor Oil
4. Level too high
Level Too High Or
5. Insufficient water flow - Level too high
Too Low
6. Excessive liquid in crankcase - Level too high
PROBLEM
Compressor
Loses Oil
Motor Overload
Relays or Circuit
Breakers Open
Compressor
Thermal
Protection Switch
Open
IOM 1206-1
7. Short cycling
1. Lack of refrigerant
2. Suction superheat too high
3. Crankcase heater burnout
1. Low voltage during high load conditions
2. Defective or grounded wiring in motor
3. Loose power wiring or burnt contactors
4. High condenser temperature
5. Power line fault causing unbalanced voltage
POSSIBLE CORRECTIVE STEPS
1. Review refrigerant piping and correct.
2. Check and add oil.
3. Check and tighten system.
4. Adjust thermal expansion valve.
5. Adjust flow.
6. Check crankcase heater. Reset expansion valve for higher
superheat. Check liquid line solenoid valve operation.
7. Stabilize load or increase staging interval.
1. Check for leaks and repair. Add refrigerant
2. Adjust superheat.
3, Replace crankcase heater.
1. Check supply voltage for excessive line drop.
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 is corrected..
1. Operating beyond design conditions
2. Discharge valve partially shut
1. Add facilities so conditions are within allowable limits.
2. Open valve.
3. Blown compressor internal gasket
4. Voltage range or imbalance
5. High superheat
6. Compressor bearing failure
3. Replace gasket.
4. Check and correct.
5. Adjust to correct superheat.
6. Replace compressor .
73
Warranty Registration Form (Scroll)
Warranty Registration Form (Scroll)
Scroll Compressor Equipment W arranty Registration Form
Attention: W arranty Department
Daikin
P.O Box 2510
Staunton, VA 24402-2510
This f orm must be completely f illed out and returned to the
Staunton Warranty Department w ithin te n (10) days of start-up in order to comply
w ith the terms of "Daikin Limited Product Warranty".
Check, Test and Commissioning for
Scroll Product (AGZ, ACZ, W GZ, TGZ)
Note : Us e OM and IM M or Late r M anuals
Job Nam e :
Startup Date :
Daik in G.O. No.:
Daik in S.O. No.:
Ins tallation Addre s s :
City/State /Zip:
Purchas ing Contractor:
Phone :
City/State /Zip:
No. of units at s ite :
Unit M ode l No.:
Se rial No.:
Com pre s s or # 1 Se rial #:
Com pre s s or # 4 Se rial No.:
Com pre s s or # 2 Se rial. #:
Com pre s s or # 5 Se rial No.:
Com pre s s or # 3 Se rial #:
Com pre s s or # 6 Se rial No.:
Be ns haw /DRC Control Box M /M #:
Be ns haw /DRC Control Box S/N #:
I. PRE START-UP PROCEDURE
II. Pre Start-Up Checklist
Pre Start-Up Checklist, All NO checks require an explanation under "Description". Please check yes or no.
YES
NO
A. Is the unit free of visible shipping damage, corrosion or paint problems?
B. Is unit installed level?
C. Does the unit meet all location, installation and service clearances per IM Bulletin?
D. Has thermostat bulb been properly installed in the well?
E. Are all set screws on all pulleys, bearings, and fans tight?
F. Does electrical service correspond to unit nameplate?
Volts
Hertz
Phase
G. Has electrical service been checked for proper phasing at each circuit power terminal block?
H. Has unit been properly grounded?
I. Has a fused disconnect and fuses or breaker been sized per product manual and installed per local code?
J. Are all electrical power connections tight?
K. Have compressor heaters and oil separator heaters been
been operating for 24 hours prior to start-up?
L. Does all field wiring conform to unit electrical specifications?
74
Form # SF-99007 • Part #: 041541502-D
Warranty Registration Form (Scroll)
M. Are all service and liquid line valves open?
N. Have all shipping hold down plates been removed?
O. Has a flow switch been installed per the IM bulletin?
P. Has the chill water circuit been cleaned, flushed, and water treatment confirmed?
Q. Does the chiller and condenser water piping conform to the IM Bulletin?
R. Are fans properly aligned and turn freely?
S. Is wind impingement against the air cooled condenser a consideration?
T. Description of unit location with respect to building structures.
Description:
III. REFRIGERATION SYSTEM
MICROTECH STATUS CHECK (Each Reading Must be Verified With Field Provided Instruments Of Known Accuracy)
YES
NO
A. Has all field piping been leak tested at 100 psig (690 kPA)?
MicroTech
Verification
C. Water Temperatures:
Leaving Evaporator..............................................................................
°F (°C)
°F (°C)
B. Has system been properly evacuated and charged?
Entering Evaporator .............................................................................
°F (°C)
°F (°C)
Entering Condenser..............................................................................
°F (°C)
°F (°C)
C. Refrigerant RCircuit 1
lbs (kg) Circuit 2
lbs. (kg)
Leaving Condenser...............................................................................
°F (°C)
°F (°C)
D. Circuit #1Refrigerant Pressures:
D. Does piping to unit appear to be
adequately
sizedpsig
and(kPa)
installed
according
to the IM bulletin?
Evaporator
_________
________
°F ( °C)
________psig
Minimum Condenser Pressure ________ psig (kPa)
E. Is a liquid line filter-drier installed
in each
circuit?Pressure ________ psig (kPa)
Maximum
Condenser
E. Circuit #2 Refrigerant Pressures:
F. Is level of oil in sightglass visible
butnot more
thanpsig
1/2(kPa)
glass________
with compressors
Evaporator
________
°F ( °C) running?
psig
Minimum Condenser Pressure _______ psig (kPa)
Maximum
Condenser
G. Is a liquid line solenoid installed
in each
circuit?Pressure _______ psig (kPa)
F. Circuit #1 Refrigerant Temperatures:
Saturated
Evaporator
Temperature.......................................................
°F (°C)
°F (°C)
H. Is expansion valve bulb properly
installed
and insulated?
Suction Line Temperature....................................................................
°F (°C)
°F (°C)
Suction
Superheat.................................................................................
°F
(°C)
°F (°C)
IV. DESIGN CONTROLS
Saturated Condenser Temperature .......................................................
°F (°C)
°F (°C)
Condenser
Approach
............................................................................
°F
(°C)
°F (°C)
A. CHILLER
Liquid
Line
Temperature
.....................................................................
°F
(°C)
°F
(°C)
Water Pressure Drop:
psig(kPa)
Ft. (kPa)
gpm (lps)
Subcooling
...........................................................................................
°F
(°C)
°F
(°C)
Water Temperatures: Entering
°F (°C) Leaving
°F (°C)
G. Circuit #2 Refrigerant Temperatures:
Saturated Evaporator Temperature....................................................... ________°F (°C)
°F (°C)
B. CONDENSER
Suction
Line
Temperature....................................................................
________°F
(°C)
°F (°C)
Water Pressure Drop:
psig(kPa)
Ft. (kPa)
gpm (lps)
Suction
Superheat.................................................................................
________°F
(°C)
°F (°C)
Water Temperatures: Entering
°F (°C) Leaving
°F (°C)
Saturated Condenser Temperature ....................................................... ________°F (°C)
°F (°C)
Condenser
Approach
............................................................................
________°F
(°C)
°F (°C)
V. START-UP
Liquid Line Temperature ..................................................................... ________°F (°C)
°F (°C)
YES
NO
Subcooling ........................................................................................... ________°F (°C)
°F (°C)
A. Does unit start and perform per sequence of operation as stated in the IM bulletin?
H.
Outdoor Air Temperature ............................................................................................................ ________°F (°C)
B. Does condenser fans rotate in the proper directions?
Form # SF-99007 • Part #: 041541502-D
°F (°C)
75
Warranty Registration Form (Scroll)
MICROTECH STATUS CHECK-Each Reading Must be Verified with Field Provided Instruments of Known Accuracy?
C. Water Temperatures:
D.
E.
F.
G.
Leaving Evaporator
………………………………
Entering Evaporator ………………………………
Entering Condenser ………………………………
Leaving Condenser
………………………………
Circuit #1 Refrigerant Pressures:
Evaporator
psig (kPa)
°F (°C)
Minimum Condensor Pressure
psig (kPa)
Maximum Condenser Pressure
psig (kPa)
Circuit #2 Refrigerant Pressures:
Evaporator
psig (kPa)
°F (°C)
Minimum Condensor Pressure
psig (kPa)
Maximum Condenser Pressure
psig (kPa)
Circuit #1 Refrigerant Temperatures:
Saturated Evaporator Temperature ……………………
Suction Line Temperature ……………………………….
Suction Superheat ……………………………………….
Saturated Condenser Temperature ……………………
Liquid Line Temperature ……………………………….
Subcooling ……………………………………………….
Circuit #2 Refrigerant Temperatures:
Saturated Evaporator Temperature ……………………
Suction Line Temperature ……………………………….
Suction Superheat ……………………………………....
Saturated Condenser Temperature ……………………
Liquid Line Temperature ……………………………….
Subcooling ……………………………………………….
H. Outdoor Air Temperature: ………………………………………………………..
MicroTech
°F (°C)
°F (°C)
°F (°C)
°F (°C)
Verification
°F (°C)
°F (°C)
°F (°C)
°F (°C)
psig
psig
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
°F (°C)
NON-MICROTECH READINGS
I. Does the system contain glycol?
Yes
No
Percentage by weight
or by volume
J. If the chilled water system include glycol, have the freezstats been adjusted lower to meet acutal job requirements?
Yes
No
Note: See operation manual for low temperature on ice bank applications.
K. Waterside Pressure Drop:
Chiller:
psig (kPa)
Ft. (kPa)
gpm (lps)
gpm (lps)
Condenser:
psig (kPa)
Ft. (kPa)
L. Unit Voltage Across Each Phase:
V
V
V
M. Unit Current Per Phase:
amps
amps
amps
N. Compressor Current Per Phase:
Comrpessor #1:
Amps
Amps
Amps
Compressor #2:
Amps
Amps
Amps
Compressor #3:
Amps
Amps
Amps
Compressor #4:
Amps
Amps
Amps
Compressor #5:
Amps
Amps
Amps
Compressor #6:
Amps
Amps
Amps
76
Form # SF-99007 • Part #: 041541502-D
Warranty Registration Form (Scroll)
VI. CONTROL CHECK AND SETPOINT VERIFICATION/STANDARD UNIT SETPOINT
MICROTECH SETPOINTS
MICROTECH
A. Leaving Evaporator …………………………………………………………………..
°F (°C)
B. Reset Leaving ………………………………………………………………………
°F (°C)
C. Reset Signa ..…………………………………………………………………………
ma
D. Reset Option………………………………………………………………………….
E. Maximum Chilled Water Reset ……………………………………………………
°F (°C)
F. Return Setpoint ……………………………………………………………………….
°F (°C)
G. Maximum Pulldown ……………………………………………………………….
°F (°C)
H. Control Band…………………………………………………………………………..
°F (°C)
I. Interstage Delay ……………………………………………………………………….
sec.
J. Start-to-Stop Delay …………………………………………………………………..
min.
K. Stop-to-Stop Delay ……………………………………………………………………
min.
L. Stage Up Error ……………………………………………………………………….
psig (kPa)
M. Stage Down Error …………………………………………………………………..
psig (kPa)
STANDARD
°F (°C)
°F (°C)
°F (°C)
°F (°C)
sec.
ALARM SETPOINTS MUST BE VERIFIED WITH INSTRUMENTS OF KNOWN ACCURACY
N.
O.
P.
Q.
R.
S.
T.
U.
V.
Low Pressure Hold ……………………………………………………………….
Low Pressure Unload…………………………………………………………….
Chilled Water Freezestat…………………………………………………………
High Pressure Cut-Out…………………………………………………………..
Unit Type =
Number of Compressors =
Number of Stages =
Number of Fan Stages =
Software Version =
psig
psig
psig
psig
(kPa)
(kPa)
(kPa)
(kPa)
psig
psig
psig
psig
(kPa)
(kPa)
(kPa)
(kPa)
VII. FOR HEAT RECOVERY CHILLERS ONLY (Must Be Taken At Full Load)
A.
B.
C.
D.
E.
F.
Place Unit in heat recovery mode.
Waterside Pressure Drop:
psig (kPa)
Ft. (kPa)
Outlet
Waterside Temperatures:
Inlet
psig (kPa) Circuit #2:
Head Pressure: Circuit #1
Suction Pressure: Circuit #1
psig (kPa) Circuit #2:
Compressor Current Per Phase
Compressor #1
AMPS
AMPS
Compressor #2
AMPS
AMPS
Compressor #3
AMPS
AMPS
Compressor #4
AMPS
AMPS
gpm (lps)
psig (kPa)
psig (kPa)
AMPS
AMPS
AMPS
AMPS
VIII. GENERAL
YES
NO
A. Are all control lines secure to prevent excess vibration and wear? ……………………………………….
B. Are all gauges shut off, valve caps, and packings tight after startup? ……………………………………
Performed By:
Title:
Company Name:
Address:
City/State/Zip Code:
Telephone:
Modem Number:
Signature:
Date:
Contractor's Signature
Form # SF-99007 • Part #: 041541502-D
77
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 to speak to the Training Department.
Warranty
All Daikin Applied equipment is sold pursuant to its standard terms and conditions of sale, including Limited
Product Warranty. Consult your local Daikin Applied representative for warranty details. To find your local Daikin
Applied representative, go to www.DaikinApplied.com.
Aftermarket Services
To find your local parts office, visit www.DaikinApplied.com or call 800-37PARTS (800-377-2787).
To find your local service office, visit www.DaikinApplied.com or call 800-432-1342.
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.
© 2014 Daikin Applied• www.DaikinApplied.com • (800-432-1342)
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