Water-Cooled Screw Compressor Chillers

Transcription

1 Installation and Maintenance Manual IMM Group: Chiller Part Number: Effective: September 014 Supercedes: March 01 Water-Cooled Screw Compressor Chillers WGS 130AW to WGS 190AW, Packaged Water-Cooled Chiller WGS 130AA to WGS 190AA, Chiller with Remote Condenser 10 to 00 Tons, 40 to 700 kw R-134A, 60 Hz

2 Table of Contents Introduction... 3 General Description... 3 Nomenclature... 3 Inspection... 3 Installation... 4 Vibration Isolators... 6 Water Piping Flow Switch... 1 Glycol Solutions Condenser Water Piping Water Pressure Drop Refrigerant Piping Unit with Remote Condenser Factory-Mounted Condenser... 1 Dimensional Data... Physical Data... 5 WGS-AW, Water-Cooled... 5 WGS-AA Remote Condenser... 6 Unit Configuration... 7 Components... 7 Wiring... 8 BAS Interface... 9 Remote Operator Interface Panel... 9 Electrical Data Wiring Diagrams Control Panel Layout Sequence of Operation Start-Up and Shutdown Pre Start-up Start-up Weekend or Temporary Shutdown Start-up after Temporary Shutdown Extended Shutdown Start-up after Extended Shutdown System Maintenance... 5 General... 5 Electrical Terminals POE Lubrication Sight Glass and Moisture Indicator Sump Heaters Maintenance Schedule System Service Troubleshooting Chart Unit controllers are LONMARK certified with an optional LONWORKS communications module. Manufactured in an ISO Certified Facility 014 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 any time without notice. WGS 130A to WGS 190A IMM 1157

3 Introduction General Description Daikin Model WGS water chillers are designed for indoor installations and are available with factorymounted water-cooled condensers (Model WGS AW), or arranged for use with remote air-cooled or evaporative condensers (Model WGS AA). Each water-cooled unit is completely assembled and factory wired before evacuation, charging and testing. They consist of two semi-hermetic rotary screw compressors, a two-circuit shell-and-tube evaporator, two shell-and-tube water-cooled condensers (WGS-AW), and complete refrigerant piping. Units manufactured for use with remote condensers (Models WGS-AA) have all refrigerant specialties factory-mounted and connection points for refrigerant discharge and liquid lines. Liquid line components are manual liquid line shutoff valves, charging valves, filter-driers, liquid line solenoid valves, sight glass/moisture indicators, and electronic expansion valves. The electrical control center includes a MicroTech II microprocessor control system and equipment protection and operating controls necessary for dependable, automatic operation. The compressor circuits are equipped with individual compressor isolation circuit breakers on single point power connection options. A unit disconnect switch is available as an option over the standard power block. Nomenclature W G S 130 A W Water-Cooled Condensing Global W = Water-Cooled Condenser A = Unit Less Condenser Rotary Screw Compressor Design Vintage Nominal Capacity (Tons) Inspection When the equipment is received, carefully check all items against the bill of lading to be sure of a complete shipment. Carefully inspect all units for damage upon arrival. All shipping damage must be reported to the carrier and a claim must be filed with the carrier. Check the unit serial plate before unloading the unit to be sure that it agrees with the power supply available. Physical damage to unit after acceptance is not the responsibility of Daikin Applied. Note: Unit shipping and operating weights are given in the physical data tables beginning on page 5. IMM WGS 130A to 190A 3

4 Installation WARNING Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment. Avoid contact with sharp edges. Personal injury can result. Start-up by Daikin Applied is included on all units sold for installation within the USA and Canada and must be performed by them to initiate the standard limited product warranty. Two-week prior notification of start-up is required. The contractor should obtain a copy of the Start-up Scheduled Request Form from the sales representative or from the nearest Daikin Applied service office. Handling Every model WGS-AW water chiller with water-cooled condensers is shipped with a full refrigerant charge. For shipment, the charge is contained in the condensers and is isolated by the condenser liquid shutoff valves and the compressor discharge valves. A nitrogen/helium holding charge is applied to remote condenser models to maintain a slight positive system pressure. After installation, the unit must be leak-tested, vacuumed, and charged with the operating charge of refrigerant. The operating charge is field-supplied and charged on remote condenser models. WARNING Escaping refrigerant can displace air and cause suffocation. Immediately evacuate and ventilate the equipment area. If the unit is damaged, follow Environmental Protection Agency (EPA) requirements. Do not expose sparks, arcing equipment, open flame or other ignition source to the refrigerant. Moving the Unit If optional factory-installed skids are not used, some means such as dollies or skids must be used to protect the unit from damage and to permit easy handling and moving. Figure 1, Lifting the Unit Remote Condenser Chiller Water-Cooled Chiller 48.0 (119.) 84.0 (133.6) 48.0 (119.) (743.) 6.0 (1574.8) 6.0 (1574.8) WGS PACKAGE WGS LESS CONDENSER LIFT ONLY WITH HOLES PROVIDED IN BASE R B000 Notes: 1. You must use lifting halo or "I" spreader equal to the dimensions shown.. Each lifting cable alone must be strong enough to lift chiller. 3. Perform all moving and handling with skids or dollies under the unit when possible, and do not remove them until the unit is in the final location. (continued next page) 4 WGS 130A to 190A IMM1157-1

5 4. In moving, always apply pressure to the base on the skids only and not to the piping or other components. A long bar will help move the unit. Do not drop the unit at the end of the roll. 5. Do not attach slings to piping or equipment. Do not attempt to lift the unit by lifting points mounted on the compressors. They are for lifting only the compressor should one need to be removed from the unit. Move unit in the upright horizontal position at all times. Set unit down gently when lowering from the truck or rollers. Table 1, Lifting Loads WGS Model AW, Package Units, lbs. (kg) RF RB LF LB Shipping Weight AA, Less Condenser Units, lbs (kg) RF RB LF LB Shipping Weight 130A (3556) (103) (770) (1003) (749) (647) (655) (69) (636) 5659 (567) 140A (3556) (103) (770) (1003) (749) (647) (655) (69) (636) 5659 (567) 160A (37) (1074) (813) (104) (790) (687) (700) (667) (679) 604 (73) 170A (3785) (1096) (8) (1065) (799) (687) (700) (667) (679) 604 (73) 190A (3785) (1096) (8) (1065) (799) (687) (700) (667) (679) 604 (73) NOTES: 1. RF=right front, RB=right back, LB=left back, LF=left front, when view from the control panel. See Figure on page 6.. The optional sound enclosure adds 650 lbs (95 kg) to the lifting weight, evenly distributed. Location WGS chillers are designed for indoor application and must be located in an area where the surrounding ambient temperature is 40 F to 1 F (4.4 C to 50 C). Because of the NEMA 1 electrical control enclosures, do not expose the units to the weather. A plastic cover over the control box is supplied as temporary protection during shipment. A reasonably level and sufficiently strong floor is required for the water chiller. If necessary, provide additional structural members to transfer the weight of the unit to the nearest beams. Note: Unit shipping and corner weights are given in Table 1. Operating weights are in the physical data tables beginning on page 5. Space Requirements for Connections and Servicing The chilled water piping enters and leaves the unit from the right side when looking at the front of the unit (control panel end). Left-hand connections are available as an option. Condenser water connections are located at the rear of the unit, opposite the control panel. Provide clearance of at least 4 feet (165 mm), or more if codes require in front of the panel. Three feet (119 mm) clearance should be provided on all other sides and ends of the unit for general servicing. The National Electric Code (NEC) may require additional clearance in front of the control panel and should be consulted. On units equipped with a water-cooled condenser (Type WGS-AW), also provide clearance for cleaning or removal of condenser tubes on one end of the unit. The clearance for cleaning depends on the type of apparatus used, but can be as much as the length of the condenser (10 feet, 3050 mm). Tube replacement requires the tube length of condenser plus one to two feet of workspace. This space can often be provided through a doorway or other aperture. Placing the Unit The small amount of vibration normally encountered with the water chiller makes this unit particularly desirable for basement or ground floor installations where the unit can be mounted directly to the floor. The floor construction should be such that the unit will not affect the building structure, or transmit noise and vibration into the structure. IMM WGS 130A to 190A 5

6 Vibration Isolators It is recommended that isolators be used on all upper level installations or in areas where vibration transmission is a consideration. Figure, Isolator Locations 3 Control Panel End 1 LF RF LB F RB 4 Condenser Connections Transfer the unit as indicated under Moving the Unit. on page 4. In all cases, set the unit in place and level with a spirit level. When springtype isolators are required, install springs running under the main unit supports. The unit should be set initially on shims or blocks at the listed spring free height. When all piping, wiring, flushing, charging, etc., is completed, the springs are adjusted upward to loosen the blocks or shims, which are then removed. Use a rubber anti-skid pad under isolators if hold-down bolts are not used. Installation of spring isolators requires flexible piping connections and at least three feet of flexible electrical conduit to avoid straining the piping and transmitting vibration and noise. NOTE: All spring isolators have four, same color springs per housing. Table, Weights & Vibration Isolators, Packaged Unit, w/o Sound Enclosure UNIT SIZE 130AW 140AW ARRANGEMENT WGS-AW, WITH WATER-COOLED CONDENSERS, WITHOUT SOUND ENCLOSURE OPR. WT. Lbs. (kg) 8557 (3881) 8557 (3881) CORNER WEIGHT LBS SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGS (KG) (806) 1778 (806) (1159) (786) (1159) (786) 491 1D-040 (1130) Black 491 1D-040 (1130) Black 1D-3600 Green 1D-3600 Green 1D-040 Black 1D-040 Black 1D-3600 Green 1D-3600 Green RP-4 RP-4 RP-4 RP-4 Brick Red Lime Brick Red Lime RP-4 RP-4 RP-4 RP-4 Brick Red Lime Brick Red Lime 160AW D-700 1D D-700 1D-3600 RP-4 RP-4 RP-4 RP-4 (45) (866) (17) (845) (141) Purple Green Purple Green Brick Red Lime Brick Red Lime 170AW D-700 1D D-700 1D-3600 RP-4 RP-4 RP-4 RP-4 (4311) (889) (194) (867) (16) Purple Green Purple Green Brick Red Lime Brick Red Lime 190AW D-700 1D D-700 1D-3600 RP-4 RP-4 RP-4 RP-4 (4309) (889) (194) (867) (16) Purple Green Purple Green Brick Red Lime Brick Red Lime NOTE: ID 040, ID 700 and ID 3600 have four same color springs per housing. 6 WGS 130A to 190A IMM1157-1

7 UNIT SIZE 130AW 140AW 160AW 170AW Table 3, Weights & Vibration Isolators, Packaged Unit, w/ Sound Enclosure OPR. WT. Lbs. (kg) ARRANGEMENT WGS-AW, WITH WATER-COOLED CONDENSERS, WITH SOUND ENCLOSURE CORNER WEIGHT LBS SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGS (KG) D-700 Purple 1D-700 Purple 1D-700 Purple 1D-700 Purple 1D-3600 Green 1D-3600 Green 1D-3600 Green 1D-3600 Green 1D-700 Purple 1D-700 Purple 1D-700 Purple 1D-700 Purple 1D-3600 Green 1D-3600 Green 1D-3600 Green 1D-3600 Green D-700 1D-700 1D-700 1D AW Purple Green Purple Green NOTE: ID 700 and ID 3600 have four same-color springs per housing. RP-4 RP-4 RP-4 RP-4 Brick Red Lime Brick Red Lime RP-4 RP-4 RP-4 RP-4 Brick Red Lime Brick Red Lime RP-4 RP-4 RP-4 RP-4 Lime Charcoal Lime Charcoal RP-4 RP-4 RP-4 RP-4 Lime Charcoal Lime Charcoal RP-4 RP-4 RP-4 RP-4 Lime Charcoal Lime Charcoal Table 4, Weights & Vibration Isolators, Remote Condenser, Without Sound Enclosure ARRANGEMENT WGS-AA, FOR REMOTE CONDENSER, WITHOUT SOUND ENCLOSURE (SEE NOTE) UNIT OPR. WT. CORNER WEIGHT LBS (KG) SPRING-FLEX MOUNTINGS RUBBER-IN-SHEAR MOUNTINGS SIZE LBS. (KG) AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick Brick (84) (713) (77) (694) (708) Black Black Black Black Red Red Red Red 140AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick (84) (713) (77) (694) (708) Black Black Black Black Brick Red Red Red Red 160AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick (3185) (794) (818) (775) (797) Black Black Black Black Brick Red Red Red Red 170AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick (3185) (794) (818) (775) (797) Black Black Black Black Brick Red Red Red Red 190AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick (3185) (794) (818) (775) (797) Black Black Black Black Brick Red Red Red Red NOTE: ID 040 has four same-color springs per housing. Table 5, Weights & Vibration Isolators, Remote Condenser, With Sound Enclosure ARRANGEMENT WGS-AA, FOR REMOTE CONDENSER, WITH SOUND ENCLOSURE (SEE NOTE) OPR. WT. CORNER WGT RUBBER-IN-SHEAR UNIT SPRING-FLEX MOUNTINGS LBS. LBS (KG) MOUNTINGS SIZE (KG) AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick Brick Black Black Black Black Red Red Red Red 140AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick Brick Black Black Black Black Red Red Red Red 160AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick Brick Black Black Black Black Red Red Red Red 170AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick Brick Black Black Black Black Red Red Red Red 190AA RP-4 RP-4 RP-4 RP D-040 1D-040 1D-040 1D-040 Brick Brick Brick Brick Black Black Black Black Red Red Red Red NOTE: ID 040 has four same color springs per housing. IMM WGS 130A to 190A 7

8 VM&C R4 Table 6, Isolator Kit Part Numbers Model AW, w/o Sound Enclosure WGS 130AW WGS 140AW WGS 160AW WGS 170AW WGS 190AW Spring Part Number R-I-S Part Number Model AW, w Sound Enclosure WGS 130AW WGS 140AW WGS 160AW WGS 170AW WGS 190AW Spring Part Number R-I-S Part Number Model AA, w/o Sound Enclosure WGS 130AA WGS 140AA WGS 160AA WGS 170AA WGS 190AA Spring Part Number R-I-S Part Number Model AA, w/ Sound Enclosure WGS 130AA WGS 140AA WGS 160AA WGS 170AA WGS 190AA Spring Part Number R-I-S Part Number NOTE: Model AW = packaged, water-cooled, Model AA = remote condenser, air-cooled Figure 3, CP-4, Spring Flex Mounting Figure 4, RP-4, R-I-S Mounting ø nc-b R TYP. VM&C R.8 TYP RECESSED GRIP RIBS R.50 TYP. R.750 TYP. DURULENE MATERIAL 1.13 ±.5 APPROX NOTES: 1. MOUNT MATERIAL TO BE DURULENE RUBBER.. MOLDED STEEL AND ELASTOMER MOUNT FOR OUTDOOR SERVICE CONDITIONS. 3. RP-4 MOUNT VERSION WITH STUD IN PLACE. RAISED GRIP RIBS DRAWING NUMBER ALL DIMENSIONS ARE IN DECIMAL INCHES 8 WGS 130A to 190A IMM1157-1

9 Figure 5, WGS-AA, Remote Condenser Configuration Discharge Connections Liquid Return Connections IMM WGS 130A to 190A 9

10 Water Piping Vessel Drains at Start-up Evaporators are drained of water in the factory and shipped with an open ball valve in the drain hole. The drain is located on the bottom of the vessel. Be sure to close the valve prior to filling the vessel with fluid. Condensers: Units are drained of water in the factory and are shipped with condenser drain plugs in the heads removed and stored in a bag in the control panel. Be sure to replace plugs prior to filling the vessel with fluid. General Due to the variety of piping practices, follow the recommendations of local authorities for code compliance. They can supply the installer with the proper building and safety codes required for a proper installation. The piping should be designed with a minimum number of bends and changes in elevation to keep system cost down and performance up. Other piping design considerations include: 1. All piping should be installed and supported to prevent the chiller connections from bearing any strain or weight of the system piping.. Vibration eliminators to reduce vibration and noise transmission to the building. 3. Shutoff valves to isolate the unit from the piping system during unit servicing. 4. Manual or automatic air vent valves at the high points of the system. Drains should be placed at the lowest points in the system. 5. Some means of maintaining adequate system water pressure (e.g., expansion tank or regulating valve). 6. Temperature and pressure indicators located within 3 feet (0.9 meters) of the inlet and outlet of the vessels to aid in unit servicing. 7. A strainer or some means of removing foreign matter from the water before it enters the pump. It should be placed far enough upstream to prevent cavitation at the pump inlet (consult pump manufacturer for recommendations). A strainer can prolong pump life and help maintain system performance. Important Note A cleanable 0-mesh strainer must also be placed in the water line just prior to the inlet of the evaporator. This will aid in preventing foreign material from entering the unit and decreasing the performance of the evaporator. 8. If the unit is used as a replacement chiller on a previously existing piping system, flush the system thoroughly prior to unit installation. Regular water analysis and chemical water treatment on the evaporator and condenser are recommended immediately upon equipment start-up. 9. In the event glycol is added to the water system as an afterthought for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance will be less, and water side pressure drop will be higher. If the percentage of glycol is large, or if propylene glycol is used instead of ethylene glycol, the added pressure drop and loss of performance could be substantial. Reset the freezestat and low leaving water alarm temperatures. The freezestat is factory set to default at 3 F (0 C). Reset the freezestat setting to approximately 8 to 10 F (4.4 to 5.5 C) below the leaving chilled water setpoint temperature. See the section titled Glycol Solutions on page 13 for additional information concerning the use of glycol. 10 WGS 130A to 190A IMM1157-1

11 10. Make a preliminary leak check of the water piping before filling the system.! WARNING This unit contains POE lubricants that must not come into contact with any surface or material that might be harmed by POE, including certain polymers (e.g. PVC/CPVC and polycarbonate piping). Note: A water flow switch or pressure differential switch must be mounted in the evaporator outlet water line to signal that there is water flow before the unit will start. Figure 6, Typical Field Evaporator Water Piping Out Drain Vent In Vibration Eliminator Valved Pressure Gauge Vibration Eliminator Water Strainer Flow Switch Balancing Gate Valve Valve Gate Valve Flow Flow Protect All Field Piping Against Freezing NOTE: Water piping must be supported independently from the unit. System Water Volume All chilled water systems need adequate time to recognize a load change, respond to that load change and stabilize, without undesirable short cycling of the compressors or loss of control. In air conditioning systems, the potential for short cycling usually exists when the building load falls below the minimum chiller plant capacity or on close-coupled systems with very small water volumes. Some of the things the designer should consider when looking at water volume are the minimum cooling load, the minimum chiller plant capacity during the low load period and the desired cycle time for the compressors. Assuming that there are no sudden load changes and that the chiller plant has reasonable turndown, a rule of thumb of gallons of water volume equal to two to three times the chilled water gpm flow rate is often used. A properly designed storage tank should be added if the system components do not provide sufficient water volume. Variable Chilled Water Flow Reducing chilled water flow in proportion to load can reduce total system power consumption. Certain restrictions apply to the amount and rate of flow change. The rate of flow change should be a maximum of 10 percent of the change, per minute. Do not reduce flow lower than the minimum flows listed in the pressure drop data on page 16. Chilled Water Piping The system water piping must be flushed thoroughly prior to making connections to the unit evaporator. A perforated metal basket strainer with 0.15-inch perforation, 40% open area. IMM WGS 130A to 190A 11

12 must be installed in the return water line before the inlet to the chiller. Lay out the water piping so the chilled water circulating pump discharges into the evaporator inlet. The return water line must be piped to the evaporator inlet connection and the supply water line must be piped to the evaporator outlet connection. If the evaporator water is piped in the reverse direction, a substantial decrease in capacity and efficiency of the unit will be experienced. A flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to prove water flow before starting the unit. Provide drain connections at all low points in the system to permit complete drainage. Air vents should be located at the high points in the system to purge air out of the system. The evaporator is equipped with vent and drain connections. Install pressure gauges in the inlet and outlet water lines to the evaporator. Pressure drop through the evaporator can be measured to determine water flow from the flow/pressure drop curves on page 16. Vibration eliminators are recommended in both the supply and return water lines. Insulate chilled water piping to reduce heat loss and prevent condensation. Perform complete unit and system leak tests prior to insulating the water piping. Insulation with a vapor barrier is recommended. If the vessel is insulated, the vent and drain connections must extend beyond the proposed insulation thickness for accessibility. Flow Switch Field Installed A water flow switch must be mounted in the leaving evaporator and condenser water line to prove adequate water flow before the unit can start. This will protect against slugging the compressors on start-up. It also serves to shut down the unit in the event that water flow is interrupted to guard against evaporator freeze-up. A flow switch is available from Daikin Applied under part number It is a paddle type switch and adaptable to any pipe size from 1 in. (5 mm) to 6 in. (15 mm) nominal. Certain flow rates are required to open the switch and are listed in Table 7. Switch terminals Y and R should be made to panel terminals 60 and 67 (chilled water) and 60 and 76 (condenser water). There is also a set of normally closed contacts on the switch that could be used for an indicator light or an alarm to indicate when a no flow condition exists. 1. Apply pipe sealing compound to only the threads of the switch and screw unit into the 1-in. (5-mm) reducing tee. The flow arrow must be pointed in the correct direction.. Piping should provide a straight length before and after the flow switch of at least five times the pipe diameter without any valves, elbows, or other flow restricting elements. 3. Trim the flow switch paddle if needed, to fit the pipe diameter. Make sure the paddle does not hang up in the pipe.! CAUTION Make sure the arrow on the side of the switch is pointed in the direction of flow. Connect the flow switch according to the wiring diagram (see wiring diagram inside control box door). Incorrect installation will cause improper operation and possible evaporator damage. 1 WGS 130A to 190A IMM1157-1

13 Table 7, Flow Switch Flow Rates Pipe Size inch 1 1/4 1 1/ 1/ (NOTE!) mm 3 () 38 () (3) (4) 17 (4) 153 (4) 04 (5) gpm Flow Min. Lpm Adjst. No gpm Flow Lpm gpm Flow Max. Lpm Adjst. No gpm Flow Lpm NOTES: 1. A segmented 3-inch paddle (1,, and 3 inches) is furnished mounted, plus a 6-inch paddle loose.. Flow rates for a -inch paddle trimmed to fit the pipe. 3. Flow rates for a 3-inch paddle trimmed to fit the pipe. 4. Flow rates for a 3-inch paddle. 5. Flow rates for a 6-inch paddle Optional Factory-Mounted The chiller may be equipped with the optional factory-mounted flow switch. The 4 Vac powered flow sensors are a solid state alternative to mechanical switches for sensing the acceptable flow rate of water. The flow sensors are extremely reliable with no moving parts that can become stuck or break in the flow process. These compact units are constructed of corrosion-resistant materials and 316 stainless steel parts and are factory-installed directly through a ¼ inch NPT into the flow. No field adjustments are required. The flow sensors operate on the calorimetric principle. The sensors use the cooling effect of a flowing fluid to provide reliable flow rate detection of liquids over a very wide flow range. The amount of thermal energy that is removed from the tip determines the local flow rate and when it exceeds a setpoint it changes the output-state. Glycol Solutions When using a glycol solution, the chiller capacity, flow rate, evaporator pressure drop, and chiller power input can be calculated using the following formulas. Refer to Table 8 for ethylene glycol and Table 9 for propylene glycol. Capacity, Capacity is reduced compared to that of plain water. To find the reduced value, multiply the chiller s capacity when using water by the capacity correction factor C to find the chiller s capacity when using glycol. Flow, Multiply the water flow by the G correction factor to determine the glycol flow required to give the same Delta-T as water. To determine evaporator gpm (or T) knowing T (or gpm) and capacity: x Glycol Capacity Glycol GPM 4 T x Flow Correction G From Tables For Metric Applications -- Determine evaporator lps (or T) knowing T (or lps) and kw: Glycol kw Lps x T x Flow Correction G from Tables Pressure Drop, To determine glycol pressure drop through the cooler, enter the water pressure drop graph on page 16 at the actual glycol flow. Multiply the water pressure drop found there by correction factor P to obtain corrected glycol pressure drop. Power, To determine glycol system kw, multiply the water system kw by factor K. IMM WGS 130A to 190A 13

14 Test coolant with a clean, accurate, glycol solution hydrometer (similar to that found in service stations) to determine the freezing point. Obtain percent glycol from the freezing point found in Table 8. On glycol applications the supplier normally recommends that a minimum of 5% solution by weight be used for protection against corrosion or the use of additional inhibitors. Note: The effect of glycol in the condenser is negligible. As glycol increases in temperature, its characteristics have a tendency to mirror those of water. Therefore, for selection purposes, there is no derate in capacity for glycol in the condenser. Table 8, Ethylene Glycol % Ethylene Freeze Point Glycol F C C Capacity K Power G Flow P Pressure Drop Table 9, Propylene Glycol % Percent Freeze Point Glycol F C C Capacity K Power G Flow P Pressure Drop ! CAUTION Do not use automotive grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors, which cause plating on copper tubes. The type and handling of glycol used must be consistent with local codes. Condenser Water Piping Arrange the condenser water so the water enters the condensers bottom connections or the single bottom manifold connection if the optional manifold has been ordered. The condenser water will discharge from the top condenser connections or the single top connection of the optional manifold. Failing to arrange the condenser water as stated above will negatively affect the capacity and efficiency. Install pressure gauges in the inlet and outlet water lines to the condenser. Pressure drop through the condenser should be measured to determine flow on the pressure drop/flow curves on page 17. Vibration eliminators are recommended in both the supply and return water lines. Water-cooled condensers can be piped for use with cooling towers or well water. Cooling tower applications should be made with consideration of freeze protection and scaling problems. Contact the cooling tower manufacturer for equipment characteristics and limitations for the specific application. 14 WGS 130A to 190A IMM1157-1

15 Evaporator Leaving Water Temperature(F) Head pressure control must be provided if the entering condenser water can fall below the curve values displayed in the graph to the right. The MicroTech II unit controller can provide this function, using entering condenser water as the control point. The control will work with or without the optional condenser manifolds. The water sensors are factoryinstalled The controller setpoints have to be adjusted for water control and Condenser Entering Water Temperature(F) certain output connections made to the tower components. See the operating manual OM WGS and the field wiring diagram in this manual for further details. Condenser Water Sensors Packaged WGS chillers are supplied with one ECWT sensor and one LCWT sensor. The option the unit is ordered with will determine the sensor location requirements. Listed below are the two possibilities. WGS Ordered Without the Condenser Manifold: If the unit is ordered without the condenser manifold option, the entering and leaving water sensors will have to be field-installed in their respective condenser water piping, at a common location. Since each WGS is supplied with an independent condenser vessel per refrigerant circuit, the water temperature sensors must be installed in a location prior to the water piping split on the entering water side and after the piping is rejoined on the leaving water side. The sensors ship with the chiller, temporarily attached to the condenser vessel. The sensors will be landed on the control panel end and provided with additional lead length for field installation. WGS Ordered With the Condenser Manifold: If the unit is ordered with the condenser manifold option, both sensors will be factoryinstalled in the manifolds. Water Pressure Drop The vessel flow rates must fall between the minimum and maximum values shown on the appropriate evaporator and condenser curves. Flow rates below the minimum values shown will result in laminar flow that will reduce efficiency, cause erratic operation of the electronic expansion valve and could cause low temperature cutoffs. On the other hand, flow rates exceeding the maximum values shown can cause erosion in the evaporator and condenser. Measure the chilled water pressure drop through the evaporator at field-installed pressure taps. It is important not to include valves or strainers in these readings. IMM WGS 130A to 190A 15

16 Figure 7, Evaporator Pressure Drop WGS 130 WGS 190 WGS 130, 140 WGS 160, 170, 190 WGS Model Minimum Flow Nominal Flow Maximum Flow Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop gpm L/s Ft. kpa gpm L/s Ft. kpa gpm L/s Ft. kpa 130AW/AA AW/AA AW/AA AW/AA AW/AA Note: Minimum, nominal, and maximum flows are at a 16 F, 10 F, and 6 F chilled water temperature range respectively and at ARI tons. 16 WGS 130A to 190A IMM1157-1

17 Figure 8, Condenser Pressure Drop WGS 130 WGS 190 WGS 170, 190 with Manifold WGS 130, 140, 160 with Manifold WGS 170, 190 without Manifold WGS 130, 140, 160 without Manifold WGS Model Pressure Drop Without Optional Condenser Manifold Minimum Flow Nominal Flow Maximum Flow Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop gpm L/s Ft. kpa gpm L/s Ft. kpa gpm L/s Ft. kpa 130AW AW AW AW AW WGS Model Pressure Drop With Optional Condenser Manifold Minimum Flow Nominal Flow Maximum Flow Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop gpm L/s Ft. kpa gpm L/s Ft. kpa gpm L/s Ft. kpa 130AW AW AW AW AW IMM WGS 130A to 190A 17

18 Refrigerant Piping Unit with Remote Condenser General For remote condenser application (WGS-AA), the chillers are shipped with a nitrogen/helium holding charge of 0 psi is used to pressurize the system with a slight positive pressure to prevent contaminants from entering the unit. This holding charge should not be mistaken as a refrigerant charge, and can not be used as part of the final total refrigerant charge. After installation, the unit should be pressurized and tested for leaks, vacuumed and charged with the correct refrigerant operating charge, taking into consideration the length of refrigerant piping. The operating charge is field-supplied and charged for remote condenser models. It is important that the unit be kept tightly closed until the remote condenser is installed and piped to the unit. It is the contractor s responsibility to install the interconnection piping, leak-test the entire system, evacuate the system, and supply the system refrigerant charge. The system should be held under vacuum until it is charged under supervision of the Daikin Applied authorized service technician who will supervise unit commissioning. The unit operating charge (less piping and condenser) can be found on page 6.! IMPORTANT NOTE! Service Form SF99006 and an isometric sketch of the Remote Piping Layout showing pipe size, location of fittings, measured lengths and elevations MUST BE SUBMITTED TO Daikin Technical Response Center and reviewed before order entry. A Daikin Applied service representative will not perform startup without reviewed Service Form SF99006 and drawing. Installation must match reviewed drawing. All field piping, wiring and procedures must comply with design guidelines set forth in the product literature, and be performed in accordance with ASHRAE, EPA, local codes and industry standards and per included sizing tables. Any product failure caused, or contributed to, by failure to comply with appropriate design guidelines will not be covered by manufacturer s warranty. The following notes apply to all size units: Daikin Technical Response: Fax: ; Phone : ; techresponse@daikinapplied.com Maximum linear line length shall not exceed 75 feet. Maximum Total Equivalent Length (TEL) shall not exceed 180 feet. The condenser shall not be located more than 15 feet above the indoor unit. The condenser shall not be located more than 0 feet below the indoor unit. No underground piping. It is important that the unit piping be properly supported with sound and vibration isolation between tubing and hanger, and that the discharge lines be looped at the condenser and trapped at the compressor to prevent refrigerant and oil from draining into the compressors. Looping the discharge line also provides greater line flexibility. The discharge gas valves, liquid line solenoids, filter-driers, moisture indicators, and thermostatic expansion valves are all factory-mounted as standard equipment with the water chiller. After the equipment is properly installed, leak tested, and evacuated, it can be charged with R-134a and started under Daikin Applied service supervision. Total operating charge will depend on the air-cooled condenser used and volume of the refrigerant piping. Note: On the arrangement WGS-AA units (units with remote condensers), the installer must record the refrigerant charge by stamping the total charge and the charge per circuit on the serial plate in the appropriate blocks provided for this purpose. 18 WGS 130A to 190A IMM1157-1

19 The following discussion is intended for use as a general guide to the piping of air-cooled and evaporative condensers. Use the tables shown in this manual for sizing the discharge and liquid lines. Discharge lines must be designed to handle oil properly and to protect the compressor from damage that can result from condensing liquid refrigerant in the line during shutdown. Careful consideration must be given for sizing each section of piping so that gas velocities are sufficient at all operating conditions to carry oil. If the velocity in a vertical discharge riser is too low, considerable oil can collect in the riser and the horizontal header, causing the compressor to lose its oil and result in damage due to lack of lubrication. When the compressor load is increased, the oil that had collected during reduced loads can be carried as a slug through the system and back to the compressor, where a sudden increase of oil concentration can cause liquid slugging and damage to the compressor. Any horizontal run of discharge piping should be pitched away from the compressor approximately 1/8-inch per foot (10.4 mm per m) or more. This is necessary to move, by gravity, any oil lying in the header. Any discharge line coming into a horizontal discharge header should rise above the centerline of the discharge header. This is necessary to prevent liquid refrigerant from draining from the condenser when the compressor is not operating. If the compressors are lower than the condenser, or refrigerant migration is possible, a check valve should be installed at the condenser. A check/relief valve may be necessary in the liquid line at the condenser for applications where the liquid line is higher than the condensing unit or where refrigerant migration is an issue. The liquid line should be insulated when it is routed where the ambient exposure is higher than the condenser s ambient temperature. A relief device may also be required in the discharge line piping. Figure 9 illustrates a typical piping arrangement involving a remote air-cooled condenser located at a higher elevation than the compressor. This arrangement is commonly encountered when the air-cooled condenser is on a roof and the compressor is on grade level or in a basement equipment room. Notice in Figure 9 that the discharge line is looped at the bottom and top of the vertical run. This is done to prevent oil and condensed refrigerant from flowing back into the compressor and causing damage. The highest point in the discharge line should always be above the highest point in the condenser coil. Include a purging vent at this point to extract non-condensables from the system. This method should also be employed if the air-cooled condenser is located on the same level as the compressor. Head Pressure Control The MicroTech II circuit controllers are capable of controlling the fans of remote air-cooled condensers connected to each of the unit s two refrigerant circuits. Control is based on condensing temperature and uses a combination of fan variable frequency drive (VFD) and fan cycling. Recommended Refrigerant Pipe Sizes NOTES: 1. Pressure drop is in equivalent degrees F.. On WGS 140 and 170, the # 1 circuit is always the smallest and is closest to the control panel. Horizontal or Downflow Discharge Line Sizes Unit, Circuit Nominal Circuit Tons Conn. Size At Unit Recommended Discharge Line Size, inch, O.D. Up to Up to Up to Up to Up to 50 Equiv.Ft 75 Equiv.Ft 100 Equiv.Ft. 15 Equiv.Ft. 150 Equiv.Ft. WGS 130, Both Line Size 5/8 5/8 5/8 5/8 5/8 65 5/8 WGS 140, Cir #1 Press Drop, F WGS 140, Cir # WGS 160, Both WGS 170, Cir #1 80 5/8 Line Size Press Drop, F WGS 170, Cir # Line Size 5/8 5/8 5/8 3 1/8 3 1/8 95 5/8 WGS 190, Both Press Drop, F / / / / / IMM WGS 130A to 190A 19

20 Recommended Vertical Upflow Discharge Line Sizes Recommended Discharge Line Size, inch, Nominal Connection O.D. Unit, Circuit Circuit Size, O.D. Up to Up to Up to Tons at WGS Unit 50 Equiv. Ft 75 Equiv. Ft 100 Equiv. Ft. WGS 130, Both Line Size 1/8 1/8 1/8 65 5/8 WGS 140, Cir #1 Press Drop, F WGS 140, Cir # Line Size 5/8 5/8 5/8 WGS 160, Both 80 5/8 Press Drop, F WGS 170, Cir #1 WGS 170, Cir # Line Size 5/8 5/8 5/8 95 5/8 WGS 190, Both Press Drop, F Recommended Liquid Line Size Nominal Conn. Recommended Liquid Line Size, inch O.D. Unit, Circuit Circuit Size, Up to Up to Up to Up to Up to Tons at Unit 50 Equiv.Ft 75 Equiv.Ft 100 Equiv.Ft. 15 Equiv.Ft. 150 Equiv.Ft. WGS 130, Both Line Size 1 3/8 1 3/8 1 3/8 1 3/8 1 3/ /8 WGS 140, Cir #1 Press Drop, F WGS 140, Cir # Line Size 1 3/8 1 3/8 1 3/8 1 3/8 1 3/8 WGS 160, Both /8 Press Drop, F WGS 170, Cir #1 WGS 170, Cir # Line Size 1 3/8 1 3/8 1 5/8 1 5/8 1 5/ /8 WGS190, Both Press Drop, F Figure 9, Condenser Above Compressor (One of Two Circuits Shown) Condenser Relief Valve Check Valve (Preferred) P i t c h Pressure Tap Discharge Line Maximum linear line length shall not exceed 75 ft. Maximum Total Equivalent Length (TEL) shall not exceed 180 ft. The condenser shall not be located more than 15 ft above the indoor unit. The condenser shall not be located more than 0 ft below the indoor unit. Loop To Evaporator 0 WGS 130A to 190A IMM1157-1

21 Factory-Mounted Condenser Units with the standard factory-mounted, water-cooled condensers are provided with complete refrigerant piping and full operating refrigerant charge at the factory. There is a possibility on water-cooled units utilizing low temperature pond or river water as a condensing medium that if the water valves leak, the condenser and liquid line refrigerant temperature could drop below the equipment room temperature on the off cycle. This problem arises only during periods when cold water continues to circulate through the condenser and the unit remains off due to satisfied cooling load. If this condition occurs: 1. Cycle the condenser pump off with the unit.. Check the liquid line solenoid valve for proper operation. Relief Valve Piping The ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration Systems, specifies that pressure relief valves on vessels containing Group 1 refrigerant (R-134a) shall discharge to the atmosphere at a location not less than 15 feet (4.6 meters) above the adjoining ground level and not less than 0 feet (6.1 meters) from any window, ventilation opening or exit in any building. The piping must be provided with a rain cap at the outside terminating point and with a drain at the low point on the vent piping to prevent water buildup on the atmospheric side of the relief valve. In addition, a flexible pipe section should be installed in the line to eliminate any piping stress on the relief valve(s). The size of the discharge pipe from the pressure relief valve should not be less than the size of the pressure relief outlet. When two or more valves are piped together, the common header and piping to the atmosphere should not be less than the sum of the area of each of the lines connected to the header. The locations of the unit relief valves are shown on the piping schematic drawing on page 7. There are six valves on the water-cooled units, one for each circuit on the compressor oil separator (54 lb. air/min., 350 psi), suction line (17.3 lb. air/min., 00 psi), and condenser (54 lb. air/min., 350 psi). Remote condenser models have four valves. NOTE: Provide fittings to permit vent piping to be easily disconnected for inspection or replacement of the relief valve. Figure 10, Relief Valve Piping IMM WGS 130A to 190A 1

22 Dimensional Data WGS-AW Water-Cooled Figure 11, WGS 130AW through WGS 190AW Packaged Chiller Without Optional Condenser Water Manifolds REMOVABLE LIFTING BRACKETS 13.8 (350.5) 8.3 (10.8) 0.5 (50.7) 9.0 (736.6) X (4315.5) RELIEF VALVE RELIEF VALVE A FIELD CONTROL KNOCKOUTS 34.0 (863.6) Z Y FIELD POWER KNOCKOUTS 10.0" (3048.0) RECOMMENDED CLEARANCE FOR CONDENSER TUBE SERVICING CONTROL PANEL 16. (411.5) 31.8 (807.7) B CIRC. #1 CIRC. # WATER OUT DRAIN CONDENSER 0.88 (.4) MOUNTING HOLES TYP (915.9) REMOVABLE LIFTING BRACKETS VENT EVAPORATOR C WATER IN RELIEF VALVES 1 PER CIRCUIT (98.4) (374.6) D WATER OUT WATER IN 4.0 IN. (101.6) SCH 40 PIPE VICTAULIC GROOVED. INLET AND OUTLET D010B WGS Packaged Notes: 1. Unit water connection handing is oriented facing the control panel.. Unit shown with standard right-hand evaporator connections. Left-hand available as option. 3. Condenser connections available only as shown. RELIEF VALVES (ONE HIDDEN) WGS Models WGS 130AW- 140AW WGS 160AW- 190AW Evaporator Additions for Sound Dimensions Center of Gravity Victualic Enclosure Inches (mm) Inches (mm) Inches (mm) Inches (mm) A B C D X Y Z Length Width Height 74.6 (1894.8) 9.3 (744.) 95.0 (413.0) (1945.6) (77.) (359.6) 6.0 (15.4) 83.9 (131.1) 35.8 (909.3) 16.8 (46.7) 4.0 (101.6).5 (63.5) 3.0 (76.) (03.) (133.6) (914.4) (46.7) (101.6) (63.5) (17.0) WGS 130A to 190A IMM1157-1

23 WGS-AW, Water-Cooled with Optional Condenser Manifolds Figure 1 WGS 130AW through 190AW with Optional Condenser Manifolds REMOVABLE LIFTING BRACKETS 13.8 (350.5) 8.3 (10.8) 0.5 (50.7) 9.0 (736.6)0 RELIEF VALVE X (4315.5) RELIEF VALVE CONTROL PANEL CIRC. #1 CIRC. # RELIEF VALVES (ONE HIDDEN) A FIELD POWER KNOCKOUTS WATER OUT VENT EVAPORATOR C DRAIN WATER IN D Y 31.8 (807.7) CONDENSER RELIEF VALVES 1 PER CIRCUIT WATER OUT WATER IN FIELD CONTROL KNOCKOUTS 34.0 (863.6) Z 16. (411.5) B 0.88 (.4) MOUNTING HOLES TYP (915.9) REMOVABLE LIFTING BRACKETS 4.0 IN. (101.6) 3.0 (81.8) SCH 40 PIPE VICTAULIC 35.0 (889.0) GROOVED. INLET AND OUTLET D010B WGS w/manifold Notes: 1. Unit water connection handing is oriented facing the control panel.. Unit shown with standard right-hand evaporator connections. Left-hand available as option. 3. Condenser connections available only as shown. WGS Models WGS 130AW- 140AW WGS 160AW- 190AW Evaporator Additions for Sound Dimensions Center of Gravity Victualic Enclosure Inches (mm) Inches (mm) Inches (mm) Inches (mm) A B C D X Y Z Length Width Height 74.6 (1894.8) 9.3 (744.) 95.0 (413.0) (1945.6) (77.) (359.6) 6.0 (15.4) 83.9 (131.1) 35.8 (909.3) 16.8 (46.7) 4.0 (101.6).5 (63.5) 3.0 (76.) (03.) (133.6) (914.4) (46.7) (101.6) (63.5) (17.0) IMM WGS 130A to 190A 3

24 WGS-AA Remote Condenser Figure 13, Dimensions, WGS 130AA through WGS 190AA Remote Condenser REAR VIEW E D 85.6 (174.) 77.8 (1976.1) " LIQUID # FIELD CONNECTION " LIQUID #1 FIELD CONNECTION 0.65" DISCHARGE #1 FIELD CONNECTION 0.65" DISCHARGE # FIELD CONNECTION 19.3 (490.) F 3.0 (81.8) (4554.) X FRONT VIEW RELIEF VALVE RELIEF VALVE FIELD POWER KNOCKOUTS CONTROL PANEL CIRC. #1 CIRC. # RELIEF VALVES (ONE HIDDEN) A VENT Y WATER OUT C EVAPORATOR DRAIN WATER IN Z 34.0 (863.6) FIELD CONTROL KNOCKOUTS 1.0 (304.8) 0.88 MOUNTING HOLES 4 PLACES B 18.0 (457.) (3944.6) LIFTING HOLES 4 PLACES VICTAULIC GROOVED INLET AND OUTLET 6.00 SCH 40 PIPE for WGS SCH 40 PIPE FOR WGS D010B WGS Less Condenser Notes: 1. Unit water connection handing is oriented facing the control panel.. Unit shown has right hand evaporator water connections. WGS Models Dimensions Inches (mm) Center of Gravity Inches (mm) Additions for Sound Enclosure Inches (mm) A B C D E F X Y Z Length Width Height WGS AW WGS AW 60.8 (1544.3) 6.8 (1595.1) 38.1 (967.7) 39.6 (1005.8) 95.0 (413.0) 9.9 (359.7) 33.1 (840.7) 3.7 (830.6) 6.1 (66.9) 5.7 (65.8) 19.7 (500.4) 1.7 (551.) 9.3 (344.4) 9.5 (349.5) 3.3 (80.4) 3.5 (85.5) 16.8 (46.7) 16.7 (44.) 4.0 (101.6) 4.0 (101.6).5 (63.5).5 (63.5) 3.0 (76.) 5.0 (17.0) 4 WGS 130A to 190A IMM1157-1

25 Physical Data WGS-AW, Water-Cooled Table 10, WGS-130AW - WGS-190AW WGS UNIT SIZE 130AW 140AW 160AW 170AW 190AW Unit ARI conditions tons, (kw) (1) (457.1) (494.7) (551.0) (596.3) 18.1 (640.3) No. Circuits COMPRESSORS, Frame 3 Nominal Horsepower Number () % Minimum Capacity (Modulated) 15 13/ /16 15 Oil Charge per Compressor oz., (l) 56 (7.6) 56 (7.6) 56 (7.6) 56 (7.6) 56 (7.6) CONDENSER Number No. Refrigerant Circuits Diameter, in., (mm) 1 (305) 1 (305) 1 (305) 1 (305) 1 (305) Tube Length, in., (mm) 10 (3048) 10 (3048) 10 (3048) 10 (3048) 10 (3048) Design W.P. psig, (kpa): Refrigerant Side 350 (413) 350 (413) 350 (413) 350 (413) 350 (413) Water Side 150 (1034) 150 (1034) 150 (1034) 150 (1034) 150 (1034) No. of Passes Pump-Out Capacity per Circuit, lb., (kg) (3) 330 (150) 330 (150) 330 (150) 96 (134) 96 (134) Connections: Water In & Out, in, (mm) victaulic 4.0 (101) 4.0 (101) 4.0 (101) 4.0 (101) 4.0 (101) Relief Valve, In., (mm) 0.5 (1.7) 0.5 (1.7) 0.5 (1.7) 0.5 (1.7) 0.5 (1.7) Purge Valve, Flare In., (mm).65 (15.9).65 (15.9).65 (15.9).65 (15.9).65 (15.9) Vent & Drain, in. (mm) FPT 0.5 (1.7) 0.5 (1.7) 0.5 (1.7) 0.5 (1.7) 0.5 (1.7) Liquid Subcooling Integral Integral Integral Integral Integral EVAPORATOR Number No. Refrigerant Circuits Water Volume, gallons, (l) 68 (57) 68 (57) 115 (435) 115 (435) 115 (435) Refrig. Side D.W.P., psig, (kpa) 354 (441) 354 (441) 354 (441) 354 (441) 354 (441) Water Side D.W.P., psig, (kpa) 15 (1048) 15 (1048) 15 (1048) 15 (1048) 15 (1048) Water Connections: Inlet & Outlet, in., (mm) victaulic 6.0 (15) 6.0 (15) 8.0 (03) 8.0 (03) 8.0 (03) Drain & Vent (NPT INT.) UNIT DIMENSIONS (4) Length In., (mm) (4315.5) (4315.5) (4315.5) (4315.5) (4315.5) Width In., (mm) 34 (864) 34 (864) 34 (864) 34 (864) 34 (864) Height In., (mm) 74 (1880) 74 (1880) 75.5 (1918) 75.5 (1918) 75.5 (1918) UNIT WEIGHTS (5) Operating Weight, lb., (kg) 8557 (3881) 8557 (3881) 9314 (45) 9505 (4311) 9505 (4311) Shipping Weight, lb., (kg) 7840 (3556) 7840 (3556) 806 (37) 8345 (3785) 8345 (3785) Operating Charge per Circuit, R-134a, lb., (kg) 17 (58) 17 (58) 18 (58) 14 (56) 14 (56) Notes: 1. Certified in accordance with ARI Standard 550/ All units have one compressor per circuit % full R-134a at 90 F (3 C) per refrigerant circuit. 4. Dimensions are without the optional sound enclosure. See dimension drawings for enclosure dimensions. 5. The optional sound enclosure adds 650 lbs (95 kg) to the shipping and operating weights. IMM WGS 130A to 190A 5

26 WGS-AA Remote Condenser Table 11, WGS-130AA - WGS-190AA WGS UNIT SIZE 130AA 140AA 160AA 170AA 190AA Unit 44 F LWT, 15 F SDT, tons, (kw) (407.9) 15.9 (44.7) (478.5) (50.4) (56.9) No. Circuits COMPRESSORS, FRAME 3 Nominal Horsepower Number () % Minimum Capacity (Modulated) 15 13/ /16 15 Oil Charge per Compressor oz., (l) 56 (7.6) 56 (7.6) 56 (7.6) 56 (7.6) 56 (7.6) CONDENSER (Remote) EVAPORATOR Number No. Refrigerant Circuits Water Volume, gallons, (l) 68 (57) 68 (57) 115 (435) 115 (435) 115 (435) Refrig. Side D.W.P., psig, (kpa) 354 (441) 354 (441) 354 (441) 354 (441) 354 (441) Water Side D.W.P., psig, (kpa) 15 (1048) 15 (1048) 15 (1048) 15 (1048) 15 (1048) Water Connections: Inlet & Outlet, in., (mm) victaulic 6.0 (15) 6.0 (15) 8.0 (03) 8.0 (03) 8.0 (03) Drain & Vent (NPT INT.) UNIT DIMENSIONS (3) Length In., (mm) (4554.) (4554.) (4554.) (4554.) (4554.) Width In., (mm) 34 (864) 34 (864) 34 (864) 34 (864) 34 (864) Height In., (mm) 60 (154) 60 (154) 61.8 (1570) 61.8 (1570) 61.8 (1570) UNIT WEIGHTS (4) Operating Weight, lb., (kg) 665 (841) 665 (841) 70 (3185) 70 (3185) 70 (3185) Shipping Weight, lb., (kg) 5659 (567) 5659 (567) 604 (73) 604 (73) 604 (73) Operating Charge per Circuit, lb., (kg) R-134a 35 (15.9) 35 (15.9) 36 (16.5) 36 (16.5) 36 (16.5) Notes: 1. Certified in accordance with ARI Standard 550/ Dimensions are without the optional sound enclosure. See dimension drawings for enclosure dimensions. 3. The optional sound enclosure adds 650 lbs (95 kg) to the shipping and operating weights. 6 WGS 130A to 190A IMM1157-1

27 Unit Configuration The chiller unit has two refrigerant circuits, each with a single semi-hermetic rotary screw compressor, a shared two-circuited shell-and-tube evaporator, a water-cooled condenser, interconnecting refrigerant piping and refrigerant specialties. A single two-section control panel contains the control and starting equipment. Figure 14, Schematic Piping Diagram (One of Two Circuits) DISCHARGE TUBING SCHRADER VALVE DISCHARGE SHUT-OFF AND CHECK VALVE SCREW COMPRESSOR SUCTION SHUT-OFF VALVE (OPTIONAL) PRESSURE RELIEF VALVE CHARGING VALVE SCHRADER VALVE SUCTION TUBING PRESSURE RELIEF VALVE ELECTRONIC EXPANSION VALVE WATER OUT WATER IN DX EVAPORATOR SCHRADER VALVE CHARGING VALVE PRESSURE RELIEF VALVE WATER COOLED CONDENSER WATER OUT WATER IN LIQUID TUBING PACKAGE UNIT ONLY LESS CONDENSER UNIT ONLY LIQUID SIGHT GLASS FIELD DISCHARGE CONNECTION. LIQUID FILTER DRYER SCHRADER VALVE (LESS CONDENSER ONLY) LIQUID SHUT-OFF VALVE C010A WGS REFRIGERANT PIPING FIELD LIQUID CONNECTION. Components Table 1, Major Components Unit Size Compressor Size Condenser Size Frame 300 Evaporator Size System #1 System # System #1 System # 130A Small Small EV40711 C C A Small Medium EV40711 C C A Medium Medium EV C C A Medium Large EV C C A Large Large EV C C IMM WGS 130A to 190A 7

28 Wiring Field Wiring, Power The WGS A vintage chillers are built standard with: Multi-point () power supply to a terminal block per circuit with no compressor isolation circuit breakers. Optional power connections include: Multi-point power connection to a non-fused disconnect switches with through-thedoor handle mounted in the control box in lieu of the power block Multi-point power connection to high interrupt rated disconnect switches with throughthe-door handle Multi-point power connection to high interrupt disconnect switches with through-thedoor handle in a high short circuit current rated panel Single point power connection to a terminal block with individual compressor isolation circuit breakers per circuit Single point power connection to high interrupt circuit breakers with through-the-door handles and with individual compressor isolation circuit breakers per circuit Single point power connection to a high interrupt rated disconnect switch in a high short circuit current rated panel and with individual compressor isolation circuit breakers per circuit. A factory installed control circuit transformer is standard. Optionally, a field-installed control power source can be wired to the unit. Circuit breakers for backup compressor short circuit protection are standard on all units. Wiring and conduit selections must comply with the National Electrical Code and/or local requirements. An open fuse indicates a short, ground, or overload. Before replacing a fuse or restarting a compressor, the trouble must be found and corrected. Tables in the Electrical Data section (page 30) give specific information on recommended wire sizes. NOTE: Use only copper conductors in main terminal block. Terminations are sized for copper only. Field Wiring, Control A factory-mounted control transformer is provided to supply the correct control circuit voltage. The transformer power leads are connected to the power block PB1 or disconnect switch DS1. Interlock Wiring, Condenser Pump Starter or Air-Cooled Condenser Fan Starter The MicroTech II controller can interlock a condenser pump starter, and tower fans, and control a tower bypass valve on water-cooled units. Up to six air-cooled condenser fan contactors per circuit can be controlled by the MicroTech II unit controller on remote condenser applications. Pressure switches supplied with the condenser can also control condenser fan operation. Coil voltage must be 115 volts with a maximum of 0 VA. An evaporator and condenser (water-cooled units only) flow switch is necessary on all units. It is also advisable to wire a chilled water pump interlock in series with the flow switch for additional evaporator freeze protection. 8 WGS 130A to 190A IMM1157-1

29 Ambient Air Sensor Units with a remote air-cooled condenser will have an outdoor air sensor furnished with the unit inside the control panel and wired to the correct terminals. It must be installed outdoors in a location that will give the true outdoor temperature that the condenser coils will see. Splicing of the sensor lead may be required. The sensor must be installed for the unit to operate. BAS Interface Connection to the chiller for all building automation systems (BAS) protocols is at the unit controller. An optional interface module, depending on the protocol being used, may have been factory-installed in the unit controller (or it can be field installed). Protocols Supported Table 13, Standard Protocol Data Protocol Physical Layer Data Rate Controller Other BACnet /IP or BACnet/Ethernet Ethernet 10 Base-T 10 Megabits/sec MicroTech II Reference ED 1506 BACnet MSTP RS , 1900 or bits/sec MicroTech II Reference ED 1506 LONWORKS FTT-10A 78kbits/sec MicroTech II Reference ED 1506 Modbus RTU RS-485 or RS or 1900 bits/sec MicroTech II Reference ED The interface kits on the MicroTech II controller are as follows: BACnet Kit P/N : BACnet/IP, BACnet MS/TP, or BACnet Ethernet LONWORKS Units equipped with a pco (with DIP switches) for CP1 require Kit P/N Units equipped with a pco3 (no DIP switches) for CP1 require Kit P/N Modbus: Modbus RTU Optional Open Choices BAS interfaces. The locations and interconnection requirements for the various standard protocols are found in their respective installation manuals. Modbus IM 743- LONWORKS IM 735- BACnet IM 736- Referenced documents may be obtained from the local Daikin Applied sales office, from the local Daikin Applied service office, or from the Daikin Technical Response Center, located in Staunton, Virginia ( ). These documents can also be found on under Product Information > (chiller type) > Control Integration. The following are trademarks or registered trademarks of their respective companies: BACnet from the American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., LonTalk, LONMARK and LONWORKS from Echelon Corporation, and Modbus and Modbus RTU from Schneider Electric. Remote Operator Interface Panel The box containing the optional remote interface panel will have installation instructions, IOM MT II Remote, shipped with it. The manual is also available for downloading from IMM WGS 130A to 190A 9

30 Electrical Data Table 14, Electrical Data, Water-cooled, Single-Point Connection WGS UNIT SIZE VOLTS MINIMUM CIRCUIT AMPACITY (MCA) POWER SUPPLY FIELD WIRE QTY MIN. WIRE GAUGE FIELD FUSE SIZE or BREAKER SIZE RECOM- MENDED MAXIMUM 08 n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 130AW / / n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 140AW / / n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 160AW / / n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 170AW / / n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 190AW / Notes 1. Table based on 75 C field wire.. Complete notes are on page WGS 130A to 190A IMM1157-1

31 Table 15, Electrical Data, Water-cooled, Multiple-Point Connection WGS UNIT SIZE 130AW 140AW 160AW 170AW 190AW VOLTS MINIMUM CIRCUIT AMPS (MCA) ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT (COMP ) POWER SUPPLY FIELD WIRE MIN. WIRE QTY GAUGE FIELD FUSING MINIMUM REC FUSE SIZE MAX FUSE SIZE CIRCUIT AMPS (MCA) POWER SUPPLY FIELD WIRE QTY MIN.WIRE GAUGE FIELD FUSING REC FUSE SIZE MAX FUSE SIZE / / / / / / / / / / / / / / / / NOTES: 1. Table based on 75 C field wire.. Complete notes are on page /0 wire is required for the disconnect switch option, /0 may be used for power block connection. IMM WGS 130A to 190A 31

32 Table 16, Electrical Data, Remote Condenser, Single-Point Connection WGS UNIT SIZE VOLTS MINIMUM CIRCUIT AMPACITY (MCA) POWER SUPPLY FIELD WIRE MIN. WIRE QTY GAUGE FIELD FUSE SIZE or BREAKER SIZE RECOM- MAXIMUM MENDED 08 n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 130AA 380 n/a n/a n/a n/a n/a MCM /0 AWG n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 140AA 380 n/a n/a n/a n/a n/a MCM /0 AWG n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 160AA 380 n/a n/a n/a n/a n/a MCM /0 AWG n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 170AA 380 n/a n/a n/a n/a n/a MCM MCM n/a n/a n/a n/a n/a 30 n/a n/a n/a n/a n/a 190AA 380 n/a n/a n/a n/a n/a () 50 MCM MCM Notes 1. Table based on 75 C field wire.. Complete notes are on page WGS 130A to 190A IMM1157-1

33 Table 17, Electrical Data, Remote Condenser, Multiple-Point Connection WGS UNIT SIZE 130AA 140AA 160AA 170AA 190AA VOLTS MINIMUM CIRCUIT AMPS (MCA) ELECTRICAL CIRCUIT 1 (COMP 1) ELECTRICAL CIRCUIT (COMP ) POWER SUPPLY FIELD WIRE QTY MIN.WIRE GAUGE FIELD FUSING MINIMUM CIRCUIT REC. MAX AMPS FUSE FUSE (MCA) SIZE SIZE POWER SUPPLY FIELD WIRE QTY MIN. WIRE GAUGE FIELD FUSING REC. FUSE SIZE MAX FUSE SIZE / / / / / / / / / / / / / / / / / / / / / / / NOTES: 1. Table based on 75 C field wire.. Complete notes are on page /0 wire is required for the disconnect switch option, /0 may be used for power block connection. IMM WGS 130A to 190A 33

34 Table 18, Water-cooled, Compressor Amp Draw WGS UNIT SIZE 130AW 140AW 160AW 170AW 190AW VOLTS RATED LOAD AMPS CIRCUIT #1 CIRCUIT # Table 19, Remote Condenser, Compressor Amp Draw WGS UNIT SIZE 130AA 140AA 160AA 170AA 190AA VOLTS RATED LOAD AMPS CIRCUIT #1 CIRCUIT # WGS 130A to 190A IMM1157-1

35 Table 0, Water-cooled, Field Wiring Information with Single-Point Power WGS UNIT SIZE 130AW 140AW 160AW 170AW 190AW VOLTS WIRING TO STANDARD UNIT POWER BLOCK TERMINAL SIZE AMPS CONNECTOR LUG RANGE PER PHASE (COPPER WIRE ONLY) WIRING TO OPTIONAL NONFUSED DISCONNECT SWITCH IN UNIT CONNECTOR LUG RANGE SIZE PER PHASE AMPS (COPPER WIRE ONLY) 08 n/a n/a n/a n/a 30 n/a n/a n/a n/a # / # # # # n/a n/a n/a n/a 30 n/a n/a n/a n/a # / # # # # n/a n/a n/a n/a 30 n/a n/a n/a n/a # / # # # # n/a n/a n/a n/a 30 n/a n/a n/a n/a # / # # # # n/a n/a n/a n/a 30 n/a n/a n/a n/a # / # # # #6-350 Table 1, Remote Condenser, Field Wiring Information with Single-Point Power WGS UNIT SIZE 130AA 140AA 160AA 170AA 190AA VOLTS WIRING TO STANDARD UNIT POWER BLOCK TERMINAL SIZE AMPS CONNECTOR LUG RANGE PER PHASE (COPPER WIRE ONLY) WIRING TO OPTIONAL NONFUSED DISCONNECT SWITCH IN UNIT CONNECTOR LUG RANGE SIZE PER PHASE AMPS (COPPER WIRE ONLY) 08 n/a n/a n/a n/a 30 n/a n/a n/a n/a 380 n/a n/a n/a n/a # / # # n/a n/a n/a n/a 30 n/a n/a n/a n/a 380 n/a n/a n/a n/a # / # # n/a n/a n/a n/a 30 n/a n/a n/a n/a 380 n/a n/a n/a n/a # / # # n/a n/a n/a n/a 30 n/a n/a n/a n/a 380 n/a n/a n/a n/a # / # # n/a n/a n/a n/a 30 n/a n/a n/a n/a 380 n/a n/a n/a n/a # / # /0-500 IMM WGS 130A to 190A 35

36 Table, Water-cooled, Field Wiring to Multiple-Point Power Block WIRING TO UNIT POWER BLOCK WGS CONNECTOR WIRE RANGE PER UNIT VOLTS TERMINAL SIZE (AMPS) PHASE (COPPER WIRE ONLY) SIZE CKT 1 CKT CKT 1 CKT #6-350 # #6-350 # AW #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AW #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AW #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AW #6-350 # #6-350 # #6-350 # #6-350 # AW #6-350 # #6-350 # #6-350 # #6-350 #6-350 Table 3, Remote Condenser, Field Wiring to Multiple-Point Power Block WIRING TO UNIT POWER BLOCK WGS CONNECTOR WIRE RANGE PER UNIT VOLTS TERMINAL SIZE (AMPS) PHASE (COPPER WIRE ONLY) SIZE CKT 1 CKT CKT 1 CKT #6-350 # #6-350 # AA #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AA #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AA #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AA #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # AA #6-350 # #6-350 # #6-350 # WGS 130A to 190A IMM1157-1

37 Table 4, Water-cooled, Field Wiring to Multiple-Point Disconnect Switc WGS UNIT SIZE 130AW 140AW 160AW 170AW 190AW WIRING TO UNIT DISCONNECT SWITCH VOLTS TERMINAL SIZE CONNECTOR WIRE RANGE PER PHASE (AMPS) (COPPER WIRE ONLY) CKT 1 CKT CKT 1 CKT #6-350 # #6-350 # #6-350 # #6-350 # #6-350 # # / #6-350 # #6-350 # #6-350 # #6-350 # / / #6-350 # #6-350 # #6-350 # #6-350 # / / # / #6-350 # #6-350 # #6-350 # / / / / #6-350 # #6-350 # #6-350 #6-350 Table 5, Remote Condenser, Field Wiring to Multiple-Point Disconnect Switch WGS UNIT SIZE 130AA 140AA 160AA 170AA 190AA WIRING TO UNIT DISCONNECT SWITCH VOLTS TERMINAL SIZE CONNECTOR WIRE RANGE PER PHASE (AMPS) (COPPER WIRE ONLY) CKT 1 CKT CKT 1 CKT / / / / #6-350 # #6-350 # #6-350 # / / / / #6-350 # #6-350 # #6-350 # / / / / #6-350 # #6-350 # #6-350 # / / / / #6-350 # #6-350 # #6-350 # / / / / #6-350 # #6-350 # #6-350 #6-350 IMM WGS 130A to 190A 37

38 Wiring Diagrams Figure 15, WGS 130AW 190AW Field Wiring Diagram 3 PHASE POWER SUPPLY DISCONNECT (BY OTHERS) UNIT MAIN TERMINAL BLOCK GND LUG TO COMPRESSOR(S) FUSED CONTROL CIRCUIT TRANSFORMER FU4 FU5 NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 600 VOLTS FACTORY SUPPLIED ALARM FIELD WIRED ALARM BELL OPTION ABR ALARM BELL RELAY CHWR EVAP. PUMP RELAY #1 (BY OTHERS) 10 VAC 1.0 AMP MAX CHWR FU7 EVAP. PUMP RELAY # (BY OTHERS) 10 VAC 1.0 AMP MAX CWR COND. PUMP RELAY #1 (BY OTHERS) 10 VAC 1.0 AMP MAX CWR COND. PUMP RELAY # (BY OTHERS) 10 VAC 1.0 AMP MAX M11 TOWER FAN #1 (BY OTHERS) 10 VAC 1.0 AMP MAX M1 TOWER FAN # (BY OTHERS) 10 VAC 1.0 AMP MAX COOLING TOWER BYPASS (BY OTHERS) (BY OTHERS) 10 VAC TB1 (115 VAC) TB1- N N N N N N 4 VAC 10 VAC 10 VAC 10 VAC 10 VAC 10 VAC 10 VAC 0-10VDC N 0-10VDC N BELL ALARM BELL RELAY COM NO 1 ALARM BELL OPTION REMOTE STOP SWITCH (BY OTHERS) ICE MODE SWITCH (BY OTHERS) TIME CLOCK OFF AUTO ON MANUAL OFF AUTO ON MANUAL TB1 (4 VAC OR 30 VDC) IF REMOTE STOP CONTROL IS USED, REMOVE LEAD 897 FROM TERM. 40 TO 53. EVAP. FLOW SWITCH (BY OTHERS) NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL) *MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED COND. FLOW SWITCH (BY OTHERS) NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL) *MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED MA FOR EVAP. WATER RESET (BY OTHERS) 4-0MA FOR DEMAND LIMIT (BY OTHERS) GND DWG REV. 0B 38 WGS 130A to 190A IMM1157-1

39 Figure 16, WGS 130AA 190AA Field Wiring Diagram (Remote Condenser) 3 PHASE POWER SUPPLY UNIT MAIN DISCONNECT (BY OTHERS) TERMINAL BLOCK GND LUG TO COMPRESSOR(S) FUSED CONTROL CIRCUIT TRANSFORMER FU4 FU5 NOTE: ALL FIELD WIRING TO BE INSTALLED AS NEC CLASS 1 WIRING SYSTEM WITH CONDUCTOR RATED 600 VOLTS FACTORY SUPPLIED ALARM FIELD WIRED ALARM BELL OPTION ABR ALARM BELL RELAY CHWR FU7 EVAP. PUMP RELAY #1 (BY OTHERS) 10 VAC 1.0 AMP MAX CHWR EVAP. PUMP RELAY # (BY OTHERS) 10 VAC 1.0 AMP MAX 10 VAC TB1 (115 VAC) TB1- N N 4 VAC 10 VAC 10 VAC BELL ALARM BELL RELAY COM NO 1 ALARM BELL OPTION CIRCUIT #1 CIRCUIT # TB M CONDENSER FAN CONTACTOR COIL # M1 145 CONDENSER FAN CONTACTOR COIL # M CONDENSER FAN CONTACTOR COIL #3 NO1 NO NO3 C N N N 10 VAC 10 VAC 10 VAC J1 (LOCATED ON CIRCUIT CONTROLLER) TB M1 45 CONDENSER FAN CONTACTOR COIL # M 45 CONDENSER FAN CONTACTOR COIL # M3 45 CONDENSER FAN CONTACTOR COIL #3 NO1 NO NO3 C N N N 10 VAC 10 VAC 10 VAC J1 (LOCATED ON CIRCUIT CONTROLLER) M CONDENSER FAN CONTACTOR COIL # M CONDENSER FAN CONTACTOR COIL # M CONDENSER FAN CONTACTOR COIL #6 C NO4 NO5 NO6 N N N 10 VAC 10 VAC 10 VAC J13 (LOCATED ON CIRCUIT CONTROLLER) M4 45 CONDENSER FAN CONTACTOR COIL # M5 45 CONDENSER FAN CONTACTOR COIL # M6 45 CONDENSER FAN CONTACTOR COIL #6 C NO4 NO5 NO6 N N N 10 VAC 10 VAC 10 VAC J13 (LOCATED ON CIRCUIT CONTROLLER) REMOTE STOP SWITCH (BY OTHERS) ICE MODE SWITCH (BY OTHERS) TIME CLOCK OFF AUTO ON MANUAL OFF AUTO ON MANUAL TB1 (4 VAC) IF REMOTE STOP CONTROL IS USED, REMOVE LEAD 897 FROM TERM. 40 TO 53. EVAP. FLOW SWITCH (BY OTHERS) NOR. OPEN PUMP AUX. CONTACTS (OPTIONAL) *MANDATORY IF FACTORY FLOW SWITCH OPTION IS NOT SELECTED MA FOR EVAP. WATER RESET (BY OTHERS) MA FOR DEMAND LIMIT (BY OTHERS) GND DWG REV. 0C See notes on page 40. IMM WGS 130A to 190A 39

40 Notes for Electrical Data Single/Multiple Point Power: 1. Wire sizing amps is 10 amps if a separate 115V power supply is used.. Unit wire size ampacity is equal to 15% of the largest compressor motor, plus 100% of the RLA of all other loads in the circuit, including the control transformer. 3. Recommended power lead wire sizes for 3 conductors per conduit are based on 100% conductor ampacity in accordance with NEC. Voltage drop has not been included. Therefore, power leads should be kept short. All terminal block connections must be made with copper (type THW) wire. 4. The recommended power lead wire sizes are based on an ambient temperature of 86 F (30 C). Ampacity correction factors must be applied for other ambient temperatures. Refer to the National Electrical Code Handbook. 5. The recommended fuse size or HACR circuit breaker size is equal to 150% of the largest compressor motor RLA plus 100% of the remaining compressor RLA. 6. The maximum fuse size or HACR circuit breaker size is equal to 5% of the largest compressor motor RLA plus 100% of the remaining compressor RLA. 7. Must be electrically grounded according to national and local electrical codes. Power Limitations: 1. Voltage within 10 percent of nameplate rating.. Voltage unbalance not to exceed % with a resultant current unbalance of 6 to 10 times the voltage unbalance per NEMA MG-1, 1998 Standard. This is an important requirement and must be adhered to. Notes for Electrical Data 1. Requires a disconnect switch per circuit to supply electrical power to the unit. If field supplied, this power supply must either be fused or use an HACR type circuit breaker.. Use copper wiring to unit power block or optional non-fused disconnect switch. 3. All field wire size values given in table apply to 75 C rated wire per NEC. Notes for Wiring Diagram Remote Condenser Units On remote condenser units, head pressure control by cycling fans can be accomplished several ways. The MicroTech II controller in the unit can be used. It senses discharge pressure and will stage up to 6 condenser fans when wired in accordance with Figure 16 on page 39. If the condenser has more than 6 fans, can be operated on a step. For example, a condenser with 10 fans would have fans on steps #1 through #4 and one fan each on steps #5 and #6. Condensers with less than 6 fans would use the appropriate MicroTech II steps beginning with #1. Wire so that the first-on, last-off fan stage has one fan on it. The Daikin ACD condensers have unit-mounted and wired single fan motor VFD combined with fan cycling by pressure switches for the balance of the fans available as an option. They can be used for staging fans instead of the WGS MicroTech II controller. See Ambient Air Sensor note on page 9. Circuit Breakers The circuit breaker used in the High Short Circuit panel option may have a higher trip rating than the unit Maximum Overload Protection (MOP) value shown on the unit nameplate. The circuit breaker is installed as a service disconnect switch and does not function as branch circuit protection, mainly that the protection device must be installed at the point of origin of the power wiring. The breaker (disconnect switch) is oversized to avoid nuisance trips at high ambient temperature conditions. 40 WGS 130A to 190A IMM1157-1

41 Figure 17, Schematic Diagram Legend Designation Description Standard Location Designation Description Standard Location ABR Alarm Bell Relay Field Mounted M1 Tower Fan 1 Field Mounted BB Bias Block Outer Panel PB1 / Power Block Inner Panel CB1 / Circuit Breaker Inner Panel REC 115V Outlet (Optional) Outer Panel CB11 / 11 Circuit Controller Output Breaker Output Panel RS1 Remote Stop Switch Field Mounted CB1 / Circuit Controller Compr. Heater Output Panel S1 System Shut-Off Switch Outer Panel CHW1 Chilled Water Flow Switch Field Mounted S01 Suction Pressure Compressor CHWR Chilled Water Relay Field Mounted S0 Discharge Pressure Compressor CWR Cond. Water Relay Field Mounted S03 Liquid Pressure Liquid Line CWI Cir. Contr. 1 / Compr 1 / Cond. Water Flow Switch Field Mounted S04 Suction Temperature Compressor Circuit Controller Outer Panel S05 Discharge Temperature Compressor Compressors Behind Control Box S06 Liquid Temperature Liquid Line DS ½ Disconnect Switch Inner Panel S07 Outside Ambient Behind Control Temperature Box FU4 T1 Primary Fuse Inner Panel S08 Leaving Water Sensor Leaving Water Nozzle FU5 T1 Primary Fuse Inner Panel S09 Entering Water Entering Water Temperature Nozzle FU6 T1 Secondary Fuse Inner Panel S10 Demand Limit Reset Field Mounted FU7 T1 Secondary Fuse Inner Panel S11 Leaving Water Reset Field Mounted F3 115v Outlet Fuse Cir. # Outer (Optional) Panel CS Circuit System Switch Outer Panel GRD Ground Inner Panel Load/Unload Load/Unload Solenoid Compressor Htr-Compr Compressor Heater Compressor T1 Control Transformer Inner Panel MHP High Pressure Switch Compressor T Unit Contr. 4V Transformer Outer Panel MHPR Mechanical High Circuit Contr. 4V Outer Panel T13 / T3 Pressure Relay Transformer Outer Panel MS1 Mode Switch Field Mounted T14 / T4 Comp. Load/Unload 4V Transformer Outer Panel SSS ½ Comp. Solid State EXV Driver 4V Inner Panel T15 / T5 Starter Transformer Outer Panel MJ Mechanical Jumper Control Box TB1 TB Terminal Blocks Outer Panel M11 Tower Fan Field Mounted WJ Wire Jumper Control Box IMM WGS 130A to 190A 41

42 D I GITA L O UTP U TS Figure 18, WGS , Circuit Controller Schematic Wiring Diagram (SEE LINE 693) TO T T V V (SEE LINE 687) MJ MJ GO G J1 0-5 VDC 0-5 VDC RED WHT BLK RED WHT BLK EVAP PRESS TRANSDUCER (S01) CONDENSER PRESS TRANSDUCER (S0) J1 J J J3 SLIDE LOAD INDICATOR 1 BIAS 5 BIAS 6 1 VDC DC GROUND SUCTION TEMP. (S04) DISCHARGE TEMP. (S05) 5 6 BLK RED BLK RED J4 J5 B4 BC4 B5 BC5 J3 J11 B- A+ 10 OHMS PE SHIELD GND VG VGD Y1 J4 C1 Y NO1 EXV DRIVER (SEE DETAIL 1) 0-10VDC 16 Y3 Y4 J1 NO D3 SA- SB+ BLACK WHITE GND A+ NO3 CIRCUIT SWITCH STARTER FAULT CS TB1-6 FLT SCOM SHLD TB1-7 GREEN ID1 ID ID3 ID4 B- C1 C4 NO4 WJ DIFFERENTIAL PRESSURE SWITCH MECHANICAL HIGH PRESSURE FAULT PE GRN BLK 130 DPS C 1 MHPR 4 WHT J5 ID5 ID6 J13 NO5 NO6 C4 ID7 ID8 C7 13 IDC1 J14 NO7 B6 C7 SLIDE LOAD INDICATOR 3 4-0MA B7 NO8 MJ MJ CONDENSER LEAVING WATER TEMP. (S1) BLK B8 J6 J15 C8 RED 134 GND NC8 0 PE GREEN OLS ID9 ID10 C9 NO9 COMPRESSOR SSS CONTACT ID11 J7 J16 NO10 J3-1 DETAIL - THERMISTOR CARD MOTOR GUARDISTOR J ID1 IDC9 ID13H J17 NO11 C9 NO1 C1 OIL SEP. HEATER 188 LP* ID13 NC1 REMOTE EVAP. ONLY. IN SERIES WITH 170 IDC13 J8 NO13 NOTES: 1) * - REPRESENTS CIRCUIT ) ONE HUNDRED SERIES FOR CIRCUIT #1 3) TWO HUNDRED SERIES FOR CIRCUIT # ID14 ID14H (LOWER LEVEL) CONTROLLER J18 C13 NC13 4 WGS 130A to 190A IMM1157-1

43 Schematic Wiring Diagram (Continued) LINE NO TERMINAL BLOCK AND LEAD NUMBERS 1 MJ (p LAN) TO OTHER CIRCUIT CONTROLLERS AND UNIT CONTROLLER BLACK (RESISTOR USED ONLY AT END OF DAISY CHAIN) WHITE FU7 1 GROUND CB NB T V (TERMINATE AT EACH CONTROLLER) MHP 1 (SEE LINE 694) MHPR TB , 114, 116, , 113, 117, , , MHP , 184, MHP- 0 1, , BLK, 130, -OIL 1 WHT, 19 3-OIL, SLIDE, SLIDE, SLIDE, , 1-LOAD 8 173, 1-UNLOAD , , , RED, 1-OIL, 136, , 134, RED , -LOAD, -UNLOAD, PE GRN - OIL PE GRN - DPS PE GRN - LOAD PE GRN - UNLOAD M* M* M* M* M* M*6 REMOTE COND T V V (SEE LINE 690) PE GRN LOAD SOLENOID 1 SV PE GRN UNLOAD SOLENOID 1 SV SSS RUN K CB HTR-OIL SEP. HEATER INT SV ANALOG OUTPUT J4-Y3 16 EXV MOTOR TB BLACK WHITE GREEN RED + - PID DETAIL 1 EXV DRIVER TO: TB1-1 TO: TB V T V AC 4V AC PUMPDOWN PUMPDOWN SCHEM REV. 0B -700 IMM WGS 130A to 190A 43

44 D IG ITAL OU TP UTS Figure 19, WGS , Unit Controller Schematic Wiring Diagram MJ PE PE SHIELD GO G J1 OUTSIDE AIR TEMP or COND. ENTERING WATER TEMP. (S07) BLK RED B1 73 DEMAND LIMIT (S10) EVAP. WATER TEMP. RESET (S11) 814 EVAP. LEAVING WATER TEMP (S08) 4-0MA 4-0MA PE SHIELD BLK MJ B B3 GND +VDC B4 J J11 B- A+ GND EVAP. ENTERING WATER TEMP (S09) RED BLK RED BC4 J3 B5 BC5 C1 884 VG NO1 885 VG0 J1 NO COOLING TOWER BYPASS (0-10VDC) Y1 NO3 COOLING TOWER VFD (0-10VDC) Y J4 C1 Y3 C4 Y4 NO4 J13 NO5 60 UNIT SWITCH REMOTE SWITCH EVAP. FLOW SWITCH MODE SWITCH COND. FLOW SWITCH FACTORY INSTALLED FLOW SWITCHES BRN BRN 807 BLU BLU S1 CHWI CWI RS1 MS1 67 WHT 76 WHT ID1 ID ID3 ID4 J5 ID5 ID6 ID7 ID8 J14 J15 NO6 C4 C7 NO7 C7 NO8 C8 800 NOTE: J-B1 OUTSIDE AIR TEMP. IS FOR TGS UNITS ONLY AND CONDENSER ENTERING WATER TEMP. IS FOR WGS UNITS ONLY. IDC1 CONTROLLER NC8 44 WGS 130A to 190A IMM1157-1

45 WGS , Unit Controller Schematic Wiring Diagram (Continued) 1 LINE NO CONTACT LOCATION TERMINAL BLOCK AND LEAD NUMBERS BLACK WHITE GROUND 80 (p LAN) TO CIRCUIT CONTROL BOXES EVAPORATOR PUMP 1 EVAPORATOR PUMP COND. PUMP 1 115V OUTLET 890 LINE 1 LOAD 1 (TERMINATE AT EACH CONTROLLER) FU T 10V 4V B W 6 G G REC BIAS BLOCK SEE LINE 301 LINE LOAD TO UNIT CONTROLLER B- TO UNIT CONTROLLER A+ TO CIRCUIT CONTROLLER J4 TO CIRCUIT CONTROLLER J4 10V CHWR 10V CHWR 10V CWR PE MJ MJ TB , 8, , , 807, , , , , , WJ COND. PUMP TOWER FAN V CWR 10V M NOTE: TB1-75 THRU TB1-89 ARE FIELD WIRING TERMINALS. TOWER FAN V M UNIT ALARM SEE LINE 307 ABR 75 SEE LINE SCHEM REV. 0B -365 IMM WGS 130A to 190A 45

46 Control Panel Layout Figure 0, Outer (Microprocessor) Panel T, Unit Controller T13, Circ#1 Controller T14, Circ#1 Load Solenoid T15, Circ#1 EXV Power T3, Circ# Controller T4, Circ# Load Solenoid T5, Circ# EXV Power Unit Controller MHPR11 &1, Mechanical High Pressure Relay Circ#1 Controller Circuit Breaker & Switch Panel External Disconnect Handle Circ#1 & EXV Drivers Circ# Controller TB3, Circ# Controller Terminal Board TBCirc#1 Controller Terminal Board NOTES: TB1 Unit Controller Terminal Board 1. Transformers T through T5 are class 100, 10V to 1V.. Switches for MHPR 11 and 1 (Mechanical High Pressure Switches) are located on the compressors. 3. Mechanical High Pressure Switches Open at 310 psi, Close at 50 psi 46 WGS 130A to 190A IMM1157-1

47 Figure 1, Inner (Power) Panel Circ#1 Solid State Starter Circ# Solid State Starter SSS1 Bypass Contactor SSS Bypass Contactor Secondary Fuses External Disconnect Handle Circ#1 Circuit Breaker Circ# Circuit Breaker Unit Disconnect Switch W/ External Handle T1, Supply Voltage to 10V Transformer Primary Fuses Outside (Microprocessor) Panel IMM WGS 130A to 190A 47

48 Figure, Circuit Breaker/Fuse Panel Open Location S1 Main Unit On-Off Switch CS, Circuit# On-Off Switch CS1, Circuit#1 On-Off Switch CB11 Circ#1 Circuit Breaker CB1, Circ#1 Sump Heater Open Location CB1, Circ# Circuit CB, Circ# Sump Heater Open Locations Location for Optional 115V Receptacle Figure 3, Inner and Outer Panel Diagrams OUTER PANEL INNER PANEL T T13 T14 T15 T3 T4 T5 UNIT CONTROLLER EXV. DRIVER #1 MHPR 1 CS1 S 1 MHPR CS S P CB11 SINGLE POINT OR CIR. #1 DS HANDLE (MULTI- POINT) D3 CONTR. BRD. CT3 SSS #1 SSS # CT CT1 THERM- ISTOR CARD BYPASS CONTACTOR D3 CONTR. BRD. CT3 CT CT1 THERM- ISTOR CARD BYPASS CONTACTOR CIRCUIT CONTROLLER #1 MODBUS CARD CB1 SP CB1 CB SP CIR. # DS HANDLE (MULTI- POINT) F U 6 CONVERTER BOARD TB1 EXV. DRIVER # CIRCUIT CONTROLLER # TB11 TB1 REC OPTION FU7 F3 F U 4 T1 F U 5 C B 1 C B (DS1 DS MULTIPOINT POWER) DS1 G N D REV Legend 48 WGS 130A to 190A IMM1157-1

49 Sequence of Operation Compressor Heaters With the control power on, 10V power is applied through the control circuit Fuse FU7 to the compressor oil separator heater(htr-oil SEP). Startup/Compressor Staging During cool mode the following must be true to start a circuit operating. The evaporator and condenser pump outputs must be energized and flow must be established for a period of time defined by the evaporator recirculate setpoint. Established flow will be detected by evaporator and condenser water flow switches. The water temperature leaving the evaporator must be greater than the Active Leaving Water Temperature setpoint, plus the Startup Delta-T, before a circuit will start. The first circuit to start is determined by sequence number. The lowest sequence numbered circuit will start first. If all sequence numbers are the same (default), then the circuit with the fewest number of starts will start first. During operation the slides for load and unload will be pulsed such that the active leaving water temperature setpoint is maintained. The second circuit start will occur once the first circuit has loaded to 75% slide capacity or is in Capacity Limit and the water temperature leaving the evaporator is greater than the active leaving water temperature Setpoint plus Stage Delta-T. The circuits will load or unload simultaneously through a continuous capacity control to maintain the evaporator leaving water temperature. If all sequence numbers are the same, the circuit with the most run hours will be shutdown first. The circuit with the most run hours will stop when the water temperature leaving the evaporator is less than the Active Leaving Water Temperature Setpoint minus Stage Delta-T. The last remaining circuit will shutdown when the water temperature leaving the evaporator is greater than the Active Leaving Water Temperature Setpoint minus the Stop Delta-T. Automatic Pumpdown The WGS has separate refrigerant circuits so the refrigerant charge is stored in the condenser when the circuit is off. Pumpdown to the condenser helps keep refrigerant from migrating to the compressor. It also helps establish a pressure differential on start for oil flow. In a normal shutdown, each circuit will close its expansion valve, causing the evaporator pressure to reach a low-pressure setpoint. Once this setpoint is reached, or a specified amount of time has elapsed, the running circuit will be shut down. Chilled Water and Condenser Water Pumps The chiller s MicroTech II controller has a total of four pump outputs, two for the evaporator and two for the condenser. There is a manual setting in the software for the user to select either pump output 1 or. It is recommended that the chiller s outputs control the water pumps, as this will offer the most protection for the unit. Cooling Tower Control The MicroTech II controller can control the cooling tower fans and/or a tower bypass valve. This provides a simple and direct method to control the unit s discharge pressure. Programming directions and the sequence of operation can be found in the MicroTech II manual. Some means of discharge pressure control must be installed if the condenser water temperature can fall below the values shown on page Error! Bookmark not defined.. Condenser Fan Control The MicroTech II controller can be programmed to cycle on and off condenser fans based on the discharge pressure. Details are in the MicroTech II manual. IMM WGS 130A to 190A 49

50 Start-Up and Shutdown Pre Start-up 1. Flush and clean the chilled-water system. Proper water treatment is required to prevent corrosion and organic growth.. With the main disconnect open, check all electrical connections in control panel and starter to be sure they are tight and provide good electrical contact. Although connections are tightened at the factory, they can loosen enough in shipment to cause a malfunction. 3. Check and inspect all water piping. Make sure flow direction is correct and piping is made to correct connection on evaporator and condenser. 4. Open all water flow valves to the condenser and evaporator. 5. Flush the cooling tower and system piping to be sure the system is clean. Start evaporator pump and manually start condenser pump and cooling tower. Check all piping for leaks. Vent the air from the evaporator and condenser water circuit, as well as from the entire water system. The cooler circuit should contain clean, treated, noncorrosive water. 6. Check to see that the evaporator water temperature sensor is securely installed. 7. Make sure the unit control switch S1 is open (off) and the circuit switches CS1 and CS are open. Place the main power disconnect switch to on. This will energize the compressor sump heaters. Wait a minimum of 1 hours before starting the unit. 8. Measure the water pressure drop across the evaporator and condenser, and check that water flow is correct (on pages 16 and 17) per the design flow rates. 9. Check the actual line voltage to the unit to make sure it is the same as called for on the compressor nameplate, within + 10%, and that phase voltage unbalance does not exceed %. Verify that adequate power supply and capacity is available to handle load. 10. Make sure all wiring and fuses are of the proper size. Also make sure that all interlock wiring is completed per Daikin Applied diagrams. 11. Verify that all mechanical and electrical inspections by code authorities have been completed. 1. Make sure all auxiliary load and control equipment is operative and that an adequate cooling load is available for initial start-up. Start-up 1. Open the compressor discharge shutoff valves until backseated. Always replace valve seal caps.. Open the two manual liquid line shutoff valves (king valves). 3. Verify that the compressor sump heaters have operated for at least 1 hours prior to start-up. Crankcase should be warm to the touch. 4. Check that the MicroTech II controller is set to the desired chilled water temperature. 5. Start the system auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch and water pumps. 6. Switch on the unit circuit breakers. 7. Set circuit switches CS1 and CS to ON for normal operation. 8. Start the system by setting the unit system switch S1 to ON. 9. After running the unit for a short time, check the oil level in each compressor, rotation of condenser fans (if any), and check for flashing in the refrigerant sight glass. 50 WGS 130A to 190A IMM1157-1

51 Weekend or Temporary Shutdown Move circuit switches CS1 and CS to the off pumpdown position. After the compressors have shut off, turn off the chilled water pump if not on automatic control from the chiller controller or building automation system (BAS). With the unit in this condition, it will not restart until these switches are turned back on. Power to the unit (disconnect closed) so that the sump heaters will remain energized. Start-up after Temporary Shutdown 1. Start the water pumps.. Check compressor sump heaters. Compressors should be warm to the touch. 3. With the unit switch S1 in the ON position, move the circuit switches CS1 and CS to the ON position. 4. Observe the unit operation for a short time, noting unusual sounds or possible cycling of compressors. Extended Shutdown 1. Close the manual liquid line shutoff valves.. After the compressors have shut down, turn off the water pumps. 3. Turn off all power to the unit. 4. Move the unit control switch S1 to the OFF position. 5. Close the discharge shutoff valves. 6. Tag all opened disconnect switches to warn against start-up before opening the compressor suction and discharge valves. 7. Drain all water from the unit evaporator, condenser and chilled water piping if the unit is to be shut down during the winter and exposed to below-freezing temperatures. Do not leave the vessels or piping open to the atmosphere over the shutdown period to help prevent excessive corrosion. Start-up after Extended Shutdown 1. Inspect all equipment to see that it is in satisfactory operating condition.. Remove all debris that has collected on the surface of the condenser coils (remote condenser models) or check the cooling tower, if present. 3. Open the compressor discharge valves until backseated. Always replace valve seal caps. 4. Open the manual liquid line shutoff valves. 5. Check circuit breakers. They must be in the OFF position. 6. Check to see that the circuit switches CS1 and CS and the unit control switch S1 are in the OFF position. 7. Close the main power disconnect switch. The circuit disconnects switches should be off. 8. Allow the sump heaters to operate for at least 1 hours prior to start-up. 9. Start the chilled water pump and purge the water piping as well as the evaporator in the unit. 10. Start the system auxiliary equipment for the installation by turning on the time clock, ambient thermostat and/or remote on/off switch. 11. Check that the MicroTech II controller is set to the desired chilled water temperature. 1. Switch the unit circuit breakers to ON. 13. Start the system by setting the system switch S1 and the circuit switches to ON. IMM WGS 130A to 190A 51

52 ! CAUTION Most relays and terminals in the control center are powered when S1 is closed and the control circuit disconnect is on. Therefore, do not close S1 until ready for start-up or serious equipment damage can occur. 14. After running the unit for a short time, check the oil level in the compressor oil sight glass and check the liquid line sight glass for bubbles. System Maintenance General To provide smooth operation at peak capacity and to avoid damage to package components, set and follow a program of periodic inspections. The following items are intended as a guide to be used during inspection and must be combined with sound refrigeration and electrical practices to help provide trouble-free performance. The liquid line sight glass/moisture indicator on all circuits must be checked to be sure that the glass is full and clear and that the moisture indicator indicates a dry condition. If the indicator shows that a wet condition exists or if bubbles show in the glass, even with a full refrigerant charge, the filter-drier element must be changed. Water supplies in some areas can foul the water-cooled condenser to the point where cleaning is necessary. The fouled condenser will be indicated by an abnormally high condenser approach temperature (saturated discharge temperature minus leaving condenser water temperature) and can result in nuisance trip-outs. To clean the condenser, mechanical cleaning or a chemical descaling solution should be used according to the manufacturer s directions. Systems with remote air-cooled condensers require periodic cleaning of the finned surface of the condenser coil. Cleaning can be accomplished by using a cold water spray, brushing, vacuuming, or high-pressure air. Do not use tools that could damage the coil tubes or fins. The compressor oil level must be checked periodically to be sure that the level is near the center of the oil sight glass located on the compressor (see Figure 4). Low oil level can cause inadequate lubrication and if oil must be added, use oils referred to in the following Compressor Lubrication section. A pressure tap has been provided on the liquid line downstream of the filter-drier and solenoid valve but before the expansion valve. An accurate subcooled liquid pressure and temperature can be taken here. The pressure read here could also provide an indication of excessive pressure drop through the filter-drier and solenoid valve due to a clogging filterdrier. Note: A normal pressure drop through the solenoid valve is approximately 3 psig (0.7 kpa) at full load conditions.! CAUTION A blown fuse or tripped protector indicates a short ground or overload. Correct the problem before replacing fuses or restarting compressor. The control panel must be serviced by a trained and qualified technician. Improper service can damage equipment. 5 WGS 130A to 190A IMM1157-1

53 ! CAUTION The panel is always energized, even when the system switch is off. Pull the main unit disconnect to de-energize the panel and crankcase heaters. Failure to do so can result in severe personal injury or death. If motor or compressor damage is suspected, do not restart until qualified service personnel have checked the unit. Electrical Terminals! DANGER To avoid severe injury or death from electric shock, turn off all power and lockout and tagout electric source before continuing with the following service. Note unit might be powered from multiple sources. POE Lubrication POE type oil is used for compressor lubrication. This type of oil is extremely hygroscopic, which means it will quickly absorb moisture if exposed to air and may form acids that can be harmful to the chiller. Avoid prolonged exposure of POE oil to the atmosphere to prevent this problem. For more details on acceptable oil types, contact your Daikin Applied service representative.! CAUTION POE oil must be handled carefully using proper protective equipment (gloves, eye protection, etc). 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. It is important that only the manufacturer s recommended oils be used. Acceptable POE oil types are: CPI/Lubrizol Emkarate RL68H Exxon/Mobil EAL Arctic 68 Hatcol 3693 Everest 68 No routine lubrication is required on WGS units. Figure 4, Compressor Oil Filter The Lub Control measures the pressure drop across the lubricant filter and shuts off the compressor if the differential pressure becomes too high. It is reset through the circuit controller. Change oil when pressure drop exceeds 15 psig. Compressor Oil Filter Lub Control Oil Level Sight Glass IMM WGS 130A to 190A 53