Daikin DWSC 050 User manual

Single/Dual Compressor Centrifugal Chillers
DWSC/DWDC 050, 063, 079, 087, 100, 113, 126, Cooling Only
DWCC 100, 113, 126
DHSC 050, 063, 079, 087, 100, 126, Heat Recovery
Original Instructions
Installation, Operation and Maintenance Manual
D-EIMWC00804-14EN

D-EIMWC00804-14EN Centrifugal Chillers 3
IMPORTANT
The units described in the present manual represent a valuable investment. Maximum care should be taken to ensure correct
installation and appropriate working conditions of the units.
Installation and maintenance must be performed by qualified and specifically trained personnel only.
Correct maintenance of the unit is indispensable for its safety and reliability. Manufacturer’s service centres are the only having
adequate technical skill for maintenance.
CAUTION
This manual provides information about the features and procedures for the complete series.
All units are delivered from factory as complete sets which include wiring diagrams and dimensional drawings with size, weight
and features of each model.
WIRING DIAGRAMS AND DIMENSIONAL DRAWINGS MUST BE CONSIDERED ESSENTIAL DOCUMENTS OF
THIS MANUAL
In case of any discrepancy between this manual and the two aforesaid documents, please refer to the wiring diagram and
dimensional drawings.
WARNING
Before starting the installation of the unit, please read this manual carefully. Starting up the unit is absolutely
forbidden if all instructions contained in this manual are not clear.

4Centrifugal Chillers D-EIMWC00804-14EN
Warnings for the operator
The operator must read this manual before using the unit.
The operator must be trained and instructed on how to use the unit.
The operator must strictly follow local safety regulation and laws.
The operator must strictly follow all instruction and limitation given for the unit
Key to symbols
Important note: failure to respect the instruction can damage the unit or compromise functioning
Note regarding safety in general or respect of laws and regulations
Note concerning electrical safety
Safe use and maintenance of the unit, as explained in this manual, is fundamental to prevent accidents
during operation and maintenance and repair work.
Therefore, it is highly recommended that this document be read carefully, complied with and stored safely.
Should additional maintenance be required, it is advisable to consult authorised staff before carrying out any
repair work.
Description of the labels applied to the electrical panel
Compressor Starter Panel
1
– Manufacturer’s logo
3
– Cable tightening warning
2
– Hazardous Voltage warning
4
– Electrical hazard symbol
WARNING
It 's absolutely forbidden to remove all the protections of the moving parts of the unit

D-EIMWC00804-14EN Centrifugal Chillers 5
Unit Control Panel
1
– Non flammable gas symbol
5
– Unit nameplate data
2
– Electrical hazard symbol
6
– Unit characteristics technical
3
– Gas type
7
– Emergency stop
4
– Control panel code
Compressor Control Panel
Motor Terminal Box
1
– Terminal box fixing
3
– Electrical hazard symbol
2
– Manufacturer’s logo
4
– Terminal connection
1– Components layout 3 – Electrical hazard symbol
2– Hazardous Voltage warning 4 – Compressor control panel code

6Centrifugal Chillers D-EIMWC00804-14EN
Table of Contents
Warnings for the operator.....................................................................................................4
Introduction .....................................................................................................8
General Description .............................................................................................................8
Application...........................................................................................................................8
Nomenclature.......................................................................................................................8
Installation........................................................................................................9
Receiving and Handling.......................................................................................................9
Location and Mounting......................................................................................................10
Operating/Standby Limits ..................................................................................................10
Safety ................................................................................................................................. 11
System Water Volume ........................................................................................................12
Low Condenser Water Temperature Operation..................................................................12
Water Piping.......................................................................................................................15
Field Insulation Guide........................................................................................................19
Physical Data and Weights.................................................................................................21
Oil Coolers.........................................................................................................................23
Oil Heater...........................................................................................................................26
Relief Valves......................................................................................................................26
Electrical............................................................................................................................27
Power Wiring .....................................................................................................................27
Remote Starter Display Wiring ..........................................................................................29
Control Power Wiring........................................................................................................29
Multiple Chiller Setup........................................................................................................34
Prestart System Checklist...................................................................................................37
Operation........................................................................................................38
Operator Responsibilities...................................................................................................38
Standby Power ...................................................................................................................38
MicroTech IIControl......................................................................................................38
Capacity Control System....................................................................................................40
Surge and Stall ...................................................................................................................43
Lubrication System ............................................................................................................43
Hot Gas Bypass..................................................................................................................44
Condenser Water Temperature...........................................................................................44
Maintenance...................................................................................................46
Pressure/Temperature Chart...............................................................................................46
Routine Maintenance .........................................................................................................46
Annual Shutdown...............................................................................................................49
Annual Startup ...................................................................................................................50
Repair of System................................................................................................................51
Oil Analysis........................................................................................................................53
Maintenance Schedule...................................................................................56
Service Programs...........................................................................................58
Operator Schools ...........................................................................................58
Warranty Statement......................................................................................58
Obligatory routine checks and starting up apparatuses under pressure.59
Important information regarding the refrigerant used .............................60

D-EIMWC00804-14EN Centrifugal Chillers 7
Information and illustrations cover the Daikin products at the time of publication and we reserve the right to make changes in
design and construction at anytime without notice.

8Centrifugal Chillers D-EIMWC00804-14EN
Introduction
General Description
Daikin Centrifugal Water Chillers are complete, self-contained, automatically controlled fluid
chilling units. Each unit is completely assembled and factory tested before shipment. Models
DWSC/DWDC/DWCC are cooling-only and Models DHSC are cooling with heat recovery
accomplished in a bundle of condenser tubes separate from the cooling tower tube bundle.
In the DWSC and DHSC series, each unit has one compressor connected to a condenser and
evaporator. The DWDC series is equipped with two compressors operating in parallel on a single
evaporator and condenser. The DWCC series is equipped with two compressors, each operating
on one refrigerant circuit of a two circuit evaporator and condenser. Information in this manual
referring to DWSC and DWDC also applies to DWCC and DHSC units except where specifically
noted.
The chillers use refrigerant R-134a to reduce the size and weight of the package compared to
negative pressure refrigerants, and since R-134a operates at a positive pressure over the entire
operation range, no purge system is required.
The controls are pre-wired, adjusted and tested. Only normal field connections such as piping,
electrical and interlocks, etc. are required, thereby simplifying installation and increasing
reliability. Most necessary equipment protection and operating controls are factory installed in
the control panel.
The basic sizes of units are the 050 063, 076, 079, 087, 100, 113 and 126. They provide a cooling
capacity range from 80 tons to 2500 tons. In this manual all references to the DWSC models will
equally apply to other models unless specifically referenced otherwise.
Application
The procedures presented in this manual apply to the standard DWSC/DWDC/DWCC family of
chillers and DHSC heat recovery chillers. Refer to the Operating Manual, OM CentrifMicro II
(latest version available on www.daikineurope.com), for details on operation of the MicroTech
IIunit controller.
All Daikin centrifugal chillers are factory tested prior to shipment and must be initially started at
the job site by a factory trained Daikin service technician. Failure to follow this startup procedure
can affect the equipment warranty.
The standard limited warranty on this equipment covers parts that prove defective in material or
workmanship. Specific details of this warranty can be found in the warranty statement furnished
with the equipment.
Cooling towers used with Daikin centrifugal chillers are normally selected for maximum
condenser inlet water temperatures between 75°F and 90°F (24°C and 32°C). Lower entering
water temperatures are desirable from the standpoint of energy reduction, but a minimum does
existHeat recovery models, DHSC, basically operate the same as cooling-only units. The heat
recovery function is controlled externally to the chiller as explained later in this manual.
Nomenclature D W D C 063
W = Water-cooled
H =
H
eat Recovery
D = Dual Compressor
S = Single Compressor
C = Dual, Counterflow
Centrifugal Compressor
Chiller Model, Based on
Impeller Diameter
D
=
D
aikin

D-EIMWC00804-14EN Centrifugal Chillers 9
Installation
Receiving and Handling
The unit should be inspected immediately after receipt for possible damage.
All Daikin centrifugal water chillers are shipped FOB factory and all claims for handling and
shipping damage are the responsibility of the consignee.
Insulation corners from the evaporator's rigging hole locations are shipped loose and should be
glued in place after the unit is finally placed. Neoprene vibration pads are also shipped loose.
Check that these items have been delivered with the unit.
If so equipped, leave the shipping skid in place until the unit is in its final position. This will
aid in handling the equipment.
Extreme care must be used when rigging the equipment to prevent damage to the control panels
or refrigerant piping. See the certified dimension drawings included in the job submittal for the
center of gravity of the unit. Consult the local Daikin sales office for assistance if the drawings
are not available.
The unit can be lifted by fastening the rigging hooks to the four corners of the unit where the
rigging eyes are located (see Figure 1). Spreader bars must be used between the rigging lines to
prevent damage to the control panels, piping and motor terminal boxes.
Figure 1, DWSC Major Component Locations
Unit Control
Panel
Rigging
Locations
(6) Available
Evaporator
Condenser
Rigging
Locations
(6) Available
Compressor Starter,
Mounting Optional
Compressor Control
Panel, At Rear
Operator Interface
Panel

10 Centrifugal Chillers D-EIMWC00804-14EN
Figure 2, DDWDC Major Component Location
Note: 1. Chilled water and condenser connection location can vary. Check markings on unit
or consult unit certified drawings for connection locations on specific units. 2. DWCC
two-circuit units have separate evaporator and condenser relief valves on each circuit.
Location and Mounting
The unit must be mounted on a level concrete or steel base and must be located to provide service
clearance at one end of the unit for possible removal of evaporator tubes and/or condenser tubes.
Evaporator and condenser tubes are rolled into the tube sheets to permit replacement if necessary. The
length of the vessel should be allowed at one end. Doors or removable wall sections can be utilized for
tube clearance. Minimum clearance at all other points, including the top, is 3 feet (1 meter). The
National Electric Code (NEC) can require four feet or more clearance in and around electrical
components and must be checked.
Operating/Standby Limits
Equipment room temperature, standby
•Water in vessels and oil cooler: 32°F to 122°F (0°C to 50°C)
•Without water in vessels and oil cooler: 0°F to 140°F (-18°C to 60°C)
•WMC without water in vessels: 0°F to 130°F (-18°C to 54.4 °C)
Equipment room temperature, operating: 32°F to 104°F (0°C to 40°C)
Condenser
Rigging
Eyes
Condenser
Dual Relief
Valves
Rigging
Eyes
Oil Sump,
Pump, Heaters
Motor
Terminal Box
Common Oil
Cooler Water
Connections
Lubrication &
Compressor
Control Boxes

D-EIMWC00804-14EN Centrifugal Chillers 11
Maximum entering condenser water temperature, startup: design plus 5 degrees F (2.7 degrees
C)
Maximum entering condenser water temperature, operating: job specific design temperature
Minimum entering condenser water temperature, operating: see page 12.
Minimum leaving chilled water temperature: 38°F (3.3°C)
Minimum leaving chilled fluid temperature with correct anti-freeze fluid: 15°F (9.4°C)
Maximum entering chilled water temperature, operating: 90°F (32.2°C)
Maximum oil cooler/VFD entering temperature: 90°F (32.2°C)
Minimum oil cooler/VFD entering temperature: 42°F (5.6°C)
Vibration Pads
The shipped-loose neoprene vibration pads should be located under the corners of the unit
(unless the job specifications state otherwise). They are installed to be flush with the sides and
outside edge of the feet. Most DWSC units have six mounting feet although only the outer
four are required. Six pads are shipped and the installer can place pads under the middle feet if
desired.
Mounting
Make sure that the floor or structural support is adequate to support the full operating weight of
the complete unit.
It is not necessary to bolt the unit to the mounting slab or framework; but should this be
desirable, 1 1/8" (28.5 mm) mounting holes are provided in the unit support at the four corners.
Note: Units are shipped with refrigerant and oil valves closed to isolate these fluids for
shipment. Valves must remain closed until start-up by the Daikin technician.
Nameplates
There are several identification nameplates on the chiller:
•The unit nameplate is located on the side of the Unit Control Panel. It has a Style No.
XXXX and Serial No. XXXX, both are unique to the unit and will identify it. These
numbers should be used to identify the unit for service, parts, or warranty questions. This
plate also has the unit refrigerant charge.
•Vessel nameplates are located on the evaporator and condenser. Along with other
information, they have a National Board Number (NB) and a serial number, either of which
identify the vessel (but not the entire unit).
•A compressor nameplate is located on the compressor itself and contains identification
numbers.
Safety
The machine must be firmly secured to the ground.
It is essential to observe the following instructions:
- The machine must be raised only by the lifting points. Only these points can support the whole weight of
the unit.
- Do not allow unauthorised and/or unqualified personnel to access the
machine.
- It is forbidden to access the electrical components without having opened the
machine's general disconnecting switch and switched off the power supply.