Daikin WCT User manual

WCT
Counter-Flow Centrifugal Chillers with Two-Stage Compressors
2200 to 3250 TONS (7750 to 11400 kW)
Series Counter-Flow with Two-Stage Compressors
4500 to 6400 TONS (15830 to 22500 kW)
HFC - 134a
Original Instructions
Installation, Operation and Maintenance Manual
D-EIMWC01308-16EN

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Table of Contents
Safety Instructions...........................................................................................4
Introduction .....................................................................................................6
Installation .......................................................................................................8
Receiving and Handling .......................................................................................................8
Rigging.................................................................................................................................9
Location and Mounting ......................................................................................................10
System Water Volume ........................................................................................................11
Low Condenser Water Temperature Operation (Needs to be updated) ..............................11
Water Piping.......................................................................................................................12
Thermal Insulation .............................................................................................................14
Weights and Dimensions ...............................................................................17
Relief Valves ......................................................................................................................25
Electrical.........................................................................................................28
Control Power Wiring ........................................................................................................29
Field Wiring Diagram ........................................................................................................31
Prestart System Checklist................................................................................33
Important information regarding the refrigerant used.............................34

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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.
WARNING
All installation and maintenance activities must be carried out in compliance with local laws and
regulations.
CAUTION
All units are delivered from the factory complete with wiring diagrams and dimensional drawings
including size and weight for 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 equipment’s document please refer to the
wiring diagram and dimensional drawings.
NOTE
This Manual is a technical aid and does not represent a binding offer for Daikin.
Daikin has drawn up this Manual to the best of its knowledge. The content cannot be held as
explicitly or implicitly guaranteed as complete, precise or reliable.
All data and specifications contained herein may be modified without notice. The data
communicated at the moment of the order shall hold firm.
Daikin shall assume no liability whatsoever for any direct or indirect damage, in the widest sense of
the term, ensuing from or connected with the use and/or interpretation of this Manual.
The entire content is protected by Daikin copyright.
Manufactured in an ISO Certified Facility
©2013 Daikin. Illustrations and data cover the Daikin product at the time of publication and we reserve the right to make
changes in design and construction at anytime without notice.
™® The following are trademarks or registered trademarks of their respective companies: BACnet from ASHRAE; LONMARK,
LonTalk, LONWORKS, and the LONMARK logo are managed, granted and used by LONMARK International under a license granted
by Echelon Corporation; Modbus from Schneider Electric; MicroTech II from Daikin.
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Safety Instructions
The following recommendations should be carefully observed as part of installation, operation, maintenance or
service.
This equipment must be installed by trained and qualified personnel experienced in the installation of
similar centrifugal chillers.
This manual contains important information on operation, safety, maintenance, installation, service and
warranty.
Prior to performing any task on this equipment, the information in this manual and any other referenced
material must be carefully read and understood.
Cautions and Warnings
At several points in the manual, items of special interest or significant impact are highlighted by one of the
following notices.
DANGER
Dangers indicate a hazardous situation which will result in death or serious injury if not
avoided.
WARNING
Warnings indicate potentially hazardous situations, which can result in property damage,
severe personal injury, or death if not avoided.
CAUTION
Cautions indicate potentially hazardous situations, which can result in personal injury or
equipment damage if not avoided.
NOTE
Important information used to obtain best results
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Description of the labels applied to the electrical panel
Unit Control Panel
1 –Non flammable gas symbol
6 –Unit characteristics technical
2 –Electrical hazard symbol
5 –Unit nameplate data
3 –Gas type
7 –Emergency stop
4 –Control panel code
Motor Terminal Box
1 –Terminal box fixing
3 –Electrical hazard symbol
2 –Manufacturer’s logo
4 –Terminal connection

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Introduction
Note: See Operating and Maintenance Manual OMM 1194 for information on operating and maintaining
the chiller. A copy can be obtained from www.Daikineurope.com.
General Description
The Daikin Two-Stage Dual Centrifugal Compressor Water Chillers (WCT) are complete, self-
contained, automatically controlled fluid chilling units. Each unit is completely assembled and factory
tested before shipment. These chillers have a separate refrigerant circuit for each compressor. They
are available in single pass arrangement only. They provide the high full load efficiency advantage of
two separate chillers arranged for counter flow operation in a single, compact unit.
The Daikin Model WCT Chillers use 2-stage compressors and provide cooling capacity from 2200 tons
(7750 kW) to 3250 tons (11400 kW) depending on operating conditions in each chiller, which comes up
5000-6000TR system capacity when chiller installs in series counter-flow configuration. In the WCT
series, each unit has two compressors and two economizers connected to a single condenser, and an
evaporator. Each condenser and evaporator has two separate refrigerant circuits.
WCT chiller is suitably designed for series counter-flow, which two WCT unit is connecting in series
and work as one chiller.
The driveline of the WCT is made up of two two-stage compressors, each with a gear set and a 2-
pole, induction semi-hermetic motor.
The controls are pre-wired, adjusted and tested. Only normal field connections such as water and
relief valve piping, electrical and interlocks, etc. are required, thereby simplifying installation and
increasing reliability. Most of the necessary equipment protection and operating controls are factory
installed in the control panel.
Application
Daikin WCT centrifugal chillers are factory tested prior to shipment and must be initially started at
the job site by a factory-trained Daikin authorized technician. Failure to follow this startup procedure
can affect the equipment warranty.
Cooling towers used with Daikin centrifugal chillers are normally selected for maximum condenser
inlet water temperatures between 75°F and 95°F (24°C and 35°C). Lower entering water
temperatures are desirable from the standpoint of energy reduction, but a minimum does exist. See
page10 for recommendations on optimum entering water temperature and cooling tower fan control.

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Nomenclature
WCTKDCCCP2Z / KDCCCP2Z / E5426-BG-1LL / C5426-BR-1LL /134
WCT : Water Cooled Two-Stage Centrifugal
COMPRESSOR
K : Frame Type of Compressor
D : Shroud Pattern of 1st Stage Impeller
C : Impeller Head of 1st Stage Impeller
C : Shroud Pattern of 2nd Stage Impeller
C : Impeller Head of 2nd Stage Impeller
P2 : Motor Rating ( kW )
Z : Voltage ( V ) and Frequency ( Hz )
EVAPORATOR
E5426 : Evaporator Diameter (in) and Length (ft)
B : Tube Count
G : Tube Type
1 : Number of Passes
L : Water Inlet Nozzle Location (R = Right Inlet ; L= Left Inlet)
L : Nozzle Configuration
CONDENSER
C5426 : Condenser Diameter (in) and Length (ft)
B : Tube Count
R : Tube Type
1 : Number of Passes
L : Water Inlet Nozzle Location (R = Right Inlet ; L= Left Inlet)
L : Nozzle Configuration
REFRIGERANT
134 : Refrigerant Type ( 134 = HFC-134a ); WCT is for R134a only.
Compressor
(No.1)
Evaporator
Compressor
(No.2)
Condenser
Refrigerant

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Installation
Receiving and Handling
The unit should be inspected immediately after receipt for possible damage.
All Daikin centrifugal water chillers are shipped ex-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.
Figure 1, WCT Major Component Locations
Note: Evaporator nozzles may be side-by-side or over-and-under depending on model.
NOTE
Chilled water and condenser connection location can vary. Check markings on unit and
consult unit certified drawings for connection locations on specific units.
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CONDENSER
Circuit 2
UNIT MONITOR
EVAPORATOR
Circuit 1
CONTROL BOX
ECONOMIZER
Circuit 2
EVAPORATOR
Circuit 2
CONDENSER
Circuit 1
ECONOMIZER
Circuit 1
COMPRESSOR
Circuit 2
COMPRESSOR
Circuit 1

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Rigging
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 shackles to the six corners of the unit where the rigging eyes
are located. It is highly recommended the unit be picked up using all 6 lifting locations (see Figure 3) and
the lifting be done with the load at all six locations being vertically up and not at an angle to prevent
possible damage to the control panel, piping, motor terminal box and tubesheets. Lift only using locations
shown in Figure 2. Recommended type of shackle is 50 Ton B.S. 3032 by Van Beest or equal.
If optional shipping skids are used, remove them before lowering the unit to its mounting position. Rig the
unit to its final location on the floor or mounting pad by lifting the unit (or shell assembly) with an
overhead lift and lower the unit to its mounting position.
Figure 2, Rigging Locations
Figure 3, Unit Rigging
6 Lifting Locations
Lifting Halo Shown for Reference Only

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Location and Mounting
The unit must be mounted on a concrete or steel base which is level end-to-end to within ¼” (6.4 mm) and must
be located to provide service clearance at one end of the unit for possible removal and replacement of evaporator
and/or condenser tubes, and if necessary, to permit brush cleaning of evaporator and condenser tubes as
required. Doors, removable wall sections and piping should be arranged for ease of disassembly at the chiller for
tube clearance and cleaning. Minimum clearance at all other points, including the top, is 3 feet (1 meter). Local
regulation can require more clearance in and around electrical components and must be checked. These chillers
are intended only for installation in an indoor or weather protected area consistent with the NEMA 1 rating on
the chiller, controls, and electrical panels. Equipment room temperature for operating and standby conditions is
40°F to 104°F (4.4°C to 40°C) for storage at higher temperatures refrigerant may need to be removed.
Vibration Pads
The unit is shipped with neoprene vibration pads having a nominal 0.375 inch (9.5 mm) operating height. They
are to be placed under the steel foot supports for contact with the foundation, and to be flush with the sides and
outside edge of the foot supports affixed to the chiller tube sheets.
Mounting
Make sure that the floor or structural support is adequate to support the full operating weight of the complete
unit.
The pads should be located in accordance with the unit dimensional drawing. After the pads have been placed
into position on the floor, lower the unit onto the pads which are to be centered under the foot supports. When
the unit is in place, remove the rigging equipment and check that the chiller is level, both longitudinally and
transversely.
First, check the longitudinal alignment of the unit by placing a “level gage” at top center of the evaporator shell
which has more compressor/motor load. Second, check the transverse alignment by placing a level gage on top
of the tube sheets at both ends of the unit. Their alignment should be within ¼”(6.4 mm) and if not, lift the unit
and place shims between the neoprene pads and the foot supports.
It is not necessary to bolt the unit to the mounting slab but should this be desirable, 1-1/8" (28.5 mm) mounting
holes are provided in the unit feet. See dimension drawing for location.
Each pad deflection is around 0.06 inch (2 mm) and if necessary, shims should be placed between the unit foot
supports and pads to equally deflect all pads.
NOTE
Units will be shipped with holding refrigerant charge and oil. All valves must remain open
until start-up by the authorized commissioning technician.
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