Goodman WCC113 User Manual

Centrifugal Compressor Water Chillers Catalog 605-5

Models WSC, WDC, WCC, HSC

Contents

Modbus

Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Overview of Water-Cooled Product Line . . . . . . . . 3

Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . 4

World-Class Design Leader . . . . . . . . . . . . . . . 4

Design Features. . . . . . . . . . . . . . . . . . . . . . . . 4

Dual Compressor Centrifugal Chillers . . . . . . . . . . 6

Heat Recovery Models . . . . . . . . . . . . . . . . . . . . . . . 9

Templifier Heat Pump Water Heaters . . . . . . . 9

Heat Recovery Models . . . . . . . . . . . . . . . . . . . . . . 10

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MicroTech® II Controls . . . . . . . . . . . . . . . . . 11

Application Considerations. . . . . . . . . . . . . . . . . . 14

Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Starters and VFDs . . . . . . . . . . . . . . . . . . . . . . . . . 26

Motor Starters . . . . . . . . . . . . . . . . . . . . . . . . 26

Variable Frequency Drives (VFD) . . . . . . . . . 26

Selection Procedures . . . . . . . . . . . . . . . . . . . . . . 28

IPLV/NPLV Defined . . . . . . . . . . . . . . . . . . . 29

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . 49

Options and Accessories . . . . . . . . . . . . . . . . . . . 52

Refrigerant Recovery Units and Monitors . . . . . 54

Pump Out Units. . . . . . . . . . . . . . . . . . . . . . . 54

Refrigerant Monitors . . . . . . . . . . . . . . . . . . . 54

Retrofit Disassembly (Knockdown Options) . . . 55

Specifications (WSC) . . . . . . . . . . . . . . . . . . . . . . 59

Specifications (WDC) . . . . . . . . . . . . . . . . . . . . . . 65

Specifications (WCC) . . . . . . . . . . . . . . . . . . . . . . 71

Starter Types and Descriptions . . . . . . . . . . . 26

Hazard Identification

DANGER

Dangers indicate a hazardous situation which will result in death or serious injury if not avoided.

WARNING

Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.

CAUTION

Cautions indicate potentially hazardous situations, which can result in personal injury or equipment damage if not avoided.

On the cover: WSC 087, 600 Tons, with Compressor VFD

Document:
Issue Date: October 1999
Revision Date:
Replaces:

CAT 605-5

September 2015
August 2015

© 2015 Daikin Applied. 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:
LEED is a registered trademark of the U.S. Green Building Council; 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, Open Choices from Daikin.

2 Cat 605-5

Engineered for flexibility and performance

Centrifugal Compressor Water Chillers Catalog 605-2

Models WSC, WDC, WCC, HSC
Includes Higher Voltage (10/11kV) WDC/WCC models

Introduction

Overview of Water-Cooled Product Line

Introduction

Included in this manual:

Centrifugal Products included in separate manuals:

Model WSC

• Capacity: 200-1250 tons (AHRI conditions)

• Excellent full load performance

Model WDC

• Capacity: 400-2500 tons (AHRI conditions)

• Outstanding part load performance

• Redundancy for increased reliability

• Some sizes available with 10/11kV50Hz power option

Model WCC

• Capacity: 1200-2700 tons (AHRI conditions)

• Two refrigerant circuits for true counterflow

• Outstanding full load performance

• Some sizes available with 10/11kV50Hz power option

Magnitude™ Magnetic Bearing Compressor Chillers

Magnitude™ Model WMC

• Capacity: 145-400 tons

• Oil-free, frictionless compressor

• Excellent part-load performance

• See CAT 602 for more information

Magnitude™ Model WME

•

Capacity: 400-1500 tons

• Oil-free, frictionless compressor

• Outstanding efficiency

• See CAT 604 for more information

Templifier™ Model TSC Water Heater

• Recovers waste heat from process applications

• 5,000 - 19,000 MBH

Model HSC

• Recycles heat normally lost in cooling towers

• Hot water - 140

•

See Templifier CAT 614 for more information

o

; COP as high as 7

• Produces simultaneous heating and cooling

Cat 605-5 3

Features and Benefits

Features and Benefits

World-Class Design Leader

As part of Daikin Industries, a Fortune 1000 company, Daikin
is the second largest air conditioning, heating, ventilating and
refrigeration company in the world. We have earned a
worldwide reputation for providing a full line of quality
products and expertise to meet the demands of our customers.
The engineered flexibility of our products allows you to fine
tune your HVAC system to meet the specific requirements of
your application. You benefit from lower installed and
operating costs, high energy efficiency, quiet operation,
superior indoor air quality (IAQ) and low cost maintenance
and service.

Daikin Centrifugal Compressor Water Chillers are
engineered for flexibility and performance - offering choices,
options and features that provide the

right solution for your
specific application-and have been doing so for over fifty
years. Some highlights of our world-class centrifugal design
are:

Design Features

Excellent Performance

Daikin offers a wide range of centrifugal vessel and
component combinations to provide the right solution for your
specific application. The single compressor WSC offers
excellent full load performance, however, in most
applications, chillers spend about 99% of their operating hours
at part-load condidtions. Our dual compressor WDC chillers
offer many attractive benefits, including outstanding part-load
efficiency, and system redundancy similar to two separate
chillers, with a lower total installed cost. WCC models also
offer the dual compressor advantage but with counterflow
vessels, and a separate refrigerant circuit for each compressor.
WCC chillers excel at full load efficiency. Contact your
Daikin representative for detailed information to decide which
model is right for your job requirements.

Table 1: Centrifugal Models & Possible Applications

Application

Cooling <1250 tons, most hours at full load WSC
Cooling >1250 tons, most hours at full load WCC
Cooling, most hours at part load WDC
Heating Application TSC Templifier™
Simultaneous Cooling and Heating HSC
Optimized Part Load Performance Optional VFD

Positive Pressure Design

Positive pressure systems offer numerous advantages over

ve pressure design. In a negative pressure system, leaks

negati
allow air, moisture, and other contaminants to seep into
system, which will gradually decrease performance, as well as
cause corrosion which must be removed. The Daikin positive
pressure design eliminates this worry, providing sustainable
performance and trouble-free ownership for the life of the unit
under normal operation.

Daikin Model

Gear Driven Advantage

Daikin’s precision-engineered gear driven design allows for
lighter components, less vibration, and ability to

select gear
ratios that will provide the optimum impeller speed for your
application. Older direct-drive designs must use large, heavy
impellers to reach similar tip speeds, which cause more
vibration and greater stress on shaft and motor during
unexpected electrical interruptions.

The compact design and lighter weight components allow for
efficient hydrodynamic bearings to be used. This means that

operation, the shaft is supported on a film of lubricant,

during
with no shaft-to-bearing contact, providing theoretical infinte
life bearings under normal circumstances. The design
simplicity of the Daikin centrifugal compressors provides
increased durability and reliable performance.

Smart Refrigerant

HFC-134a refrigerant contains no chlorine and has zero Ozone
Depletion Potential (ODP), making it an environmentally
superior alternative to other refrigerants such as HCFC-123. It
also has an A1 ASHRAE Safety Classificiation - the lowest
toxicity and flammability rating. R-134a provides the
assurance of a safe, smart, and sustainable solution.

R-123 requires about 6 times the gas flow rate (cfm/ton) of R­134a, which means that the suction and discharge

piping must
also be six times larger. Using R-134a allows Daikin to
provide you with a smaller footprint chiller.

Table 2: Refrigerant Comparison

HFC-134a HCFC-123

No Ozone Depletion

Potential

No Refrigerant Phase Out

Date

ENVIRONMENTAL

Physically smaller, requiring

less mechanical room space.

In the event of a small leak,

refrigerant escapes, allowing

easy detection and repair

No purge unit required

No oil change is required

INSTALLATION AND MAINTENANCE

A1 ASHRAE Safety

Classification -

lowest

toxicity/flammability

SAFETY

RefrigerantResourceCenter for references and more information.

rating

See www.DaikinApplied.com /Daikin/DesignSolutions/

Ozone-depleting substance

Montreal Protocol requires

phase out in new equipment by

2020; production cease by 2030

Requires larger refrigerant flow

rate, with subsequent increase in

component and unit size.

In the event of a small leak, air

leaks into the chiller, making

detection and repair difficult. Can

degrade efficiency

Added cost and additional space

for a purge unit. Must

periodically purge unit to remove

contaminants

Annual oil change is

recommended

B1 ASHRAE Safety

Classification- higher toxicity

level

4 Cat 605-5

Features and Benefits

Unmatched Unloading

Daikin pioneered the use of moveable discharge geometry to
lower the surge point of centrifugal
which the compressor enters a stall or surge condition
generally limits compressor unloading. Chillers with a fixed
discharge will experience stall or surge at low loads due to
refrigerant re-entering the impeller. When in a stall condition,
the refrigerant gas is unable to enter the volute due to its low
velocity and remains stalled in the impeller. In a surge
condition the gas rapidly reverses direction in the impeller
causing excessive vibration and heat. Daikin compressors
reduce the discharge area as load decreases to maintain gas
velocity and greatly reduce the tendency to stall or surge.

Figure 1: Fixed vs. Movable Discharge Geometry

In Figure 1, above, the drawing on the left shows a cross­section view of the operation at full load of a unit with a fixed
compressor discharge. At full load, a large quantity of gas is
discharged with a fairly uniform discharge velocity as
indicated by the arrows.

The center drawing shows a fixed compressor discharge at
reduced capacity. Note that the velocity is not uniform and the
refrigerant tends to reenter the impeller. This is caused by low
velocity in the discharge area and the high pressure in the
condenser, resulting in unstable surge operation and with noise
and vibration generated.

The following cutaway picture shows the unique Daikin
movable discharge geometry. As the capacity reduces, the
movable unloader piston travels inward, reducing the
discharge cross section area and maintaining the refrigerant
velocity. This mechanism
capacity reduction.

allows our excellent unloading

compressors. The point at

Figure 2: Movable diffuser closes impeller discharge area
as load decreases.

Controls Flexibility

MicroTech II® controls with our Open ChoicesTM feature
allow easy integration with the BAS of choice using
LonTalk®, BACnet® or Modbus® protocol

Retrofit Flexibility

Easy to retrofit with flexible knock-down options. See page 55
for details.

Trouble-Free Startup

All Daikin chillers are factory tested on AHRI qualified
computer-controlled test stands. Each chiller is run-tested
under load conditions for a minimum of one hour with
evaporator and condenser water flow at job conditions
(excluding glycol applications). Operating controls are
checked and adjusted, and the refrigerant charge is adjusted for
optimum operation and recorded on the unit nameplate. Units
operating with 50-Hz power are tested with a 50-Hz power
supply. The testing helps ensure correct operation prior to
shipment, and allows factory calibration of chiller operating
controls.

All domestic Daikin centrifugal chillers are commissioned by
Daikin Factory Service personnel, or by authorized and
experienced
ensure that proper starting and checkout procedures are
employed and helps in a speedy commissioning process,
giving you confidence that your chiller is operating as
expected.

Lubrication System

A separately driven electric oil pump assembly supplies
lubrication at controlled temperature and pressure to all
bearing surfaces and is the source of hydraulic pressure for the
capacity control system.

Daikin startup technicians. This procedure helps

The control system will not allow the compressor to start until
oil pressure, at the proper temperature, is established. It also
allows the oil pump to operate after compressor shutdown to
provide lubrication during coast-down. Lubricant from the
pump is supplied to the compressor through a water-cooled,
brazed-plate heat exchanger and single or dual five-micron oil
filters internal to the compressor. All bearing surfaces are

Cat 605-5 5

Dual Compressor Centrifugal Chillers

pressure lubricated. Drive gears operate in a controlled
lubricant mist atmosphere that efficiently cools and lubricates
them.

Lubricant is made available under pressure from the
compressor oil filter to the unit capacity control system and is
used to position the inlet guide vanes in response to changes in
leaving chiller water temperature.

If a power failure occurs, an emergency oil reservoir provides
adequate lubrication flow under pressure, and prevents damage
that could occur during the coast-down period with the oil
pump stopped.

Since the Daikin chillers are positive pressure, there is no
need to change the lubricant or filter on a regular basis. As
with any equipment of

this type, an annual oil check is

recommended to evaluate the lubricant condition.

Figure 3: Lubrication System Schematic

is gas rapidly reversing direction through the impeller). A
number of things can contribute to this condition including
inadequate maintenance of condenser tube cleanliness, a
cooling tower or control malfunction, or unusual ambient
temperatures among others.

For these abnormal conditions, Daikin compressor
designers have developed a protective control system that
senses the potential for a surge, looks at the entire chiller
system operation and takes corrective action if possible;

or
stops the compressor, to help prevent any damage from
occurring. This protection is provided as standard on all
Daikin centrifugal compressors.

Dual Compressor Centrifugal Chillers

Dual Compressor Experience

Daikin is the expert when it comes to dual centrifugal
compressor technology. We

have been successfully building
dual compressor centrifugal chillers since 1971. Daikin is the
only company that builds them with either a single refrigerant
circuit (Model WDC) or two refrigerant circuits (Model
WCC).

Benefits of Dual Compressor Chillers

Superior Efficiency

When coupled with a variable frequency drive, the extremely
efficient Dual Compressor Chillers are considerably more
efficient than single compressor chillers in the same size range,
with IPLVs (Integrated Part Load Value) as low as 0.3 kW per
ton. IPLV conditions are set by AHRI and subject to stringent
testing. Insist on AHRI-certified IPLV efficiency when making
efficiency comparisons.

Enhanced Surge Protection

When centrifugal compressors operate at part load, the volume
of refrigerant gas entering the impeller is reduced. At the
reduced flow, the impeller's capacity to develop the peak load
head is also reduced. At conditions of low refrigerant flow and
high compressor head (pressure difference), stall and/or surge
can occur (a stall is gas static in the impeller, a surge condition

The Redundancy Feature

Daikin dual centrifugal chillers have two of everything
connected to the evaporator and condenser - two
compressors, two lubrication systems, two control systems,
and two starters.

If any component on a compressor system fails, the component
can be removed or repaired without shutting down the other
compressor; providing an automatic back-up with at least 60
percent of the chiller design capacity available on WDC units
and 50 percent on WCC units.

Redundancy is also built into the distributed control system,
which consists of a unit controller, a compressor controller for
each compressor and an operator interface touch screen. The
chiller will operate normally without the touch screen being
functional. If a compressor controller is unavailable, the other
compressor will operate normally and handle as much of the
load as possible.

Lower Installed Costs

The redundancy feature pays off in lower installed costs. An
example of how to incorporate dual compressor chillers into a
system requiring redundancy:

6 Cat 605-5

Dual Compressor Centrifugal Chillers

WSC Single Compressor Chillers WDC Dual Compressor Chillers

(2)

600 ton (2100 kW) On Line Units

(2)

750 ton (2100 kW) Units with

+(1)

600 (2100 kW ) t on Standby Unit 1,200 (4200 kW ) On Line tons

*

1,800 ton (6300 kW) Installed Capacity 1500 ton (52 50 kW ) Ins ta lled Capacit y

Job requirement: 1,200 tons (4200 kW), 50% Backup

*One 750-ton (2100 kW) dual chiller running on two compressors for 750 tons (2100
kW), plus one 750-ton (2100 kW) dual chiller running on one compressor for 60% of 750
tons (2100 kW) = 450 tons (1575 kW), for a total of 1200 tons (4200 kW) on any 3 of the
4 total compressors.

The elimination of the extra pumps, valves, piping, controls,
rigging, and floor space can result in as much as a 35%
reduction in the installation cost for a chiller plant, plus the
savings on the chillers themselves.

Dual Compressor Chiller Overview

There are subtle but important differences between the single
circuit WDC and two circuit WCC chillers.

Dual Circuit WCC Counterflow Chillers

These chillers have a separate refrigerant circuit for each
compressor. They are available in single pass only. They
provide the high full load efficiency advantage of two separate
chillers arranged for counterflow operation in a single,
compact unit.

Single Circuit WDC Chillers

These chillers have a single-refrigerant circuit for the
evaporator and condenser with two compressors running in
parallel and are available in one, two or three-pass
configurations. Their salient feature is that at single­compressor, part load operation, the running compressor can
utilize the entire chiller's heat transfer surface, providing
outstanding part load performance.

Application of Dual Compressor Chillers

Designers and owners must decide which chiller type, or
combination of chiller types, is best for their installation.
Considerations include first cost, system efficiency, system
reliability, space requirements, and total owning costs.

Use WCC chillers when:

• Project requirement is lowest kW per ton performance at full
load with high electrical demand charges.

• Project has a large central plant where cycling chillers for
system capacity reduction is expected (three or more
chillers).

• High chilled water delta-T and low water pressure drops are
desired.

• Built-in redundancy is required. A single compressor will
provide 50% of the unit's full load capacity.

• High efficiency and large capacity is required with series
flow. Use two WCC units in series-counterflow in the 3,000
to 4,000 ton range.

Use WDC chillers when:

• Project requirement is overall lowest energy consumption
with best part load performance.

• Project has smaller chilled water plant where unit unloading
is expected versus cycling of chillers associated with large
multi-chiller plants.

• Floor space is limited (16-foot vessel length compared to 20­foot for WCC).

• Two or three pass vessels are required, typical of retrofit
applications.

• Built-in redundancy is required. A single compressor will
provide 60% of the unit's full load capacity.

Use a combination of WDC and WCC chillers when:

• Peak overall system efficiency is important; for example,
use three WCC and one WDC chiller, all in parallel. The
WCC units are optimized for running at full load and the
WDC is optimized for part load operation. The WCC units
cycle on and off and the WDC unit (consider variable
frequency drives on this unit) trims the load, running
between five and one hundred percent capacity.

Why a Compressor Motor Failure Will Not Contaminate the
Common Refrigerant Circuit on WDC dual chillers

Some people are concerned with the result of a motor burnout
on a single-circuit dual compressor chiller. This is not a
problem on the Daikin WDC chillers because of compressor
construction and chiller layout.

The compressor motor is isolated from the main refrigerant
flow circuit so that any contaminants generated by a motor
failure will not pass into the main refrigerant circuit. Moisture,
acid and/or carbon particles will be automatically trapped
within the compressor's dedicated coolant feed and exit lines.

Internally, the compressor motor compartment is separated and
sealed from the main refrigerant compression chamber. A
double shaft seal on the motor side of the gear housing
prevents cross flow of refrigerant along the motor shaft. The
motor coolant feed line is equipped with both a solenoid valve
and a check valve. These mechanical components, plus the
higher pressure of the liquid refrigerant, prevent back feed into
the main refrigerant system. Refrigerant vapor exiting the
motor compartment must pass through a high pressure drop
filter-drier, sized to immediately plug up and seal off the motor
compartment. Both the coolant feed and return lines are
equipped with manual shutoff valves to permit component
service.

Cat 605-5 7

Dual Compressor Centrifugal Chillers

Over 30 years of field experience have proven the reliability of
these compressor motors. Despite the reliability inherent in the
motor design and the protective control, electrical distribution
system faults and lightning strikes can occur that are beyond
the control of the most conscientious designer. The coolant
protective system protects the unit charge from being
contaminated.

Special WDC Warranty: In the unlikely event of a motor
burnout, the chiller refrigerant charge will not be

Figure 4: Motor Cooling

contaminated. This is so well proven that it is guaranteed for
five years. In areas supported by Daikin Factory Service, if a
motor burnout occurs in one compressor and contaminates the
refrigerant circuit, any resultant damage to the other
compressor will be repaired and the refrigerant charge replaced
at no cost to the customer for parts and labor. The terms of the
original chiller warranty apply to the original burned out
compressor.

Efficiency

Chillers usually spend 99% of their operating hours under part
load conditions, and most of this time at less than 60% of
design capacity. One compressor of a dual WDC chiller
operates with the full heat transfer surface of the entire unit.
For example, one 500-ton (1,750 kW) compressor on a 1,000
ton (3,500 kW) dual chiller utilizes 1,000 tons (3500 kW) of
evaporator and condenser surface. This increases the
compressor's capacity and also results in very high efficiency.

Typical efficiencies for a WDC dual chiller, taken from a
selection computer run, look like this:

Full load efficiency: 0.550 kW per ton (6.5 COP)

60% load, one compressor: 0.364 kW per ton (9.6 COP)

IPLV: 0.415 kW per ton (8.5 COP)

The addition of VFDs to the WDC dual
produces an astonishing AHRI certified IPLV of 0.340 for the
above case. Specific selections can vary up or down from this
example. IPLV is defined in the Selection section of this
manual beginning on page 28 .

8 Cat 605-5

compressor chiller

WCC chillers, with their counterflow design, excel at full load
efficiency. Each of the two compressors operates at a lower
head (pressure differential) than single compressor chillers in
parallel. With any pump or compressor, lower head means
lower power for a given flow. As shown on the right, the #2
(downstream compressor) makes 42 F water but has only 89 F
condenser water leaving instead of 95 F typical of a single
compressor unit. The #1 compressor has 95 F condenser water
leaving, but only has to make 47.6 F chilled water.

The Replacement Market Advantage

• Bolt-together construction on single and dual compressor
chillers along with factory disassembly available as an
option simply the tough entrance situations.

• Put 20% or more tons in the same footprint.

• Add dual compressor redundancy.

• Greatly reduce chiller energy consumption.

• Install a refrigerant with no phase-out date.

• Opens many options for multiple chiller plants using WSC,

WDC and WCC combinations.

Heat Recovery Models

EVAPORATOR

TOW E R

COND ENSER

RE COV E RY

COND E N SE R

AUXILI ARY

HE ATER

HEAT L OAD

TCTCCOO LI N G

LOAD

OPEN
CI RC UI T
TOWER

HEAT REC OVERY

CHI LLER

LEGEND

TC TEMPERATURE CONTROL POINT

PUMP

Typical Building Types

Hotels/Motels
Health Care
Athletic Facilities
Resorts
Schools
Food Service
Nursing Homes

Typical Applications

Space Heating
Outside Air Heating
Reheat
Service Hot Water
Laundries
Kitchens

G

TOWER

)

G

HEATER

R

R

CONDENSER

R

COOLING

R

90° F

(35°C)

F

CHILLER

TC

TC

C

Heat Recovery Models

Heat Recovery Models

For decades, Daikin has pioneered the use of heat recovery
chillers and the unique Daikin
Water Heater to reduce energy costs. These products have
become more important than ever with the current emphasis
on total building efficiency. ASHRAE Efficiency Standard

90.1 mandates the use of heat recovery equipment of this
type in a wide range of buildings.

Heat Recovery Chillers

Model HSC heat recovery chillers, with a single compressor,
have a single condenser with split bundles, i.e., two separate
water passages divided by separate water heads as shown in
the photograph to the right. The inboard water connections are
connected to the cooling tower, the other water side is
connected to the heating system.

The economic feasibility of hot water generated with these
units depends on heating and cooling load profiles and on the
relative cost of the available energy sources. A compressor's
kW per ton is heavily influenced by the pressure head it is
pumping against. During heat recovery operation, the entire
cooling load is operating against the high head required by the

Templifier Heat Pump

hot water temperature. For this reason, it is desirable to
maximize the percentage of the

total rejected heat used for the
heating load. Daikin's economic evaluation program, Energy
Analyzer , available on CD from your local Daikin sales
office, is the perfect tool to determine the economic feasibility
of using this proven technology.

Figure 5: Heat Recovery Chiller Piping Schematic

Templifier Heat Pump Water Heaters

Model TSC: 5,000 to 19,000 MBH

The Model TSC Templifier was developed in the 1970s, after
the 1973 oil embargo, as a device to replace fossil-fired water
heaters with electric heaters. The concept was simple; direct a
stream of warm waste heat to the evaporator of a refrigeration
unit, amplify the temperature of the heat through the
compression cycle, and then deliver the heat from the
condenser, at a higher useful temperature, to a heating load.

The flow diagram shown to the left illustrates just how the
Templifier unit is placed
decision to include a Templifier water heater is almost always
a financial one. Evaluation of load profiles, energy costs, and
owning costs is made simple by using the Daikin Energy
Analyzer evaluation program to determine if the return on
investment meets the owner's requirements.

When there is sufficient waste heat available, Templifier units
can be very attractive where fossil fuels are not available, or
where their use is restricted due to pollution problems or other
reasons. Compared to electric resistance heating, the energy
cost for a Templifier unit to heat domestic water, for example,
could be 7 to 8 times less!

Where to Use Templifier Water Heaters:

in a chilled water system. The

Table 3: Typical COP’s

Hot Water

Temperatures

COP (Based on 85F
off Chiller to Templifier)

110F 120F130F 140F

8.3 6.8 6.0 4.5

Figure 6: Templifier Heat Pump Water Heater Schematic

COOLI N

85°

(29°C)

55°F

(13°C)

EVAPO RATO

12 5°F
(52°C

45°F
(7 ° C )

95 °F

HEATIN

LOAD

TEMPLI FI ER HEAT

PUMP WAT ER HEATE

T

SUPPLE-

MENTAL

CONDE NSE

EVAPORAT O

TEMPE RATURE CONTRO L

13 5°F
(57°C)

(32° )

Cat 605-5 9

LOA D

Heat Recovery Models

Intermediate Heat Exchanger

Ground Water Heat Source

Service Hot Water Piping

CONDENSER

EVAPORATOR

ST OR AG E

TA N K

140°F
(60°C)

TEMPLIFIER

HEAT

SOURCE

140°F

(60°C)

140°F

(60°C)

RETURN /

MAKEUP

OUTP UT

STANDBY /

A UXI LI AR Y HE AT

T- C

Figure 7: Typical Templifier Applications

Heat Recovery Models

10 Cat 605-5

Controls

Controls

MicroTech® II Controls

Daikin Centrifugal chillers are equipped with the proven
reliability of the MicroTech® II controls system with touch­screen interface. The control system is designed for easy and
intuitive operation, and configured for efficient and reliable
operation. Plus, Daikin's Open Choices™ feature allows
integration with your building automation system (BAS)
through an optional communication module
(see Options and Accessories section, page 52).

Designed with the System Operator in Mind

Reliable, economic use of any chiller depends on an easy
operator interface. That's why operation simplicity was one of
the primary considerations
MicroTech® II controller and Operator Interface Touch-Screen
(OITS). The 15-inch color touch-screen is mounted on a fully
adjustable arm. The chiller is graphically displayed, with key
operating parameters viewable on the screen. Alarm history
and operation setpoints are easily accessed through intuitive
touch-screen buttons. The chiller operating manual is also
viewable on the touch screen and can be downloaded via USB.

MicroTech® II Controls Enhance Operating Economy

Many features have been integrated into MicroTech II controls
to ensure optimum operating economy. In addition to replacing
normal relay logic circuits, we've enhanced the controller's
energy saving capabilities with the following features:

• Direct control of water pumps Optically isolated, digital
output relays provide automatic lead-lag of the evaporator
and condenser pumps, permitting pump operation only when
required.

• User-programmable compressor soft loading Prevents
excessive power draw during pull down from high chilled
water temperature conditions.

in the development of the

• Chilled-water reset Reset the leaving water temperature
based on the return water temperature. Raising the chilled
water setpoint during periods of light loads dramatically
reduces power consumption.

• Demand limit control Maximum motor current draw can be
set on the panel, or can be adjusted from a remote 4-20ma or
1-5 VDC BAS signal. This feature controls maximum
demand charges during high usage periods.

• Condenser water temperature control Capable of four
stages of tower fan control, plus an optional analog control
of either a three-way tower-bypass valve or variable speed
tower-fan motor. Stages are controlled from condenser-water
temperature. The three-way valve can be controlled to a
different water temperature or track the current tower stage.
This allows optimum chilled water plant performance based
on specific job requirements.

• Staging Options (Multiple Chiller Installations) The
MicroTech® II controller is capable of compressor
staging decisions and balancing compressor loads
between up to four WSC,WDC or WSC Daikin chillers
using defaults or operator-defined staging.

• Plotting Historic Trends Past operation of the chiller can be
plotted as trend lines and even downloaded to a spreadsheet
for evaluation and analysis.

Proactive Controls

MicroTech® II controls constantly monitor chiller status, and
automatically take

proactive measures to relieve abnormal
conditions or shut the unit down if a fault occurs. For example,
if a problem occurs in the cooling tower and discharge
pressure starts to rise, the controller will automatically hold the
load point and activate an alarm signal. A further rise in
pressure will initiate compressor unloading in an effort to
maintain the setpoint pressure. If the pressure continues to rise,
the unit will shut off at the cutout pressure setting to protect
the unit.

Table 4: Daikin MicroTech® II Controls Features and Benefits

FEATURE BENEFIT

Open Choices™ Option

Touch-screen Interface

Alarm/Fault History and Trend Logging Historical trend data can be downloaded from an onboard USB port

Precise  0.2 F chilled water controls Provides stability in chilled water system

Proactive Controls

Integrated lead/lag pump control

Condenser Water Temperature Control Provides tower fan control /modulation based on system conditions

Multiple language capability -

Metric or IP units of measure

Cat 605-5 11

Easy integration into a building management system via a factory or field-installed

module communicating with BACnet , LONMARK or Modbus protocols.

Easy to read, adjustable, large 15-inch, color touch screen;

See chiller operation at a glance; easily view and change setpoints

Proactive correction of “unusual conditions” allows chiller to stay online; activates

alarm and modifies chiller operation to provide maximum possible cooling

Automatic control of chilled water and condenser water pumps; permits pump

operation only when required

Great asset for world-wide applications

Controls

Alarm History for Easy Troubleshooting

The controller memory can retain and display the cause of the
current fault and the last twenty-five fault conditions. This
feature is extremely useful for troubleshooting and
maintaining an accurate record of unit performance and
history.

The Home Screen shown below is the primary viewing screen
on the Operator Interface Touch Screen (OITS). It gives real­time data on unit status, water temperatures, chilled water
setpoint and motor amp draw.

Figure 8: OITS Home Screen

Trend Logging

Ever wonder how your chiller performed last night? Were you
holding the correct chilled water temperature? What kind of
cooling load did the chiller have? The Daikin MicroTech® II
controller can provide the answers, thanks to its huge
memory, and plot water temperatures, refrigerant pressures,
and motor load data. These values can also be downloaded
through a convenient USB port (located on the unit control
panel) into a spreadsheet for detailed evaluation and analysis.

Figure 10: OITS Trend History Screen

If an alarm occurs, a red button appears on the screen that
leads to the Active Fault Screen whichgives complete fault
information so that the fault can be corrected and cleared.

Changing Setpoints

Changing setpoints is easy with the MicroTech II control. For
example, to change the chilled water setpoint, press SET
button from any screen, then press WATER and this screen
appears, now press button #1, Leaving Water Temperature, and
you are ready to input a password and a new value. (The
controller features a three-level password security system to
provide protection against unauthorized use.)

Figure 9: OITS Setpoint Screen

WDC/WCC Chiller Controls

Dual compressor model centrifugal chillers feature a
MicroTech® II unit controller and a separate controller for
each compressor. This distributed control scheme allows the
operation of each compressor in
Performance data for each compressor is monitored separately
by each controller, and can be controlled and monitored on the
interface panel.

Compressor staging and the load balance function are standard
features
the compressor with the fewest number of starts first, and will
only start remaining compressors when sufficient load has
been established. The staging function will stop the
compressor with the most run-hours as the load decreases to
single compressor range. During two-compressor operation,
the load balance function will equalize the load between each
compressor, providing optimum unit efficiency.

Versatile Communications For Even More Control

For flexibility there are three ways to interface with the
MicroTech® II controller:

• Direct entry via Operator Interface Touch-Screen.

• Direct entry as above, plus remote digital and analog input/

of MicroTech® II controllers. Smart scheduling starts

output signals for certain functions such as enable run input,
alarm signal output, chilled water reset and load limiting,
outputs for pump and tower fan control, for variable speed
tower fan and/or tower bypass valve.

dependently from the other.

12 Cat 605-5

Controls

• Interface with a building automation system (BAS) with
optional modules, communicating directly with BACnet,

have received LONMARK certification with the optional
LONWORKS communication module.

LONMARK or Modbus protocols.

Protocol Options

Building Automation Systems

All MicroTech II®

controllers are capable of communication
with BAS, providing seamless integration and comprehensive
monitoring, control, and two-way data exchange with industry
standard protocols such as LONMARK , Modbus or BACnet .

•BACnet MS/TP

•BACnet IP

• BACnet Ethernet

• LONWORKS (FTT-10A)

• Modbus RTU

Open Choices Benefits

• Easy to integrate into your building automation system

• Factory- or field-installed communication modules

The BAS communication module can be ordered factory­mounted with your chiller, or can be field-installed at any time
after the chiller is installed.

• Comprehensive point list for system integration, equip­ment monitoring and alarm notification

• Comprehensive data exchange

Electric Power Options

In order for the BAS to read the full complement of power data
on low and medium voltage solid state, across-the-line, and

Integration Made Easy

Daikin unit controllers strictly conform to the interoperability
guidelines of the LONMARK Interoperability Association
and the BACnet Manufacturers Association. They

Table 5: Typical BAS Read/Write Data Points

Typical Data Points
Active Setpoint R Cond EWT R Evap Water Pump Status R
Actual Capacity R Cond Flow Switch Status R Heat Recovery EWT R
Capacity Limit Output R Cond LWT R Heat Recovery LWT R
Capacity Limit Setpoint W Cond Pump Run Hours R Heat Setpoint W

Chiller Enable W Cond Refrigerant Pressure

Chiller Limited R Cond Sat. Refrigerant Temp

Chiller Local/Remote R Cond Water Pump Status R Liquid Line Refrigerant Temp R
Chiller Mode Output R Cool Setpoint W Maximum Send Time W
Chiller Mode Setpoint W Current Alarm R Minimum Send Time W
Chiller On/Off R Default Values W Network Clear Alarm W
Chiller Status R Evap EWT R Oil Feed Pressure R
Compressor Discharge Temp R Evap Flow Switch Status R Oil Feed Temp R
Compressor Percent RLA R Evap LWT for Unit R Oil Sump Pressure R
Compressor Run Hours R Evap LWT for Compressor R Oil Sump Temp R
Compressor Select W Evap Pump Run Hours R Outdoor Air Temp
Compressor Starts R Evap Refrigerant Pressure R2 Pump Select W
Compressor Suction Line Temp R Evap Sat. Refrigerant Temp R2 Run Enabled R

1.) Data points available are dependent upon options selected

2.) Per compressor

wye-delta starters, the optional Field Metering Package must
be ordered with the chiller. Otherwise the BAS will only read
the average unit amps. This power data is not available to a

BAS on all other starter voltages and types.

1

(W = Write, R = Read)

2

Ice Setpoint W

R

2

Liquid Line Refrigerant Pressure

R

Cat 605-5 13

Application Considerations

Application Considerations

Location

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. If indoor sub­freezing temperatures are possible, special precautions must be
taken to avoid equipment damage. Equipment room
temperature for operating and standby conditions is 40°F-

122°F (4.4°C-50°C)

CAUTION

Daikin Centrifugal Chillers are intended only for installation in indoor
areas protected from temperature extremes. Failure to comply may
result in equipment damage and may void the manufacturer warranty.

Operating/Standby Limits

Table 6: Operating/Standby Limits

Equipment room operating temperature: 40°-104°F (4.4°-40°C)

Equipment room temperature, standby,
with water in vessels and oil cooler:

Equipment room temperature, standby,
without water in vessels and oil cooler:

Maximum entering condenser water
temperature, startup:

Maximum entering condenser water
temperature, operating:

Minimum entering condenser water
temperature, operating:

Minimum leaving chilled water
temperature:

Minimum leaving chilled fluid temperature
with correct anti-freeze fluid:

Maximum entering chilled water
temperature, operating:

Maximum oil cooler entering
temperature:

Minimum oil cooler entering
temperature:

Piping

Piping must be adequately supported to remove weight and
strain on the chiller's fittings and connections. Do not use
PVCor CPVC piping. Be sure piping is adequately insulated.
Install a cleanable 20-mesh water strainer upstream of the
evaporator and condenser. Install enough shutoff valves to
permit draining water from the evaporator or condenser

without draining the complete system.

CAUTION

Freeze Notice: The evaporator and condenser are not self­draining. Both must be blown out to completely remove water
to help prevent freeze-up

.

Include thermometers and pressure gauges at the chiller inlet
and outlet connections and air vents at the high points of
piping. The water heads can be interchanged (end for end),
allowing water connections to be made at either end of the

40°-104°F (4.4°-40°C)

0°F-122F (-18°C-50°C)

design + 5°F (2.7°C)

job-specific design
temperature

see this page.

38°F (3.3°C)

15°F (9.4°C)

90°F (32.2°C)

80°F (26.7°C)

42°F (5.6°C)

unit. Use new head gaskets when interchanging water heads.
When water pump noise is objectionable, use rubber isolation
sections at both the inlet and outlet of the pump. Vibration
eliminator sections in the condenser inlet and outlet water lines
are not normally required. Where noise and vibration are
critical and the unit is mounted on spring isolators, flexible
piping and conduit connections are necessary. If not factory
installed, a flow switch or pressure differential switch must be
installed in the leaving chilled water line in accordance with
the flow switch manufacturer's instructions.

Note: Victaulic connections are AWWA C-606. Field supply

transitions if Victaulic brand AGS® (Advanced Groove
System) type grooves are used on the field piping.

Optimum Water Temperatures and Flow Rates

A key to improving energy efficiency for any chiller is
minimizing the lift, or pressure difference, between the
compressor suction and discharge pressures. Reducing the lift
reduces the compressor work, and hence its energy
consumption per unit of output. The chiller typically has the
largest motor of any component in a chilled water system.

Higher leaving chilled water temperatures

Warmer leaving chilled water temperatures will raise the
compressor's suction pressure and decrease the lift, improving
efficiency. Using 45 F (7.0 C) leaving water instead of 42 F
(5.5 C) will make a significant improvement.

Evaporator temperature drop

The industry standard has been a ten-degree temperature drop
in the evaporator. Increasing the drop to 12 or 14 degrees will
improve the evaporator heat transfer, raise the suction
pressure, and improve chiller efficiency. Chilled water pump
energy will also be reduced.

Condenser entering water temperature

As a general rule, a one-degree drop in condenser entering
water temperature will reduce chiller energy consumption by
two percent. Cooler water lowers the condensing pressure and
reduces compressor work. One or two degrees can make a
noticeable difference. The incremental cost of a larger tower
can be small and provide a good return on investment.

Minimum Condenser Water Temperature Operation

When ambient wet bulb temperatures are lower than design,
the condenser water temperature can be allowed to fall. Lower
temperatures will improve chiller performance.

Up to 600 Tons

Daikin centrifugal chillers up to 600 Tons are equipped with
electronic expansion valves (EXV) and will start and run
with entering

condenser water temperatures as low as shown
in Figure 11 (based on a 10 degree F condenser Delta-T) or
as calculated from the following equation on which the
curves are based

14 Cat 605-5

Application Considerations

LChWT

42
LChWT

Min. ECWT = 5.25 + 0.88*(LWT) - DT

FL*

(PLD/100) + 22 *(PLD/1 00)2

 ECWT = E nt erin g c ond en ser water te mperat ur e
 LWT = Leaving chilled water temperature
 DT

FL

= Ch ille d Wate r D elta -T at full l oad

 PL D = The pe rc ent ch ille r load poin t to b e chec ked

 For example; at 44F LWT, 10 degree F Delta-

water temperature could be as low as 44.5F. This provides excellent operation with water­economizer systems.

Figure 11: Minimum Entering Condenser Water Temperature (With Electronic Expansion Valve)

Minimum Entering Condenser Water Temperature - 10 F Range

65.0

60.0

55.0

50.0

F
,

T
W
C

E

45.0

40.0

35.0

30.0
0 10 20 30 40 50 60 70 80 90 100 110

44

Percent Load

T, and 50% full load operation, the entering condenser

Cat 605-5 15

side

Application Considerations

44
LChW
T

Over 600 Tons

Chillers over approximately 600 Tons are equipped with
thermal expansion valves (TXV) and will start and run with
entering condenser water temperatures as low as calculated by
the following equation and shown in the chart following.

"ECWT = Entering condenser water temperature

"LWT = Leaving chilled water temperature

"DTFL = Chilled Water Delta-T at full load

"PLD = The percent chiller load point to be checked

Min. ECWT = 7.25 + LWT- 1.25* DTFL(PLD/100) +

65. 0

60. 0

55. 0

50. 0

45.0

40. 0

2

Minimu m Ent er ing C ond ens er Wate r Temp er atur e - 10 F R an ge

42

LChWT

22*(PLD/100)

Figure 12: Minimum Entering Condenser Water Temperature (Thermal Expansion Valve)

F
,

T
W
C

E

35. 0

30. 0
0 102030405060708090100110

Percen

t Load

For example; at 44 F LWT, 10 degree F Delta-T, and 50% full
load operation, the entering condenser water temperature could
be as low as 50.5 F. This provides excellent operation with
water-side economizer systems.

Depending on local climatic conditions, using the lowest
possible entering condenser water temperature may be more
costly in total system power consumed than the expected
savings in chiller power would suggest, due to the excessive
fan power required.

Cooling tower fans must continue to operate at 100% capacity
at low wet bulb temperatures. As chillers are selected for lower
kW per ton, the cooling tower fan motor power becomes a
higher percentage

of the total peak load chiller power.
Daikin's Energy Analyzer program can optimize the chiller/
tower operation for specific buildings in specific locales.

Even with tower fan control, some form of water flow control,
such as tower bypass, is recommended.

Condenser water temperature rise

The industry standard of 3 gpm/ton or about a 9.5-degree
delta-T works well for most applications. Reducing condenser
water flow to lower pumping energy will increase the water
temperature rise, resulting in an increase in the compressor's

condensing pressure and energy consumption. This is usually
not a productive strategy.

System analysis

Although Daikin is a proponent of analyzing the entire
system, it is generally effective to place the

chiller in the most
efficient mode because it is, by far, a larger energy consumer
than pumps. The Daikin Energy Analyzer program is an
excellent tool to investigate the entire system efficiency,
quickly and accurately. It is especially good at comparing
different system types and operating parameters. Contact your
local Daikin sales office for assistance on your particular
application.

For Best Chiller Efficiency

The designer must determine the proper chiller efficiency for a
given application. The most efficient chiller is not always the
best. A life cycle analysis (as performed by Daikin's Energy
Analyzer program, for example) is the only way to be sure of
the best selection. Utility costs, load factors, maintenance
costs, cost of capital, tax bracket; in other words, all the factors
affecting owning cost, must be considered.

Generally, the attempts to save the last few full load kW are
very costly. For example, the cost to go from 0.58 to 0.57 kW/

16 Cat 605-5

Application Considerations

ton could be very costly because of the large number of copper
tubes that would have to be added to the heat exchangers.

Table 7:

Vessel Activity Example

Evaporator

Evaporator

Evaporator Lower flow rates

Condenser

Condenser

Higher leaving water
Temperatures

Higher water temperature
drops

Lower entering water
temperature

Higher flow rates (3.0 gpm/
ton or higher)

44F instead of 42F

12°F instead of 10°F

2.4 gpm/ton instead of

3.0 gpm/ton

84F instead of 85F

3.0 gpm/ton instead of

2.5 gpm/ton

Mixing Single and Dual Compressor Chillers

WDC dual compressor chillers excel at part load operation,
while single compressor chillers usually have better full load
efficiency. A good chiller plant strategy is to install one dual
and one or more single compressor units. Run the dual until it
is fully loaded, then switch to the single compressor unit and
run it only at full load, using the dual to trim the load.

Series Counterflow and Series Parallel Chillers

The design of piping systems can greatly impact chiller
performance. A popular system is to place the evaporators in
series with the chilled water flowing from one evaporator to
the next as shown in Figure 13 and Figure 14. Two different
condenser water piping arrangements can be used. Parallel
flow (Figure 13) divides the total condenser flow between the
two condensers. The counterflow system (Figure 14) puts all
of the condenser water through the condenser of the lag chiller
(chiller producing the coldest evaporator leaving water) and
then through the lead chiller (chiller seeing the warmest
evaporator water temperatures).

tons) combines counterflow design into one unit. See page 6
for details.

Figure 13: Series Parallel Flow

Figure 14: Series Counterflow Flow

Typically, since the lead machine will see the warmest
evaporator water, it will have the greater capacity and larger
portion of the total system evaporator temperature drop. Again
referring to Figure 13 and Figure 14, the lead machine has an

8.4 degree drop (56.0
degree drop (47.6

°F-47.6°F) and the lag machine has a 5.6

°F - 42.0°F).

Condenser water flow is important to overall system
efficiency. With parallel flow (Figure 13), the condensers have
identical flow conditions (95 to 85 degrees in this example)
with the compressor lift shown. With counterflow arrangement
the lift on the lead machine is significantly lower, reducing
compressor work and making the overall system efficiency
about 2% better. Even though the chiller performance is
different, it is good practice to use the same chiller models.

Both the WSC and WDC chillers are suitable for series
counterflow arrangement and include controls specifically
designed for series chillers. For more information, please refer
to Application guide AG -31-003: Chiller Plant Design.
Daikin's model WCC dual compressor chiller (1200 to 2700

Cat 605-5 17

Application Considerations

CHILLER

OIL COOLER

STOP
VALVE

STRAI NER

MAX. 40 MESH

SOLENO ID

VA LV E

DRA IN VALVE
OR PLUG

PUMP

OPEN

DRAIN VALVE

OR PLUG

SOL EN OID

VA LVE

OIL COOLE R

STRAINE R

MAX. 40

MESH

DISCHARGE ABOVE
HI GH EST POSSIBLE
WATER LEVEL

Oil Coolers

Daikin centrifugal chillers have a factory-mounted, water­cooled oil cooler with a temperature controlled water
regulating v
Cooling water connections are located at the rear of the unit,
near the compressor and are shown on the specific unit
certified drawings. Models WDC 063 through 087 and all
WCC have the cooling water connections in the lower portion
of one tube sheet.

WDC 063, 079, 087, 100 and 126 dual compressor chillers are
equipped as above, but the water piping for the two oil coolers
is factory piped to a common inlet and outlet connection.

Field water piping to the inlet and outlet connections must be
installed according to good piping practices and must include
stop valves to isolate the cooler for servicing. A 1" minimum
cleanable filter (40 mesh maximum) and drain valve or plug
must also be field installed. The water supply for the oil cooler
must be from the chilled water circuit, or from an independent
clean source such as city water. When using chilled water, it is
important that the water pressure drop across the evaporator is
greater than the pressure drop across the oil cooler or
insufficient oil cooler flow will result. If the pressure drop
across the evaporator is less than the oil cooler, the oil cooler
must be piped across the chilled water pump, provided that its
pressure drop is sufficient. The water flow through the oil
cooler will be adjusted by the unit's regulating valve so that the
temperature of oil supplied to the compressor bearings
(leaving the oil cooler) is between 90

C).

43

NOTE: The system must be designed for the highest cooling
water temperature possible, which may occur for a short time
during startup.

alve and solenoid valve for each compressor.

F and 110F (32C and

Table 9: WSC with VFD Oil Cooler Data

Hot
Side
POE
Lub.

Cold Side Water

WSC/HSC 063 - 087

Flow, gpm 9.9 13.4 4.0 2.9 2.3
Inlet Temperature, F 118.0 80.0 65.0 55.0 45.0
Outlet Temp., F 100.0 90.3 99.6 103.1 105.6
Pressure Drop, ft. - 30.5 6.7 4.8 3.6

WSC/HSC 100 - 126

Flow, gpm 15.8 24.4 7.0 5.0 4.0
Inlet Temp., F 120.0 80.0 65.0 55.0 45.0
Outlet Temp., F 100.0 89.8 100.1 103.6 106.2
Pressure Drop, ft. - 30.6 15.7 11.4 9.3

NOTES:

1WDC and WCC units have twice the cooling water flow rate

of the comparable WSC chiller.

2

Pressure drops include valves on the unit.

When supplied with city water, the oil piping must discharge
through a trap into an open drain to prevent draining the cooler
by siphoning. The city water can also be used for cooling
tower makeup by discharging it into the tower sump from a
point above the highest possible water level.

Note: Particular attention must be paid to chillers with variable

chilled water flow through the evaporator. The pressure
drop available at low flow rates can very well be
insufficient to supply the oil cooler with enough water. In
this case an auxiliary booster pump can be used or city
water employed.

Cooling Water Connection Sizes: WDC/WCC 100/126 have 1­1/2 in. FPT connections, all other WDC and WSCs are 1 in.
FPT.

Figure 15: Oil Cooler Piping Across Chilled Water Pump

Compressors using chilled water for oil cooling will often start
with warm "chilled water" in the system until the chilled water
loop temperature is pulled down. With cooling water in the

F to 55F (4C to 13C) range, considerably less water will

40

R

S

be used and the pressure drop will be greatly reduced. The
following table contains oil cooler data at various inlet water
temperatures.

Table 8: WSC Oil Cooler Data

Hot
Side
POE

Lube

Cold Side Water

WSC 063 - 087

Flow, gpm 9.9 11.9 2.9 2.0 1.54
Inlet Temperature, F 118.0 80.0 65.0 55.0 45.0
Outlet Temp., F 100.0 87.3 94.5 98.3 101.4
Pressure Drop, psi - 4.3 0.3 0.14 0.09

WSC 100 - 126

Flow, gpm 15.8 21.9 5.11 3.5 2.7
Inlet Temperature, F 120.0 80.0 65.0 55.0 45.0
Outlet Temp., F 100.0 87.0 95.0 99.0 102.3
Pressure Drop, psi - 3.78 0.23 0.11 0.07

18 Cat 605-5

Figure 16: Figure 17, Oil Cooler Piping With City Water

R

S

COOLING TOWER

COOLING TOWER MAKEUP

DRA IN

STOP
VALU E

Application Considerations

5.0

2

....

2

2

2

1













n

DDD

Common

D

Pumps

Model WSC, WDC and WCC chiller compressor motors
operate at 3600 rpm on 60 Hz power (3000 rpm on 50 Hz).
When VFDs are employed, the hertz/speed can be reduced by
70%. To avoid the possibility of objectionable harmonics in
the system piping, 4-pole, 1800/1500 rpm system pumps
should be used. The condenser water pump(s) must be cycled
off when the last chiller of the system cycles off. This will
keep cold condenser water from migrating refrigerant to the
condenser. Cold liquid refrigerant in the condenser can make
start-up difficult. In addition, turning off the condenser water
pump(s) when the chillers are not operating will conserve
energy.

Include thermometers and pressure gauges at the chiller inlet
and outlet connections and air vents at the high points of
piping. The water heads can be interchanged (end for end),
allowing water connections to be made at either end of the
unit. Use new head gaskets when interchanging water heads.
When water pump noise is objectionable, use rubber isolation
sections at both the inlet and outlet of the pump. Vibration
eliminator sections in the condenser inlet and outlet water lines
are not normally required. Where noise and vibration are
critical and the unit is mounted on spring isolators, flexible
piping and conduit connections are necessary. If not factory
installed, a flow switch or pressure differential switch must be
installed in the leaving chilled water line in accordance with
the flow switch manufacturer's instructions.

Victaulic connections are AWWA C-606 on 14-inch and larger
sizes. Field supply transitions if Victaulic brand AGS®
(Advanced Groove System) type grooves are used on the field
piping.

Filtering and Treatment

Owners and operators must be aware that if the unit is
operating wit
cooling tower is required. Make sure tower blow-down or
bleed-off is operating. Atmospheric air contains many
contaminants, which increases the need for water treatment.
The use of untreated water will result in corrosion, erosion,
slime buildup, scaling, or algae formation. A water treatment
service should be used. Daikin is not responsible for damage
or faulty operation from untreated or improperly treated
water.

Machine Room Ventilation

In the market today, centrifugal c
either hermetic or open type motors. Hermetic motors are
cooled with refrigerant and dissipate their heat through the
cooling tower. On the other hand, open motors circulate
equipment room air across themselves for cooling and reject
the heat to the equipment room. Daikin chillers have hermetic
motors and DO NOT require additional ventilation.

For chillers with open-drive type, air-cooled motors, good
engineering practice dictates that the motor heat be removed to

h a cooling tower, cleaning and flushing the

hillers are available with

prevent high equipment room temperatures. In many
applications this requires a large volume of ventilation air, or
mechanical cooling to properly remove this motor heat.

EXAMPLE: 1000 tons x 0.6 kW/Ton x 0.04 motor heat loss x

0.284 Tons/kW = 7 tons (24 kW) cooling

The energy and installation costs of ventilation or mechanical
cooling equipment must be considered when evaluating
various chillers. For a fair comparison, the kW used for the
ventilation fans, or if mechanical cooling is required, the
additional cooling and fan energy must be added to the open
motor compressor energy when comparing hermetic drives.
Additionally, significant costs occur for the purchase,
installation, and maintenance of the ventilation or air handling
units.

Equipment room ventilation and safety requirements for
various refrigerants is a complex subject and is updated from
time to time. The latest edition of ASHRAE 15 should be
consulted.

Thermal Storage

Daikin chillers are designed for use in thermal storage
systems. The chillers
must be considered. The first is normal air-conditioning

The second condition occurs during the ice making process
when leaving fluid temperatures are in the 22

(-5.6

°C to -3.3°C) range.

The MicroTech II control system will accommodate both
operating points. The ice mode can be started or stopped by an
input signal to the microprocessor from a BAS or through a
chilled water reset signal. When a signal is received to change
from the ice mode to the normal operating mode, the chiller
will shut down until the system fluid temperature rises to the
higher setpoint. The chiller will then restart and continue
operation at the higher leaving fluid temperature. When
changing from normal cooling to the ice mode, the chiller will
load to maximum capacity until the lower setpoint is reached.

Computer selections must be made to check that the chiller
will operate at both conditions. If the "ice mode" is at night,
the pressure differentials between the evaporator and
condenser are usually similar to normal cooling applications.
The leaving fluid temperature is lower, but the condensing
temperature is also lower because the cooling tower water is
colder. If the ice mode can also operate during the day, when
cooling tower water temperatures are high, a proper selection
becomes more difficult because the two refrigerant pressure
differentials are significantly different.

A three-way condenser water control valve is always required.

have two operating conditions that

duty where leaving
evaporator fluid
temperatures range
from 40
(4.4

°F to 45°F

°C to 7.2°C).

°F to 26°F

Cat 605-5 19

Application Considerations

Variable Speed Pumping

Variable speed pumping involves changing system water
flow relative to cooling load change
chillers are designed for this duty with two limitations.

First, the rate of change in the water flow needs to be slow, not
greater than 10% of the change per minute. The chiller needs
time to sense a load change and respond.

Second, the water velocity in the vessels must be 3 to 10 fps
(0.91 and
occurs which reduces heat transfer. Above 10 fps (3.0 m/sec),
excessively high pressure drops and tube erosion occur.
These flow limits can be determined from the Daikin
selection program.

We recommend variable flow only in the evaporator because
there is virtually no change in chiller efficiency compared to
constant flow. In other words, there is no chiller energy
penalty. Although variable speed pumping can be done in the
condenser loop, it is usually unwise. The intent of variable
flow is to reduce pump horsepower. However, reducing
condenser water flow increases the chiller's condensing
pressure, increasing the lift that the compressor must overcome
which, in turn, increases the compressor's energy use.
Consequently, pump energy savings can be lost because the
chiller operating power is significantly increased.

Low condenser flow can cause premature tube fouling and
subsequent increased compressor power consumption.
Increased cleaning and/or chemical use can also result.

Vibration Mounting

Every Daikin chiller is run tested and compressor vibration is
measured and limited to a maximum rate
second, which is considerably more stringent than other
available compressors. Consequently, floor-mounted spring
isolators are not usually required. Rubber mounting pads are
shipped with each unit. It is wise to continue to use piping
flexible connectors to reduce sound transmitted into the pipe
and to allow for expansion and contraction.

AHRI Standard 575 Sound Ratings

Sound data in accordance with AHRI Standard 575 for
individual units are available from your local Daikin
representative. Due to the large number of
combinations and variety of applications, sound data is not
included in this catalog.

3.0 m/sec). Below 3 fps (0.91 m/sec), laminar flow

s. Daikin centrifugal

of 0.14 inches per

component

Discharge Line Sound Packages

For extremely sensitive projects, an optional discharge line
sound package is offered consisting of sound insulation
installed on the unit's discharge line. An additional 2 to 4 dbA
reduction normally occurs.

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.

Relief Valves

Relief valve connection sizes are 1-inch
quantity shown in Table 10 for the evaporator and condenser.
In addition, there is a relief valve (3/8 inch flare) on the top of
the oil sump of all units.

All relief valves (including the oil sump) must be piped to the
outside of the building in accordance with ANSI/ASHRAE 15-

2001. The new 2001 standard has revised the calculation
method compared to previous issues.

Twin relief valves, mounted on a transfer valve, are used on
the condenser so that one relief valve can be shut off and
removed for testing or replacement, leaving the other in
operation. Only one of the two valves is in operation at any
time. Where 4 valves are shown, on some large vessels, they
consist of two relief valves mounted on each of two transfer
valves. Only two relief valves of the four are active at any
time.

FPT and are in the

20 Cat 605-5

Application Considerations

Figure 17: Typical Vent Piping

Vent piping is sized for only one valve of the set since only one
can be in operation at a time.

Relief Pipe Sizing (ASHRAE Method)

Daikin centrifugal chillers have the following relief valve
settings and discharge capacity:

• WSC/WCC evaporator (1 valve) and condenser (2 valves
piped together to common vent pipe) = 200 psi, 75.5 lb of
air/min

• WDC evaporator (1) = 180 psi, 68.5 lb of air/min

• WDC condenser(2) = 225 psi, 84.4 lb of air/min

• Note: some large condensers have 4 relief valves

Since the pressures and valve size are fixed for Daikin
chillers, the ASHRAE equation can be reduced to the simple
tabl

e shown below.

Table 10: Relief Valve Piping Sizes

Pipe Size inch

(NPT)

Moody Factor

Equivalent
length (ft)

Note: A 1-inch pipe is too small to handle these valves. A pipe

increaser must be installed at the valve outlet.

1.25 1.5 2 2.5 3 4

0.0209 0.0202 0.0190 0.0182 0.0173 0.0163

2.2 18.5 105.8 296.7 973.6 4117.4

Per ASHRAE Standard 15, the pipe size cannot be less than
the relief device. The discharge from more than one relief
valve can be run into a common header, the area of which shall
not be less than the sum of the areas of the connected pipes.
For further details, refer to ASHRAE Standard 15.

The above information is a guide only. Consult local codes
and/or latest version of ASHRAE Standard 15 for sizing data.

Relief valve pipe sizing is based on the discharge capacity for
the given evaporator or condenser and the length of piping to
be run.

Cat 605-5 21

Application Considerations

MODEL CODE EXAM PLE: W S C - 063M - AQ - 18S / E2012- E - 2 * A / C1812- B L Y Y - 2 * A Y Y Y R / 134B

Packaged Water Cooled
Centrifugal Chiller

S = Single Compressor
D = D ual Compressor
C = Dual Counterflow

Hermet ic Co mpressor Model

Compressor/Impeller Code

Gear Ratio

Motor/Voltage Code

Evaporator Shell Description
[Diameter (in.), Length (ft.)]

Tube Count Code

Tube Type Code

Number of Passes (1, 2, 3)

Water Inlet Location (R = Right Inlet; L = Left Inlet)

Connection Type

Condenser Shell Description [Diameter (in.), Length (ft.)]

Tube Count Code

Type Type Code

Tube Count Code (Heat Recovery Condenser)

Tube Type Code (Heat Recovery Conderser)

Number of Passes (1, 2, 3)

Water Inlet Location (R = Right Inlet; L = Left Inlet)

Connection Type

Number of Passes (Heat Recovery Condenser)

Water Inlet Location (Heat Recovery Condenser)

Connection Type (Heat Recovery Condenser)

Motor Manufacturer

Refrigeration Type (134 = HFC-134a)

COMPRESSOREVAPORATOR

CONDENSER

R

Figure 18: Chiller Identification (Code String Index)

22 Cat 605-5

Electrical Data

Wiring and Conduit

Wire sizes must comply with local and state electrical codes.
Where total amperes require larger conductors than a single
conduit would permit, limited by dimensions of motor terminal
box, two or more conduits can be used. Where multiple
conduits are used, all three phases must be balanced in each
conduit. Failure to balance each conduit will result in
excessive heating of the conductors and unbalanced voltage.

An interposing relay can be required on remote mounted
starter applications when the length of the conductors run
between the chiller and starter is excessive.

Note: On WDC and WCC dual compressor units, dual power
leads are standard, requiring separate power leads properly
sized and protected to each compressor starter or VFD.
Separate disconnects must be used.

Use only copper supply wires with ampacity based on 75°C
conductor rating. (Exception: for equipment rated over 2000
volts, 90°C or 105°C rated conductors shall be used).

Power Factor Correction Capacitors

Do not use power factor correction capacitors with centrifugal
chillers with a compressor VFD. Doing so can cause harmful
electrical resonance in the system. Correction capacitors are
not necessary since VFDs inherently maintain high power
factors.

Control Power

The 115-volt control power can be supplied from the starter or
a transformer (meeting the

requirements of Daikin Starter

Electrical Data

Specification 359999 Rev 29) separate from the starter. Either
source must be properly fused with 25-amp dual element fuses
or with a circuit breaker selected for motor duty. If the control
transformer or other power source for the control panel is
remote from the unit, conductors must be sized for a maximum
voltage drop of 3%. Required circuit ampacity is 25 amps at
115 volts. Conductor size for long runs between the control
panel and power source, based upon National Electrical Code
limitations for 3% voltage drop, can be determined from the
table below.

Control Power Line Sizing

Maximum Length, ft (m)

0 (0) to 50 (15.2) 12 120 (36.6) to 200 (61.0) 6

50 (15.2) to 75 (22.9) 10 200 (61.0) to 275 (83.8) 4

75 (22.9) to 120 (36.6) 8 275 (83.8) to 350 (106.7) 3

Wire Size

(AWG)

Maximum Length, ft (m)

Notes:

1 Maximum length is the distance a conductor will traverse

between the control power source and the unit control
panel.

2 Panel terminal connectors will accommodate up to

number 10 AWG wire. Larger conductors will require an
intermediate junction box.

Starters and VFDs

Information on starters and VFDs can be found in Daikin
Catalog CAT 608.

Wire Size

(AWG)

Cat 605-5 23

Electrical Data

NOTES for Following Wiring Diagram

1 Compressor motor starters are either factory mounted

and wired, or shipped separate for field mounting and
wiring. If provided

by others, starters must comply with
Daikin specification 359999 Rev 29. All line and load
side power conductors must be copper.

2 If starters are freestanding, then field wiring between the

starter and the control panel is required. Minimum wire
size for 115

Vac is 12 GA for a maximum length of 50
feet. If greater than 50 feet, refer to Daikin sales office
for recommended wire size minimum. Wire size for 24
Vac is 18 GA. All wiring to be installed as NEC Class 1
wiring system. All 24 Vac wiring must be run in
separate conduit from 115 Vac wiring. Main power
wiring between starter and motor terminal is factory­installed when units are supplied with unit-mounted
starters. Wiring of free-standing starter must be wired in
accordance with NEC and connection to compressor
motor terminals must be made with copper wire and
copper lugs only. Control wiring on free-standing starters
is terminated on a terminal strip in the motor terminal
box (not the unit control panel). Wiring from the unit
control panel to the motor terminal is done in the factory.

3 For optional sensor wiring, see unit control diagram. It is

recommended that dc wires be run separately from 115
Vac wiring.

4 Customer furnished 24 or 120 Vac power for alarm relay

coil can be connected between UTB1 terminals 84 power
and 51 neutral of the control panel. For normally open
contacts, wire between 82 & 81. For normally closed
contacts, wire between 83 & 81. The alarm is operator
programmable. The maximum rating of the alarm relay
coil is 25 VA.

5 Remote on/off control of unit can be accomplished by

installing a set of dry contacts between terminals 70 and

54.

6 Evaporator and condenser flow switches are required and

must be wired as shown. If field supplied pressure
differential switches are used then these must be installed
across the vessel and not the pump.

7 Customer supplied 115 Vac, 20 amp power for optional

evaporator and condenser water pump control power and
tower fans is supplied to unit control terminals (UTBI)
85 power / 86 neutral, PE equipment ground.

8 Optional customer supplied 115 Vac, 25 VA maximum

coil rated chilled water pump relay (EP 1 & 2) can be
wired as shown. This option will cycle the chilled water
pump in response to building load.

9 The condenser water pump must cycle with the unit. A

customer supplied 115 Vac 25 VA maximum coil rated

condenser water pump relay (CP1 & 2) is to be wired as
shown.

10 Optional customer supplied 115 Vac, 25 VA maximum

coil rated cooling tower fan relays (CL - C4) can be
wired as shown. This option will cycle the cooling tower
fans in order to maintain unit head pressure.

11 Auxiliary 24 Vac rated contacts in both the chilled water

and condenser water pump starters can be wired as
shown for additional protection.

12 For VFD, Wye-Delta, and solid state starters connected

to six (6) terminal motors, the conductors between the
starter and motor carry phase current and their ampacity
must be based on 58 percent of the motor rated load
amperes (RLA) times 1.25. Wiring of free-standing
starter must be in accordance with the NEC and
connection to the compressor motor terminals shall be
made with copper wire and copper lugs only. Main
power wiring between the starter and motor terminals is
factory-installed when chillers are supplied with unit­mounted starters.

13 Optional Open Choices BAS interfaces. The locations

and interconnection requirements for the various
standard protocols are found in their respective
installation manuals, obtainable from the local Daikin
sales office and also shipped with each unit: Modbus
IM 743-0LonWorks IM 735-0BACnet IM 736-0.

14 The "Full Metering" or "Amps Only Metering" option

will require some field wiring when free-standing
starters are used. Wiring will depend on chiller and
starter type. Consult the local Daikin sales office
for information on specific selections.

24 Cat 605-5