Goodman WME0500S Installation Manual
Installation, Operation,
IOM 1209-1
and Maintenance Manual
Magnitude
®
Magnetic Bearing Centrifugal Chillers
Model WME
1000 to 1500 Tons (3500 to 5300 kW)
HFC-134a Refrigerant
Group: Chiller
Part Number: IOM1209-1
Date: July 2015
TABLE OF CONTENTS
TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . .4
The Control System . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Nameplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Receiving and Handling . . . . . . . . . . . . . . . . . . . . . . . 6
Unit Dimensions and Shipping Weight . . . . . . . . . . . .7
Retrofi t Knockdown. . . . . . . . . . . . . . . . . . . . . . . . . . .8
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Vessel Drains at Startup . . . . . . . . . . . . . . . . . . . . . .16
Condenser Water Temperature Control . . . . . . . . . .17
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Field Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Field Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Communication Setup for Multiple Chillers. . . . . . . .24
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pre-Start Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Operator Responsibilities . . . . . . . . . . . . . . . . . . . . . 26
Operator Schools . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Sequence of Unit Operation . . . . . . . . . . . . . . . . . . .26
Unit Enabling/Disabling. . . . . . . . . . . . . . . . . . . . . . . 27
Operator Interface Touch Screen (OITS) . . . . . . . . .28
Controller Inputs and Outputs. . . . . . . . . . . . . . . . . .54
Building Automation Systems (BAS) . . . . . . . . . . . .56
Use with On-Site Generators . . . . . . . . . . . . . . . . . . 56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Service Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Chiller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .57
Seasonal Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 57
Seasonal Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 58
Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Defi nitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Temperature / Pressure Chart. . . . . . . . . . . . . . . . . .61
Manufactured in an ISO 9001 & ISO 14001 certifi ed facility
©2015 Daikin Applied. Illustrations and data cover the Daikin Applied product at the time of publication and we reserve the right to
make changes in design and construction at any time without notice.
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 2 www.DaikinApplied.com
Pre-Start Checklist – Centrifugal Chillers
Must be completed, signed and returned to Daikin Applied service dept. at least 2 weeks prior to requested start date.
Job Name
Installation Location
Customer Order Number
Model Number(s)
G.O. Number(s)
Chilled Water
Piping Complete
Water System – flushed, filled, vented; Water treatment in place
Pumps installed and operational (rotation checked, strainers installed and cleaned)
Controls operational (3-way valves, face/bypass dampers, bypass valves, etc.)
Water system operated and tested; flow meets unit design requirements
Condenser Water
Cooling tower flushed, filled, vented; Water treatment in place
Pumps installed and operational (rotation checked, strainers installed and cleaned)
Controls (3-way valves, bypass valves, etc.) operable per IM/IOM
Water system operated and flow balance to meet unit design requirements
Electrical
115 volt service completed, but not connected to control panel;ƌĞŵŽƚĞŵŽƵŶƚĞĚƐƚĂƌƚĞƌƐͿ
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All interlock wiring complete and compliant with Daikin Applied specifications
Starter complies with Daikin Applied specifications
*Oil cooler solenoid wired to control panel as shown on wiring diagram (See Notes)
Pump starter and interlocks wired
Cooling tower fans and controls wired
Wiring complies with National Electrical Code and local codes (See Note 4)
Condenser pump starting relay (CP1,2) installed and wired (See Note3)
Miscellaneous
*Oil cooled water piping complete. (Units with water-cooled oil coolers only)
Relief valve piping complete (per local codes)
Thermometers, wells, gauges, control, etc., installed
Minimum system load of 80% capacity available for testing/adjusting controls
Document Attached: Technical Breakdown from Daikin Tools
Document Attached: Final Order Acknowledgement
Notes: The most common problems delaying start-up and affecting unit reliability are:
1. Field installed compressor motor power supply leads too small. Questions: Contact the local Daikin Applied sales representative. State size, number and type of
conductors and conduits installed:
a. From Power supply to starter
b. From starter to chiller unit (remote mounted)
2. Centrifugal chillers with water cooled oil coolers must have a 115 volt normally closed water solenoid valve installed in the oil cooler water supply line. Daikin
Cut Here
Applied recommends ASCO Type 8210B27 solenoid valve or approved equal and 40-mesh strainer. Daikin Applied does not supply these components.
3. A 115-volt field-supplied relay (CP1,2) must be used to start/stop condenser water pump on most applications. Cold condenser water must not flow through
condenser during compressor off cycle. Provisions have been made in control center for connecting CP relay, but must not have a rating in excess of 100 VA.
4. Refer to NEC Article 430-22 (a) *Does Not Apply to Magnetic Bearing Chillers (WMC/WME)
Contractor Representative
Signed:
Name:
Company:
Date:
Phone/Email:
Daikin $SSOLHG Sales Representative
Signed:
Name:
Company:
Date:
Phone/Email:
Yes No N/A Initials
Yes No N/A Initials
Yes No N/A Initials
Yes No N/A Initials
©2014 Daikin A pplied Form SF01017 05AUG2014
INTRODUCTION
This manual provides installation, operation, and maintenance information for Daikin WME Magnitude® centrifugal chillers with the
INTRODUCTION
MicroTech
®
E controller.
WARNING
Electric shock hazard. Improper handling of this equipment can cause personal injury or equipment damage. This equipment must
be properly grounded. Connections to and service of the MicroTech
knowledgeable in the operation of the equipment being controlled.
®
E control panel must be performed only by personnel that are
CAUTION
Static sensitive components. A static discharge while handling electronic circuit boards can cause damage to the components.
Discharge any static electrical charge by touching the bare metal inside the control panel before performing any service work.
Never unplug any cables, circuit board terminal blocks, or power plugs while power is applied to the panel.
CAUTION
When moving refrigerant to/from the chiller from an auxiliary tank, a grounding strap must be used. An electrical charge builds
when halo-carbon refrigerant travels in a rubber hose. A grounding strap must be used between the auxiliary refrigerant tank and
the chiller’s end sheet (earth ground), which will safely take the charge to the ground. Damage to sensitive electronic components
could occur if this procedure is not followed.
NOTICE
This equipment generates, uses, and can radiate radio frequency energy . If not installed and used in accordance with this instruction
manual, it may cause interference with radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the owner will be required to correct the interference at the owner’s own expense.
Daikin Applied disclaims any liability resulting from any interference or for the correction thereof.
HAZARD IDENTIFICATION INFORMATION
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.
www.DaikinApplied.com 3 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
General Description
Daikin Magnitude® Centrifugal Chillers are complete, selfcontained, automatically controlled, liquid-chilling units
featuring oil-free, magnetic bearing compressors. All
Magnitude
a single condenser along with either one or two compressors
depending on the model.
Magnitude
installation only. The chillers use refrigerant HFC-134a that
operates at a positive pressure over the entire operation range,
so no purge system is required.
Only normal fi eld connections such as water piping, relief valve
®
chillers are equipped with a single evaporator and
®
chillers are designed for indoor, non-freezing
NOMENCLATURE
W M E 1000 D BS
Water-Cooled
Magnetic Bearings
Centrifugal Compressor
INTRODUCTION
piping, electric power, and control interlocks are required,
thereby simplifying installation and increasing reliability.
Necessary equipment protection and operating controls are
included.
All Daikin Applied centrifugal chillers must be commissioned by
a factory-trained Daikin Applied 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. Specifi c
details of this warranty can be found in the warranty statement
furnished with the equipment.
Vintage/Single Circuit
D = Dual Compressors
S = Single Compressor
Nominal Tons
Figure 1: WME Major Component Locations
Compressor #1
Power Panel
Tube Sheet
Condenser Vessel
Power Panel
Compressor #2
Operator
Interface Touch
Screen (OITS)
Evaporator Vessel
Control Panel
Tube Sheet
NOTE: Unit shown with left-hand condenser water connections and right-hand evaporator water connections. Water connection
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 4 www.DaikinApplied.com
orientation is based on facing the unit power panel.
INTRODUCTION
The Control System
The centrifugal MicroTech® E control system consists of an
operator interface touch screen (OITS), a microprocessorbased unit controller, and compressor on-board controllers,
providing monitoring and control functions required for the
effi cient operation of the chiller.
Operator Interface Touch Screen
The operator interface touch screen (OITS), see Figure 2 for
an example of a screen display, is the device used for viewing
unit operation information and entering commands and entries
into the control system. Select information from the OITS panel
can be downloaded via a USB port located in the unit control
panel.
A single OITS is used per unit. The OITS panel, see
1
, is mounted on a moveable arm to allow placement in
a convenient position for the operator. The Unit Control
Processor, which is used to control the chiller as well as the
OITS is located in the Control Panel, as shown in
For more information on the OITS, see the
Touch Screen (OITS)”
Figure 2: Operator Interface Touch Screen
section starting on page 28.
“Operator Interface
Figure
Figure 3.
Unit Controller
The purpose of the MicroTech® E unit controller is to acquire
and process data relating to chiller operation, issue instructions
to various components of the chiller, and maintain controlled
operation of the chiller. As a part of operating the chiller
successfully, the unit controller offers necessary condenser
water control. See
page 17
information to the operator interface touch screen (OITS) for
graphic display.
Figure 3: Control Panel
for more information. The unit controller also sends
Switch Bracket
“Condenser Water Temperature Control” on
Unit Control I/O Board
USB Ports
Ethernet Switch
USB Ports
Unit Control Processor
www.DaikinApplied.com 5 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
INSTALLATION
Nameplates
There are several identifi cation nameplates on the chiller:
• The unit nameplate is located on the exterior of the Unit
Power Panel. Both the Model No. and Serial No. are
located on the unit nameplate; the Serial No. is unique to
the unit. These numbers should be used to identify the
unit for service, parts, or warranty questions. This plate
also has the unit refrigerant charge and electrical ratings.
• Vessel nameplates are located on the evaporator and
condenser. They have a National Board Number (NB)
and a serial number, either of which identify the vessel
(but not the entire unit).
Receiving and Handling
The unit should be inspected immediately after receipt for
possible damage. All Daikin Applied centrifugal water chillers
are shipped FOB factory and all claims for handling and
shipping damage are the responsibility of the consignee.
On units with factory-installed insulation, the insulation
is removed from the vessel lifting hole (also used for
transportation tie-downs) locations and is shipped loose. It
should be secured in place after the unit is fi nally placed.
Neoprene vibration isolation pads are shipped loose in the
power panel. If the unit is equipped with a shipping skid, leave
INSTALLATION
the skid in place until the unit is in its fi nal position. This will aid
in handling the equipment.
CAUTION
Extreme care must be used when rigging the unit to prevent
damage to the control panels and refrigerant piping. See the
certifi ed dimension drawings included in the job submittal for
the weights and center of gravity of the unit. If the drawings
are not available, consult the local Daikin Applied sales offi ce
for assistance.
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 4. A spreader bar must be used between the rigging
lines to prevent damage to the control panels, piping, and
electrical panels. The spreader-bar length should be equal
to, or no more than 1-foot shorter than, the distance between
the lifting holes located at opposite ends of the chiller. The
unit will require a single spreader-bar of this length capable
of supporting 1.5 times the shipping weight of the unit.
Separately, all cables and hooks by themselves must also be
capable of supporting 1.5 times the shipping weight of the unit.
If a knockdown option was ordered on the unit, reference the
“Retrofi t Knockdown” section starting on page 8 for more
information.
Figure 4: WME Unit Rigging
NOTE: The spreader bars in
needed.
FRONT VIEW
Figure 4 are a representation only and may not refl ect the appearance of the actual spreader bars
RIGHT VIEW
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 6 www.DaikinApplied.com
Unit Dimensions and Shipping Weight
Figure 5: WME0500-0700S (2-pass, right-hand confi guration, with grooved connections)
L
H
Figure 6: WME1000-1500D (2-pass, right-hand confi guration, with grooved connections)
L
INSTALLATION
W
W
H
Table 1: WME0500-1500 Dimensions and Shipping Weights
Model Heat Exchanger
E3012 / C2612 168.5 (4280)
WME0500S
WME0700S
WME1000D E4216 / C3616 218.3 (5545) 89.0 (2261) 102.8 (2611) 28172 (12779)
WME1500D E4816 / C4216 230.0 (5842) 101.0 (2565) 109.8 (2789) 38114 (17288)
* Shipping weight is based on unit with standard tube confi guration.
** Unit height does not include height of removable eye bolt.
*** Dimension for unit with M2 standard motor (60Hz 440/460/480V).
**** Dimension for unit with M2 standard motor (50Hz 380/400/415V, 60Hz 380/575V), M2 standard motor (60Hz 380/460V) with factory-mounted harmonic fi lter, or M3 low THD motor
(50Hz 380/440/460/480/575V).
E3012 / C3012 168.5 (4280) 71.3 (1811) 96.8 (2459) 14163 (6424)
E3612 / C3012 170.0 (4318) 77.3 (1963) 96.8 (2459) 16329 (7407)
E3612 / C3012 170.0 (4318) 77.3 (1963) 96.3 (2446) 17726 (8040)
E3612 / C3612 170.0 (4318) 83.0 (2108) 102.3 (2598) 20094 (9115)
Length
in (mm)
Width
in (mm)
68.4 (1737) ***
70.7 (1796) ****
Height **
in (mm)
92.8 (2357) 12864 (5835)
Shipping Weight *
lb (kg)
www.DaikinApplied.com 7 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
INSTALLATION
Retrofi t Knockdown
It is estimated that fi fty percent of retrofi t applications require partial or complete disassembly of the chiller. Magnitude® WME
chillers are relatively easy to disassemble due to the small compressor size, simplifi ed refrigerant piping, and the absence of a
lubrication system with its attendant components and piping. Various knockdown arrangements are available as options.
“Bolt-Together Construction”
Chillers are built and shipped completely assembled with bolt-together construction on major components for fi eld disassembly and
reassembly on the job site. “Bolt-Together Construction” applies to the following:
• Type A Knockdown for models WME 1000 and 1500
• Type III Knockdown for models WME 500 and 700
Figure 7: “Bolt-Together Construction”
OITS PANEL BOXED
AND SECURELY STRAPPED
TO UNIT CONTROL BOX
FOR SHIPPING
POWER
BOX
VESSEL
BREAKPOINTS
TYP. (IF NEEDED)
Scope:
• Chiller components are manufactured with bolt-together
construction designed for fi eld disassembly and
reassembly on-site.
• Unit ships completely assembled to the jobsite.
• Suction and discharge lines have bolt-on fl anges.
• Motor cooling line is brazed at mechanical connections.
• Unit ships with vessel and/or head insulation, if ordered.
• Unit ships with full factory refrigerant charge in the chiller.
• Unit ships with replacement refrigerant gaskets and
O-rings, stick-on wire ties, and touch-up paint.
UNIT
CONTROL
BOX
NOTE: ALL STEEL PIPING &
COPPER TUBING IS DESIGNED WITH
MECHANICAL BREAKPOINTS
• Unit is fully tested at the factory prior to shipment.
• Site disassembly and reassembly must be supervised or
completed by Daikin Applied service personnel.
• Blockoff plates are required to cover any refrigerant
connection left open for extended periods of time. Contact
Daikin Applied service to obtain these parts.
• Ideal for retrofi t applications where site disassembly is
needed due to installation clearances.
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 8 www.DaikinApplied.com
INSTALLATION
“Partial Disassembly”
Compressor(s), power box(es), and control box are removed and shipped on separate skids; combined vessel stack is shipped
together as a sub-assembly. “Partial Disassembly” applies to the following:
• Type B Knockdown for models WME 1000 and 1500
• Type I Knockdown for models WME 500 and 700
Figure 8: “ Partial Disassembly”
MECHANICAL
BREAKPOINTS
VESSEL
BLOCKOFF
COMPRESSOR(S)
BLOCKOFF AT
MAIN LIQUID LINE
FOR UNITS WITH
RANGE EXTENSION
VESSEL
BREAKPOINTS
TYP. (IF NEEDED)
VESSEL
BLOCKOFF
UNIT CONTROL BOX
(REMAINS ATTACHED ONLY ON
MODELS WME 500 & 700)
GLUE
INSULATION & OTHER
MISCELLANEOUS ITEMS
CRATE 1
ROTOR COOLING SUPPLY & RETURN LINES
STATOR COOLING SUPPLY & RETURN LINES
BOXED OITS PANEL
LOOSE INSULATION
GLUE
MISCELLANEOUS ITEMS
Scope:
• Compressor(s) and power box(es) are removed (at the
factory) and shipped on separate skids; vessel stack is
shipped as a complete sub-assembly.
• The control box for models WME 1000 and 1500 (Type B
Knockdown) is removed (at the factory) and shipped on a
separate skid. The control box for models WME 500 and
700 (Type I Knockdown) is shipped attached to the unit,
as shown in
Figure 8.
• All associated piping and wiring remain attached, if
possible.
• Suction and discharge lines have bolt-on fl anges and, if
possible, remain attached.
• All free piping ends are capped.
• Unit ships with vessel and/or head insulation, if ordered.
• Refrigerant will not be shipped with the chiller and must
be procured by others.
CRATE 2
RANGE EXTENSION PIPING
DISCHARGE PIPING
SUCTION ELBOW
• Compressor(s) and vessels receive an inert gas holding
charge.
• Unit ships with replacement refrigerant gaskets and
O-rings, stick-on wire ties, and touch-up paint.
• Unit is fully tested at the factory prior to shipment.
• Site reassembly must be supervised or completed
by Daikin Applied service personnel. Cost for unit
reassembly and supervision by Daikin Applied service
is not included in the purchase price of the equipment.
Contact Daikin Applied service for pricing.
• Ideal for retrofi t applications where it is desired that
the compressor(s), power box(es), and control box be
removed at the factory, prior to shipment, and where
refrigerant may be secured by others.
POWER BOX(ES)
6 Phz. SHOWN
www.DaikinApplied.com 9 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
Unit Knockdown Dimensions
RIGHT END VIEW
LEFT ENDVIEW
FRONT VIEW
TOP VIEW
Figure 9: Unit Dimensional Diagram for Typical WME Knockdown
W29
W28
EVAPORATOR
CONDENSER
INSTALLATION
H25
W27
CONDENSER
W24
H27
H28
H26
W23
NOTE: See
page 7 for overall unit length, width, and height dimensions for WME models.
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 10 www.DaikinApplied.com
Table 2: Label Descriptions for Unit Dimensional Diagram
Label Description
W23 Width (Condenser Tubesheet with Mounting Brackets)
W24 Width (Evaporator Tubesheet with Mounting Brackets)
W27 Width (Mounting Foot with Mounting Brackets)
W28 Width (Center of Outside Foot Mounting Hole to Center of Suction #1)
W29 Width (Center of Outside Foot Mounting Hole to Center of Suction #2)
H25 Height (Mounting Foot with Mounting Brackets)
H26 Height (Condenser Tubesheet with Mounting Brackets)
H27 Height (Evaporator Tubesheet with Mounting Brackets)
H28 Height (Unit Height from Bottom of Foot to Top of Suction)
Table 3: WME Knockdown Dimensions (in)
Dimensions (in)
Label
E3012/C2612 E3012/C3012 E3612/C3012 E3612/C3012 E3612/C3612 E4212/C3612 E4812/C4212
W23 32.3 37.3 37.3 43.3 43.3 49.2
W24 42.4 42.4 48.4 48.4 54.4 60.4
W27 66.0 71.0 77.0 83.0 89.0 101.0
W28 48.7 48.7 48.7 48.7 48.6 48.6
W29 N/A N/A N/A N/A 126.3 126.3
H25 27.8 28.5 28.5 34.3 26.3 26.5
H26 39.9 44.7 44.7 49.9 49.9 56.9
H27 37.8 37.7 44.3 44.6 44.6 50.0 56.4
H28 62.5 63.2 69.8 70.2 75.9 73.8 79.5
WME0500S WME0700S WME1000D WME1500D
INSTALLATION
Table 4: WME Knockdown Dimensions (mm)
Dimensions (mm)
Label
E3012/C2612 E3012/C3012 E3612/C3012 E3612/C3012 E3612/C3612 E4212/C3612 E4812/C4212
W23 819 946 946 1099 1099 1249
W24 1078 1078 1230 1230 1383 1535
W27 1676 1803 1956 2108 2261 2565
W28 1237 1237 1237 1237 1234 1234
W29 N/A N/A N/A N/A 3208 3208
H25 705 725 725 871 668 672
H26 1014 1135 1135 1268 1268 1446
H27 960 957 1124 1134 1134 1270 1432
H28 1588 1605 1773 1782 1929 1874 2019
WME0500S WME0700S WME1000D WME1500D
www.DaikinApplied.com 11 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
INSTALLATION
Compressor Dimensions
The compressor dimensions on WME models vary.
Compressor dimensions for models WME0500S and
WME1000D are identical. Likewise, compressor dimensions
for models WME0700S and WME1500D are identical. All
dimensions are listed in
Figure 10: Dimension Representation for Compressors
Used on WME Models
HEIGHT
Table 5: Compressor Dimensions for WME Models
Model
WME0500S 45.03 (1144) 30.81 (783) 24.50 (622)
WME0700S 44.99 (1143) 31.97 (812) 25.19 (640)
WME1000D 45.03 (1144) 30.81 (783) 24.50 (622)
WME1500D 44.99 (1143) 31.97 (812) 25.19 (640)
Table 5.
WIDTH
Length
in (mm)
LENGTH
Width
in (mm)
Height
in (mm)
Compressor Rigging Requirements
To properly rig the compressor, install eye-bolts in the 2 holes
on the top of the compressor. Use a spreader bar between
the two chain hoists, as shown in Figure 11, to safely lift the
compressor.
Figure 11: WME Compressor Rigging Setup
NOTE: The spreader bar in
only and may not refl ect the appearance of the actual
spreader bar needed.
Figure 11 is a representation
Compressor Removal and ReAttachment Instructions
Follow the steps listed to remove and re-attach the
compressor.
Compressor Removal Preparation
1. Close the king valve at condenser liquid line outlet.
2. Close all other related shut-off valves.
3. Pump the refrigerant charge down into the condenser.
4. Ensure that the charge has been removed from the
compressor and evaporator and that the discharge check
valve is holding the charge in the condenser.
5. Loosen and remove bolts on the compressor discharge
nozzle (see
6. Disconnect motor cooling lines.
7. Cover openings to prevent foreign objects entering.
Figure 12, fl ag #5).
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 12 www.DaikinApplied.com
INSTALLATION
Figure 12: Compressor Removal Preparation
5
332749306
0A
Compressor Removal
1. Loosen and remove bolts on either side of the cast
suction elbow (see Figure 13, fl ag
#1).
Figure 13: Compressor Removal / Re-Attachment
1
332749307
0A
9
8
TYP
4 PLCS.
4. Remove rotor stepping valve control wire. The wire ties
will have to be cut away during this process.
5. Remove the following wires coming from the VFD:
• 300V DC power supply (yellow cable)
• 25 pin “D” shell connector
• power leads on the top of the motor housing
6. Remove the Ethernet cable coming from the unit control
box.
7. Remove the wireway box assembly from the compressor
to the back of the VFD.
8. Loosen the (4) bolts from the compressor’s bottom
mounting feet (see Figure 13, fl ag #8).
NOTE: Do not loosen or remove bolts securing the
compressor brackets as height is pre-set from
the factory.
9. Rig compressor for removal as shown in Figure 11.
Compressor Re-Attachment
1. Set the suction elbow back on top of the evaporator and
install the screws loosely at the evaporator fl
ange.
Use new O-rings provided.
2. Set compressor on mounting brackets and install the (4)
mounting bolts loosely. Reconnect the discharge nozzle
with new gasket provided.
3. Install (12) bolts at suction elbow to compressor and
torque to 25 ft-lbs; do not over-tighten.
4. Install (18) bolts at evaporator fl ange to the suction line
and torque to 62 ft-lbs; do not over-tighten.
5. Torque the (8) bolts at the discharge nozzle to 205 ft-lbs.
6. Re-install the wireway between the compressor and the
VFD.
7. Re-attach all associated power wiring & Ethernet cable.
8. Re-attach rotor cooling return line on the underside of
the compressor motor housing along with both liquid
injection lines.
9. Evacuate the evaporator and VFD cooling lines to
500 microns and perform a standing hold to verify no
moisture or leaks.
10. After verifying that pumps are running and water fl ow
has been established on both evaporator and condenser,
add vapor refrigerant to bring the saturated temperature
above freezing. Open all valves.
11. Perform refrigerant leak check to ensure all connections
and fi ttings are securely fastened.
2. Remove rotor cooling return line on the underside of the
compressor motor housing along with both rotor cooling
supply lines.
3. Remove (2) DIN connectors from the solenoid coils along
refrigerant piping.
www.DaikinApplied.com 13 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
INSTALLATION
Unit Knockdown Diassembly and
Reassembly Notes
Type A
Type A units are designed for a wide range of disassembly
and the degree of knockdown varies. Observe the following
recommendations.
1. The chiller is shipped with the full refrigerant charge,
which must be recovered before breaking any refrigerant
connection. Before attempting any disassembly, assume
the condenser isolation valves may have leaked and that
any component of the chiller may be pressurized with
refrigerant. Exert the proper precautions with this caveat
in mind.
2. Check that power has been removed from the unit.
Before disconnecting any wire, it is prudent to label its
function and connection point to facilitate reconnection.
3. The refrigerant charge must be removed from the unit if
the vessels are to be separated.
4. Some insulation repair and touch-up painting may be
required..
Type B
Type B Knockdown units are shipped disassembled except for
the vessel stack and are shipped less refrigerant. If the stack
size or weight dictates further disassembly, the vessels can
be separated by disconnecting any interconnecting wiring and
tubing and then unbolting them. The vessels and compressors
have an inert gas holding charge that must be released prior to
attempting to open any connection.
Clearance
The unit must be placed in an area that allows for adequate
clearance around the unit. See
requirements around the sides of the chiller. Doors and
removable wall sections can be utilized to meet these
clearance requirements. There must be a minimum 3-feet
clearance above the top of the chiller. The U.S. National
Electric Code (NEC) or local codes can require more clearance
in and around electrical components and must be checked for
compliance.
Figure 14 for clearance
CAUTION
Standard torque specs must be followed when re-installing
bolts. Contact Daikin Applied service for this information.
WARNING
Remove compressor, piping or vessel holding charge
through the Schrader valve in the block off plates before
attempting to loosen any fi ttings on them. Failure to do so
can cause severe bodily injury.
Location
WME 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).
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 14 www.DaikinApplied.com
INSTALLATION
Mounting
The unit must be mounted on a concrete or steel base. Make
sure that the fl oor or structural support is adequate to support
the full operating weight of the complete unit.
The neoprene vibration pads (shipped loose in the power
panel) should be placed under the corners of the unit (unless
the job specifi cations state otherwise). They must be installed
Figure 14: Minimum Clearances Based on Standard Waterboxes
Minimum 13’ Clearance on one end for tube service (Models WME 500 and 700)
Minimum 17’ Clearance on one end for tube service (Models WME 1000 and 1500)
so that they are fl ush with the edges of the unit feet.
It is not necessary to bolt the unit to the mounting slab or
framework. Should this be required by local codes, 1-1/8 inch
(28.5 mm) mounting holes are provided in the unit supports at
the four corners.
When mounted, the base pad of the unit must be level to within
± 1/2 inch (12.7 mm) across the length and width of the unit.
WME TOP VIEW
Minimum 4’ Clearance
in front of control boxes and electrical panels
Minimum 3’ Clearance
Minimum 3’ Clearance
NOTE: Hinged type waterboxes may require more clearance. Consult a Daikin Applied sales representative for details.
www.DaikinApplied.com 15 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
INSTALLATION
Water Piping
All vessels come standard with groove-type nozzles (also
suitable for welding) or optional fl ange connections. The
installing contractor must provide matching mechanical
connections of the size and type required. Grooved
connections are AWWA C-606. Be sure that water inlet and
outlet connections match certifi ed drawings and nozzle
markings.
NOTE: The contractor must supply the appropriate transition
connectors if the fi eld piping uses AGS
Groove System) manufactured by Victaulic.
CAUTION
If welding is to be performed on the mechanical or fl ange
connections:
1. Remove the solid-state temperature sensor, thermostat
bulbs, and nozzle mounted fl ow switches from the wells
to prevent damage to those components.
2. Properly ground the unit or severe damage to the
MicroTech
NOTE: ASME certifi cation will be revoked if welding is
The water heads can be interchanged (end for end) so that
the water connections can be made at either end of the unit.
If this is done, use new head gaskets and relocate the control
sensors.
Field installed water piping to the chiller must include:
performed on a vessel shell or tube sheet.
• air vents at the high points.
• a cleanable water strainer with 0.125” perforations in
water inlet lines.
• a fl ow proving device for both the evaporator and
condenser to prevent freeze up. Flow switches, thermal
dispersion switches, or Delta-P switches can be used.
Note that fl ow switches are factory installed. Additional
fl ow switches can be used only if they are connected in
series with the ones already provided. Connect additional
fl ow switches in series between CF1 and CF2, shown
in
“Figure 19: WME0500-0700S Wiring” and “Figure 20:
WME1000-1500D Wiring”
• suffi cient shutoff valves to allow vessel isolation. The
chiller must be capable of draining the water from the
evaporator or condenser without draining the complete
system.
®
E unit controller can occur.
starting on page 20.
®
(Advanced
It is recommended that fi eld installed water piping to the chiller
include:
• thermometers at the inlet and outlet connections of both
vessels.
• water pressure gauge connection taps and gauges at the
inlet and outlet connections of both vessels for measuring
water pressure drop.
CAUTION
When common piping is used for both building heating and
cooling modes, care must be taken to provide that water
fl owing through the evaporator cannot exceed 110°F. Water
this hot can damage controls or cause the relief valve to
discharge refrigerant.
Piping must be supported to eliminate weight and strain on
the fi ttings and connections. Chilled water piping must be
adequately insulated.
Vessel Drains at Startup
The unit is drained of water at the factory and shipped
with open drain valves in each head of the evaporator and
condenser. Be sure to close the valves prior to fi lling the vessel
with fl uid.
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 16 www.DaikinApplied.com
INSTALLATION
Condenser Water
Temperature Control
Condenser water control is an important consideration in chiller
plant design since condenser water temperature will directly
impact chiller operation and effi ciency. When the ambient
wet bulb temperature is lower than peak design, the entering
condenser water temperature from the cooling tower can
be allowed to fall, improving chiller performance. However,
operational issues may occur when the condenser water
temperatures are either too high or too low. The WME chiller
provides several options to assist the chiller plant designer in
providing the optimum control of condenser water temperature.
Cooling Tower Control
Control of the cooling tower is required to maintain stability and
avoid operational issues. This can be achieved through a BAS
or by using the MicroTech
common condenser water loop for multiple purposes, the BAS
contractor must provide the control but use of the MicroTech
E output signal is still recommended.
The preferred cooling tower control utilizes a variable speed
fan. MicroTech
proper fan speed. It can also control up to three stages of fan
cycling. Note that fan cycling can cause cooling tower water
temperature to fl uctuate as fans stage on/off, potentially adding
instability to the system.
Special consideration must be given to starting the chiller when
cold condenser water is present, such as with inverted starts or
changeover from free (tower) cooling to mechanical cooling. It
is required that some method be used to control the condenser
water to maintain proper head pressure as indicated by the
MicroTech
Acceptable methods include the following (Each of these
options can be controlled by the MicroTech
a BAS utilizing the MicroTech
1. Three-Way Bypass Valve Operation
A traditional method for building condenser pressure at
startup with colder condenser water is with the use of
a three-way bypass valve. The device blends warmer
water leaving the condenser with cooler water from the
cooling tower at the condenser inlet. The bypass valve
position will change until full fl ow from the tower to the
condenser is obtained. The MicroTech
the valve position control signal. Main power to drive the
valve’s actuator must be provided by the installer. The
three-way valve should be located close to the chiller
within the equipment room to minimize the volume of
water.
2. Two-Way Valve Operation
Another condenser control method is to use a modulating
two-way control valve located on the outlet connection of
the condenser. The valve will be nearly closed at startup
to restrict water fl ow, which keeps generated heat in
the condenser until an acceptable minimum condenser
®
E will provide a control signal to determine the
®
E controller.
®
E controller. For systems utilizing a
®
®
E output signals.):
E or through
®
E provides only
®
pressure is reached. As heat builds, the valve will open
slowly until a full fl ow condition from the cooling tower
is established. A separate power source is required to
provide power to the valve actuator.
NOTE: To ensure proper operation, caution should be
3. VFD Operating with a Condenser Water Pump
A third method of condenser control for startup is
utilizing a variable frequency drive with the condenser
water pump. The speed will change as directed by the
MicroTech
Speed adjustments may be required during the initial
chiller startup as determined by the service technician.
NOTE: Not using the MicroTech
used when utilizing the two-way valve option.
®
E output signal until design fl ow is reached.
®
and variable frequency drives may result in system
instability, capacity reduction, and issues starting the
chiller with cold condenser water temperature.
E logic to control valves
Condenser Pump Sequencing
It is recommended to utilize the logic built into the MicroTech®
E controller to start the condenser pump. MicroTech
capability to operate a primary pump and a secondary standby
pump. The condenser water fl ow should be stopped when
the chiller shuts off. This will conserve energy and prevent
refrigerant from migrating to the condenser.
®
E has the
Lenient Flow Operation
For chiller startup, the condenser control systems can reduce
the fl ow to low rates, which can make operation of a fl ow
sensing device unreliable. The MicroTech
“lenient fl ow” feature that acts as an override of the fl ow sensor
while protecting the chiller by monitoring a condenser pressure
setting that is below the high pressure cutout.
®
E controller has a
Water Side Economizer Cycle Operation
Water side economizers are commonly used for ASHRAE 90.1
compliance and energy savings. This system utilizes a heat
exchanger external to the chiller when cold cooling tower water
is available to provide cooling. The most common system
has a heat exchanger used in conjunction with the chiller’s
evaporator.
The BAS contractor will need to provide controls for the heat
exchanger including isolation valves and temperature control.
The BAS contractor will also need to control the isolation
valves for the chiller. It is important to use slow-acting type
valves to prevent rapid changes in system fl ows. Changeover
from economizer cooling to mechanical cooling requires one
of the methods previously mentioned to maintain suitable
condenser head pressure.
Contact your local Daikin Applied representative for more
information on this application.
www.DaikinApplied.com 17 IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS
INSTALLATION
Relief Valves
As a safety precaution and to meet code requirements, each
chiller is equipped with pressure relief valves located on
the condenser and evaporator for the purpose of relieving
excessive refrigerant pressure (caused by equipment
malfunction, fi re, etc.) to the atmosphere.
• Condensers have two 200 psi, 1.0-inch female NPT relief
valves as a set with a three-way valve separating the two
valves. (See
times and the second valve acts as a standby.
• Evaporators have a single 200 psi valve. Each valve has
a 1.0-inch female NPT connection.
• Vessel valve capacity is 75 lb/min air.
Units are shipped with refrigerant valves closed to isolate the
refrigerant in the unit condenser. Valves must remain closed
until startup by the factory service technician.
Most codes require that relief valves be vented to the outside
of a building. Relief piping connections to the relief valves must
have fl exible connectors.
Remove plastic shipping plugs (if installed) from the inside of
the valves prior to making pipe connections. Whenever vent
piping is installed, the lines must be in accordance with local
code requirements; where local codes do not apply, the latest
issue of ANSI/ASHRAE Standard 15 code recommendations
must be followed.
Figure 15.) One valve remains active at all
CAUTION
Figure 16: Three-Way Valve, Front Seated Position
Figure 17: Three-Way Valve, Back Seated Position
Condenser Relief Valves
As stated previously and as shown in Figure 15, condensers
have two 200 psi, 1.0-inch female NPT relief valves separated
by a three-way valve.
Figure 15: Condenser Three-Way Relief Valve
Three-Way Valve
Relief Valves
In order to ensure proper installation, it is important to know
how the three-way relief valve functions. When the stem of the
three-way valve is pushed into the valve completely, the valve
is in “Front Seated Position” and all refrigerant will fl ow through
the back outlet port, as shown in
the three-way valve is pulled back completely, the valve is in
“Back Seated Position” and all refrigerant will fl ow through the
front outlet port, as shown in
Figure 16. When the stem of
Figure 17.
When the valve stem is not pushed forward or pulled back
completely, the valve is in “Mid Position,” as shown in
18.
Figure
CAUTION
Do not operate the system with the three-way valve stem in
the Mid Position.
Figure 18: Three-Way Valve, Mid Position
IOM 1209-1 • MAGNITUDE® MODEL WME CHILLERS 18 www.DaikinApplied.com
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