IOM1206 - Daikin Trailblazer (AGZ).pdf

Installation, Operation, and Maintenance Manual

Trailblazer® Air-Cooled Scroll Compressor Chillers With High Efficiency Variable Speed Fan Technology

Model AGZ, E Vintage 30 to 241 Tons (100 to 840 kW) HFC-410A Refrigerant 50/60 Hz

IOM 1206-13

Group: Chiller

Part Number: IOM1206-13

Date: September 2020

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 2 www.DaikinApplied.com

Table of Contents

Manufactured in an ISO 9001 & ISO 14001 certified facility

©2020 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.

Table of Contents

Installation and Application Information Refrigerant Schematics Dimensions and Weights - Packaged Units Dimensions and Weights - Heat recovery Units . . . 32 Refrigerant Charge Isolator Information Pressure Drop Data Electrical Data Unit Controller Operation Sequence of Operation

Unit Functions Circuit Functions Alarms Using the Controller Fan VFD Controller Startup and Shutdown Procedures Unit Maintenance Troubleshooting Chart Warranty Registration Form (Scroll) Limited Product Warranty

Table of Contents

* Heat Recovery option is outside the scope of AHRI ACCL Certification Program.

C ut

H er e

©2019 Daikin Applied Form SF-18002 19 Feb 2019

Pre-Start Checklist – Scroll Compressor Chillers Must be completed, signed, and provided to Daikin Applied 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 and Condenser Water for Water-cooled Chiller Yes No N/A Initials Piping Complete Water strainer(s) installed in piping per manual requirements Water System – flushed, filled, and vented; Water treatment in place Cooling tower flushed, filled, vented; Water treatment in place (if applicable) Pumps installed and operational (rotation checked, strainers cleaned) Controls operational (3-way valves, face/bypass dampers, bypass valves, etc.)

Water system operated and tested; flow meets unit design requirements Flow switch(es) - installed, wired, and calibrated Vent installed on evaporator Glycol at design % (if applicable) Electrical Yes No N/A Initials Building controls operational *Power leads connected to power block or optional disconnect Power leads have been checked for proper phasing and voltage All interlock wiring complete and compliant with Daikin specifications Power applied at least 12 hours before startup Oil heaters energized at least 12 hours before startup Chiller components (EXV Sensors Transducers) installed and wired properly.

*Wiring complies with National Electrical Code and local codes (See Notes) Remote EXV wired with shielded cable Miscellaneous Yes No N/A Initials Unit control switches all off Remote Evaporator / Condenser Piping factory reviewed All refrigerant components/piping leak tested, evacuated and charged Thermometers, wells, gauges, control, etc., installed Minimum system load of 80% capacity available for testing/adjusting controls Document Attached: Technical Breakdown from Selection Software Document Attached: Final Order Acknowledgement Document Attached: Remote piping approval 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 sales representative*. State size, number and type of conductors and conduits installed:

a. From Power supply to chiller

* Refer to NFPA 70-2017, Article 440.35

2. Remote Evaporator piping incomplete or incorrect. Provide approved piping diagrams.

3. Items on this list incorrectly acknowledged resulting in delayed start and possible extra expenses incurred by return trips.

Contractor Representative Daikin Applied Sales Representative Signed: Signed:

Name: Name:

Company: Company:

Date: Date:

Phone/Email: Phone/Email:

Installation and Application Information www.DaikinApplied.com 5 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Installation and Application Information

This manual provides installation, operation, and maintenance information for Daikin Trailblazer model AGZ-E air-cooled scroll chillers with the MicroTech® III controller and using R-410A. Packaged unit configurations and optional heat recovery installations are covered in this manual. Information for units with either the pump package or remote evaporator options can be found at www.

DaikinApplied.com.

NOTE: Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.

DANGER

LOCKOUT/TAGOUT all power sources prior to starting, pressurizing, de-pressuring, or powering down the Chiller. Failure to follow this warning exactly can result in serious injury or death. Be sure to read and understand the installation, operation, and service instructions within this manual.

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® III control panel must be performed only by personnel that are knowledgeable in the operation of the equipment being controlled.

CAUTION

Static sensitive components. A static discharge while handling electronic circuit boards can cause damage to the components. Use a static strap 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 using 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.

WARNING

Escaping refrigerant can displace air and cause suffocation. Immediately evacuate and ventilate the equipment area. If the unit is damaged, follow Environmental Protection Agency (EPA) requirements. Do not expose sparks, arcing equipment, open flame or other ignition source to the refrigerant.

WARNING

Polyolester Oil, commonly known as POE oil is a synthetic oil used in many refrigeration systems, and may be present in this Daikin product. POE oil, if ever in contact with PVC/CPVC, will coat the inside wall of PVC/CPVC pipe causing environmental stress fractures. Although there is no PVC/CPVC piping in this product, please keep this in mind when selecting piping materials for your application, as system failure and property damage could result. Refer to the pipe manufacturer’s recommendations to determine suitable applications of the pipe.

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.

NOTE: Indicates important details or clarifying statements for information presented.

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 6 www.DaikinApplied.com

General Description Daikin Trailblazer® air-cooled water chillers are complete, self-contained, automatic chillers designed for outdoor installation.

Packaged units are completely assembled, factory wired, charged, and tested.

The electrical control center includes all equipment protection and operating controls necessary for dependable automatic operation. Components housed in a centrally located, weather resistant control panel with hinged and tool-locked doors.

NOMENCLATURE

A G Z XXX E D SE

Operating and Standby Limits Table 1: Operating Limits for AGZ-E Chillers

Maximum standby ambient temperature 130°F (54°C) Maximum operating ambient temperature 105°F (41°C) -with optional high ambient package (see information under High Ambient Operation) 125°F (52°C) Minimum operating ambient temperature (standard control) 32°F (0°C) Minimum operating ambient temperature (with optional low-ambient control) -10°F (-23°C) Leaving chilled water temperature 40°F to 65°F (4°C to 18°C) Leaving chilled fluid temperatures (with anti-freeze) - Note that in cases of high ambient temperature, the lowest leaving water temperature settings may be outside of the chiller operating envelope; consult Daikin Tools to ensure chiller is capable of the required lift.

15°F to 65°F (-9°C to 18°C)

Operating chilled water delta-T range 6°F to 16°F (3.3°C to 8.9°C) Maximum evaporator operating inlet fluid temperature 81°F (27°C) Maximum evaporator non-operating inlet fluid temperature 100°F (38°C)

Nameplates Identification 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.

• Evaporator data plate is under insulation and contains the serial number.

• Compressor nameplate is located on each compressor and gives pertinent electrical information.

WARNING

Installation is to be performed by qualified personnel who are familiar with local codes and regulations.

CAUTION

Sharp edges and coil surfaces are a potential injury hazard.

Avoid contact with them.

Inspection Check all items carefully against the bill of lading. Inspect all units for damage upon arrival. Report shipping damage and file a claim with the carrier. Check the unit nameplate before unloading, making certain it agrees with the power supply available. Daikin Applied is not responsible for physical damage after the unit leaves the factory.

Handling Be careful to avoid rough handling of the unit. Do not push or pull the unit from anything other than the base while sitting on appropriately-sized roller dollies.

To lift the unit, 2-1/2” (64mm) diameter lifting eyes are provided on the base of the unit. Arrange spreader bars and cables to prevent damage to condenser coils or cabinet (see Figure 1).

CAUTION

All lifting locations must be used to prevent damage to unit.

Air-Cooled

Global Design

Scroll Compressor

Application, Efficiency, Unit Type

Design Vintage

Nominal Tons # of Compressors D = Tandem per Circuit T = Trio per Circuit www.DaikinApplied.com 7 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

DANGER

Improper rigging, lifting, or moving of a unit can result in property damage, severe personal injury or death. Follow rigging and moving instructions carefully. Do not stand beneath the unit while it is lifted or being installed.

Figure 1: Required Lifting Arrangement

Unit Placement Trailblazer® units are for outdoor applications and can be mounted either on a roof or at ground level. For roof mounted applications, install the unit on a steel channel or I-beam frame to support the unit above the roof. Spring isolators for roof applications are recommended. For ground level applications, install the unit on a substantial base that will not settle. Use a one-piece concrete slab with footings extended below the frost line. Be sure the foundation is level within 0.5” (13 mm) over its length and width. The foundation must be strong enough to support the unit weight - see “Dimensions and Weights - Packaged Units” on page 24.

The addition of neoprene waffle pads (supplied by customer) under the unit may allow water to drain from inside the frame, which can act as a dam. Installation of optional spring or rubber-in-shear isolators can also assist with drainage, see page 39 for information.

Mounting The inside of the base rail is open to allow access for securing mounting bolts, etc. Mounting location dimensions are given in Dimensional Drawings beginning on page 24.

All compressor bolts, rubber grommets, and fasteners should be left in place on the base plate as shown in Figure 2. None of these fasteners are considered to be ‘temporary shipping bolts.’

Figure 2: Compresssor Base Plate Mounting

Service Clearance The control panels are located on the end of the chiller and require a minimum of four feet of clearance in front of the panels. Compressors, filter-driers, and liquid line shutoff valves are accessible on each side or end of the unit. Do not block access to the sides or ends of the unit with piping or conduit.

These areas must be open for service access. Minimum service clearance is as follows:

Sides

• 4 Fan Models: Minimum of 4 ft (1.2 m)

• 6 to 14 Fan Models: It is highly recommended to provide a minimum of 8 ft (2.4 m) on one side to allow for coil replacement. Coils can be removed from the top, allowing a minimum of 4 ft (1.2 m) of side clearance; however, the unit performance may be derated.

Control Panel End

• All Models: Minimum of 4 feet (1.2 meters) Opposite Control Panel End

• 4 Fan Models: Minimum of 8 ft (2.4 m) for coil removal.

• 6 to 14 Fan Models: Minimum of 8 ft (2.4 m). Clearance may be reduced to 4 ft (1.2 m) if side clearance is sufficient for evaporator service and removal.

Figure 3: Service Clearance

NOTE: Number of fans and rigging holes may vary from this diagram.

The lifting method will remain the same.

Minimum = 4 ft (1.2 m)

Minimum = 4 ft (1.2 m)

Minimum = 4 ft (1.2 m)

Minimum = 8 ft (2.4 m) for 4 Fan Models

C on tro l P an el

Minimum = 4 ft (1.2 m) for 6-14 Fan Models if other clearance requirements are met

6-14 Fan Models: 8ft (2.4 m) recommended on one side for coil removal

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 8 www.DaikinApplied.com

Operational Spacing Requirements Sufficient clearance must be maintained between the unit and adjacent walls or other units to allow the required unit air flow to reach the coils. Failure to do so will result in a capacity reduction and an increase in power consumption. No solid obstructions are allowed above the unit at any height, see page 10 for details.

The clearance requirements shown are a general guideline and cannot account for all scenarios. Such factors as prevailing winds, additional equipment within the space, design outdoor air temperature, and numerous other factors may require more clearance than what is shown. Additional clearances may be required under certain circumstances.

Graphs on the following pages give the minimum clearance for different types of installations and also capacity reduction and power increase if closer spacing is used. The graphs are based on individual cases and should not be combined with other scenarios.

CAUTION

Unit performance may be impacted if the operational clearance is not sufficient.

Case 1: Building or Wall on One Side of Unit NOTE: Assumes a solid height wall taller than unit. Refer to

Case 4 for partial wall openings.

For models AGZ030-101E, maintain a 4 feet minimum from a wall of any height.

For models AGZ110-130E, maintain a 6 feet minimum from a wall of any height.

For models AGZ140-241E, maintain a 8 feet minimum from a wall of any height.

Figure 4: Building or Wall on One Side of Unit

Case 2: Two Units, Side-by-Side For models 030-180, there must be a minimum of 4 feet between two units placed side-by-side; however, performance may be affected at this distance. For models 191-241, the minimum is 6 feet as closing spacing may cause air recirculation and elevated condenser pressure. Assuming the requirement of one side having at least 8 feet of service clearance is met, Case 2 figures show performance adjustments as the distance between two units increases.

Figure 5: Two Units, Side-by-Side

Figure 6: Case 2 - Full Load Capacity Reduction

Figure 7: Case 2 - Power Increase

Height of

Wall

Distance Between

Wall and Unit

D

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4 5 6 8

C ap ac ity R ed uc tio n

Distance Between Units (ft)

Full Load Capacity Reduction

AGZ030-070E AGZ075-101E

AGZ110-130E AGZ140-180E

AGZ191-211E AGZ226-241E

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

4 5 6 8

P ow er

In cr ea se

Distance Between Units (ft)

Power Increase

AGZ030-070E AGZ075-101E

AGZ110-130E AGZ140-180E

AGZ191-211E AGZ226-241E

www.DaikinApplied.com 9 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Case 3: Three or More Units, Side-by-Side For all models, there must be a minimum distance between any units placed side-by-side; however, performance may be affected at this distance. Minimum distances are: models 030 to 070 - 4 feet, models 075 to 101 - 5 feet, models 110 to 241

- 6 feet. Figure 9 and Figure 10 depict Case 3 performance adjustments as the distance between units increases.

NOTE: Data in Figure 9 and Figure 10 is for the middle unit with a unit on each side. See Case 2 adjustment factors for the two outside units.

Figure 8: Three or More Units, Side-by-Side

Figure 9: Case 3 - Full Load Capacity Reduction

Figure 10: Case 3 - Power Increase

Case 4: Open Screening Walls Decorative screening walls are often used to help conceal a unit either on grade or on a rooftop. When possible, design these walls such that the combination of their open area and distance from the unit (see Figure 11) do not require performance adjustment. If the wall opening percentage is less than recommended for the distance to the unit, it should be considered as a solid wall. It is assumed that the wall height is equal to or less than the unit height when mounted on its base support. If the wall height is greater than the unit height, see Case 5: Pit Installation for performance adjustment factors.

The distance from the sides of the unit to the side walls must be sufficient for service, such as opening control panel doors.

For uneven wall spacing, the distance from the unit to each wall can be averaged providing no distance is less than 4 feet.

Values are based on walls on all four sides.

Figure 11: Case 4 - Allowable Wall Open Area

0.0

1.0

2.0

3.0

4.0

5.0

6.0

4 5 6 8

C ap ac ity R ed uc tio n

Distance Between Units

Full Load Capacity Reduction

AGZ030-035E AGZ040-070E AGZ075-101E

AGZ0110-130E AGZ140-180E AGZ191-211E

AGZ226-241E

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

4 5 6 8

P ow er

In cr ea se

Distance Between Units (ft)

Power Increase

AGZ030-035E AGZ040-070E AGZ075-101E

AGZ0110-130E AGZ140-180E AGZ191-211E

AGZ226-241E

3.0

4.0

5.0

6.0

7.0

8.0

9.0

0 10 20 30 40 50

D is ta nc e fr om W al l t o U ni t ( ft)

% Open Wall Area

Wall Free Area vs. Distance

AGZ030-070E AGZ075-101E

AGZ110-130E AGZ140-180E

AGZ191-241E

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 10 www.DaikinApplied.com

Case 5: Pit Installation Pit installations can cause operating problems resulting from air recirculation and restriction and require care that sufficient air clearance is provided, safety requirements are met and service access is provided. A solid wall surrounding a unit is substantially a pit and this data should be used.

Steel grating is sometimes used to cover a pit to prevent accidental falls or trips into the pit. The grating material and installation design must be strong enough to prevent such accidents, yet provide abundant open area to avoid recirculation problems. Have any pit installation reviewed by the Daikin Applied sales representative prior to installation to ensure it has sufficient air-flow characteristics and approved by the installation design engineer to avoid risk of accident.

Models AGZ030-070E:

The Case 5 figures for models AGZ030-070E show adjustment factors for pit/wall heights of 4 feet, 5 feet, and 6 feet.

Figure 12: Case 5 - Full Load Capacity Reduction

(AGZ030E-070E)

Figure 13: Case 5 - Power Increase (AGZ030-070E)

Figure 14: Case 5 - Pit Installation

Models AGZ075-130E:

The Case 5 figures for models AGZ075-130E show adjustment factors for pit/wall heights of 5 feet, 6 feet, and 8 feet.

Figure 15: Case 5 - Full Load Capacity Reduction

(AGZ075-130E)

Figure 16: Case 5 - Power Increase (AGZ075-130E)

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0 8 10 12 13 14

C ap ac ity R ed uc tio n

Depth of Pit / Wall Height (ft)

Full Load Capacity Reduction (AGZ030-070E)

Distance = 4 f t Distance = 5 f t Distance = 6 f t

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

0 8 10 12 13 14

P ow er

In cr ea se

Depth of Pit / Wall Height (ft)

Power Increase (AGZ030-070E)

Distance = 4 f t Distance = 5 f t Distance = 6 f t

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0 8 10 12 13 14

C ap ac ity R ed uc tio n

Depth of Pit / Wall Height ft)

Full Load Capacity Reduction (AGZ075-130E)

Distance = 5 f t Distance = 6 f t Distance = 8 f t

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

0 8 10 12 13 14

P ow er

In cr ea se

Depth of Pit / Wall Height (ft)

Power Increase (AGZ075-130E)

Distance = 5 f t Distance = 6 f t Distance = 8 f t www.DaikinApplied.com 11 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Models AGZ140-241E:

The Case 5 figures for models AGZ140-241E show adjustment factors for pit/wall heights of 6 feet, 8 feet, and 10 feet.

Figure 17: Case 5 - Full Load Capacity Reduction

(AGZ140-180E)

Figure 18: Case 5 - Full Load Capacity Reduction

(AGZ191-241E)

Figure 19: Case 5 - Power Increase

(AGZ140-211E)

Figure 20: Case 5 - Power Increase

(AGZ226-241E)

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0 8 10 12 13 14

C ap ac ity R ed uc tio n

Depth of Pit / Wall Height (ft)

Full Load Capacity Reduction (AGZ140-180E)

Distance = 6 ft Distance = 8 ft Distance = 10 ft

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

0 8 10 12 13 14

C ap ac ity R ed uc tio n

Depth of Pit / Wall Height (ft)

Full Load Capacity Reduction (AGZ191-241E)

Distance = 6 ft Distance = 8 ft Distance = 10 ft

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

0 8 10 12 13 14

P ow er

In cr ea se

Depth of Pit / Wall Height (ft)

Power Increase (AGZ140-211E)

Distance = 6 f t Distance = 8 f t Distance = 10 f t

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

0 8 10 12 13 14

P ow er

In cr ea se

Depth of Pit / Wall Height (ft)

Power Increase (AGZ226-241E)

Distance = 6 ft Distance = 8 ft Distance = 10 ft

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 12 www.DaikinApplied.com

Chilled Water Piping

CAUTION

To prevent damage to the evaporator and potential chiller failure, a supply strainer is required in the inlet water piping which connects to this evaporator. This strainer must be installed prior to operation of the chilled liquid pumps.

Field installed water piping to the chiller must include:

• A cleanable strainer installed at the water inlet to the evaporator to remove debris and impurities before they reach the evaporator. Install cleanable strainer within 5 feet (1500 mm) of pipe length from the evaporator inlet connection and downstream of any welded connections (no welded connections between strainer to evaporator). AGZ-E models 030-241 require a strainer with perforations no larger than 0.063” (1.6 mm) diameter.

See the Inlet Strainer Guidelines on page 13 for more information.

• A water flow switch must be installed in the horizontal piping of the supply (evaporator outlet) water line to avoid evaporator freeze-up under low or no flow conditions. The flow switch may be ordered as a factory-installed option, a field-installed kit, or may be supplied and installed in the field. See page 15 for more information.

• Piping for units with brazed-plate evaporators must have a drain and vent connection provided in the bottom of the lower connection pipe and to the top of the upper connection pipe respectively, see Figure 21. These evaporators do not have drain or vent connections due to their construction. Purge air from the water system before unit start-up to provide adequate flow through the evaporator.

• Adequate piping support, separate from the unit, to eliminate weight and strain on the fittings and connections.

• An expansion tank and regulating valve to maintain water pressure.

• matching mechanical connections. All evaporators have

OGS-type grooved water connections (adhering to Standard AWWA C606) or optional flange connections.

PVC piping should not be used.

WARNING

Polyolester Oil, commonly known as POE oil is a synthetic oil used in many refrigeration systems, and is present in this Daikin product. POE oil, if ever in contact with PVC/CPVC, will coat the inside wall of PVC/CPVC pipe causing environmental stress fractures. Although there is no PVC/CPVC piping in this product, please keep this in mind when selecting piping materials for your application, as system failure and property damage could result. Refer to the pipe manufacturer’s recommendations to determine suitable applications of the pipe.

It is recommended that the field installed water piping to the chiller include:

• Temperature sensors at the inlet and outlet connections of the evaporator.

• Water pressure gauge connection taps and gauges at the inlet and outlet connections of the evaporator for measuring water pressure drop.

• Shutoff valves to isolate the unit from the piping during unit servicing.

• Minimum bends and changes in elevation to minimize pressure drop.

• Vibration eliminators in both the supply and return water lines to reduce transmissions to the building.

• Flush the system water piping thoroughly before making connections to the unit evaporator.

• Piping insulation, including a vapor barrier, helps prevent condensation and reduces heat loss.

• Regular water analysis and chemical water treatment for the evaporator loop is recommended immediately at equipment start-up.

NOTE: Failure to follow these measures may result in performance and reliability issues.

Figure 21: Typical Piping for Brazed-Plate Evaporator, Models 30-241

Air Vent

Flow Switch

Vibration Eliminators

Drain

Outlet

Inlet

P Isolation Valves

Strainer

WELDED PIPE CONNECTIONS ARE NOT ALLOWED

BETWEEN THE STRAINER AND EVAPORATOR DUE

TO THE CHANCE OF SLAG ENTERING THE EVAPORATOR

www.DaikinApplied.com 13 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Inlet Strainer Guidelines An inlet water strainer kit must be installed in the chilled water piping before the evaporator inlet. Several paths are available to meet this requirement:

1. Factory installed option is available - models 030 to 241.

2. A field-installed kit shipped-loose with the unit is available for all unit sizes and consists of:

• Y-type area strainer with 304 stainless steel perforated basket, grooved pipe connections and strainer cap [a strainer with perforations as listed below by model.]

• Extension pipe with two Schrader fittings that can be used for a pressure gauge and thermal dispersion flow switch. The pipe provides sufficient clearance from the evaporator for strainer basket removal.

• ½-inch blowdown valve

• Two grooved clamps

Both are sized per Table 2 and with the pressure drop shown in the Strainer Pressure Drop graph. Connection sizes are given in the Dimensions and Weights section on page 24.

3. A field-supplied strainer that meets specification and installation requirements of this manual.

Verify total system water pressure drop including the strainer and the chiller using Figure 22 and Figure 50.

Table 2: Strainer Data

Trailblazer® Model

Strainer Size in (mm)

Maximum perforation size in (mm)

Factory Installed Option

Field Installed Option

030-070E 2.5 (64) 0.063 (1.6) Y Y

075-130E 3.0 (76) 0.063 (1.6) Y Y

140-180E 4.0 (102) 0.063 (1.6) Y Y

191-241E 6.0 (152) 0.063 (1.6) Y Y

Figure 22: Strainer Pressure Drop (Data on page 46)

Figure 23: Factory Installed Strainer

Water Flow Limitations Constant Evaporator Flow The evaporator flow rates and pressure drops shown on page 44 for various system designs. The maximum flow rate and pressure drop are based on a 6°F temperature drop. Flow rates above the maximum values will result in unacceptable pressure drops and can cause excessive erosion, potentially leading to failure.

The minimum flow and pressure drop is based on a full load evaporator temperature drop of 16°F. Evaporator flow rates below the minimum values can result in laminar flow causing low pressure alarms, scaling and poor temperature control.

Variable Evaporator Flow Reducing evaporator flow in proportion to load can reduce system power consumption. The rate of flow change should be a maximum of 10 percent of the flow per minute. For example, if the maximum design flow is 200 gpm and it will be reduced to a flow of 140 gpm, the change in flow is 60 gpm.

Ten percent of 200 gpm equals 20 gpm change per minute, or a minimum of three minutes to go from maximum to desired flow. The water flow through the evaporator must remain between the minimum and maximum values listed in Table 11 on page 44. If flow drops below the minimum allowable, large reductions in heat transfer can occur. If the flow exceeds the maximum rate, excessive pressure drop and tube erosion can occur. See Variable Evaporator Flow on page 70 for set point information.

System Water Considerations All chilled water systems need adequate time to recognize a load change, respond to the change and stabilize to avoid undesirable short cycling of the compressors or loss of temperature 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

2.5 in 3.0 in

4.0 in

8.0 in.

6.0 in.

2.0 in.

0.1

1.0

10.0

100.0

10.0 100.0 1000.0

Pr es su re

D ro p ( f t)

Flow Rate (gpm)

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 14 www.DaikinApplied.com 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 storage tank may have to be added to the system to reach the recommended system volume. Refer to AG 31-003 for method of calculating “Minimum Chilled Water Volume”.

The water quality provided by the owner/occupant/operator/ user to a chiller system should minimize corrosion, scale buildup, erosion, and biological growth for optimum efficiency of HVAC equipment without creating a hazard to operating personnel or the environment. Strainers must be used to protect the chiller systems from water-borne debris. Daikin will not be responsible for any water-borne debris damage or water side damage to the chiller heat exchangers due to improperly treated water.

Water systems should be cleaned and flushed prior to chiller installation. Water testing and treatment should be verified during initial chiller installation/commissioning and maintained on a continuous basis by water treatment professionals (see Limited Product Warranty).

CAUTION

The improper use of detergents, chemicals, and additives in the chiller system water may adversely affect chiller performance and potentially lead to repair costs not covered by warranty. Any decision to use these products is at the discretion of the owner/occupant/operator/user as such they assume full liability/responsibility for any damage that may occur due to their use.

Evaporator Freeze Protection Evaporator freeze-up can be a concern in the application of air-cooled water chillers in areas experiencing below freezing temperatures. To protect against freeze-up, insulation and an electric heater are furnished with the evaporator. Models 030 to 241 have an external plate heater and thermostat. These heaters help protect the evaporator down to -20°F (-29°C) ambient air temperature. The evaporator heater cable is factory wired to the 115 volt control circuit transformer in the control box. A 115V power source for the heater and controls may also be supplied from a separate power feed to maximize unit protection if desired. Refer to the field wiring diagram on page 48 for additional information on supplying a separate 115V power feed.

Operation of the heaters is automatic through the sensing thermostat that energizes the evaporator heaters for protection against freeze-up. Unless the evaporator is drained in the winter or contains an adequate concentration of anti-freeze, the disconnect switch to the evaporator heater must not be open.

Although the evaporator is equipped with freeze protection, it does not protect water piping external to the unit or the evaporator itself if there is a power failure or heater burnout, or if the chiller is unable to control the chilled water pumps. Use one of the following recommendations for additional freeze protection:

1. If the unit will not be operated during the winter, drain the evaporator and chilled water piping and flush with glycol.

2. Add a glycol solution to the chilled water system. Burst protection should be approximately 10°F below minimum design ambient temperature.

3. Insulate the exposed piping.

4. Add thermostatically controlled heat by wrapping the lines with heat tape.

5. When glycol is added to the water system for freeze protection, the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop greater. See “” on page 15 for flow rate and pressure drop adjustment factors.

Chilled Water Pump It is important that the chilled water pumps be wired to, and controlled by, the chiller’s microprocessor. When equipped with optional dual pump output, the chiller controller has the capability to selectively send the signal to a pump relay (by others) to start pump A or B or automatically alternate pump selection and also has standby operation capability. The controller will energize the pump whenever at least one circuit on the chiller is enabled to run, whether there is a call for cooling or not. This helps ensure proper unit start-up sequence.

The pump will also be turned on when the water temperature goes below the Freeze Setpoint for longer than a specified time to help prevent evaporator freeze-up. Connection points are shown in the Field Wiring Diagram beginning on page 48.

CAUTION

Adding glycol or draining the system is the recommended method of freeze protection. If the chiller does not have the ability to control the pumps and the water system is not drained or does not have adequate glycol in temperatures below freezing, catastrophic evaporator failure may occur.

Failure to allow pump control by the chiller may cause the following problems:

1. If the chiller attempts to start without first starting the pump, the chiller will lock out on the No Flow alarm and require manual reset.

2. If the chiller evaporator water temperature drops below the “Freeze setpoint” the chiller will attempt to start the water pumps to avoid evaporator freeze. If the chiller does not have the ability to start the pumps, the chiller will alarm due to lack of water flow.

3. If the chiller does not have the ability to control the pumps and the water system is not to be drained in temperatures below freezing or contain glycol, the chiller may be subject to catastrophic evaporator failure due to freezing. The freeze rating of the evaporator is based on the evaporator heater and pump operation. The external brazed plate heater itself may not be able to properly protect the evaporator from freezing without circulation of water.

www.DaikinApplied.com 15 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Flow Switch All chillers require a chilled water flow switch to check that there is adequate water flow through the evaporator and to shut the unit down if necessary to avoid evaporator freeze-up under low or no flow conditions. A factory-included thermal dispersion flow switch will be installed on packaged models.

On remote evaporator models, the flow switch may be separately field-provided, or optionally shipped loose for field installation. Terminals are provided in the unit control center for field mounting and wiring of the water flow switch. Wire from switch terminals Y and R to the unit control panel terminals shown on the field wiring diagrams, page 48 to page 51.

Mount the flow switch in the leaving water line to shut down the unit when water flow is interrupted. A flow switch is an equipment protection control and should never be used to cycle a unit.

Installation should be per manufacturer’s instructions included with the switch. Flow switches should be calibrated to shut off the unit when operated below the minimum listed flow rate for the unit as listed on page 44. Flow switch installation and calibration is further discussed on page 104.

There is also a set of paddle switch contacts on the switch that can be used for an indicator light or an alarm to indicate when a “no flow” condition exists. Freeze protect any flow switch that is installed outdoors. Differential pressure switches are not recommended for outdoor installation. They can freeze and not indicate a no-flow conditions.

Glycol Solutions The use of glycol may impact system performance depending on its concentration and should be considered during initial system design. When glycol is added to the chilled water system for freeze protection, recognize that the refrigerant suction pressure will be lower, cooling performance less, and water side pressure drop will be higher. The reduction in performance depends upon the glycol concentration and temperature.

Test coolant with a clean, accurate glycol refractometer to determine the freezing point.

CAUTION

The installed glycol level must align with the rated glycol percentage indicated on the submitted chiller technical data sheet. Failure to adhere to the rated glycol percentage may result in unit damage and loss of unit warranty.

CAUTION

Do not use an automotive-grade antifreeze. Industrial grade glycols must be used. Automotive antifreeze contains inhibitors which will cause plating on the copper tubes within the chiller evaporator. The type and handling of glycol used must be consistent with local codes.

Low Ambient Operation Compressor staging is adaptively determined by system load, ambient air temperature, and other inputs to the MicroTech® III control. The standard minimum ambient temperature is 32°F (0°C). A low ambient option with fan VFD allows operation down to -10°F (-23°C). The minimum ambient temperature is based on still conditions where the wind is not greater than 5 mph. Greater wind velocities will result in reduced discharge pressure, increasing the minimum operating ambient temperature. Field installed louvers are available and recommended to help allow the chiller to operate effectively down to the ambient temperature for which it was designed.

High Ambient Operation Trailblazer™ units for high ambient operation (105°F to 125°F, 40°C to 52°C) require the addition of the optional high ambient package that includes a small fan with a filter in the air intake to cool the control panel. All units with the optional VFD low ambient fan control automatically include the high ambient option. Note that in cases of high ambient temperature, capacity could be reduced or the lowest leaving water temperature settings may be outside of the chiller operating envelope; consult with a Daikin Applied sales representative to ensure chiller is capable of the required lift.

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 16 www.DaikinApplied.com

Partial Heat Recovery Partial heat recovery for Trailblazer® chillers is achieved by adding an auxiliary heat exchanger in each unit refrigerant circuit between the compressors and the condenser coils.

The heat exchangers transfer the heat from the compressor discharge gas to a separate water loop which can be used for various heating applications. The heating recovery cycle is only available when the chiller is running. The partial heat recovery auxiliary heat exchanger can return water up to 155°F; however, this value cannot be set. The amount of heat produced can be up to 50% of the nominal cooling capacity and is dependent on the requested cooling load, the operating temperatures, and the water flow rate through the auxiliary heat exchangers. Contact a local Daikin Applied sales representative for information on specific applications.

WARNING

Potable water cannot be used in the partial heat recovery system due to the single wall construction of the heat exchangers.

Partial heat recovery components that are factory-supplied:

• Brazed plate heat exchangers - one in each circuit with the water piped together in parallel for one inlet and one outlet water connection, see Figure 51 for pressure drops.

• Insulation of heat exchangers and water piping at the unit.

• Separate temperature sensors for inlet and outlet water piping at the heat exchangers.

• Connections for air vent at the outlet water piping and drain at the inlet water piping.

• Immersion heater for each auxiliary heat exchanger for freeze protection.

Required partial heat recovery field piping (see next page) and connections are listed below.

• an external 3-way valve or a variable speed pump in the auxiliary heat exchanger water piping for modulation of flow through the heat exchangers by the unit controller.

Heat recovery water loop pump must also be controlled by the chiller controller.

• a cleanable strainer with perforations no larger than 0.063” (1.6 mm) diameter must be installed within 5 feet (1500 mm) of pipe length from the heat exchanger inlet and downstream of any welded connections, see Figure 22 for pressure drop.

• water piping and other portions of the heat recovery water loop must be insulated to prevent heat loss and possible injury due to hot surfaces.

• separate 120 volt power supply for immersion heaters. A junction box for a 120 Volt power connection is provided.

NOTE: If the partial heat exchanger is drained, the heater must be turned off to avoid damaging the heat exchanger. The heater should only be on when the heat recovery heat exchanger has water in it.

It is recommended that the field installed heat recovery water piping include:

• a field-installed safety or relief valve and expansion tank on the water side to prevent risks in case the water temperature thermostat should fail.

• a water tank and an additional water heater in the heat recovery piping loop for initial water temperature control and better loop stability. Typical loop sizing guidance is water volume (in gallons) be greater than or equal to approximately two to three times the heat recovery water flow rate (in gallons/minute).

Partial Heat Recovery Freeze Avoidance The heat recovery condenser is insulated; a factory-installed heater will protect the heat exchanger from freezing in ambient temperatures down to -20°F (-29°C). When the ambient temperature drops to approximately 39°F (3.9°C) the thermostat energizes the heaters. The inlet and outlet piping should be protected against freezing by one of the following methods:

• Install heat tape on all field-installed water piping

• Add freeze-inhibiting fluid to the partial heat recovery water loop. If adequate amounts of glycol are supplied, it is not required to power the heater.

www.DaikinApplied.com 17 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Figure 24: AGZ075-241E Heat Recovery Field Piping

Condenser Coil Options and Coating Considerations The standard coils on the Trailblazer™ chiller are an all aluminum alloy microchannel design with a series of flat tubes containing multiple, parallel flow microchannels layered between the refrigerant manifolds. The microchannel coils are designed to withstand 1000+ hour acidified synthetic sea water fog (SWAAT) test (ASTM G85-02) at 120°F (49°C) with 0% fin loss and develop no leaks.

Figure 25: Epoxy Coil Coating

Epoxy coating is a water-based extremely flexible and durable polymer coating uniformly applied to all coil surfaces through a multi-step, submerged electrostatic coating process. Epoxy coated coils provide a 10,000+ hour salt spray resistance per ASTM B117-90, applied to both the coil and the coil headers.

The epoxy coated coils also receive a UV-resistant urethane top-coat to provide superior resistance to degradation from direct sunlight. This coil coating option provides the best overall protection against corrosive marine, industrial or combined atmospheric contamination to provide extended longevity.

Table 3: Coil/Coating Selection Matrix

Coil Option Non- Corrosive1

Unpolluted Marine2 Industrial3

Combined Marine-

Industrial4 Standard Microchannel +++ - - -

Epoxy Coated Coils +++ +++ +++ ++

NOTE: 1. Non-corrosive environments may be estimated by the appearance of existing equipment in the immediate area where the chiller is to be placed.

2. Marine environments should take into consideration proximity to the shore as well as prevailing wind direction.

3. Industrial contaminants may be general or localized, based on the immediate source of contamination (i.e. diesel fumes due to proximity to a loading dock).

4. Combined marine-industrial are influenced by proximity to shore, prevailing winds, general and local sources of contamination.

BACK END OF UNIT

ELECTRONIC

3-WAY VALVE

THERMOMETER

(USER OPTION)

HEAT

RECOVERY

HEAT LOAD

SHUT OFF SHUT OFF

FIELD INSTALLED

WATER PUMP

TEE

CONNECTION

1,2

1,2

TEE CONNECTION & ELECTRONIC 3-WAY VALVE

ARE NOT REQUIRED WHEN USING A VFD

CONTROLLED WATER PUMP

FIELD

CONNECTIONS

INLET WATER

STRAINER

NOTES:

A VFD CONTROLLED WATER PUMP OR AN ELECTRONIC 3-WAY VALVE IS REQUIRED AND MUST BE CONTROLLED BY THE CHILLER.1.

FIELD INSTALLED 3-WAY VALVE OR WATER PUMP VFD TO BE CONTROLLED BY 0-10 DCV OR 4-20 mA OUTPUT FROM2.

THE CHILLER UNIT CONTROLLER.

GALLONS OF WATER VOLUME FOR THE HEAT RECOVERY PIPING LOOP SHOULD EQUAL 2 TO 3 TIMES THE3.

HEAT RECOVERY LOOP GPM FLOW RATE.

FOR POTABLE WATER USE - A SECONDARY HEAT EXCHANGER IN A SEPARATE LOOP IS REQUIRED.4.

WATER PIPING CONNECTIONS AT THE UNIT ARE 2.0" VICTAULIC.5.

AGZ075-241E PACKAGE CHILLER

WITH HEAT RECOVERY

MICROCHANNEL ALUMINUM COIL

*FIELD INSTALLED HEAT RECOVERY LOOP

VIBRATION

ELIMINATOR

VIBRATION

ELIMINATOR

TERMINAL BOX FOR FIELD WIRING TO HEAT

EXCHANGER FREEZE PROTECTION HEATERS

0B334549813

IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 18 www.DaikinApplied.com

Refrigerant Schematics

Refrigerant Schematics

Figure 26: AGZ030-070E Package Chiller with Microchannel

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B www.DaikinApplied.com 19 IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS

Figure 27: AGZ075-101E Package Chiller with Microchannel

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IOM 1206-13 • TRAILBLAZER® MODEL AGZ CHILLERS 20 www.DaikinApplied.com

Figure 28: AGZ110-130E Package Chiller with Microchannel

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