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Daikin Pathfinder AWV User Manual

Daikin Pathfinder AWV
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Installation, Operation,
and Maintenance Manual

®
Air-cooled Screw Chillers
Model AWV
100 to 565 Tons (350 to 1985 kW)
HFC-134a Refrigerant
60/50 Hz
IOM 1242-8
Group: Chiller
Part Number: IOM1242-8
Date: April 2022
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Daikin Pathfinder AWV Specifications

General IconGeneral
BrandDaikin
ModelPathfinder AWV
CategoryChiller
LanguageEnglish

Summary

Pre-Start Checklist - Screw Chillers

Chilled Water and Condenser Water for Water-cooled Chiller

Checklist items for water systems in water-cooled chillers.

Electrical

Checklist items for electrical systems.

Miscellaneous

Checklist items for miscellaneous systems.

Introduction

DANGER - LOCKOUT/TAGOUT

Critical safety warning for lockout/tagout procedures before maintenance.

WARNING - Electric shock hazard

Hazard warning for electric shock during handling and service.

CAUTION - Static sensitive components

Warning about static discharge damaging electronic components.

HAZARD IDENTIFICATION INFORMATION

Explanation of DANGER, WARNING, CAUTION, and NOTE symbols.

General Description

NOMENCLATURE

Explanation of unit model designation codes.

Table 1: Operating Limits for AWV Chillers

Table detailing operating temperature and fluid limits for AWV chillers.

INSTALLATION AND APPLICATION CONSIDERATIONS

Nameplates

Information on identifying unit nameplates and their locations.

Receiving and Handling

Procedures for inspecting and handling the unit upon receipt.

DANGER - Rigging

Danger warning about improper rigging leading to severe injury or death.

Service Access

Guidelines for ensuring adequate space for servicing chiller components.

Case 1: Building or Wall on One Side of Unit

Figure 4: Spacing Guidelines for Sufficient Airflow

Diagram showing spacing recommendations for optimal airflow.

Figure 6: Case 1 for AWV 008-010 Models

Performance charts for capacity reduction and power increase.

Case 2: Two Units Side-by-Side

Figure 15: Case 2 - Full Load Capacity Reduction

Performance charts showing capacity reduction for side-by-side units.

Figure 16: Case 2 - Power Increase

Performance charts showing power increase for side-by-side units.

Case 3: Three or More Units, Side-by-Side

Figure 21: Case 3 - Full Load Capacity Reduction

Performance charts for multiple side-by-side units.

Figure 22: Case 3 - Power Increase

Performance charts for multiple side-by-side units.

Case 4: Open Screening Walls

Figure 26: Case 4 - Adjustment Factor

Charts for adjustment factors based on wall area and distance.

Figure 27: Case 4 - Adjustment Factor - IWSE Option

Charts for adjustment factors for IWSE models with screening walls.

Case 5: Pit/Solid Wall Installation

Figure 29: Case 5 for AWV008-010

Performance charts for pit installations.

Figure 30: Case 5 for AWV012-014

Performance charts for pit installations.

Chilled Water Piping

WARNING - POE Oil

Warning about POE oil interaction with PVC/CPVC piping.

Installing Inlet Strainer (Field-installed Kit)

System Water Volume

Considerations for system water volume and compressor short cycling.

Flow Switch

Evaporator Freeze Protection

Methods and recommendations for protecting the evaporator from freezing.

Chilled Water Pump

Importance of controlling chilled water pumps via the chiller's microprocessor.

Integrated Waterside Economizer

Figure 44: Integrated Waterside Economizer Operation

Diagram illustrating IWSE operation modes.

Figure 45: Mechanical Cooling Operation Only

Diagram showing mechanical cooling operation.

Electrical Connections

DANGER - Electrical Safety

Critical safety warning for electricians performing wiring.

Use with On-Site Generators

Guidelines for connecting and operating the chiller with on-site generators.

Figure 46: Field Wiring Diagram - Single Point Power

CAUTION - Power Factor Correction

Caution against using power factor correction capacitors with AWV chillers.

Figure 47: Field Wiring Diagram - Multiple Point Power

NOTE: Separate grounding

Note regarding grounding requirements for multiple power sources.

Figure 48: Representative Refrigerant Diagram - Packaged Unit With Shell & Tube Evaporator Without Optional Economizer

Figure 49: Representative Refrigerant Diagram - Packaged Unit With Shell & Tube Evaporator With Optional Economizer

Figure 50: Representative Refrigerant Diagram - Packaged Unit With Braze Plate Evaporator Without Optional Economizer

Figure 51: Representative Refrigerant Diagram - Packaged Unit With Braze Plate Evaporator With Optional Economizer

Figure 52: Representative Refrigerant Diagram - Packaged Unit With Optional Integrated Waterside Economizer

INSTALLATION AND APPLICATION CONSIDERATIONS - REMOTE EVAPORATORS

Derate Procedure

Step-by-step procedure for calculating performance derates for remote evaporators.

Table 5: Fitting Losses Equivalent Feet of Pipe

Remote Evaporator Field Wiring Notes

Notes and guidelines for field wiring of remote evaporator components.

Specific Wiring Guidance per Component

Detailed wiring instructions for specific components like solenoid valves and sensors.

Figure 54: Piping Schematic, Remote Evaporator (One of Two Circuits)

Table 6: Sizing Guidelines for Horizontal or Downflow Suction Lines and Liquid Lines

Piping Layout

Description of piping layout for units with remote evaporators.

Table 7: Sizing Guidelines for Horizontal or Downflow Suction Lines and Liquid Lines

Table 8: Sizing Guidelines for Horizontal or Downflow Suction Lines and Liquid Lines

Table 9: Alternate Sizing Guidelines for Horizontal or Downflow Suction Lines - Steel

Table 10: Sizing Guidelines for Upflow Lines

Guidelines for sizing upflow suction lines.

DIMENSIONAL DRAWINGS

Figure 55: Reference Dimensional Drawing - 08 Fan to 14 Fan Configurations With Brazed Plate Evaporator

Dimensional drawing for specific fan configurations with brazed plate evaporator.

Table 11: Unit Dimensions by Configuration with Brazed Plate Evaporator

Table detailing unit dimensions for various configurations.

Figure 56: Reference Dimensional Drawing - 12 Fan and 14 Fan Configurations with Shell and Tube Evaporator

NOTE: Water connection sizes

Note about water connection sizes and IWSE option changes.

Table 12: Unit Dimensions by Configuration with Shell and Tube Evaporator

ISOLATOR INFORMATION

Isolator Installation

Guidelines for installing isolators to reduce vibration and noise transmission.

Figure 58: Rubber-in-Shear Isolator Schematic

Schematic diagram of a rubber-in-shear isolator.

Figure 59: Spring Isolator - 2 Spring Schematic

Schematic diagram of a 2-spring isolator.

Figure 60: Spring Isolator - 4 Spring Schematic

Schematic diagram of a 4-spring isolator.

PRESSURE DROP DATA

Figure 62: Model ACH1000DQ

Chart showing pressure drop vs. flow rate for ACH1000DQ models.

Figure 63: Model EV4027

Chart showing pressure drop vs. flow rate for EV4027 models.

Figure 64: Model EV5027

Figure 65: Model EV5039

Chart showing pressure drop vs. flow rate for EV5039 models.

Figure 66: Model EV6633

Figure 67: Model EV6639

Chart showing pressure drop vs. flow rate for EV6639 models.

CONTROLLER OPERATION

Operator Responsibilities

Importance of operator familiarity with the equipment and proper logging.

Software Version

How to view unit software and BSP versions via the keypad.

WARNING - Electric shock hazard

Safety warning for personnel working on the control panel.

Figure 68: System Architecture Schematic

MicroTech® III Inputs/Outputs

CC Modules - Circuit #1 and #2

Lists of inputs/outputs for CC modules related to circuits.

EEXV Modules - Circuit #1 and #2

Lists of inputs/outputs for EEXV modules.

Economizer EXV Module

RapidRestore® Module

Information on digital inputs for the RapidRestore module.

Compressor VFDs

Information on digital inputs for compressor VFDs.

Waterside Economizer Module

Information on analog and digital inputs/outputs for the waterside economizer module.

Set Points

Unit Level Set Points

Discussion of set points applicable to the entire unit.

Table 36: Set Point Default and Range

Table detailing default values and ranges for various unit set points.

Table 37: Set Point Default and Range (continued)

Unit Sensor Offsets

Settings for adjusting sensor readings to account for calibration drift.

Table 38: Unit Test Mode Set Points

Table 39: Administration and Service Support

Set points related to unit administration and service support.

Dynamic Set Point Ranges

Discussion of set points with adjustable ranges based on other settings.

Circuit Level Set Points

Table 45: Set Points for Individual Circuits

Table detailing set points for individual circuits.

Fan Staging Deadbands

Explanation of fan staging deadband settings and their dependency on VFD configuration.

Save and Restore Settings

UNIT FUNCTIONS

Calculations

Explains calculations for evaporator approach, slope, and pulldown rate.

Unit Enable

How to enable or disable the chiller using set points and inputs.

Unit Mode Selection

How unit operating modes are determined by set points and inputs.

Unit Control States

Unit Status

Explanation of the unit status display and its associated conditions.

Ice Mode Start Delay

Low Ambient Lockout

Operation of the chiller in response to low ambient temperatures.

Lockout and Stop Operation

Details of the "Lockout and Stop" operation mode for low ambient conditions.

Lockout Only Operation

Details of the "Lockout Only" operation mode for low ambient conditions.

Freeze Protection

Pump Selection

How pump outputs are determined based on the Evap Pump Control set point.

Primary/Standby Pump Staging

Logic for staging primary and standby pumps based on flow and time.

Auto Control

How auto pump control logic compares pump run hours.

Unit Capacity Control

Maximum Circuits Running

Limits on the number of compressors that can run simultaneously.

Cool Mode Operation

Details of unit capacity adjustment in Cool Mode.

Staging Circuits On

Staging Circuits Off

Conditions for shutting down circuits.

Circuit Capacity Change Commands

When load and unload commands are issued.

Unit Capacity Limits

Demand Limit

How unit capacity can be limited by a 4-20 mA signal.

Network Limit

How unit capacity can be limited by a network command.

RapidRestore®

Capability for faster restart and loading after power loss.

CIRCUIT FUNCTIONS

Approach Values

Calculation of approach values for evaporator and condenser.

Superheat Values

Calculation of superheat values for suction, discharge, and economizer.

Differential Pressure Values

Calculation of oil pressure differential and pressure difference.

Pressure Ratio

Calculation of pressure ratio for compressor operation.

Saturated Condenser Temperature Limit

High Saturated Condenser – Hold Value

Value used for triggering high condenser pressure hold alarms.

High Saturated Condenser – Unload Value

Value used for triggering high condenser pressure unload events.

Condenser Fan Control

Physical Fan Layout

Explanation of fan numbering and physical layout.

Condenser Fan Control State

Describes the two control states for condenser fans.

Fan Control – No VFD or 1st Fan VFD

Fan control logic for units without VFDs or with only the first fan VFD.

Staging

Test Mode Control

Manual control of fans for testing purposes.

Evaporator EXV Control

Positioning logic for the Evaporator EXV.

VFD Speed Control

Stage Up Compensation

How VFD compensates for smoother fan stage increases.

Speed Signal to VFD

How the VFD speed signal is sent.

Fan Control In Waterside Econ State

Fan control logic when the unit is in Waterside Econ state.

Fan Control In Hybrid Cooling Modulation State

Evaporator EXV Control

Positioning logic for the Evaporator EXV.

EXV States

Describes the different states of the EXV.

Operation - Closed State

Operation – Purge State

Operation of the EXV in the purge state.

Operation - Superheat Control State

Operation of the EXV in the superheat control state.

ALARMS AND EVENTS

Signaling Alarms

Actions that signal an alarm has occurred.

Clearing Alarms/Faults

Methods for clearing alarms and faults.

Description of Alarms

Explanation of the table format used for alarm details.

Unit Alarms

Details of unit-level alarms like GFP Fault.

Evaporator Flow Loss

Evaporator Water Freeze Protect

Alarm triggered if evaporator water temperature drops too low.

Evaporator Water Temperatures Inverted

Alarm for inverted evaporator water temperatures (EWT > LWT).

Evaporator LWT Sensor Fault

OAT Sensor Fault

Alarm for faults with the Outside Air Temperature sensor.

External Alarm

Alarm triggered by an external input signal.

AC Module Comm Failure

Alarm indicating communication failure with the AC module.

Evaporator EXV Module Comm Failure

Evaporator Pump #1 Failure

Alarm indicating failure of Evaporator Pump #1.

Evaporator Pump #2 Failure

Alarm indicating failure of Evaporator Pump #2.

Bad Demand Limit Input

Alarm for an invalid demand limit input signal.

Bad LWT Reset Input

Economizer EXV Module Comm Failure

Alarm for communication failure with the Economizer EXV module.

Economizer Temperature Sensor Fault

Alarm for faults with the economizer temperature sensor.

Waterside Economizer Valve Fault

Alarm for faults with the waterside economizer valves.

Waterside Economizer Valve Problem

Circuit Alarms

Introduction to circuit-specific alarms.

Low Evaporator Pressure

Alarm triggered by low evaporator pressure.

Figure 76: Low Evaporator Pressure Fault Diagram

Diagram illustrating the conditions for low evaporator pressure faults.

High Condenser Pressure

Mechanical Low Pressure Switch

Alarm related to the mechanical low pressure switch.

Low Pressure Difference Or Ratio

Alarm triggered by low pressure difference or ratio.

Mechanical High Pressure Switch

Alarm related to the mechanical high pressure switch.

High Discharge Temperature

High Oil Pressure Drop

Alarm for a significant drop in oil pressure.

Compressor VFD Output High

Alarm for high compressor VFD output current.

Compressor VFD Temperature High

Alarm for high compressor VFD temperature.

Compressor VFD Current Input High

Compressor VFD Temperature Low

Alarm for low compressor VFD temperature.

Compressor VFD Comm Failure

Alarm for communication failure with the compressor VFD.

CC Module Comm Failure

Alarm for communication failure with the CC module.

EEXV Module Comm Failure

Condenser Pressure Sensor Fault

Alarm for faults with the condenser pressure sensor.

Oil Pressure Sensor Fault

Alarm for faults with the oil pressure sensor.

Suction Temperature Sensor Fault

Alarm for faults with the suction temperature sensor.

Discharge Temperature Sensor Fault

Economizer Pressure Sensor Fault

Alarm for faults with the economizer pressure sensor.

Economizer Temperature Sensor Fault

Alarm for faults with the economizer temperature sensor.

Economizer EXV Motor Error

Alarm for motor errors in the economizer EXV.

ECM/DC Fan Motor Fault

Power Loss While Running

Event logged when power is lost while the unit is running.

Failed Pumpdown

Alarm indicating a failed pumpdown operation.

High Condenser Pressure - Unload

Event that unloads compressor due to high condenser pressure.

Low Pressure Difference Or Ratio Shutdown

High VFD Output Current - Unload

Event that unloads compressor due to high VFD output current.

High VFD Line Current Hold

Event that holds compressor capacity due to VFD line current.

High VFD Line Current Unload

Event that unloads compressor due to high VFD line current.

High VFD Temperature Hold

Unit Controller Operation

Overview of the unit controller's interface and operation.

Figure 78: Unit Controller

Diagram of the unit controller interface.

Passwords

Explanation of password levels and entry procedures.

Navigation Mode

Edit Mode

How to enter and use Edit Mode for changing set points.

Figure 80: Example of Screen Menu

Example screen menu structure.

STARTUP AND SHUTDOWN

Pre-startup

Steps to take before performing the initial startup procedure.

Startup

Step-by-step procedure for starting the unit.

Temporary Shutdown

Procedure for temporarily shutting down the unit.

Extended (Seasonal) Shutdown

Startup After Extended (Seasonal) Shutdown

Procedure for starting the unit after an extended shutdown.

Flow Switch Installation and Calibration

Detailed instructions for installing and calibrating the flow switch.

IMPORTANT: Flow switch MUST be calibrated

Critical note emphasizing the necessity of flow switch calibration.

SYSTEM MAINTENANCE

General

General service checks to perform during startup and operation.

Vibration Monitoring (Optional)

Using vibration readings as an indicator of potential maintenance issues.

Lubrication

Information on fan motor bearing lubrication and potential issues.

CAUTION - POE oil

Handling precautions for POE oil.

Cleaning Microchannel Aluminum Coils

WARNING - Cleaning coils

Safety warning prior to cleaning coils.

Remove Surface Loaded Fibers

Procedure for removing surface loaded fibers before water rinsing.

Periodic Clean Water Rinse

Recommended monthly clean water rinsing for coils.

Cleaning Epoxy Coated Coils

Harsh Chemical and Acid Cleaners

Warning against using harsh chemicals or acid cleaners on coils.

High Velocity Water or Compressed Air

Precautions for using high velocity water or compressed air for cleaning.

WARNING - Coil cleaning chemicals

Warning about chemicals used for coil cleaning.

Liquid Line Sight Glass

Lead-Lag

System for alternating compressor sequence to balance starts and run hours.

Compressor VFD

Inspection areas for compressor VFDs.

Table 65: Preventative Maintenance Schedule

Warranty and Training

Daikin Applied Training and Development

Information on training programs offered by Daikin Applied.

Warranty

Details on the Limited Product Warranty and how to consult for details.

Aftermarket Services

Information on locating parts and service offices.

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