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Daikin Trailblazer AGZ030-101E User Manual

Daikin Trailblazer AGZ030-101E
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Installation, Operation,
and Maintenance Manual
Trailblazer
®
Air-Cooled Scroll Compressor Chillers
󰀩

30 to 241 Tons (100 to 840 kW)

50/60 Hz
IOM 1206-13
Group: Chiller
Part Number: IOM1206-13
Date: September 2020

Questions and Answers:

Daikin Trailblazer AGZ030-101E Specifications

General IconGeneral
BrandDaikin
ModelTrailblazer AGZ030-101E
CategoryChiller
LanguageEnglish

Summary

Pre-Start Checklist

Chilled Water and Condenser Water for Water-cooled Chiller

Checklist items for water systems and piping.

Electrical

Checklist items for electrical connections and power.

Miscellaneous

Checklist items for general components and system readiness.

Installation and Application Information

HAZARD IDENTIFICATION INFORMATION

Details on hazard symbols and their meanings.

General Safety Warnings

Critical safety warnings for installation and operation.

General Description

Overview of Daikin Trailblazer® chillers.

NOMENCLATURE

Explanation of unit model naming conventions.

Operating and Standby Limits

Defines operational and standby temperature and flow limits.

Nameplates

Information on identifying unit nameplates and their data.

Inspection

Procedures for inspecting units upon arrival.

Handling

Guidelines for safe and proper unit handling.

Unit Placement

Guidance on selecting and preparing unit installation locations.

Mounting

Instructions for securing the unit to its base or frame.

Service Clearance

Required clearances around the unit for maintenance access.

Operational Spacing Requirements

Guidelines for maintaining clearance between units and walls.

Case 1: Building or Wall on One Side of Unit

Spacing requirements for units adjacent to buildings or walls.

Case 2: Two Units, Side-by-Side

Spacing requirements for placing two units next to each other.

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

Spacing requirements for multiple units placed side-by-side.

Case 4: Open Screening Walls

Guidelines for using screening walls and maintaining airflow.

Case 5: Pit Installation

Spacing and clearance requirements for pit installations.

Chilled Water Piping

Requirements and recommendations for chilled water piping installation.

Inlet Strainer Guidelines

Specifications for installing inlet strainers before the evaporator.

Water Flow Limitations

Information on acceptable evaporator flow rates and pressure drops.

System Water Considerations

Factors to consider for chilled water system design and operation.

Evaporator Freeze Protection

Methods and components for protecting the evaporator from freezing.

Chilled Water Pump

Requirements for wiring and controlling chilled water pumps.

Flow Switch

Importance and installation of chilled water flow switches.

Glycol Solutions

Impact of glycol on system performance and requirements.

Low Ambient Operation

Operating the chiller in low ambient temperature conditions.

High Ambient Operation

Operating the chiller in high ambient temperature conditions.

Partial Heat Recovery

Explanation of the optional heat recovery system and its configuration.

Partial Heat Recovery Freeze Avoidance

Methods to prevent freeze-up in the heat recovery loop.

Condenser Coil Options and Coating Considerations

Details on condenser coil design and protective coating options.

Refrigerant Schematics

Dimensions and Weights - Packaged Units

Dimensions and Weights - Heat recovery Units

Refrigerant Charge

Isolator Information

Isolator Installation Information

Guidelines for installing spring and rubber-in-shear isolators.

Pressure Drop Data

Electrical Data

Electrical Connection

Details on power connection types and wiring requirements.

Use with On-Site Generators

Guidelines for connecting the chiller to generators.

Generator Sizing

Considerations for properly sizing generators for the chiller.

Transfer Back to Grid Power

Procedures for safely transferring power from generator to grid.

Unit Controller Operation

General Description

Overview of the MicroTech® III controller's features.

System Architecture

Explanation of the controller's system components and connections.

Controller Inputs and Outputs

Lists and defines controller's analog and digital signals.

Main Controller

Details of inputs and outputs for the main controller.

Compressor Module 1

Inputs and outputs specific to Compressor Module 1.

Compressor Module 2

Inputs and outputs specific to Compressor Module 2.

EXV Module 1 and 2

Details on electronic expansion valve modules.

Condenser Fan Output Labels

Mapping of fan outputs to specific fans for different configurations.

AGZ-E Models with 1 VFD per Circuit

Condenser fan output configurations with one VFD per circuit.

AGZ-E Models with 2 VFDs per Circuit

Condenser fan output configurations with two VFDs per circuit.

RapidRestore®

Information on the RapidRestore® option for faster restarts.

Set Points

Overview of adjustable set points and their ranges.

Basic Unit Configuration

Set points for fundamental unit parameters.

Staging and Capacity Control

Set points related to compressor and fan staging.

Evaporator Pump Control

Set points for configuring evaporator pump operation.

Power Conservation and Limits

Set points for energy saving features and operational limits.

Dynamic Set Point Ranges

Set points with variable ranges based on other parameters.

Unit Test Mode Set Points

Set points for operating the unit in test mode.

Communication Configuration

Parameters for configuring network communication.

Circuit Level Set Points

Set points that apply individually to each circuit.

Special Set Point Operation

Set points with unique operational considerations.

Dynamic Set Point Ranges and Defaults

Set points varying by configuration group.

Security

Information on password protection for set points.

Entering Passwords

Procedure for accessing the controller with passwords.

Editing Setpoints

How to modify set points after entering a password.

Sequence of Operation

Unit Sequence of Operation - Cool Mode

Step-by-step logic for chiller operation in cool mode.

Circuit Sequence of Operation

Step-by-step logic for individual circuit operation.

Unit Functions

Unit Capacity Control

How the unit manages its cooling capacity.

Evaporator Delta T

Calculation and importance of evaporator temperature difference.

LWT Slope

Calculation of leaving water temperature change rate.

Pulldown Rate

Calculation of how quickly the unit cools down.

LWT Error

Calculation of the difference between target and actual LWT.

Unit Capacity

Estimation of total unit capacity based on running compressors.

Control Band

Defines the range for capacity adjustments without changes.

Constant Evaporator Flow

How the control band is calculated for constant flow systems.

Variable Evaporator Flow

How the control band is calculated for variable flow systems.

Staging Temperatures

Set points for compressor staging based on temperature.

Unit Enable

Conditions and methods for enabling or disabling the chiller.

Unit Mode Selection

How the chiller's operating mode (Cool, Ice) is selected.

Glycol Configuration

Settings related to the use of glycol in the system.

Unit States

Describes the different operational states of the unit.

Motor Protection Module Power Up Start Delay

Delay for motor protection modules after power-up.

Ice Mode Start Delay

Adjustable timer to limit chiller starts in ice mode.

Low Ambient Lockout

How the chiller responds to low ambient temperatures.

BAS Annunciation

How low ambient lockout conditions are reported to BAS.

Unit Status

Table defining various unit status indicators and their conditions.

Evaporator Pump Control

Control states and transitions for evaporator pumps.

Freeze Protection

Conditions that trigger and end evaporator freeze protection.

Pump Selection

How the primary and backup pumps are selected.

Primary/Standby Pump Staging

Logic for staging primary and standby pumps.

Auto Control

Operation of pumps when auto pump control is selected.

LWT Target

Factors influencing the leaving water temperature target.

Leaving Water Temperature (LWT) Reset

How the LWT target is adjusted based on reset signals.

Unit Capacity Control

Methods for controlling and limiting unit capacity.

Compressor Staging in Cool Mode

Logic for starting and stopping compressors in cool mode.

Stage Up Delay

Minimum time between capacity stage increases.

Stage Down Delay

Minimum time between capacity stage decreases.

Compressor Staging in Ice Mode

Logic for compressor staging in ice mode.

Staging Sequence

Determines which compressor starts or stops next.

Unit Capacity Overrides

Limits on total unit capacity in specific modes.

Demand Limit

Limiting unit capacity based on a 4-20 mA signal.

Network Limit

Limiting unit capacity based on a network signal.

Maximum LWT Pulldown Rate

Limit on the rate of leaving water temperature drop.

High Ambient Limit

Active limit for high ambient temperatures on single point power connections.

RapidRestore® Option

Overview of the RapidRestore® option for faster restarts.

Enabling

Requirements for enabling the RapidRestore® option.

Operation Following Power Cycle

How the chiller operates after a power loss.

Fast Loading

Process of quickly increasing unit capacity during RapidRestore®.

Capacity Changes

Delays between compressor staging during fast loading.

Compressor Starts Per Hour

Limit on the number of compressor starts per hour.

Sound Reduction

Special mode to reduce sound levels by limiting fan speeds.

Scheduling

Configuring sound reduction active times based on a daily schedule.

Operation When Active

How sound reduction impacts fan speed and operation.

Heat Recovery Option

Information on the optional heat recovery system and its configuration.

Heat Recovery States

Describes the Off, Recirculate, and On states of heat recovery.

PID Loop

Control loop used for valve position or pump speed.

Circuit Functions

Calculations By Controller

Formulas used by the controller for various calculations.

Circuit Control Logic

Rules for enabling circuits and compressor availability.

Low Ambient Starts

How the circuit operates during low ambient start conditions.

Circuit Status

Table defining various circuit status indicators.

Compressor Control

Conditions for starting and stopping compressors.

Cycle Timers

Minimum times between compressor starts and stops.

Condenser Fan Control

How condenser fans are staged and controlled.

Condenser Staging

Logic for staging condenser fans and solenoid valves.

Condenser Target

Selecting condenser target based on circuit capacity.

Staging Up

Process and conditions for staging condenser fans up.

Skipping First Stage

Circumstances where the first condenser stage is skipped.

Staging Down

Process and conditions for staging condenser fans down.

Limiting Last Stage

Restrictions on the last fan stage activation.

VFD Control

How Variable Frequency Drives control fan speed.

VFD State

Conditions for VFD speed signals to be active or inactive.

Stage Up Compensation

How VFDs compensate during fan staging up.

Sound Reduction Operation

How sound reduction impacts VFD operation.

High IPLV Mode

Operation of the High IPLV mode.

Special Operation During Heat Recovery

Circuit settings during heat recovery operation.

EXV Control

Overview of Electronic Expansion Valve control states.

Superheat Target

Selecting suction superheat targets based on compressor status.

Position Commands

Filtering and issuing EXV position commands.

EXV Position Range

Minimum and maximum EXV positions based on compressor count.

Operation Considerations

Factors affecting EXV maximum position adjustments.

Manual Control

Manual setting of EXV position.

Liquid Line Solenoid Valve

Maintenance and replacement of liquid line solenoid valves.

Hot Gas Bypass Solenoid Valve

Operation of the HGBP solenoid valve.

Alarms

Capacity Overrides – Limits of Operation

Conditions overriding automatic capacity control.

Low Evaporator Pressure

Alarm triggered by low evaporator pressure.

High Condenser Pressure

Alarm triggered by high condenser pressure.

Unit Fault Alarms

General unit fault alarms and their actions.

PVM/GFP Fault

Alarm related to power configuration and PVM/GFP input.

Evaporator Flow Loss

Alarm triggered by loss of evaporator water flow.

Evaporator Water Freeze Protect

Alarm for evaporator freeze protection activation.

Evaporator LWT Sensor Fault

Alarm for faulty leaving water temperature sensor.

Evaporator EWT Sensor Fault

Alarm for faulty entering water temperature sensor.

Outdoor Air Temperature Sensor Fault

Alarm for faulty outdoor air temperature sensor.

External Alarm

Alarm triggered by an external input signal.

Evaporator Pump #1 Failure

Alarm indicating failure of the primary evaporator pump.

Evaporator Pump #2 Failure

Alarm indicating failure of the backup evaporator pump.

External Event

Event triggered by an external input signal.

Bad Demand Limit Input

Alarm for out-of-range demand limit input.

Bad LWT Reset Input

Alarm for out-of-range LWT reset input.

Heat Recovery LWT and EWT Sensor Fault

Alarm for faulty heat recovery sensors.

RapidRestore Module Comm Failure

Alarm for failed communication with RapidRestore module.

Circuit Fault Alarms

General circuit fault alarms.

PVM/GFP Fault

Fault related to power configuration and PVM/GFP input.

Low Evaporator Pressure

Alarm for low evaporator pressure during run or freeze conditions.

High Condenser Pressure

Alarm for high condenser pressure.

Mechanical Low Pressure Switch

Alarm triggered by a mechanical low-pressure switch.

Mechanical High Pressure Switch

Alarm triggered by a mechanical high-pressure switch.

Motor Protection Fault

Alarm indicating a motor protection fault.

Low OAT Restart Fault

Alarm for repeated low OAT start attempts.

No Pressure Change After Start

Alarm for lack of pressure change after compressor start.

Evaporator Pressure Sensor Fault

Alarm for faulty evaporator pressure sensor.

Condenser Pressure Sensor Fault

Alarm for faulty condenser pressure sensor.

Suction Temperature Sensor Fault

Alarm for faulty suction temperature sensor with electronic EXV.

Compressor CC Module Comm Failure

Alarm for communication failure with compressor module.

EEXV Module Comm Failure

Alarm for communication failure with EXV module.

Failed Pumpdown

Alarm for pumpdown taking longer than specified.

Alarm Logs

How to access and interpret alarm logs.

Active Alarms

Viewing and understanding the list of currently active alarms.

Alarm Log

Stores a history of past alarms and events.

Event Log

Stores a log of events, separate from alarms.

Clearing Alarms

Procedures for clearing active alarms.

Events

Situations logged for future reference but not as alarms.

Unit Events

Specific events related to the unit's operation.

Circuit Events

Specific events related to individual circuit operation.

Compressor Communications

Diagnostics and features of the CoreSense module.

Warnings and Alerts

Indicators for module status and error conditions.

Using the Controller

Navigating

How to navigate through the controller menus and screens.

Passwords

User access levels and password management.

Edit Mode

How to enter edit mode and change parameter values.

Fan VFD Controller

VFD Interface

Overview of the VFD controller's display and functions.

Optional BAS Interface

Connecting the chiller to a Building Automation System.

Recommended Periodic Inspection

Routine checks for VFD components.

Inverter Output to the Motor

Wiring and safety considerations for inverter motor connections.

Startup and Shutdown Procedures

Pre-Startup

Initial inspection steps before starting the chiller.

Pre-Startup Checkout

Detailed checks required before startup.

Pre-Startup Electrical Check Out

Electrical checks to perform before starting the unit.

Startup

General guidance and requirements for unit startup.

Post Startup

Checks to perform after the chiller has been running stably.

Shutdown

Procedures for temporarily shutting down the chiller.

Temporary Shutdown

Steps for a short-term shutdown.

Extended Shutdown

Procedures for long-term shutdown and winterization.

Flow Switch Installation and Calibration

Steps for installing and calibrating the flow switch.

Mounting

Guidelines for mounting the flow switch.

Wiring

Wiring instructions for the flow switch.

Flow Switch Setup

Procedure for adjusting and teaching the flow switch set point.

Unit Maintenance

General

Routine service checks for initial start-up and operation.

Compressor Maintenance

Standard maintenance practices for scroll compressors.

Crankcase Heaters

Function and power requirements for crankcase heaters.

Lubrication

Information on permanent lubrication and bearing noise.

All-Aluminum Condenser Coils

Design and corrosion resistance of condenser coils.

Cleaning Microchannel Aluminum Coils

Routine cleaning of coil fins and surfaces.

Cleaning Epoxy Coated Coils

Recommended cleaning procedures for epoxy coated coils.

Remove Surface Loaded Fibers

Methods for removing fibers from coil surfaces.

Periodic Clean Water Rinse

Monthly cleaning recommendation for coils in coastal/industrial areas.

Routine Quarterly Cleaning of Epoxy Coated Coil Surfaces

Required quarterly cleaning for epoxy coated coils.

Recommended Coil Cleaner

Approved agents for cleaning epoxy coated coils.

Harsh Chemical and Acid Cleaners

Warning against using harsh chemicals on coils.

High Velocity Water or Compressed Air

Caution regarding using high pressure water or air on coils.

Evaporator

Description of the evaporator's design and freeze protection.

Liquid Line Solenoid Valve

Maintenance and replacement of liquid line solenoid valves.

Battery

Recommendation for controller battery replacement.

High Ambient Control Panel

Function and requirements of the high ambient option.

System Adjustment

Adjusting system superheat and subcooling for peak performance.

Liquid Line Sight Glass and Subcooling

How to interpret sight glass and check subcooling.

Expansion Valve

Function of expansion valves and superheat targets.

Filter-Driers

When and how to replace filter-driers.

Hot Gas Bypass (Optional)

Function and operation of the HGBP option.

R-410A Refrigerant

Terminology, safety, and handling of R-410A refrigerant.

Safety

General safety guidelines for handling R-410A and POE oil.

POE Lubricants

Information on POE oil properties and usage.

Troubleshooting Chart

Refrigerant Charging

Procedures for charging and verifying refrigerant levels.

Service

Special tools and considerations for R-410A service.

Warranty Registration Form (Scroll)

PRE START-UP CHECKLIST

Checklist for verifying unit readiness before startup.

REFRIGERANT PIPING FOR REMOTE EVAPORATOR APPLICATIONS

Checks for field-installed refrigerant piping.

DESIGN CONTROLS

Design parameters for chiller and condenser.

START-UP

Checks related to the initial startup sequence.

MICROTECH STATUS CHECK

Verifying readings against field instruments.

NON-MICROTECH READINGS

Readings not managed by the MicroTech controller.

VI. MICROTECH SETPOINTS

List of settable parameters within the MicroTech controller.

ALARM SETPOINTS MUST BE VERIFIED WITH INSTRUMENTS OF KNOWN ACCURACY

Verification of alarm setpoints using external instruments.

VIII. GENERAL

General checks for control lines, gauges, and refrigerant leaks.

Limited Product Warranty

Daikin Applied Training and Development

Warranty

Information on standard warranty terms and conditions.

Aftermarket Services

Information on obtaining parts and service.

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