Installation and Maintenance Manual

IMM HTS/HTD/HTC
Installation and Maintenance Manual

Group: Water Chiller
Date: Oct. 2019
New part No.: Z8100190-13
Old part No.: Z8100190-12
Centrifugal Water Chiller
This Manual is applicable to following models and their derived and

modified models.
HTS/HTD/HTC Water-cooled Chiller
Thanks for purchasing DAIKIN chiller.
The Manual specifies safety，installation and maintenance precautions.
Please read through the manual before installation and operation.

For future reference, please be sure to keep it safe.
Engineered for Flexibility and Performance

- Installation and Maintenance Manual for Centrifugal Water Chiller
Table of Contents
I. INTRODUCTION.................................................................................................................1
1.1 GENERAL DESCRIPTION............................................................................................................................. 1
1.2 APPLICATION............................................................................................................................................. 1
1.3 NOMENCLATURE....................................................................................................................................... 1
II. MAJOR COMPONENT LOCATIONS................................................................................2
III. WORKING PRINCIPLE AND TECHNICAL DATA............................................................3

3.1 WORKING PRINCIPLE................................................................................................................................. 3
3.2 MAJOR COMPONENTS............................................................................................................................... 3
EVAPORATOR.................................................................................................................................................. 3
3.3 FIELD INSULATION GUIDE........................................................................................................................... 4
3.4 OIL COOLERS........................................................................................................................................... 4
IV. ABOUT SAFETY..............................................................................................................6
4.1 PRECAUTIONS (INSTALLATION)................................................................................................................... 6
4.2 PRECAUTIONS (OPERATION)...................................................................................................................... 7
4.3 PRECAUTIONS (REMOVE AND REPAIR)........................................................................................................ 8
V. RECEIVING AND HANDLING...........................................................................................9
5.1 AFTER THE CHILLER ARRIVED AT THE SITE.................................................................................................. 9
5.2 LIFTING.................................................................................................................................................... 9
5.3 HORIZONTAL TRANSITING......................................................................................................................... 10
VI. INSTALLATION...............................................................................................................11
6.1 INSTALLATION AND FOUNDATION............................................................................................................... 11
6.2 SOUNDPROOFING AND ANITI-VIBRATION WORKS.......................................................................................15
6.3 CHILLER PIPING...................................................................................................................................... 15
6.4 ELECTRICAL CONSTRUCTION................................................................................................................... 17
VII OPERATION OF OITS....................................................................................................29
7.1 OPERATOR'S RESPONSIBILITY.................................................................................................................. 29
7.2 STANDBY POWER SUPPLY....................................................................................................................... 29
7.3 MICROTECH II CONTROL......................................................................................................................... 29
7.4 ENERGY CONTROL SYSTEM..................................................................................................................... 30
7.5 THERMAL FLOW SWITCH (ONLY FOR HIGH- VOLTAGE CHILLERS)...............................................................33
7.6 OIL CIRCUIT SYSTEM.............................................................................................................................. 34
VIII. CONFIRMATION BEFORE TEST RUN........................................................................35
8.1 CHECK POWER CIRCUIT.......................................................................................................................... 35
8.2 CONFIRMATION OF WRING....................................................................................................................... 35
8.3 CONFIRMATION BEFORE POWER ON................................................................................................... 36
8.4 WATER SYSTEM CONFIRMATION............................................................................................................... 36
8.5CONFIRMATION OF CHILLER...................................................................................................................... 38
8.6 PRESTART SYSTEM CHECKLIST................................................................................................................ 39
IX. OPERATION MODE........................................................................................................40
9.1 DURING THE FIRST OPERATION............................................................................................................... 40
9.2 ROTATION DIRECTION OF COMPRESSOR MOTOR......................................................................................40
V. FUNCTIONS OF THE CHILLER......................................................................................41
10.1 MOTOR OVER-HEATING PROTECTION...................................................................................................... 41
10.2 CHILLER STOP ALARM........................................................................................................................... 41
10.3 SURGE AND STALL................................................................................................................................. 41
10.4 RELIEF VALVE PROTECTION EQUIPMENT.................................................................................................. 41
10.5 VARIABLE FREQUENCY DRIVER (VFD)................................................................................................... 42
10.6 HOT GAS BYPASS................................................................................................................................. 42
10.7 HEAT RECOVERY CHILLER..................................................................................................................... 42
Engineered for Flexibility and Performance 1

Installation and Maintenance Manual for Centrifugal Water Chiller
10.8 HEAT PUMP........................................................................................................................................... 43
10.9 RAPID START........................................................................................................................................ 43
XI. MAINTENANCE..............................................................................................................44
11.1 TEMPERATURE/PRESSURE CHART.......................................................................................................... 44
11.2 MAINTENANCE ROUTINE......................................................................................................................... 44
11.3 ROUTINE MAINTENANCE DETAILS............................................................................................................ 44
11.4 ABOUT REFRIGERANT, CHILLER OIL....................................................................................................... 45
11.5 CLEANING & MAINTENANCE................................................................................................................... 46
11.6 OIL HEATER INFORMATION..................................................................................................................... 47
XII. OFF-SEASON PRECAUTIONS.....................................................................................48
12.1 ANNUAL SHUTDOWN............................................................................................................................. 48
12.2 ANNUAL STARTING UP........................................................................................................................... 48
XIII. CHILLER ALARM LIST................................................................................................49
13.1 CHILLER SHUTDOWN ALARM.................................................................................................................. 49
13.2 CHILLER WARNING NOTES...................................................................................................................... 51
XIV OPERATING LIMITS.....................................................................................................52
14.1 OPERATING RANGE............................................................................................................................... 52
14.2 WATER FLOW SCOPE............................................................................................................................. 53
14.3 MINIMUM WATER CONTENT IN PIPING SYSTEM......................................................................................... 53
14.4 APPLICATION STANDARD........................................................................................................................ 54
14.5 WATER QUALITY MANAGEMENT............................................................................................................. 54
14.6 ABOUT COOLANT................................................................................................................................. 55
Table.....................................................................................................................................56
Maintenance and Inspection Schedule.............................................................................................56

I. Introduction
1.1 General Description
Basing on matching with an optimized refrigerating system, the DAIKIN centrifugal water chiller utilizes
an advanced automatic control system to accurately control each procedure in the running process, so
as to maintain the chiller be always to optimal operation state. As strict requirement of manufacture
process， and strict management of imported parts quality, so DAIKIN centrifugal water chiller is more
stable and reliable in actual operation. Before ex-factory, each chiller will be strict structure quality
inspected and accurate performance tested, to ensure the reliability of the chiller using and running.
The HTS/HTD/HTC series chiller is single cooling mode. The TSC/HTC-HP series chiller is cooling and
heating mode.
According to the different climate in different areas and also the customers’ different requirements on
the operation status of each chiller, DAIKIN offers different chillers with different specifications to satisfy
customer’s requirements.
DAIKIN centrifugal chiller use environment-friendly R134a refrigerant. The standard water chiller runs at
normal pressure, so the purity is ensured, the utilization rate of the refrigerant is improved, the running
stability is also improved.
1.2 Application
The installation, operation and maintenance procedures are applicable to HTS/HTD/HTC, HSC series
chillers. If any change is required to the structure and installation of the chiller, please be sure to contact
DAIKIN for inquiry.
All DAIKIN centrifugal water chillers have been performed ex-factory test. The first commissioning on
the customer site must be completed by the DAIKIN authorized technical service personnel, or else, the
caused damage will not belong to the warranty range.
The warranty covers the parts certified to be caused by material defect or be the inferior product
manufactured by the plant. For the details about the warranty, see the accompanying Warranty or the
final party of this Manual.
The operation on the HSC heat recovery chiller is basically the same as that of the cooling chiller. There
are detailed descriptions as below.
1.3 Nomenclature
Fig. 1-1

II. Major Component Locations
Fig. 2-1
Fig. 2-2
The appearance dimension is different for different type, and the water connecting pipe direction in
above figure is correct and standard; For the details about the appearance, please see the appearance
figure.
Structures of evaporator entering water pipe and outing water pipe are two kinds, one is left and right,
the other is up and down.

III. Working Principle and Technical Data
Fig. 3-1
3.1 Working Principle
Take HTS as the example below to explain the operating principle and the refrigerant flow diagram is
shown as the figure 4:
1. The low-temperature and low-pressure refrigerant enters the compressor and becomes a high-
temperature and high-pressure gas after compressed, then enters the condenser from compressor, and
exchanges the heat with cooling water in the condenser.
2. The high-pressure liquid refrigerant after cooled by the condenser is throttled down in the expansion
valve, and then enter the evaporator after temperature and pressure reduction.
3. The refrigerant is evaporated in the evaporator and takes use of latent heat to make the chilled water
temperature decrease and thus achieve cooling.
4. The refrigerant gas enters the compressor and begins the next cycle.
3.2 Major Components
Evaporator
The evaporator of the DAIKIN centrifugal chiller is a hydraulic filling type tube shell heat exchanger with
the refrigerant loaded in the shell layer, and the water circulating in the heat exchange tube. The inner
surface and outer surface are subjected to enhanced heat exchange treatment. The refrigerant gas
returns to the compressor through the upper part of the evaporator.
Condenser
The condenser of the DAIKIN centrifugal chiller is a hydraulic filling type tube shell heat exchanger. The
inner surface and outer surface are subjected to enhanced heat exchange treatment. The liquid
refrigerant gas passes the right-angle stop valve through the bottom of the chiller and reaches the
expansion valve.
Electronic Expansion Valve
The electronic expansion valve adjusts the liquid supply amount of the evaporator according to the
preset procedure, and the driving method is that the control calculates the parameters collected by the
sensor, then an adjusting command is sent to the driving plate, the driving plate sends the electric
signal to the electronic expansion valve, and the electronic expansion valve is driven to act. Therefore,
the adjusting speed is high, while the opening degree of the electronic expansion valve is limited, so it
is not suitable for the large-cold quantity requirement and is only applied to certain cold quantity range.
Compressor
The centrifugal refrigeration compressor of the DAIKIN centrifugal chiller is a speed type compressor; it
utilizes high-speed rotating impeller to transfer energy to the refrigerant gas; the gas obtains higher
speed and is subjected to speed reducing and pressure increasing by the pressure increaser, and then
the speed energy (kinetic energy) of the gas is converted into the pressure energy to complete the
compression process.

The weight of the compressor is shown as below.
Table 3-1
CE079-129,chillers motor voltage lower than 10KV
Compressor Size 079~087 100~129
Weight (kg) 1440 2700
CE100-129, chillers motor voltage 10/11KV
Compressor Size 100~129
Weight (kg) 3000
CE140-143,motor code 5T/6T/7T/8T/9T
Weight (kg) 3127
CE140-143,motor code 5S/6S/7S/8S/9S
Weight (kg) 3991
CE160,motor code P8/P9/R5/R6/R7/R8
Compressor Size 160
Weight (kg) 5054
3.3 Field Insulation Guide
DAIKIN use 20mm thick flexible foam to prevent emerging of condensing water.
If the chiller requires insulation at site by the factory, the insulation is performed in accordance with the
chiller insulation guidance document from factory.
If insulation by customer, the insulation area includes: 1. Compressor (include suction line and motor
casing); 2. Evaporator cylinder, side plates and water cap;3. Main liquid supply pipeline;4. Oil cooling
water circuit and motor liquid return pipeline.
Fig.3-2& Fig.3-3 show the parts requiring heat insulation.
Fig. 3-2
Fig. 3-3

3.4 Oil Coolers
The DAIKIN centrifugal 063-160 compressor model WSC/WDC/WCC/TSC/HSC water chiller has been
equipped with the water cooling type oil cooler before ex-factory, which is controlled by flow adjustment
valve and solenoid valve. And also customer could select refrigerant oil cooling for option. The oil
temperature is allowed 38℃±5℃.
The water circuit of the entering and leaving water joint on site must have a good pipe distribution
scheme, and the stop valve, clean filter (40 meshes), and water drain valve or screw plug must be
installed for convenient maintenance. The oil cooling water source must be chilled water or sufficiently
clean water (see 14.5 Water Quality Management), and the temperature cannot exceed 15°C. The
water flow is adjusted through the flow adjusting valve, and the temperature of oil supplied to the
compressor bearing is 38°C±5°C.
The oil cooling parameters are shown in Table 3-2:
Table 3-2
Parameters of Water Side
HTS 063~087
Flow LPM 7.6 5.7
Entering Water Temperature °C 12.8 7.2
Leaving Water Temperature °C 36.9 38.6
HTS 100~160
Flow LPM 13.2 10.2
The oil cooling parameters of the onboard frequency inverter chiller are shown in Table 3-3.
Table 3-3
Parameters of Water Side
HTS 063~087
Flow LPM 11 8.7
HTS 100~160
Flow LPM 18.9 15.1
Notes: The oil cooling flow of the HTD/HTC chiller is 2 times of that of the HTS chiller while the
pressure drop is the same.
The water pressure drop between in and out of the oil pump should not be less than 10 kpa.
The flow chart of the cooling of chiller oil circuit is shown as below (internal water source–chilled water).
Solenoid
Valve
Fig. 3-4
The size of the oil cooling connection is shown in Table 3-4.
Table 3-4
HTD100-126/HTC；
Model HTS 079-160/HTD079-087
HTS160（only E4816/C4216）
Connection Size (NPT) 1 1 1/2

IV. About Safety

Precautions in this section include:
Warning: a faulty operation that may cause death or serious injuries.
Caution: a faulty operation that may cause injuries or equipment failure. It may lead to even more
serious consequences according to severity.
Above two precautions are essential for safety. After reading the Manual, please keep it accessible to
each chiller operator. Be sure to hand over the Manual to the next person on duty.
4.1 Precautions (Installation)
Make sure chiller is installed as per below requirements, otherwise rectifying measures must be taken.
Warning：
A）All valves must be closed during shipping.
After arrive at the site, do not open the valves until DAIKIN technicians start the chiller.
B）Chiller installation must be carried out by qualified person.
Inappropriate installation might cause refrigerant leakage, electrical shock, fire accident etc.
C) Prevent refrigerant leakage.
In case of refrigerant leakage, certain measure shall be taken to prevent suffocation caused by high
concentration refrigerant in air.
D) Strictly follow this manual during installation.
Inappropriate installation might cause refrigerant leakage, electrical shock, fire accident etc.
E）Electrical cable shall be wired or connected by qualified and professional electrical engineers.
Please size the cable according to local electrical standard or refer to "6.4 Electrical Construction".
Undersize cable might cause electrical shock or fire, etc.
F）Chiller foundation shall be capable to carry chiller weight.
Chiller shall be installed in horizontal foundation and fixed by the anchor bolts. Chiller may overturn
if the foundation is not strong enough.
G）Chiller shall be installed in indoor space.
If chiller is installed in rainy or water dropping place, creep age or electrical shock might happen.
H) Use specified cable and ensures the connections are firm.
Ensure the connections of cables are firm. Otherwise it may cause fire accident.
I) Danger
If an individual power distribution line is used, to avoid injuries and death .Please follow:
1. Stick a label on the chiller: multiple power supply;
2. Stick a label on the main switch of main power and control power: Another power supply to the
motor.
J) The cables connecting to the compressor motor must be copper line and copper cold-pressed
terminal.
Attention：
A）It is forbidden to install the chiller in flammable gas leakage condition.
Fire accident or even explosion will happen when flammable gas concentration achieves certain
level.
B）Chiller shell shall be grounded.
Ground cable shall avoid gas pipe\ water pipe\lightning rod or telecom cable, wrong grounding might
cause shock.
C）Ground protector shall be equipped for the chiller.
Leakage protector shall be installed as per local electrical standard. No leakage protector or
improper installation may cause electrical shock.
D）Each chiller shall be equipped with dedicated circuit breaker.
If only one main breaker is equipped for multiple chiller plant, it may cause shock or fire accident.
E）Draining system shall be smooth at chiller installation location.
A wrong draining system may cause draining failure which in turn may harm chiller electric parts.
F）It is prohibited to lay the power cables between chillers, otherwise it may cause fire accident.
G）Chiller plant floor shall go through water proof treatment.
Water proof floor will protect chiller from moisture.
H）It is prohibited to locate chiller in severe environment.
Hot well, coast area, etc. will cause chiller corrosion which might cause shock or fire accident.
I）The water(cooling water\chilled water) in chiller system shall follow the criteria of local water quality
standard.
Bad water quality will cause leakage and reduced chiller efficiency.
J）Follow the local regulations or rules while handling waste brine, cleaning agent, refrigerant, etc.
Illegally discharged waste liquid or gas will harm health and environment.
K）It is forbidden to close the AC contactor to start the compressor.
It may cause electric shock or fire accident.
L）It is forbidden to weld on the chiller.
Welding on chiller may cause refrigerant leakage. And too high concentration of refrigerant in air will
cause suffocation.
M）It is forbidden to charge other kinds of refrigerant or lubricant oil in chiller.
It may cause chiller instability, chiller efficiency decrease, or even fire accident.
N）Ensure sufficient space for chiller service and maintenance.
Insufficient space will threaten operator or service people’s safety.
O)Dual compressor chiller oil cooling connection.
The oil cooling connections of HTD except as shown in Fig. 8 are located at below the right tube
sheet of the evaporator.
P) Law & regulation.
Highest possible to comply with all local and international regulations on lifting and refrigerant
emissions.
4.2 Precautions (Operation)
Warning:
A）If chiller running abnormally (smell of burning), please cut off the power and contact local DAIKIN
office or distributors.
Running the chiller after abnormity happen might damage the chiller or shock and fire accidents.
B）It is prohibited to start or stop the chiller by main breaker or switch during normal working condition.
It may cause shock or fire accident.
C）It is prohibited to use other category coolant, otherwise it will cause fire accident or explosion.
D）Prevent leakage of refrigerant.
If refrigerant leakage happens, certain measure shall be taken to prevent suffocation caused by high
concentration of gas refrigerant in air.
Attention:
A）Chiller can't be used for other condition which goes beyond its designed working scope.
It may cause tubes damage, refrigerant leakage or even explosion. Chilled water and heating water
can’t be used for preserving animals, plants, precision devices, artworks, etc. Otherwise it will degrade
their quality.
B）Do not operate the chiller with wet hands.
This is one of the causes of electrical shock.
C）It is prohibited to use oversized fuse.
An oversized fuse will cause protection failed. And it might damage the chiller or cause fire accident.
D）It is prohibited to local the chiller in flammable gas circumstance.
It might cause fire accident.
E）It is prohibited to operate contactor to start the chiller manually.
It may cause fire accident or electrical shock.
F）It is prohibited to bypass chiller protection device to start the chiller.
It may cause fire accident or explosion.
G）It is prohibited to start the chiller when open the starter cabinet door.
It may cause electrical shock or fire accident.
H）Ensure the power supply is correct.
Using the power supply other than the rated one specified on chiller name plant might cause
electrical shock or fire accident.
I）It is prohibited to change the protection set point.
It may cause fire or explosion.
J）It is prohibited to put or hang any object upon the chiller.
Dropping of the object might damage the chiller.
K）It is prohibited to put any container which contain water on the chiller.
If water seeps in control cabinet, the insulation may become worse or even cause electrical shock.
L）Check the foundation after chiller operates for certain period.
Unfirm foundation may cause chiller distortion or even accident.

M）Stop the chiller and cut off the power supply when cleaning the chiller.
Otherwise it may cause accident.
N）It is prohibited to flush the chiller.
It will cause electrical shock.
O）It is prohibited to drink chilled water or cooling water.
It’s not healthy to drink cooling or chilled water.
P）Water quality must be ensured.
Bad water quality might cause chiller capacity reduce or water leakage.
Q）Don't feed other category of refrigerant or oil in chiller.
This might cause chiller operating abnormal or efficiency reducing. And it is also a cause of fire or
explosion.
R）Don't touch the compressor and discharge pipes.
It will cause scald.
S）Drain the water in chiller unit if chiller will stop for a long time.
Before long period stop, drain the water or add anti-freeze in chiller, or it might cause chiller water
side leakage or refrigerant side leakage.
T）Treat the chilled water\cleaning agent\wasted refrigerant according to local rules.
Illegally dump the waste will break the law and harm environment.
U) Measure the resistance.
Do not measure the resistance when the chiller is in a vacuum condition, otherwise serious
consequences may be caused.
V) Evaporator water temperature.
The evaporator entering water temperature shall not be more than 43°C, otherwise it may open the
relief valve, leak refrigerant and damage control components.
W) Make sure the pressure is “0” before starting ANY WORK.
Do not remove the plug and flange of compressor or vessel or refrigerant pipes during operating.
Make sure the pressure is “0” before starting ANY WORK, otherwise the pressure will make small parts
like bolts or flange fly and hurt operators.
4.3 Precautions (Remove and repair)

Warning:
A）Chiller transit and service shall be done by vender.
Inappropriate installation will cause electrical shock or fire accident.
B）Chiller relocation shall be done by chiller vender.
Inappropriate relocation will cause electrical shock or fire accident.
C）It is prohibited to modify the chiller without DAIKIN authorization.
Unauthorized chiller alteration will cause electrical shock or fire accident.
Attention:
A ） Client shall follow the local regulations or rules when handling the wasted chilled water, cleaning
agent and refrigerant.
It is harmful to the environment and health.
B）Don't mix with other categories of refrigerant or oil in chiller.
It may cause fire accident or explosion.
C）It is prohibited to change the set point of protection device.
It may cause fire accident.
D）It's prohibited to bypass the protection device when starting the chiller.
It will cause fire accident.
E）Ventilation is required during chiller servicing.
Refrigerant leakage will reduce the concentration of oxygen. So it may cause suffocation when
ventilation is insufficient.

V. Receiving and Handling

5.1 After the chiller arrived at the site
Check chiller model and quantity of accessories, ensure there is no damage on the chiller appearance.
Any parts of accessories loss and any damage on machine caused by client after delivery will be out of
warranty scope.
Anti-vibration Pad
The neoprene vibration pads should be located under the corners of the unit. HTS units have four
mounting feet. Four pads are shipped.
If customer need other isolation device, flow switch, butterfly valve etc., DAIKIN could provide any parts
based on order request and put into the accessary box shipped with the unit.
5.2 Lifting
The insulation on Evaporator hoist position hole and anti-vibration pad should be removed in
transportation, put them back in place after chiller had been arrived at installation site. And the unit
mounting support should be dismantled after it finally landed.
Please keep careful when it is to be hoisted in order to avoid damage on the controller box and pipeline.
..
On the four chiller corners having a hole for hoist, when lifting unit, shaft support should be used in case
of damaging controller box and other parts.
Fig. 5-1
HTS100-160 models will be shipped with lifting protection cushions to protect the insulation of the motor
from being damaged； The protection cushion must be used when the chiller is hoisted.
The green part in the following figure shows the protection cushion.
Fig. 5-2

Notes:
1) It is only allowed to lift with the marked lifting location on the chiller.
2）Ensure chiller should be horizontal when lifting in case of rollover.
3）It is recommended to use cable or chain to lift the chiller via the lifting holes marked on the chiller to
prevent damage during lifting.
4 ） In case chiller can't be lifted via the lifting hole. Client might use cable to frap the condenser and
evaporator before lifting. But it is forbidden to lift the chiller via compressor or starter lifting lug. And
please make protection on the controller box or other chiller parts during lifting.
5 ） Chiller shall be located in horizontal foundation and sufficient space shall be provided on top for
lifting.
6）During lifting, use flexible material to cover the chiller to protect it without damage.
7) All chiller’s weight is based on the nameplate. Please check the nameplate for the chiller’s weight
before lifting. The package weight of unit is between 200 to 600KG according to the size of chiller.
Warning:
A）Don't use compressor or starter lift lug to lift the entire chiller.
B）The lifting cable shall not contact chiller pipes. It might crack the pipes.
Note: Derived, modified or customerized chiller weight is subjected to the nameplate and may vary with
design changes.
5.3 Horizontal transiting
To prevent bending of chiller main foundation, please pay special attention when handling.
As copper tubes is located under the chiller. Please be careful not to scratch the lower part of chiller
when tilted or moved across the stage.

VI. Installation
6.1 Installation and Foundation
A) Chiller shall not be located in rainy or exposed directly under the sun. If chiller is placed near beach
or chemical plant etc., corrosion might occur to electronic parts or chiller painting. Special location will
have special chiller condition design. Please consult the local sales office for details.
B) Please install proper ventilation device so as to prevent suffocation caused by refrigerant leakage.
C) Standard chiller is not designed for explosion condition. It is forbidden to install the chiller in
flammable gas space.
D) The chiller plant should be install in the area which environment temperature shall be within
0℃~40℃,relative humidity shall be less than 90%,and temperature fluctuation shall be within 8℃/hour.
If chiller is installed in cold area, anti-freezing measure shall be taken not only for chiller but also for
other device in chilled water and cooling water system.
E) It is not recommended to put chiller and boiler in the same plant. It will affect chiller performance.
Please confirm with local sales office and distributor if required.
F) It shall keep certain distance between cooling tower and easily corrosive metal, electrical parts, etc.
Locate the cooling tower in appropriate place to avoid cooling water contamination. It is forbidden to
locate the chiller near coast, plating plant, chemical plant, etc. where the cooling water might be
contaminated. Check cooling water periodically. And chiller shall keep certain distance from ammonia
device, toilet and surgery vent and cloaca. Otherwise condenser tube corrosion might cause refrigerant
leakage. If client use sea water or river water as source of the cooling water, then special design of
condenser shall be considered.
G) Chiller shall be installed in the place which is not sensitive to vibration or noise.
Isolator of vibration or noise should be used if chiller is installed in noise and vibration sensitive place.
The vibration may come from installation location, floor or wall; thereby the chiller plant room should be
set at bottom floor of the basement.
H) Please locate the chiller where the chiller's weight is bearable.
The surface of the foundation shall be horizontal and smooth. ( levelness ＜2mm/1,000mm ) ，please
refer to GB 50209.
Fig. 6-1
Table of Chiller Foundation Drawing Parameters

Table 6-1 Chiller: mm
Model C D E F G H
HTS 079~087/E2609/C2209 156 2808 3120 200 1041 1441
HTS 079~087/E2609/C2609 156 2808 3120 200 1105 1505
HTS 079~087/E3009/C2609 156 2808 3120 200 1226 1626
HTS 079~087/E3009/C3009 156 2808 3120 200 1276 1676
HTS 079~087/E2612/C2212 156 3694 4006 200 1041 1441
HTS 079~087/E2612/C2612 156 3694 4006 200 1105 1505
HTS 079~087/E3012/C2612 156 3694 4006 200 1226 1626
HTS 079~087/E3012/C3012 170 3694 4034 230 1276 1736
HTS 079~087/E3612/C3012 170 3694 4034 230 1682 2142
HTS 079~087/E3612/C3612 170 3694 4034 230 1834 2294
HTS 079~087/E4212/C3612 185 3694 4064 250 1988 2488
HTS 100~129/E3012/C3012 170 3694 4034 230 1530 1990
HTS 100~129/E3612/C3012 170 3694 4034 230 1682 2142
HTS 100~129/E3612/C3612 170 3694 4034 230 1835 2295
HTS 100~129/E3312/C3012 170 3694 4034 230 1633 2093
HTS 100~129/E3912/C3612 170 3694 4034 230 1928 2388
HTS 100~129/E4212/C3612 185 3694 4064 250 1988 2488
HTS 100~129/E4212/C4212 200 3694 4094 250 2140 2640
HTS 100~129/E4512/C4212 200 3694 4094 250 2282 2782
HTS 100~129/E4812/C4212 220 3694 4134 260 2292 2812
HTS 100~129/E4812/C4812 220 3694 4134 260 2446 2966
HTS 140~143/E3912/C3612 185 3758 4128 250 2064 2564
HTS 140~143/E4212/C3612 185 3758 4128 250 2134 2634
HTS 140~143/E4212/C4212 220 3758 4198 260 2287 2807
HTS 140~143/E4512/C4212 185 3758 4128 250 2363 2863
HTS 160/E4214/C4214 260 4345 4865 250 2287 2787
HTS 160/E4512/C4212 260 3758 4278 250 2363 2863
HTS 160/E4812/C4212 220 3758 4198 260 2408 2928
HTS 160/E4816/C4216 260 4974 5494 250 2343 2843
HTC
280 6193 6753 260 1834 2354
100~129/E3620/C3620（380V）
HTC
280 6193 6753 260 2102 2622
100~129/E3620/C3620（10kV）
HTC
280 6193 6753 260 1970 2490
100~129/E4220/C3620（380V）
HTC
280 6193 6753 260 2187 2707
100~129/E4220/C3620（10kV）
HTC
280 6193 6753 260 2139 2659
100~129/E4220/C4220（380V）
HTC
280 6193 6753 260 2340 2860
100~129/E4220/C4220（10kV）
HTC
280 6193 6753 260 2444 2964
100~129/E4820/C4820（380V）
HTC
280 6193 6753 260 2644 3164
100~129/E4820/C4820（10kV）

Description:
1. The chiller can be installed on the concrete floor directly because of small vibration.
2. If chiller foundation is needed, please refer to above dimensions.
3. If the machine room isn't located on the ground floor, the floor should be rigid enough to bear the
operating weight.
4. The recommended size of anchor bolts is M27. Anchor bolts are not in our standard scope of
supply. You can order them if required.
5. The rubber pad along with the chiller is good enough to absorb the vibration. If required, we also
can supply spring isolator to achieve better effection, such as the machine room located on the middle
floor.
Spring isolator installation
Chiller Foot
Adjusting bolt B
Foundation
L
A
Fig. 6-2
In Figure 6-2, it is used for the spring isolator mounting, in which AB is the edge length of the spring
isolator and L is the distance between the two bolt holes on the bottom.
Please check the model of spring isolator first before mounting. Then put the spring isolator under
chiller and put down chiller slowly. Use the M27 bolts to fix the chiller and spring isolator but do not
tighten completely right now.
Use the M16 bolts to fix the spring isolator and the steel frame structure foundation. If the foundation is
not steel frame structure, put the spring isolator on the floor directly. Or customers also can fix them
with anchor bolts according to their own needs.
After installation, please check whether the unit is horizontal. If the chiller is not horizontal, contra rotate
the adjusting bolt to make it keep horizontal . And tighten the M27 bolts to fix the chiller completely.
The location of the four spring isolators is the same to anti-vibration pads shown in Figure 15, the two
holes in each corner match the two bolts on spring isolator.
I) The chiller must be located to provide sufficient service space.
One side of chiller shall be reserved with enough space (at least the length of one container) to provide
necessary service clearance for changing the evaporator/condenser heat exchange pipes possibly
occurred, and the specific parameters are as shown in the following table.
J)For easy drainage, the chiller foundation should be higher than its surrounding.
Water proof treatment is suggested for the floor to ensure maintenance of the chiller.
Please locate the drain and auxiliary facilities surrounding the chiller. It is forbidden to install the chiller
in potentially flooded area.
K) For regular maintenance, please consider the light condition of the chiller. Please install lights for

insufficient lighting condition.
L) Cushion block on the bottom of unit must be removed before installation.
Fig. 6-3 079-087 chillers
Fig. 6-4 100-160 chillers
Table 6-2 floor type chillers

Evaporator/Condenser Barrel Length A（ft/m B（ft/m C（ft/m D（ft/m
E（ft/m）
(ft/m) ））））
9/2.75 3/1 3/1 3/1 11/3.35 3/1
12/3.66 3/1 3/1 3/1 14/4.27 3/1
14/4.27 3/1 3/1 3/1 16/4.88 3/1
16/4.88 3/1 3/1 3/1 18/5.49 3/1
20/6.10 3/1 3/1 3/1 22/6.71 3/1
Table 6-3 none floor type chillers
Evaporator/Condenser A（ft/m B（ft/m D（ft/m E（ft/m
C（ft/m） chillers
Barrel Length (ft/m) ））））
9/2.75 5/1.5 3/1 3/1 11/3.35 3/1 079~087
12/3.66 5/1.5 3/1 3/1 14/4.27 3/1
100~129
12/3.66 3/1 5/1.5 3/1 14/4.27 3/1


6.2 Soundproofing and Aniti-Vibration Works
A) Please pay attention to the echo.
As the effect of echo and other equipment operation, sometimes the unit internal sound will become big
a lot.
Please take the setting statuses of chiller and surrounding machines into account, and sufficient
soundproof measures shall be taken.
B) Prevent vibration from piping transferring.
The chilled water pipe, cooling water pipe and relief valve drain pipe all may transfer vibration to unit,
and may produce noise, Please use flexible joint in unit water connection to cut off the vibration source.
C) Take suitable anti-vibration measures according to jobsite condition.
The neoprene vibration pads are standard option of unit, please refer to figure 6 to install, and it is
enough to get good anti-vibration effect.
But if install in buildings middle floor or particularly worried about vibration place, please according to
the requirement to use spring isolator.
McQuay can provide the spring isolator according to user's requirement.
6.3 Chiller Piping
The piping works are responsibilities of the water system design chiller, and the following contents are
for reference only.
Chilled Water Pump
Fig. 6-5
A）Aniti-Vibration:
1. To limit the spread of vibration which would affect other equipment, flexible joints for the unit
connection pipe installation are suggested.
2. Please install proper number of the pipeline support.
3. Ensure that the unit in and out water pipe will not bear the excessive force on equipment.
B）For proper Flow Rate:

1. Check the air tightness of pipe works before connecting chillers.
Notices：Ensure the correct connection of condenser and evaporator inlet/outlet pipeline.
2. Please use the same or greater diameter pipe to the chiller connection.
3. Flow regulation valve (if any) must be set in the central of entrance pipe nearby the chiller; it is
suggested to install the valve on horizontal pipe. The pipes before and after the valve shall be straight,
with a length of 5 times the pipe diameter.
4. Inlet/outlet of the water pipe should be equipped with pressure gauge to calculate the pump running
status according to the characteristics of the pump.
5. Qualified water flow detecting devices must be installed on each chiller water pipe, such as water
flow switch or differential pressure switch interlocked to the chiller controller.
6. The chiller would control the cooling water pump, chilled water pump and cooling tower fan on and
off, so as to achieve best efficiency of energy saving and reliability.
Caution: Chiller flow detecting device shall be interlocked with pumps. When the flow metering device
detects the flow rate is insufficient or no flow, chiller won’t start but trip. If the flow detecting device is
not connected with chiller controller, the protection will not be active and client must ensure the pump
start and flow is established before chiller start. Otherwise McQuay won’t be responsible for any loss
caused by this.
C）Eliminate the impurities in water loop:
1. Strainer and drain pipe shall be installed in water loop.
Sand\muck\rust in water loop will corrupt metals such as chiller tubes.
2. The strainer shall be installed near and in the inlet pipe of chiller.
Please use 40 mesh filter.
3. Check the filter and drain port periodically.
Consider its service space during installation.
4. In order to easily clean chiller tubes, isolation valves are requested for both inlet and outlet chiller
pipes. To easily remove the water box, please use flexible pipe connection in both chiller inlet and outlet
pipes.
5. Install ventilation valve and draining valve in water loop for water system inspection or cleaning use.
Connect the draining valve and gutter.
D）Prevent air mix in water loop:
1. Install ventilation valves to ventilate the air in the system.
Air in water system will reduce chiller efficiency and shorten service life of tubes.
2. Be careful on the water flow rate, too high flow rate will cause tube cavitation, etc.
3. Unit is using circulating water as the prerequisite. Use treated water (warm water), especially in
cooling water system internal or free oxygen dissolved oxygen can cause damage to the pipe, so
please avoid.
4. When the heat recovery unit outlet water is high temperature, please note not make the water flow is
too large, and please set degassing equipment in unit water inlet.
5. Too much oxygen in water will increase water causticity.
E）Follow the chiller operation guide:
1. Please ensure chiller operates within the maximum working pressure.
2. Condenser entering water temp. Range refer to 14.1.
3. To prevent unit frequent start/stop, and steady operation, please ensure the chilled water system
water volume over than minimum.
Minimum water volume refer to 14.3
F）Pipe and tube internal anti-corruption treatment:
1. It is forbidden to install grounding cable on water pipe to prevent electrical erosion.
2. Anti-corrosion treatment shall be taken for buried pipes.
3. Prevent condenser and evaporator from water and air interface.
4. Refer to recommended water quality Chapter 14.5 for the Chiller water quality requirement.
For the half-sealed cooling water system with a cold storage tank, please change the water regularly
and clean and inspect the bottom of the cold storage tank (one time per one to two years).
The pH value of the newly set cold storage tank may increase to above 10. If the pH value exceeds the
standard, it will increase the corrosion rate of the copper product； Therefore, it is necessary to change
the water in advance. If using for a long term, the cold storage tank will be cracked, thus leading to the
water penetration or water leakage. There is little effect of water leakage to the water quality control, but
if penetrating in the sea water or polluted ground water, the water in the cold storage tank will contain
particles or calcium carbonate due to vast microorganism.
5. Please enhance the water quality control especially that of the cooling water. Otherwise, it will reduce

the performance and damage the heat transfer pipe.
G）Anti-freezing measures:
1. Sufficient thermal insulation and damp proof are requested. If not, it will lead to heat loss or damage
of tubes in cold winter due to freeze.
2. If the ambient temperature is below 0℃, heat the water in chiller tubes to prevent freezing.
3. Chiller plant room might equip heater to prevent water freezing in chiller unit.
4. If chiller seasonally stop in the plant room where temperature goes below 0 ℃, operator must drain
the water in chiller tubes. Otherwise Wuhan won't be responsible for the damage or loss caused by this.
5. Notice the water inlet\outlet indications when connect the chiller to the water system.
6.4 Electrical Construction
A) Accessories have indeed connection;
Confirm the correct wiring, prevent inverse phase or phase.
Please note do not let the port connection under external force.
All the wiring shall be confirmed after completion of wiring.
Conform to the wiring table and wiring diagram below:
B）Control wiring precautions.
1、 If the starter is not installed on the unit, the connection between the starter and the
control box needs to be connected on site. For the control cable between the starter and
the control box, please refer to the recommended wire specification of table 10.
2、 For optional sensor wiring see units control diagram. It should be noted that the pipe
between the DC and AC cables should be separated from each other.
3、 The customer provides the power of alarm circuit to be connected to 84 and 81
terminals of the control box terminal (UTB1). The alarm relay is connected between
terminals 81 and 82 (often open) or between terminals 81 and 83 (often closed), and the
maximum power of the alarm relay coil is 25VA.
4、 Remote on/off control of unit can be accomplished by installing a set of dry contacts
between terminals 70 and 54.
5、 The user's self-provided evaporator and condenser flow switch or water pressure
difference switch must be connected according to the control schematic diagram, and
the pressure difference switch provided by the factory is completed in the factory.
6、 The customer needs to provide the control power of evaporator, condenser pump and
cooling tower (20AMP). The control power is connected to 85 (L), 86 (N) and PE
(ground) terminals of the control box terminals (UTB1).
7、 The chilled water pump relay provided by the customer (EP1, EP2) shall be connected
according to figure 18, and the maximum rated power of single relay (EP1, EP2) shall
not exceed 25VA.
8、 The condenser pump must work with the unit. The chilled water pump relay provided by
the customer (CP1,CP2) shall be connected according to figure 18, and the rated power
of a single relay (CP1,CP2) shall not exceed 25VA.
9、 The cooling tower fan relay (C1 ~ C4) provided by the customer shall be connected
according to figure 18, and the rated power of single relay (C1 ~ C4) shall not exceed
25VA.
10、 The 24VAC auxiliary contactor in the coolant pump and the coolant pump starter must
be connected according to figure 18.
11、 Optional communication protocol BAS interface. The installation and connection of
various standard specifications can be found in their respective installation manuals,
and can be obtained from local sales companies or provided with the unit.
Modbus IM 743-0
BACnet IM 736-0
LonWorks IM 735-0(only Microtech II)
12、 A signal cable is a low voltage cable connected to a control terminal below 15V.
Signal shielding wire is used to prevent electrical noise interference caused by
improper operation.
The voltage withstand voltage of the signal cable is at least 300V.
The signal cable should be as far as possible from the control cable and power cable.
13、 The control cable is the cable connected to the control terminal, and the normal load
voltage is 24V--220V.
Cable meet local electrical specifications.
Other cables should be maximally removed from the power cable connected to the motor.
Different cable group (110 v power cable and control cable, the cable and the cable of 110 v
and above) should be left to different metal hose, store a variety of control cable should keep a
certain distance between the metal hose(>76mm).Such isolation can reduce electromagnetic
interference between circuits. There should be some isolation between different cable groups
(>152mm).
Whether the power cable or the control cable, the different cable groups should be
perpendicular.
The voltage of the control of McQuay centrifugal unit is ac 110V or 220V. The power supply in the
control is provided by the transformer in the starter.
Fig. 6-6 Site connection diagram

A set（L1，L2，L3）
of power supply for
WSC units.Two sets
(L1.L2.,L3 ) of power
supply for WDC/WCC
unit.Connected to the
corresponding starter.
Fig. 6-7 Site connection diagram

Table 6-4Cable wiring table
Cable wiring table
starting point Stop point
Block of copper core
No cable（mm2） Electrical comment
Electrical Name *A *A
Name
16~100m 0~15m
1 6 4 Motor starter CP1 control box CP1 Controlbox power
2 6 4 Motor starter CP2 control box CP2 AC110V
3 2.5 0.5 Motor starter 1 control box 1 Motor running
4 2.5 0.5 Motor starter 2 control box 2 currentO~5Vsignal
5 2.5 1.0 Motor starter 3 control box 3 Motor frequency
0~10Vsignal（VFD
6 2.5 1.0 Motor starter 4 control box 4
Chiller）
7 2.5 1.0 Motor starter 11 control box 11 Public end
Complete signal of
starter
9 2.5 1.0 Motor starter 22 control box 22 fault signal of

Cable wiring table

starting point Stop point
Block of copper core
No cable（mm2） Electrical comment
Electrical Name *A *A
Name
16~100m 0~15m
starter
Switch signal of
starter
13 4 4 Motor starter 38 control box 38 Start the box
breaker.Pump is
14 4 4 Motor starter 39 control box 39 running （ 3-11kV
Chiller）
15 6 4 Motor starter P1 UPS cabinet P1
16 6 4 Motor starter P2 UPS cabinet P2 UPS power of
17 6 4 Motor starter L1 UPS cabinet L1 Quick Start
18 6 4 Motor starter N UPS cabinet N
interface of Quick
Start
22 2.5 1.0 Motor solid starter 305 control box 305
solid start
23 2.5 1.0 Motor solid starter T4-C control box T4-C
24 2.5 0.5 Motor ASP solid starter + control box +A CC control BMS
25 2.5 0.5 Motor ASP solid starter - control box -B card
26 4 2.5 Motor solid starter PE control box PE PE
Notes:
1. The maximum length of the cable is the distance between the power source and the unit control box.
2. A wire greater than 6.0 mm2 requires an external transfer box .
3. More than 100 m in length. Consult factory .
4. For 380 ~ 460 V starter, column A is the terminal number; For the 3000 to 1100V starter, column A is
the cable number.
C) Power cable precautions.
1、 The compressor starter can be mounted on the airborne or floor type, and the high voltage
starter (3~11kV) can only be installed in the ground. For starting the machine load installation,
the power supply power cable completes the wiring in the factory. For the starter to be installed
independently, the power cable is connected to the site. If it is the user's own starter, the starter
must comply with GB 14048.1 or GB/T 11022(3-11kv). The starter control interface must meet
the requirements of Z9690333 or Z9690088(3~11kV). Start the starter power into the cable and
load the attachment must be based on BVR copper wire and cable of rated current under 70 ℃,
rated current of the YC cable under 60 ℃ (for 3 ~ 11 kv, based on the rated current of the YJV
cable under 60 ℃), the selected power cable must be satisfied and failure occurs when the
motor first starts, however, the main circuit of the current flow. The selection of power cables
should be in accordance with local electrical specifications, and the power cable selection
should refer to table 11.
2 Low voltage VFD, wye-delta, and solid state starters can be used to have 6 terminals of the motor,
starter and motor connected to each cable should be able to bear 58% of 1.25 times the rated current
operation, please choose copper wires and copper connectors. The main power cable between the
starter and the motor terminal is installed by the factory when the unit is on board. High pressure unit
starter (high voltage variable frequency starter, cable starter, soft starter, reactance starter, self coupling
starter) connected to the motor 3 wires, start by is the cable between the tank and motor current, is the
motor rated current (RLA). Connection to compressor motor terminal can only be copper wire and
copper cold pressure end.
3Ac cable shall not be worn in metal conduit (wire slot) alone.
The same ac circuit cable shall be worn in the same metal conduit (wire groove) and the cable
shall not have a joint in the pipe (wire groove). For example:
Note: PE wire wear in any a catheter (trough), the figure of T1, T2, T3, T4, T5, T6,
corresponding is compressor motor of no. 1, 2, 3, 4, 5, 6 power supply terminal of the power
cable.
Table 6-5
Voltage Class Maximum Length of cable section / Copper wiring
(V) Working Electric Wire per phase (mm2) terminal maximum
Current (A) (Cable) (meter) size
（L×B，mm）
330 ≤100 ≥185 80×24
420 ≤100 ≥240 80×30
560 ≤100 ≥370 120×30
670 ≤100 ≥480 130×30
780 ≤100 ≥555 150×40
380-460 930 ≤100 ≥720 170×50
1050 ≤100 ≥750 170×50
1180 ≤100 ≥900 170×50
1250 ≤100 ≥960 170×50
1430 ≤100 ≥1200 190×50
1600 ≤100 ≥1300 200×50
200A ≤100 120 -
3000-11000 100A ≤100 95 -
75A ≤100 70 -
Copper wiring terminal maximum size（L×B，mm）
Notes: (1) Cable to be selected to meet the working voltage level, Table 6-5 shows specifications of
power wire, and data is only for reference. Refer to the local standards when executing, BVR, VVR,
YJV of the cable type is recommended to use. (Parallel connect several cables can meet the
requirement of sectional area), no pipe use for truss wiring, for specific wires (cable), the heat-
dissipating condition shall be taken into considering (If required to wear a tube the sectional area of
cable shall be enlarged); ）
(2) For the connection of the centrifuge, it is easy to cause the force of the terminal to affect

the sealing of the compressor because of the connection of the terminal, so please pay attention to the
following points:
a. The cable or copper is connected with the compressor terminal. The cable should be
equipped with the bending radius of the selected cable, and the flat mat and cushion
should not be used.
b. Do not exceed torque on copper stud when installing terminals on stud ends. Use two
wrench method to tighten stop nuts. Do not run nuts into end of thread. Failure to comply
may result in equipment damage! Terminal torque requirements:
c. For 10~11kV motor, do not operate the terminal nut 3 and 4; Incorrect installation mode may cause
damage to the terminal.
d. The installation of power cable of the compressor terminal shall be operated by qualified
service personnel or qualified construction party according to the wiring requirements.
e. 3 ~6.6kV compressor has a diameter of 9.5mm, and the outer diameter of the terminal of
10~11kV compressor is 14.3mm. High voltage starter (3~11kV) with a diameter of 11mm
and a diameter of 10mm. Please refer to this size to select the copper nose specification.
f. WSC100-129 unit voltage (<600V) expansion copper row is installed in the motor junction
box, and the connection power cable in the copper row is 4*φ15, as shown in fig6-9.
（3）Other parts of the power cable installation, cable laying chooses the bending radius of the
cable to be fulfilled, through bolt connection of both lateral due and flat washer, power cables
between adjacent bolt washer should have the clear distance more than 3 mm, nut side should be
equipped with a spring washer or lock nut, bus bar should be compact connection, contact surface
between the connecting bolt application torque wrench fastening shall refer to the following table 6-
6 required value.
Table 6-6
Bolt Specifications
Torque value (N·m)
(mm)
M8 8.8~10.8
M10 17.7~22.6
M12 31.4~39.2
M14 51.0~60.8
M16 78.5~98.1
M18 98.0~127.4
M20 156.9~196.2
M24 274.6~343.2
(4) Before connecting the power cable, it is necessary to determine that the switch of the main main
cable is disconnected, and the warning sign should be suspended in a prominent position. Connection
to tidy, for 380 v to 460 v of bare wire spacing to keep more than 30 mm, if less than 30 mm, to be in
the interval and the insulation of the dry rubber, and in the wire insulation layer and start the ark shell
have squeezed also want to add dry rubber insulation. For the 3~11kV cable, it is not allowed to be
exposed. The electrical part of the metal strip must be treated with a random insulation tape.
（5）Cable connection instruction specification.
The cable joint shall be made of copper cold pressure end without a peep hole.
Install the cable connector down.
On-site installation contractor or qualified institutions must be the terminal voltage of 600 v or
compressor motor insulation processing, high voltage cable do withstand voltage test on the
spot, and to provide the qualified test report.
Treatment materials:
1. Loctite ODC-Free Cleaner&Degreaser (E1602007).
2. Scotchfil putty shape electrical insulating material of 3M Company Putty rubber tape (E1602003).
3. CRC company Insulating Sprays: PLASTICOTE 70 (E9001082).
4. 130C high-voltage insulating rubber tape of 3M Company (E1602004).
5. 88# Electrical insulating rubber tape of 3M Company (E1602005).
Treatment steps:
1. Use Loctite ODC-Free Cleaner & Degreaser to eliminate oil and scale at terminal joints and keep dry
and clean.
2. Firstly, use Scotchfil Putty to fill irregular parts within the area; after filling, the whole part shall be
smooth and neat for wrapping operations of subsequent other rubber tapes.
3. Use PLASTICOTE 70 to smear the magnetic bushing of the leads up to 1/2’’, and apply
PLASTICOTE 70 onto the rubber surface of a section of 10’’ cable along the cable direction evenly;
after spraying, keep aside for about 15 minutes for supplementary insulation.
4. Wrap the high-voltage insulating rubber tape in semi-overlapping to completely cover the whole part
that requires for insulating treatment, when performing wrapping, the stretching shall be uniform, with
the stretch rate of about 100% and the wrapping thickness up to 8mm, which means the external
diameter needs to increase 16mm to reach major insulation.
5. Wrap four layers of Super88 PVC rubber tape at the part wrapped with 130C rubber tape to cover the
whole part to provide good mechanical and surface protection.
6. After wrapping, apply again one layer PLASTICOTE 70 to wrap up the whole part and increase the
safety and reliability. (The drying time for PLASTICOTE 70 is about 30 minutes).
D）Ground cable must be wired
To prevent electrical shock, control box grounding terminals and chiller foot print shall be grounded.
Cable wiring work shall be done by qualified and professional engineers.
Grounding Terminal:
1. Chiller Grounding Terminal.
The water chiller grounding terminal is installed on the water chiller bottom plate, and the size of the
connecting thread hole is M20, see Fig. 6-8.
2. chiller Control Box Grounding Terminal.
The chiller control box grounding terminal is arranged on the control box wiring terminal block, see Fig.
6-9.
3. Grounding terminal of the unit control box.
Earthing terminal unit control box, as shown in figure 6-10, for MicroTech Ⅱ control platform earthing
terminal diagram, as shown in figure 6-11 for MicroTech Ⅴ control platform grounding cable diagram.
4. Ground terminal of UPS cabinet.
The grounding terminal of the UPS cabinet is shown in figure 6-12.
5. Chiller Starter Grounding Terminal.
The chiller starter grounding terminal, see Fig. 6-13.
It’s recommended to separately ground the four grounding wires of the chiller. If the starter is in the
onboard mode, the two or four grounding wires can be connected to the common grounding point.
★ Grounding resistance shall be less than 0.1Ω.
Attention: Grounding cable shall be kept certain distance with natural gas \lightening rod and telephone
cables. And don’t connect water pipes to earthing cable.
Gas pipe---gas leak can cause explosions or fires.
Water pipe--- there is no ground effect if hard vinyl material is used.
Telephone grounding cable and the lightning rod--- under thunderstorm weather, it may cause
abnormal rise of grounding voltage.
The grounding of the chiller electric starter can refer to national standard GB50169;
The diameter of the grounding inlet wire (cable) is generally half of that of the three-phase cable (cable)
(for one, two and four wiring terminals).
The diameter of the chiller control box grounding cable is 1.5mm 2.

Fig. 6-8 Chiller Grounding Terminal Fig. 6-9 Motor Grounding Terminal
Fig. 6-10 Unit Control Box Grounding Terminal Fig. 6-13 Chiller Starter Grounding Terminal
UPS
Cabinet
Unit Control Grounding
Box Grounding Teminal
Teminal
Fig.6-11 MicrotechV Box Grounding Fig.6-12 UPS Starter Grounding
E) UPS wiring precautions.

Configure the quick start unit customer needs live wire. If the customer is equipped with the
UPS power supply cabinet, the input power supply of UPS is provided by the customer, and the
power supply from UPS is connected to the starter P1 and P2 terminal. If is factory provide ark
of UPS power supply, UPS input power is provided by starter, for 380 v unit, UPS power supply
cabinet of input power if it is from the power cable into one of L1 / L2 / L3 and N thread, it is
important to note that the N cable can't be replaced with PE cable. For the unit of 10kV, the input
power of the UPS power supply cabinet comes from the transformer in the starter. For the unit
with quick start function, the power supply of the control box is provided by UPS.
Note: the PE cable is strictly prohibited to replace the N cable when the UPS power supply
cabinet is connected.
F) Wiring confirmation has been connected.

Make sure the wiring is accurate to prevent reverse or missing phase.
Please be careful not to allow any external force on the connection part of the port.
Once the wiring is finished, please confirm again that there is no connection error.
Note: the wiring must be operated by a qualified professional.

VII Operation of OITS

7.1 Operator's responsibility
It is important that the operator become familiar with the equipment and the system before attempting to
operate the chiller. Please read Operating Manual (Z8100163- 《 OM Centrifigul MicroTech  》 ;
Z8100297-《OM Centrifigul MicroTech V》)and unit control schematic diagram and related document
first.
During the initial startup of the chiller, the DAIKIN technician will be available to answer any questions
and instruct in the proper operating procedures.
It is recommended that the operator maintain an operating log for each individual chiller unit. In
addition, a separate maintenance log should be kept of the periodic maintenance and servicing
activities.
The DAIKIN centrifugal water chiller shall be maintained within good operating state for it’s expensive.
Any abnormal or rare conditions of chiller shall be reported to the technical personnel of DAIKIN service
technicians.
DAIKIN offers some factory training for DAIKIN centrifugal operators every year. Further information
please contact local DAIKIN.
Microtech  Operator Interface Touch Screen (OITS)
Fig. 7-1
Microtech V Operator Interface Touch Screen (OITS)
Fig. 7-2
Notes: For the detailed information, please refer to the operation manual of centrifugal control.
7.2 Standby Power Supply
For any centrifugal water chiller equipped with the standby power supply, if the chiller has rapid-start
function, the standby power supply must work in 35s. if the chiller do not has rapid-start function, the
standby power supply must be started until the chiller is completely stopped. In the running process of
the compressor, the attempting to switch the conventional power source to the auxiliary power supply
would severally damage the compressor.
7.3 MicroTech II Control
All chillers are equipped with the DAIKIN MicroTech control system. The control systems consist of:
●Operator Interface Touch Screen. A setting and input equipment for chiller's information and
parameters.
● Chiller controller, which is a device used for controlling the function of each water cooling water chiller

and communicating with other controllers. If the screen does not work, the parameter settings can be
inputted.
● Compressor controller to control each compressor, which can still run when there is no chiller control
or operation interface.
● The oil system is also controlled by the compressor controller ,all the parameters of the oil system are
monitored by the compressor controller .
7.4 Energy Control System
7.4.1 CE063-CE129 Inlet Guide Vanes(IGV) operation
The capacity of the compressor is controlled by the IGV. When the solenoid valves SA and SB act along
with the control information, the vanes will be pushed to rotate through the oil flowing.
Operation of IGV
The pressure system for energy control of refrigerant inlet vanes consists of a normally-opened cross
valve and an oil pipe, wherein the normally-opened cross valve is located at the refrigerant suction port
of the compressor. The opening and closing states of the normally-opened cross valve are determined
by the loading, unload and maintaining of the control signals, so as to determine that the high-pressure
oil from the oil filter flows to one side or both sides of the vane piston.
Open the vanes (loading of compressor, see Fig. 7-4). The solenoid valve SA is de-energized, and the
solenoid valve SB is energized. The high-pressure oil flows to one side of the piston, and the low-
pressure oil at the other side is dischargeed through the port of the solenoid valve SB.
The vanes are closed (unload of compressor, see Fig. 7-4). The solenoid valve SB is de-energized, and
the solenoid valve SA is energized. The vane piston moves to the unload direction, and the vanes are
slowly closed.
When both of the solenoid valves SB and SA are de-energized, the high-pressure oil flows to the two
sides of the piston through the ports of the solenoid valves SB and SA, and the vanes are maintained in
the original position. See Fig. 7-3 for the actions of the solenoid valves.
Chiller with rapid start has two solenoid valves to unload quickly. This two valves will be turn on to close
the IGV quickly when chiller is in rapid start.
Fig. 7-3

Fig. 7-4
Measurement Values
The speed of the switch for energy control vanes is adjusted to meet the requirements of the system.
The needle valve on the oil drain pipe can be used for adjusting the oil drain speed, so as to further
control the “vane speed”. The needle valve is a part of the cross solenoid valve in the compressor
lubricating oil distributing box.
These valves are usually set in the factory. The time for complete opening to complete closing is shown
in Table 7-1.
The location of the needle valve is shown in Fig.7-5.

Fig. 7-5
The ex-factory settings of the vane speed are shown in the following table:
Table 7-1
Model of Compressor Starting Time Closing Time
CE063-CE087 3min-5 min 1min-2 min
CE100-CE129 5min-8 min 1min-2 min
The speed of vane shall be slow enough to prevent the control losing and the damage to the
assemblies. The oil drain speed at the vane opening part controls the opening and closing speed of the
energy control vane. The oil drain speed can be adjusted through the needle valves of the solenoid
valve SA and the solenoid valve SB in the lubricating oil box. The circular box plate on the lubricating oil
box is opened from the left side by a screwdriver to adjust. During loading, the needle valve of the
solenoid valve SB is adjusted to change the opening speed of the vane, the opening speed of the vane
is reduced clockwise, and the opening speed of the vane is increased counterclockwise. During unload,
the needle valve of the solenoid valve SA is adjusted to change the closing speed of the vane, the
closing speed of the vane is reduced clockwise, and the closing speed of the vane is increased
counterclockwise.
Since the adjusting flexibility is higher, the nut is slowly rotated during adjusting.
The opening speed of the vane can be readjusted according to different working conditions.
7.4.2 CE140/143/160 IGV Operation
Operation of Vanes
The IGV of CE140/143/160 compressors is controlled by the dedicated IGV control module.This module
needs dedicated IGV control program which must be loaded by DAIKIN service person.
IGV control principle is as follows：

When the unit is powered on, the control module sends out a signal of automatic calibration, we call it
a calibration cycle, This process is mainly to complete the action guide vane is from any location on the
first position, then from the biggest opening gradually close to the minimum, Compressor controller
records of maximum to minimum location signal difference to complete the validation process. This
whole process will take about 3 minutes. Check completed rear can start the compressor.
In the process of automatic calibration, IGV driver module will keep flashing yellow lights. After
completion of calibration, control module work will keep long bright lights, signal from new action until
the compressor controller.
The opentage of the IGV is controlled by the compressor controller. The speed of the IGV movement can be
changed by changing the settings.Enlarge the T1-T3 can quicken the loading speed. Otherwise ,enlarge the T4-
T5can quicken the unloading speed. These settings are always set before shipping, service people can re-adjust the
settings according to different conditions. The values of T1-T6 are as below:
IGV opentage Standard range
value
＜5 T1=6 T4=6 1～9
5～30 T2=2 T5=2 1～9
＞30 T3=6 T6=6 1～9
The following table shows the alarm information of the IGV control module:
Table 7-2
The module wiring diagram is shown in Fig.7-6

Fig.7-6
7.4.3 Electronic expansion valve operation
Electronic expansion valve (EXV)

Unit which use Mcquay homemade new electronic expansion valve, the control module is the same
with HTS140-160 vanes control.The only difference is program. Electronic expansion valve control is
mainly divided into two stages, the evaporation pressure control and program control. For more details,
please contact DAIKIN.
Note: The dedicated EXV control program must uploaded to EXV control module.
Before unit operation, it is necessary to test the movement of the EXV, the operation is as follows:
1. Power on the control box of the chiller. First please check the EXV control module. If the module
shows alarm, check the resistance between the EXV phases. The normal resistance is 2~3Ω. If
there is no alarm, change the EXV control mode to manual in chiller controller.
2. Change the position of the EXV to 100%, using the sight glass on the EXV to check the movement
of the EXV. The correct movement of the EXV is moving away from the wiring port, this direction is
the opening direction. Otherwise, moving towards the wiring port is the closing direction.
3. When the EXV is moving, the green light on the EXV control module is always lighted and the
yellow one is twinkling. Once the yellow light stopped twinkling, means the EXV has arrived at the
target position, If the movement of EXV is abnormal, please check the wiring of the EXV.
7.5 Thermal Flow Switch (Only for High- voltage Chillers)
All the HTS100-160 chillers with high-voltage motor install the thermal flow switch on the motor-cooling
pipe. This switch is used to monitor the flow of the cooling refrigerant.
7.5.1 Indication of Thermal Flow Switch:
7.5.2 Setting of Thermal Flow Switch

supply
Reset the factory setting

Press the pushbutton at least 15 seconds.
Release the pushbutton. Reset all setting to the factory setting.
7.6 Oil Circuit System
The oil system provides lubrication for the compressor and cools the gears and bearings. All centrifugal
compressors are equipped with the oil systems.
Only the recommended oil can be used. Every chiller has charged sufficient lubricating oil before
shipping. When chiller is running, the oil sight glass installed on the oil tank can display the oil level.
CE063-CE129 compressors have independent oil tank to supply oil. The oil pump, oil heater and oil
separator are installed inside the oil tank.
The oil tank of the CE140/160 compressors is inside the compressor. All the components of the oil
system are installed inside.
The oil feed temperature depends on the cooling effect of the oil cooler. The temperature is controlled
within 38 °C±5 °C by the temperature control valve. The lubricating protection depends on the oil
pressure difference. One abrupt shutdown may cause fault and damage to the bearing. To prevent
damage, compressors will be lubricated by emergency oil feed equipment.
The recommended oil type is shown in the table as below.
Table 7-3
Model of Compressor CE079-CE143 CE160
Number of DAIKIN Part Z1502131 (Oil A for Service) Z1502132 (Oil B for Service)
The typical oil flow chart is shown as follows:
Fig. 7-7
Notes:
1. The relative positions of the pipes may not conform to the practical chiller positions.
2. R=relief valve, P=pressure sensor, T=temperature sensor, S=solenoid valve.

VIII. Confirmation before Test Run

In order to ensure the safety of personal and equipment, please confirm the following before operation:
8.1 Check Power Circuit.
Wiring
Important Caution:
Voltage unbalance that exceeds 2% with a resultant current unbalance of 6 to 10 times of the
voltage unbalance.
Wiring check has risk of electric shock. It is forbidden to operate without certification.
Power wiring to compressors must be in proper phase sequence. Motor rotation is set up for clockwise
rotation facing the lead end with phase sequence.
The DAIKIN start-up technician will confirm the phase sequence.
Notes: The wiring of the compressor motor cannot be completed until the DAIKIN commissioning
engineer checks and approves.
Wrong rotation direction will result in serious damage. Such damage is not covered by product
warranty.
Wiring between power supply and starter:
Correct wiring means reliable power supply. The wiring must satisfy the requirement in Fig 6-6. The
diameter of the cable must no less than the requirements in table 6-17.
Wiring between Motor and starter:
The wiring must satisfy the requirement in Fig 6-6. The diameter of the cable must no less than the
requirements in table 6-17. The teminal box of the motor must completely installed after finish the
wiring.
8.2 Confirmation of Wring

The voltage of the control box is 110V. The control power supply has three different sources:
1. In case of unit mounted starter, the control power supply is provided by the transformer in the unit
mounted starter , and the wires are connected in the factory;
2. In case of free standing starter, the transformer has already installed inside the starter. This
transformer must connected to control box on site,
3. he power of the pumps and cooling tower must supplied by independent circuit. The air switch and
fuse(20A) are necessary for this circuit.
4. When chiller has the rapid-start function, control power is supplied by UPS. Need to connect the UPS
power supply to the terminals inside the starter on site.
Wiring between starter and control box:
Correct wiring between starter and control box means reliable compressor control. The wiring must
satisfy the requirement in Fig 6-6. The diameter of the cable must no less than the requirements in table
6-16.
Check the protection settings of the motor:
Different motor or different protection device has different settings. The settings must satisfy the
parameters written on the paper pasted behind the cabinet door.
Except the commissioning period, keep the air switch on so that the oil heater is always heating to keep
the oil temperature.
Wiring for Optional BAS Interface
The optional Building Automation System (BAS) interface is field wired and will be set-up by the DAIKIN
startup service technician. The following manuals explain the wiring and mounting procedures:
LONWORKS@——>Z8100139（only for Micro Tech II）
MODBUS@——>Z8100138
BACNET/IP@——>Z8100140
BACNET/MSTP@——>Z8100141
Control Panel Switches
Three On/Off switches are located in the upper left corner of the main Unit Control Panel, which is
adjacent to the operator interface panel, and have the following function:
●Unit: shuts down the chiller through the normal shutdown cycle of unloading the compressor(s) and
provides a post-lube period.
●compressor: one switch for each compressor on a unit, executes an immediate shutdown without the
normal shutdown cycle.
●Circuit Breaker: disconnects optional external power to system pumps and tower fans.

The fourth switch located on the left outside of the Unit Control Panel and labeled EMERGENCY STOP
SWITCH stops the compressor immediately. It is wired in series with the COMPRESSOR On/Off
switch.
For Micro Tech V controller:
●The unit switch and compressor switch located on the HMI.
●Circuit Breaker: disconnects optional external power to system pumps and tower fans.
Absorption capacity
All chillers (except solid starter cabinet and variable-frequency starter cabinet) are equipped with
standard absorption capacities to prevent the compressor motor suffering electrical damages from high-
voltage zones.
● For unit mounted, the capacitor is installed in the starter cabinet in the factory.
● For free standing starter, the capacitor is installed on the terminal box of the motor. In case of motor
wiring, the capacity shall be connected onto the leads of the motor by conductors of 18 inch (460mm)
long at least.
8.3 Confirmation before power on.
Equipment room temperature, standby
-Water in vessels and oil cooler: (3°C to 40°C)
-Without water in vessels and oil cooler: (-18°C to 40°C)
Equipment room temperature, operating: (3°C to 40°C)
Maximum entering condenser water temperature, operating: job specific design temperature
Minimum entering condenser water temperature, operating: refer to 14.1
Minimum leaving chilled fluid temperature without anti-freeze fluid: 3°C
Maximum entering chilled water temperature, operating: 30°C
Maximum oil cooler entering temperature: 15°C
Minimum oil cooler entering temperature: 5 °C
Nameplate
There is a group of digits sculpted in the nameplate of each centrifugal chiller to describe the
characteristics of the chiller and differences between different chillers. The nameplate is installed at one
side of the chiller’s control box. On the nameplate, there is sculpted with the model and serial number
which are uniquely assigned to each of the chiller, and they could provide identification for the chiller
during its running or while other problem occurs. Additionally, the information of refrigerant charging
volume is included on the nameplate. Nameplates for the large composites of the chiller are also
equipped for providing necessary information to the installers and operators.
Compressor named with CE, example CE087 compressor used in HTS/HTD/HTC 087, HSC 087 from
compressor nameplate you could tell the compressor model, type, product number and compressor
motor feature.
Condenser and Evaporator nameplate mark with vessel maximum working pressure, Product number
and vessel type.
8.4 Water system confirmation
Every chiller needs some time to recognize the demand and operating stable. In HVAC system, too
small capacity requirement or too small water flow will lead to compressor surge.
If job site could not provide sufficiency water supply, suggest provide an appropriate storage tank.
During operation, the fluctuation of the condenser entering water temperature should be lower than
2℃/min.
For variable cooling water flow system, the rate change of the flow must less than 30% per minute.
Water pump.
Water pump:1)operating with compressor;2)unstop operate;3)remote control the start and stop.
Cooling tower must operation with unit, start cooling tower wiring mush 110VAC,50Hz,maximum rated
power is 100VA.If power exceed the rated, must install a control relay, see field wiring photo32.
All interlock contact point rated ampere no less than 10A, alarm circuit is also 110VAC,alarm relay
power no more than 10VA.
See Micro Tech IOMM control part for detail.
Note: Do not use 3600 RPM, 3000 RPM or bipolar motor pumps (for 50 Hz power terms), because
this pump is accompanied by excessive noise and vibration.
If the bipolar motor pumps, which are basically the same speed and the compressor motor, this may
resonate. If possible, we recommend using 1450rpm (50Hz power on terms) or four-pole motor pumps,
1750 rpm (for 60Hz power is concerned).
Startup the drainage of the chiller.
When the chiller goes out the factory, it will be drained of water. When shipment, it will open the drain

plug or ball valve to transport. Before filling liquid vessel, the chiller should to ensure good plug or ball
valve closed.
Evaporator and condenser water pipe
The evaporator and condenser are use clamp or flange connection, the installer must provide
corresponding connection according to the requirement of the system. HSC has two sets of condenser
pipes, one is for the condenser, and another is for heat recovery.
HSC heat recovery chiller is as shown in Fig. 8-4.
Fig. 8-1
Important considerations when welding

Note:To prevent damage, the temperature sensor and wrap installed on the pipe should be
removed before welding.
Every inlet and outlet pipe on water head is equipped with a plug screw which is provided to connect
the test equipment (the position of the plug screw is determined by the plant as per the customer’s
design); connect the water inlet and outlet pipe of the condenser according to the drawing
requirements and sign on the pipe.
A proper support for pipes shall be installed to reduce the stress at the connection port The chilled
water pipes shall be wrapped with thermal insulation materials; a filter shall be installed at each of the
water inlet point, and enough stop valves shall be provided for fully discharging the water accumulated
in the system.
Flow control
Standard centrifugal water chiller is equipped with water-pressure-drop switch to make the judgement if
there is sufficient water flow into the vessels. When the flow is not sufficient, it can rapidly switch off the
chiller. The water-pressure-drop switch is installed on the water head of the vessels, and the internal
wiring is finished in the factory.
For single-pass or three-pass centrifugal chillers, The water-pressure-drop switch is not suitable and
the thermal switch or target-slice switch are substitute. The target-slice flow switch is installed at the
middle part of the entering/leaving piping near the chiller; it is suggested to installed on the horizontal
pipeline; the straight pipe sections before and after the valve shall be reserved with a distance of five
times of the pipe diameter. The thermal flow switch is installed on the water head pipes, and the internal
wiring is finished in the factory.
Standard HTC centrifugal chiller has standard configuration of flow switches, which have been installed
on the water connections of chiller containers before leaving the factory (the default installation position
of the flow switch is on the inlet pipe), and the flow switches use thermal flow switches without setting.
If customer need to use thermal switch, please follow the below steps by DAIKIN service person:
a. Confirm the power supply is OK.
b. All the LED on the display will lighting and then extinguish one by one from right side to left side.
The green LED on the leftmost will flicker every second, The red LED shows the setpoint of the
switch and the default setpoint is 70cm/s which corresponding the seventh LED on the display.
c. Push the ◁” button, when the red LED is flickering, push the button to change the setpoint to the
second LED.

For standard centrifugal chillers, if the customers use thermal switch or target-slice switch by themself,
the signal wires of the condenser flow switch shall be connected to CF terminals and T3-S terminals,
For evaporator flow switch, the signal wires shall be connected to EF terminals and T3-F terminals.
Please refer to the instructions of the electric for more details of the wiring.
The water connections shall have thermometers at the inlet and outlet as well as an emptying opening
at the highest point. The water head is interchangeable, so the water connection can be connected to
any side of the heat exchanger; in this case, the gasket of the water head shall be replaced and the
sensor must be re-installed.
If customer want to reduce the noise, it is recommended to use sound insulation and noise reduction
measures at the pump inlet and outlet to reduce the noise of the pump. The inlet and outlet of the
condenser usually do not need any noise reduction measures, but with strict requirements on noise and
vibrations, it is necessary to install noise reduction facilities.
Cooling Tower
Must confirm the cooling water flow rate satisfy the system design. If the cooling tower without
temperature control can’t keep the temperature more than 18℃, it is necessary to install the
temperature control. If the temperature can’t be controlled by the fans on the cooling tower, our
suggestion is to install the cooling tower by-pass valve. Unless system or chiller required, it is
deprecated to use by-pass valve or variable flow for condenser because this will lead to unstable
operation and serious fouling. The condenser water pump must on/off according to the chiller’s switch.
Cooling water pump and chiller start-stop shall be synchronization.
8.5Confirmation of chiller
Open the valves installed on the chiller.
Below mentioned stop valves are installed on the chiller for maintenance and these valves should open
before running:
Table 8-1
Installation position Valve Type Notes
Compressor suction piping Manual Butterfly Valve(option)
liquid pipe Stop Valve
Prior EXV pipe Ball Valve
Noise reducing pipe Ball Valve
Motor cooling pipe Ball Valve
The valves on the heads of heat exchangers are closed.
Open the valves installed on the oil cycle:
Including: oil pump outlet valve, inlet valve of the emergency oil feeding reservoir, oil inlet valve of the
four-pass valve, oil return pipeline valve of the oil pump and return air pipe valve of the oil tank.
Open water system valves
Open the evaporator and condenser water valves and oil cooling valves. Make sure there is no water
leak.
Open the water pump and cooling tower fan
Set all the parameters of the chilled water and cooling water, such as flow rate, temperature target. This
can be done by the chiller controller. Once all the parameters have been confirmed, turn on the chilled
water pump, the cooling water pump, the cooling tower pump and the cooling tower fans, The controller
will automaticly keep the parameters always satisfy the requirements. If the parameters can’t satisfy the

setpoint, customer can adjust manually.
Check chiller control parameters
The correct control parameter is the guarantee of normal operation of the chiller.
Soft Load Ramp Time OFF
Cooling rate of the maximum value 0.3-0.5°C
Cooling rate of the minimum value 0.1-0.3°C
Lower oil pressure alarm value 350 kPa (400KPa for CE105\121\129 ,207 kPa for CE140\143\160)
Other parameters can follow the default settings in the controller. HTC/HTC-HP need to set “HTC
available ”to “ON”.
8.6 Prestart System Checklist

Chilled water Yes No N/A
Pipe connection complete □ □ □
Water system filled, vented □ □ □
Pumps installed, (rotation checked), strainers cleaned □ □ □
Controls (3-way, face and bypass dampers, bypass valves, etc.) operable □ □ □
Water system operated and flow balanced to meet unit design requirements □ □ □
Condenser Water □ □ □
Cooling tower flushed, filled □ □ □
Pumps installed, (rotation checked), strainers cleaned □ □ □
Water system operated and flow-balanced to meet unit requirements □ □ □
Electrical □ □ □
The chain wiring of OITS and qualified pump starter has been completed □ □ □
Power leads connected to the unit power panel(s) □ □ □
(Do not connect the wiring terminal of the starter cabinet or compressor) □ □ □
All the controller connection in accordance with relevant provisions of the manual □ □ □
The cabinet conforms to the manual □ □ □
Pump starters and interlock wired □ □ □
Cooling tower fans and controls wired □ □ □
Wiring complies with National Electrical Code and local codes □ □ □
Condenser pump starting relay (CWR) installed and wired □ □ □
Miscellaneous □ □ □
Oil cooler pipe is connected □ □ □
Relief valve piping complete □ □ □
Thermometer wells, thermometers, gauges, control wells, controls, etc., installed □ □ □
Note: This checklist must be completed and sent to the local DAIKIN Factory Service location two
weeks prior.

IX. Operation Mode

9.1 During the First Operation
The chiller shall be operated and watched during its first operation.
1. The chiller should be powered on for 6 hours before starting,. And the power must be supplied to the
electric heater continuously to preheat the oil. The oil temperature shall be higher than the saturated
evaporating temperature by 17 °C.
2. When the unit start up, the power is supply, make sure the starter and control cabinet switch is open,
closed the upper switch of the starter, after closed, measure each two phases of power supply to check
whether it's 380V,use phase sequence meter to check if sequence is right. Make sure it's correct, Close
the power inlet switch, separately check the starter voltage meter is conform to actual voltage, use
meters to measure the starter power L1 and L2 terminals to see if it's 110V, after correction, closed the
control cabinet switch, observe the unit controller and compressor controller communication and data
display if it is normal, if abnormal, please conduct the inspection and calibrated.
After long time shut down period(above 6 months),the first start should follow above instruction.
9.2 Rotation Direction of Compressor Motor
The right motor rotation direction is as follows: face the sightglass of compressor motor, and the
clockwise direction is right. Switch on chiller control and compressor control, and after the countdown is
over, the compressor is started. And then close the chiller control and compressor control within two
seconds, and then observe if the compressor rotation direction is right. Pay attention that if there are
abnormal noises in compressor during operation and inertia, and only when the mechanical inertia is
confirmed to be lost completely, and the compressor and oil pumps stop totally, can the compressor be
restarted.
Warning: The compressor cannot be operated in case of incorrect compressor rotation

direction.

V. Functions of the Chiller

10.1 Motor over-heating protection
There are four to six thermistors pre-buried inside the motor. Controller monitor the motor temperature
according to these thermistors. Once the temperature rise up to the alarm setpoint, the thermistors
send the signal to controller to stop the chiller.
10.2 Chiller Stop Alarm
Temperature sensors and pressure sensors are installed in every area wherever there are pipes lying.
These sensors can provide temperature and pressure information of the pipes for judging the operation
condition of the chiller.
Table 10-1
Temperature Sensor High Pressure Sensor Low Pressure Sensor
Compressor Suction Temperature
Compressor Discharge Temperature
Main Feed Flow Temperature Evaporator Pressure
Discharge pressure
Oil tank temperature Sensor
Oil supply temperature of plate heat
exchanger exit
Evaporator entering water temperature
Evaporator leaving water Temperature Oil supply pressure of Return oil pressure of oil
Condenser entering water temperature oil pump pump/oil tank pressure
Condenser leaving water Temperature
10.3 Surge and stall
Surge and stall are typical faults of all centrifugal chillers. This happens when the chiller is running low
load and high lifting condition. The gas velocity out of the impeller is insufficient and the gas remains in
the diffuser or delays to discharge when stall occurs. At this time the sound of compressor decreases
and impeller turns to be hot without gas discharging. The gas with high temperature reflows to the
impeller when surge occurs and the big noise and vibration cause severe damage to the compressor.
A temperature sensor is equipped in the compressor and the chiller will be closed when the condition
above occurs.
10.4 Relief valve protection equipment
As a security measure,each vessel(condenser.evaporator and oil pump)install relief valve,relief gas
when pressure is too high inside.
Dual relief valve design, adjust the three way stop valve rod, make sure one valve could working when
the other is in maintenance.
Note:when three way stop valve rod adjust to the right, No.1 valve is open,when adjust valve rod to
left,No 2 valve is open.
Fig. 10-1
If it is needed according to the local standard, customer need to install a pipe on the relief valve to
exhaust the gas. Relief piping connections to the relief valves must have flexible connectors.Typical
discharge pipe line is as follows:

Fig. 10-2
Note: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 run in accordance with
local code requirements.
When install discharge pipe on relief valve, the size of discharge pipe selection as per the size of relief
valve,then connnect to the valve.For large vessel condenser,both two relief valve should working
together,discharge pipe size selection as per the size of both two relief valve.
Refrigerant discharge pipe specification.
DAIKIN centrifugal units have relief valve settings of 160psi, 180 psi, 200 psi, and 225 psi.
Table 10-2
Chiller Safety Valve Installation Location Pressure Setting Discharge Capacity (air)
Evaporator Top of Evaporator 200psi 34.2kg/min
HTS/HTC
Condenser Top of Condenser 200psi 34.2kg/min
Oil pump Oil pump Oil pump top 200psi 2.27kg/min
Diameter of relief valve
Table 10-3
Equivalent Length (M) ≤0.67 0.67~5.6 5.6~32.2 32.2~90.4 90.4~296.8 296.8~1255
Connection Size (NPT) 1 1/4 1 1/2 2 2 1/2 3 4
Notes: 1 inch pipe is too small for the fluid from the valve. The reducing tube must be connected
on the valve outlet.
Common Piping
The discharge from more than one relief valve can be run into a common header, the area of which
cannot be less than the sum of the areas of the connected pipes.The common header can be
calculated by the formula:
D1,D2,Dn is the branch pipe area

Inspection
Inspect safety valves at least once a year. And it should be done by the customers. Replace safety
valve if corrosion or rust or grease stain is detected inside and outside of the valve body.Specific
inspection methods can be referred to the "Safety Technical Supervision Regulations for Safety Valves".
10.5 Variable Frequency Driver (VFD)
The chiller equipped with VFD can adjust the cooling capacity by both VFD and inlet guide vane.The
control logic is: at 70%~100% load arrange, maintain the guide vane fully open, adjust the unit load only
by VFD. because it is much efficient and the chiller has little risk of surge in this area. When load is
lower than 70%, Inlet guide vane is going to close. The capacity of the chiller is controlled by both VFD
and IGV in this area. It could enlarge unit operation scope.
VFD(variable frequency driver) has two advantages, One is reduce inrush current, the other is to make
chiller much more efficient according to change the RPM of the compressor.
Warning: The capacitance inside the VFD has power storage function, it is forbidden to maintain the
VFD unless 5 min after power off.
10.6 Hot Gas Bypass
All chillers can choose hot-gas bypass function. When the system load is lower than the preset
minimum capacity of the compressor, the compressor can directly discharge the gas to the evaporator
which applies to the situation where the capacity is very low.
Mirotech II control panel uses the percentage of rated current to indicate the operating state of
unloading. When the current drops to the set point, the hot-gas bypass solenoid valve is open, and the
hot air-bypass begins operation and provides a stable refrigerant for the compressor to prevent the
refrigerant from short-circuit loop under light load and surging in heat recovery operation.
10.7 Heat Recovery Chiller
HSC heat recovery chiller controls the leaving water temperature of evaporator. The cooling load
decides whether the compressor increases or decreases the load, which is the same as that of ordinary
chillers. And its control mode is also the same as that of ordinary chillers.
The hot water temperature (namely thermal load) provided by Heat Recovery Condenser is determined
by the water temperature of Cooling tower. Tee Cooling tower bypass-valve is regulated by the entering
water temperature of hot water to Heat Recovery Condenser. By sensing the signal from the

temperature sensor of tee valve, the Cooling tower can bypass enough water to warm the condensed
water and produce the hot water required by Heat Recovery Condenser.
Fig. 10-3
10.8 Heat pump
TSC/HTC-HP is heat pump. The structure and operation mode is same as chiller. The only difference is:
the control target of chiller is evaporator leaving water temperature and for heat pump ,the target is
condenser leaving water temperature. In addition, once customer choose a high leaving water heat
pump, the design pressure of the condenser will increase and the relief valve will be different.
10.9 Rapid start
Rapid start is an optional function. When chiller has this function, if chiller suffered suddenly power lose
and the standby power source is work, it can be started and supply capacity quickly. UPS and water
pump must work reliable when chiller has rapid-start function.
Note: When chiller has rapid-start function, the chilled water/cooling water pump must work with a
reliable UPS. Otherwise the tube will be frozen when chiller is rapid starting. In addition, the units still
need to keep the start-start time from when compressor starts to when it can start again.
UPS supply power to oil pump and control cabinet when chiller is suffering suddenly power lose, so it is
very important to choose a UPS. If UPS is supplied by user, it must meet these requirements.
Subject Requirement
Rated Power 5kVA/5kW
Working Mode IGBT
Rated Voltage 110Vac/120Vac±3％
Rated Frequency 50/60Hz±5Hz
Work Environment Temperature-5~40℃；Humidity5%~95%
Storage Temp. -20℃~55℃
Overload 105%~125%-1min，125%~150%-100ms
In addition, UPS must start and charge automatic when the power supply is back.
Warning: Before the power of battery is run out, any operation of UPS is not allowed!

XI. Maintenance
11.1 Temperature/Pressure Chart
Table 11-1
Temperature & Pressure Corresponding Table under Saturation Condition of R134a

°C kPa °C kPa °C kPa °C kPa
-15 64 7 275 29 648 51 1251
-14 71 8 288 30 670 52 1285
-13 78 9 301 31 693 53 1320
-12 85 10 315 32 715 54 1355
-11 93 11 329 33 739 55 1392
-10 101 12 343 34 763 56 1428
-9 109 13 358 35 787 57 1466
-8 117 14 373 36 812 58 1504
-7 125 15 388 37 837 59 1542
-6 134 16 404 38 863 60 1582
-5 143 17 421 39 890 61 1622
-4 153 18 437 40 917 62 1663
-3 162 19 454 41 944 63 1704
-2 172 20 472 42 972 64 1747
-1 182 21 490 43 1001 65 1790
0 193 22 508 44 1030 66 1834
1 204 23 527 45 1060 67 1878
2 215 24 546 46 1090 68 1924
3 226 25 565 47 1121 69 1970
4 238 26 585 48 1153 70 2017
5 250 27 606 49 1185 71 2065
6 262 28 627 50 1218 72 2113
Notes: the pressure in the above table are all relative pressure.
11.2 Maintenance routine
Maintenance routine is very important for chillers. Good maintenance could make chiller run at the best
performance and have designed life cycle.
Before maintenance you should contact with DAIKIN service person. Below are the major items to be
checked before maintenance.
1. (About safety) please refer to chapter 4.
2. When the chiller was in remote mode , you have to change the operation mode into "site operation"
on the Operator Interface Touch Screen.
3. Please hang on "Chiller Maintenance" warning to ensure the safety.
11.3 Routine maintenance details
Replace Oil Filter
DAIKIN water-cooled chiller can operate under positive pressure at any time, so the leakage will not
cause the moist air to flow inside the refrigerant loop.
The oil filter was located in the compressor. Different compressor model will have different oil filter and
location. Please contact with DAIKIN service person to change the oil filter.
Before the filter replacement, the chiller must be shut down. You will need pump all the refrigerant into
the condenser and Vacuum the compressor side. Since the compressor was connected with Evaporator

and Condenser, you need to isolate the condenser for pump down.
Cautions here, before Vacuum, open the compressor filter cover was forbidden. The positive pressure
of refrigerant might cause accident if loosen oil filter cover.
After Vacuum, Close the main oil supply stop valve of the compressor then start the replacement. when
the replacement work was done, please do the Vacuum again for compressor and Evaporator before
free the refrigerant in the condenser..
Cooling Cycle
Refrigerant Cycle
Maintenance of the refrigerant cycle includes maintaining a log of the operating conditions and checking
that the unit has the proper refrigerant charge.
At every inspection, the suction, and discharge pressures should be noted and recorded, as well as
condenser and chiller water temperatures.
The suction line temperature at the compressor should be taken at least once a month. With suction
temperature and suction pressure we could get the suction superheat. Extreme changes in sub-cooling
or suction superheat over a period of time will indicate losses of refrigerant.
Since different combination of compressor and Heat exchanger will have different performance, below
are the only reference number for superheat and sub-cooling.
The superheat temperature of suction pipe measured by temperature sensor is about 0℉～2.7℉(0℃
~1.5℃)at full-load.
The discharge superheat should be around in the range of 13℉～16℉(7℃～9℃) full load.
Liquid sub-cooling is in the range of 2ºC-5 ºC full load.
The MicroTech operator interface touch-screen panel can display all superheat and sub-cooling
temperatures.
Electric System
Maintenance of the electrical system involves the general requirement of keeping contactor clean and
connections tight and checking on specific items as follows:
1. The compressor operating current should be checked and compared to nameplate RLA value.
Normally, the actual current will be lower, since the nameplate rating represents full load operation. Also
check all pumps and fan motor amps, and compare with nameplate ratings.
2. At least once a quarter, all equipment protection controls, except compressor overloads, should be
made to operate and their operating points checked. A control can shift its operating point as it ages,
and this must be detected so the controls can be adjusted or replaced. Pump interlocks and flow
switches should be checked to be sure they interrupt the control circuit when tripped.
3. Check the motor starter contactor quarterly, keep them clean, and fasten all the connecting terminals.
4. Check the ground insulation resistance of the compressor motor every half a year and keep records
from which the insulation status can be determined. The reading of 50MΩ or less reveals the possibility
of insulation layer failure which means a further check may be necessary.
5. The rotation direction of the centrifugal compressor should be in compliance with the arrow direction
of the rear motor viewer. If the operator suspects that power supply is mistakenly connected (for
example, opposition) and hopes to regulate, please contact DAIKIN service department.
11.4 About Refrigerant, Chiller Oil
Lubricating oil
Warning!
The incorrect maintenance of lubricating system including too much oil or wrong oil brands, unqualified
oil filter and maloperation can damage oil system. And only well trained and certified service personnel
can perform maintenance. Please contact with local DAIKIN technical service agency for technical
support.
Generally no additional oil needs to be charged unless that the oil pump needs maintenance or a large
amount of lubricating oil leaks. Please contact with DAIKIN service for oil charge if necessary.
The oil and refrigerant shall avoid exposure to moist air.
The status of compressor oil reflects the compressor abrasion. It is necessary to conduct high-quality
maintenance and oil check every year. The first oil analysis can provide a benchmark for future
maintenance. The local DAIKIN branch can recommend appropriate equipment for these tests. And the
table below lists the upper limit value of metallic impurities and water content allowed by DAIKIN chiller.

Table 11-2
Element Upper limit (PPM) Operation
Aluminum 50 1
Copper 100 1
Iron 100 1
Water 150 2&3
Silicon 50 1
Total acid number (TAN) 0.19 3
Operation instructions
1) Resample after chiller operation for 500h.
a) If the upper limit value is between 100%-110%, replace the oil and oil filter, and then resample in
normal interval (generally once annually).
b) If the upper limit value is between 110%-125%, replace the oil and oil filter, and then resample after
chiller operation for 500h.
c) If the upper limit value is above 125%, check the compressor to find problems.
2) Resample after chiller operation for 500h.
a) If the upper limit value is between 100%-110%, replace the dry filter, and then resample in normal
interval (generally once annually).
b) If the upper limit value is between 110%-125%, replace the dry filter, and then resample after chiller
operation for 500h.
c) If the upper limit value is above 125%, check the situation of water leakage.
3) If TAN is smaller than 0.10, the system is safe in terms of acid number.
a) If TAN is between 0.10 and 0.19, resample after chiller operation for 1,000h.
b) If TAN is above 0.19, replace the oil, oil filter and dry filter, and then resample in normal interval.
Refrigerant charging
The chiller leak detection had been done before delivery and sufficient refrigerant has been charged
with a mark above the chiller nameplate. If additional refrigerant is needed due to transportation
damage, please repair the leak area and recharge the refrigerant after evacuation.
Refrigerant charge cautions:
1,Connect refrigerant tank with Evaporator bottom service valve, then exclude air in the pipe line. This
is to avoid non condensing air absorbing into refrigerant system.
2,Open chiller water pumps and cooling water pump, make sure the water flow through the evaporator
and condenser to keep from frozen. Water flow through the vessels must be maintained anytime
refrigerant is added or removed from the system.
Warning: After charging refrigerant to system, you have to do all the check items
per IOMM required before starting compressor.
11.5 Cleaning & Maintenance
The chiller fault is usually caused by excessive water system dirty, so routine maintenance is very
important for keep good performance.
Every time inspection on the chiller should wash the filters in the chilled water system, cooling water
system.
Replacement of Relief Valve
All the chiller condensers adopt the two relief valve for pressure protection. One for running and the
other was for backup. When the relief valves were in year inspection, we could still have the other one
for chiller running.
Replacement procedures
1. If there is a safety leak near the three-way valve rod end, switch the three-way valve to the longest,
shut directly the leaked relief valve passage, and replace the broken relief valve. The three-way valve
shall be in a shut status before and after the replacement. If there is a safety leak which is far from the
three-way valve, switch the three-way valve to the shortest and repeat the said operations.
2. Do not remove both of the relief valves on one three-way valve.
3. After replacement, please do leak check before on the relative three way valve.
Pumping down
Pump the system down, extreme care must be taken to avoid the water side from freezing. Always
make sure that full water flow is maintained through the chiller and condenser while pumping down. To
pump the system down, close all liquid line valves. With all liquid line valves closed and water flowing,
using the specified refrigerant pump to move refrigerant into condenser or other container.

Leak Testing
In case of chiller leakage, the unit must be done leak check before charging the complete system.
Please use nitrogen gas to raise the chiller system pressure, adding sufficient dry nitrogen to bring the
pressure up to a maximum of 125 psig (860 kPa), do the leak check with right device.
Note: Do not use the Refrigerant and air mixture or oxygen to raise the pressure, it
prevent explosion.
After leak checking, make sure no leakage of unit, you need to vacuum the chiller system.
Evacuation
If no leak point is found after detection, vacuum the chiller with vacuum pump, the vacuum-pump
capacity of which should reach 133Pa.
Halogen leak detector should be used to test if there is a leak point after changing the refrigerant.
11.6 Oil Heater information
The oil heater is installed at bottom of oil sump, so it can be directly for maintenance or replacement.
1. The oil heater circuit needs to be powered on for long time to separate the oil from refrigerant. If the
control circuit is powered off, the oil temperature will decrease.
Notes:
a. The Electric Heater must be supplied with electricity continuously to preheat the oil. Before heating, it
must ensure that oil feed valve and vent line balance valve are closed totally. Open the oil return valve
to avoid high oil sump pressure, which benefits the separation of oil from refrigerant .
b. If the chiller needs shutdown for long time (more than one month), please close all valves of oil pump
before power off.
c. In case of lose power over than 20 minutes, the vent line balance valve and oil feed line valve must
be closed immediately.

XII. Off-season Precautions

When the unit is shut down, the oil heater and controller shall also be powered on to maintain
the oil tank temperature.
In case of shutdown for long time, please ensure that the power supply is cut off, before that the
vent line balance valve on oil Sump(ball valve above the gear housing for CE140-160), oil feed
valve and oil return valve must be closed .
The above pictures from left to right are valve’s position of CE079-129/CE140/CE160.
The following maintenance is mandatory before the off-season and the restart.
12.1 Annual Shutdown
Where the chiller plant room temperature can be freezing temperature, the condenser and evaporater
must be drained of all water. Dry nitrogen blown through the condenser and evaporator will aid in
forcing all water out. Removal of vessel heads is also recommended. The condenser and evaporator
are not self-draining. If Water remains in the piping or vessels, lower temp may cause freeze and tube
might be broken.
Forced circulation of anti-freeze through the water circuits is one good method of
avoiding freeze.
1. Make sure the shutoff valve in the water supply line was closed.
2. Make sure to remove the water pump line drain plug, leave all water out.
3. Open the compressor disconnect switch. Set the manual COMPRESSOR and UNIT ON/OFF
switches in the Unit Control Panel to the OFF position.
4. Check for corrosion and clean and paint rusted surfaces.
5. Clean and flush cooling tower of all units for next starting up.
6. Remove condenser heads at least once a year to inspect the condenser tubes and clean if required.
12.2 Annual Starting up
If the chiller starter was broken, apply the power to chiller is forbidden. Before starting up, you have to
check each major component per instruction.
Firstly All motor coil grounding resistance needs to be checked, every six months and docking ground
resistance value check detailed record, because the resistance value will reflect the aging of the coil
insulation. New electrical wiring of the unit and the resistance value should be higher than 100 M Ω.
Once reading changed or average reading value is less than 50 M Ω, need to inspection for motor
terminals or motor inside. When reading less than 5 M Ω, the motor need to replace and repair. Please
contact with DAIKIN service person.

XIII. Chiller alarm list
13.1 Chiller Shutdown Alarm

The following table 20 described fault type: all alarm can cause the chiller to shut down quickly (it needs
to clear alarm manually).
Table 13-1
Fault Possible reasons Inspection methods
1. The leaving water temperature of 1. Check if the water flow rate is too
chilled water is too low small.
2. The leaving water temperature 2. Replace the temperature sensor.
sensor of chilled water fault. 3. Charge refrigerant.
Lower evaporator pressure 3. The chiller lacks refrigerant. 4. Open the chilled water pump or
4. No chilled water circulation or check the status of water pump.
water pump fault. 5. Open liquid line valve.
5. The main liquid supply valve is
not opened.
1. The inlet temperature of cooling 1. Increase the flow rate of cooling
water is too high. water
2. The condenser leaving water 2. Replace temperature sensor.
temperature sensor . 3. Check the status of cooling tower
3. Inadequate cooling water flow and water pump.
rate or water pump fault. 4. Clean the valve and filter.
High condenser pressure
4. The valve of cooling water is 5. Clean the condenser and heat
blocked. exchanger
5. Heat exchange tubes of 6. Discharge non-condensable gas.
condenser scales seriously.
6. The system is mixed with non-
condensable gas.
1.Inadequate oil supply pressure 1. Observe the low oil pressure
2. The sensor of vane position items.
The guide vane is not
detection faults. 2. Check the sensor.
opened.
3.Mechanical faults inside the 3. After the exclusion of other
compressor reasons, check the compressor.
1. Oil pump motor faults. 1. Check the working status of oil
2. Oil pressure adjusting valve pump.
faults. 2. Replace the adjusting valve.
3. Oil filter is blocked. 3. Replace the oil filter.
Low oil pressure difference
4. The oil feed three way valve is 4. Check the oil supply valve.
not opened enough. 5. Replace the sensor
5. The sensor of oil supply pressure
faults.
1. The oil feed temperature is low. 1. Check the oil feed temperature
2. The amount of oil and cooling 2. Reduce the amount of oil and
Low oil feed temperature water is adjusted inappropriately. cooling water
3. The thermal valve of oil and 3. Check the thermal valve of oil and
cooing leaving water faults. cooing leaving water
1. Oil supply temperature is high. 1. Check the oil supply temperature.
2. The amount of oil and cooling 2. Increase amount of oil and
High oil feed temperature water is adjusted inappropriately. cooling water
3. The thermal valve of oil and 3. Check the thermal valve of oil and
cooing leaving water fails. cooing leaving water

Fault Possible reasons Inspection methods
Low motor current The current set value is too high. Reset
1. Compressor overload. 1. Limit the compressor load.
High motor current 2. The current set value is too low. 2. Replace the current set value.
3. Motor damage. 3. Replace the motor
1. HP sensor faults. 1. Check and replace it
Mechanical HP switch 2. Condenser water temp too high 2. Check cooling tower and
condenser water flow
Discharge temperature sensor Check and replace it
High discharge temperature
faults.
Control cabinet faults or the control Rapidly check all the wiring and all
shutdown signal is not received due electric components of the control
No alarms shutdown
to line fault (no shutdown from such cabinet.
alarm)
1. Contactor fault. 1. Check contactor.
2. Relay fault. 2. Check relay
3. The protection circuit is 3. Check starting sequence line per
disconnected. schematic.
Starter fault 4. Power supply problems 4. Verify line voltage within 90%
-110% of rated voltage. Then, phase
sequence protection alarm can be
reset by manually rebooting the
cabinet.
1. Control circuit fault. 1. Check and exclude

2. Electric parts fault in control 2. Check and exclude or replace.
Starter has no transition
circuit. 3. Check and exclude or replace
3. Contactor fault
1. The pilot valve is adjusted 1. If the pilot valve is damaged,
inappropriately. replace it.
Surge 2. EXV or liquid level sensor issue 2. Check EXV movement or liquid
3. Suction temperature sensor fails. level sensor
2. Check the sensor
leaving water temperature
sensor fault of chilled water
Evaporating pressure
sensor fault
Condensing pressure
sensor fault 1. Check if the sensor is short
Suction temperature sensor circuited or open circuited, if so
fault reconnect it.
Discharge temperature The sensor is short circuited, open 2. Use the ammeter to check if the
sensor fault circuited or damaged. output signal of the sensor is within
Oil supply temperature the working range.
sensor fault 3. If the sensor is damaged, replace
Oil pump temperature it.
sensor fault
Oil supply pressure sensor
fault
Pressure sensor fault of oil
pump
The following pre-alarm fault: no shutdown in case of such pre-alarm, but some operations may be
restricted.

Table 13-2
Low evaporator pressure (see the above table for low
prohibit load up. evaporator low pressure )
Low evaporator pressure, force
unload.
Evaporator freezing protection. Low saturated pressure in Rapid starting of evaporator
evaporator. water pump
Condenser freezing protection. Low condenser saturated pressure. Rapid starting of condenser
water pump
13.2 Chiller warning notes
The following belongs to warning notes show on the chiller, chiller still running.
Table 13-3
Alarm of liquid supply 1. Check if the sensor is short
temperature sensor fault circuited or open circuited, if so
Evaporate entering water reconnect it.
temperature sensor fails. The sensor is short circuited, open 2. Use the ammeter to check if the
circuited or damaged. output signal of the sensor is within
Alarm of condenser the working range.
leaving water temperature
3. If the sensor is damaged, replace
sensor fault
it.
1. High discharge temperature2.
Take appropriate measures of
High discharge overheat Condensing saturated temperature is
increasing load.
too low.

XIV Operating Limits

14.1 Operating range
Typical Starting up envelope for DAIKIN water-cooled chiller. Customized unit will have different start
up window.
EXV
Positive temperature difference across evaporator and condenser must be established in 5 minutes
after the chiller start to run. If not, add cooling water bypass valve.
Operation of low condenser water temperature
If the wet bulb temperature of the ambient temperature is lower than the designed conditions, the water
temperature of condenser can be reduced. The low temperature can improve the chiller performance.
DAIKIN centrifugal chiller applying HTS063-160 compressor is equipped with electronic expansion
valve (EXV), and the condenser entering water temperature curve is shown in the figure below, and can
be obtained by the formula edited by the curve. The formula is shown as follows.
Lowest entering water temperature of cooling water (EXV)
Fig. 14-1

Min. CEWT=0.78+0.88*（ELWT）-DTFL*（PLD/100）+12.2*（PLD/100）2
●CEWT= Condenser Entering Water Temperature
●ELWT= Evaporator Leaving Water Temperature
●DTFL=△T Under Full-load
●PLD=Chiller Load Point To Be Tested

For example, if the leaving water temperature is 6.7 °C, and when the chilled water is under full load,
the △t=5.6 °C. In case of 50% of full load, the cooling entering water temperature can reach as low as
6.9 °C. This provision can ensure the economy of water circuit system.
Fig. 14-2 has shown the operation of cooling tower bypass.
Operating mode of cooling tower bypass
Fig. 14-2
Condenser Water Temperature
When the ambient wet bulb temperature is lower than design, the entering condenser water
temperature can be allowed to fall, improving chiller performance.
DAIKIN chillers will start with entering condenser water temperature as low as 12.8°C providing the
chilled water temperature is below the condenser water temperature.
Depending on local climatic conditions, using the lowest possible entering condenser water temperature
can be more costly in total system power consumed than the expected savings in chiller power would
suggest due to the excessive fan power required.
Control cooling tower fan or adopt some measures to control water flow rate: for example, the water
bypass passing through the cooling tower.
14.2 Water flow scope
For the cooling water: the turbulent condition cannot be reached in the slow flow velocity, and the heat
exchange efficiency drops greatly;
And if flow velocity too high, the chiller water pressure drop enlarges, the water pump power
consumption raised and the lifetime of the heat exchange tube shortens.
V min=3 ft/s =0.9 m/s
V max=12ft/s=3.6 m/s
7500
Vmin  
For the chilled water: D , wherein - kinematic viscosity; D – pipeline diameter;
V max=12 ft/s=3.6 m/s
14.3 Minimum water content in piping system
To avoid the frequent start and stop of the chiller, and keep the running continuously, the minimum
water retaining capacity of the chilled water system shall take the following calculation value.
The minimum water retaining water calculation formula Ｑ(m3)＝(Ｔ×６０)×Ｈ/(Δｔ×Ｃｐ×ρ)
WhereinＴ: Compressor’s minimum running time (time) is calculated by 15 min
H: Chiller’s capacity control capacity (kW) = cooling capacity under full load (kW) ×0.3
Δt: Constant temperature fluctuation = 3.4°C.
Cp: Secondary refrigerant specific heat (kJ/kg°C) ρ: secondary refrigerant proportion (kg/m 3)
The cooling capacity under full load: calculated by the chiller’s maximum cooling capacity as for the
single compressor chiller; calculated by 50% of the maximum cooling capacity as for the double
compressor chiller.

14.4 Application Standard
Using standard benchmark chiller running environment is as follows:
Table 14-1
Supply Voltage 380V±10%
Phase Voltage Unbalance Rate ±2%
Frequency 50 Hz±2%
Operating Temperature 3-40°C
Relative Humidity Water chiller(EEWT≥5℃), for environment temperature10-32℃，the
max humidity available is 70% of 20mm’s thermal insulation of
evaporator, 80% of 40mm’s thermal insulation of evaporator
Ice storage chiller(-6℃≤EEWT ＜ 5℃), for environment
temperature10-32℃ ， the max humidity available is 70% of 40mm’s
thermal insulation of evaporator
Atmospheric Corrosive Gas Sulfur Dioxide: ≤10 mg/m3
Contents Hydrogen Fluoride: ≤5 mg/m3
Hydrogen Sulfide: ≤5 mg/m3
Nitrogen Oxides: ≤5 mg/m3
Nitrogen: ≤1 mg/m3
Hydrogen Chloride: ≤5 mg/m3
Installation Indoor installation, no rain or direct sunlight (for installations of the
outdoor, seaside, chemical plant, or places of high concentration of
corrosive gas, please contact the local McQuay office and distributors)
Water Temperature Range of
See 14.1
water chiller
Water Capacity Range See 14.2
Heat Exchange Tube Waterside Standard chiller 1.0Mpa (may be designed as per the customer’s
Pressure requirements)
14.5 Water Quality Management
When the chiller is running, the water quality of cooling water, chilled water will directly affect the
machine performance and service life. So you must survey water quality in advance. And manage the
water quality.
The following table contains some parameters of the water quality of open system:
Table 14-2
Reference Item
Item Chiller
Value Corrosion Scaling
pH (25°C) — 6.5-8.0 O O
Specific (25°C) s/cm ＜800 O O
 
Chloridion Cl Mg( Cl )/L ＜200 O
Basic
2 2
Item Sulfate ion SO 4 mg SO /L 4 ＜200 O
Acid consumption (pH=4.8) mg( CaCO3 )/L ＜100 O

Full hardness mg( CaCO3 )/L ＜200 O
Iron Fe) Mg(Fe)/L ＜1.0 O O
2 2
Referenc Sulphion S Mg( S )/L Not Detected O
e  
Item Ammonium ion NH mg( NH )/L ＜1.0 O
Silicon oxide SiO 2 mg( SiO 2 )/L ＜50 O
Notes: 1. Water quality indicators with reference to the vapor compression cycle cold water (heat pump)
unit of GB/T18430.1, appendix D cooling water quality.
2. "O" in the table the relevant factors of corrosion or scaling tendency.
3. Such as water quality can’t meet the above requirements, reference GB50050-2007 specification for
design of industrial circulating cooling water treatment for processing.

14.6 About Coolant
When the coolant is ethylene glycol, please according to the evaporator leaving water temperature to
correspond recommended ethylene glycol, please check table, and due to the temperature condition of
the concentration of the cold should not be less than the recommended value:
Table 14-3
Evaporator leaving water Recommended Glycol
Temperature Range (°C) Concentration (%)
0 ～３１５
－3 ～0 ２０
－6 ～－3 ２５
－１０～－6 ３０

Table
Maintenance and Inspection Schedule
Interval or run time Replacement standards

6 months 1 year 2years 3years 5years 7years 15years in case of abnormalities
2500 4000 8000 12000 20000 28000

Inspection items
Hours Hours Hours Hours Hours Hours 　
Monthly inspection items 1. Check the color of liquid supply pipe liquid sight glass test paper (the yellow shows
that the water content in refrigerant exceeds standard)
2. Check if the refrigerant circuit has leakage (if there is greasy dirt around the pipe
and noise leakage)
Compressor During operation,

abnormal situation
(noise and surge)
occurs or small
fragments are found
during inspection;
replace sealing
Impeller ● ▲ components.
Gear ● ▲
During inspection, the

insulation resistance is
Motor stator ● ▲ found abnormal
Solenoid valve During inspection, the

(energy control insulation resistance is
and spray) ● ▲ found abnormal
Oil heater ● ▲
During operation, the

pressure difference
between main oil supply
Compressor oil outlet and four-way
filter ▲ ▲ ▲ ▲ valve exceeds 1.5bar.
During operation, the

pressure difference
exceeds the range: 0.1-
Oil pump oil filter △ ● ▲ 0.2bar
Lubricating oil Implement based on

● ▲ Item 11.5 in Table 19
Heat Heat exchange ● ▲ The small heat

exchanger tube: physical exchange temperature
cleaning or difference is larger than
chemical cleaning 3 °C


2500 4000 8000 12000 20000 28000

Inspection items
Oil cooler: Inspect based on Item

chemical cleaning ● ▲ 3.4.
Water pressure If the water pressure

difference difference is too large
between vessel or too small, adjust the
inlet and outlet water flow rate to the
(see the table of standard
chiller model
selection) ●
Valves During inspection, the

overheat degree cannot
Thermal be opened, closed and
expansion valve ● ▲ controlled normally
During inspection, the

Electronic switch cannot be
expansion valve ● ▲ operated normally
Electric The signal cannot be

control input and output
cabinet Control ● ▲ normally
Fuse ● Disconnect
During inspection, there

is serious contact
electro-corrosion or
Contactor ● noise during operation
The corrective test

valve is larger than the
Pressure sensor ● ▲ ▲ actual value by 7kPa
The test valve is larger

Temperature than the actual value by
sensor ● ▲ ▲ 1 °C
Send alarm signal when

it fails to reach the
alarm value or send no
alarm signal when it
HV switch ● ▲ reaches the alarm value
capacitor leak, safety
Capacitor of VFD ▲
valve swell,
IF VFD equipped
the capacitance value
is below 85% of the
nominal
capacity


2500 4000 8000 12000 20000 28000

Inspection items
Turn the connection

Check if the wiring wires, and find that the
point is loose connection point is
(retighten) ● loose or can rotate
Others
Rated voltage ±10%,
Power supply and interphase
inspection ● imbalance＜2%
Water quality
inspection
(scaling, Inspect according to
impurities) ● international standards
This is critical part for

the compressor
protection, excluding
the situation of water in
chiller. It is suggested
to replace it in
accordance with
requirements in this
Dry filter cartridge ▲ Table.
Notes:
1.●:Conduct inspection based on this cycle, and replace it when the abnormality reaches replacement
standards.
△: The first replacement and cleaning time are suggested.
▲: The next replacement and cleaning time are suggested.
2. Replaced parts should be determined based on interval and run time, whichever occurs first shall
govern.
3. Monthly inspection items shall be checked and recorded by customers, and other inspection items
shall be conducted by DAIKIN professional service personnel.
Notes:
1. Some compressor using the power factor correction capacitor, and all compressor use absorption
capacitor (in addition to using soft starter ), absorption capacitor is installed inside the compressor
motor terminal box. In all cases, the capacitance must break from the circuit to get the correct
resistance reading, otherwise will get a low data. When dealing with electrical components, the operator
must have related certification for qualified technical personnel.
2. The approximate temperature of condenser/evaporator(Containers of water temperature and
saturated temperature difference between refrigerant) is a reaction to tube fouling. Especially when
the condenser water flow fixed, fouling reflected in pipe is obvious. DAIKIN efficient heat exchanger has
a fairly low close to the temperature difference, generally from 0.8 ℃ to 1.5 ℃.
The chiller can display the temperature and saturation temperature of the refrigerant. A simple
subtraction can get approximate temperature .This method of reading is a recognized (including
condenser water pressure drop is determined.) If the approximate temperature increase 2 degrees
even above it, means there is too much dirt in the pipe. The discharge pressure and the size of current
also reflect the tube fouling conditions.
3. In the use of treated water or antifreeze liquid evaporator in closed loop is generally not affected by
dirt, but must also be hard to detect the contents of the dirt on a regular basis.
4. After the expiration of the contract will no longer provide the original standard service.

5. The oil filter should be replaced, and the compressor cannot be dismantled and tested before the
annual oil quality test results are available.

Service Procedure
The proper maintenance prolongs service life and enhances performance of the AC
system.
The maintenance starts basically as the chiller starts. 3 to 4 weeks after the first start-up, it
must be overall inspected, followed by periodical maintenance.
DAIKIN provides diversified maintenance service according to different customer needs.
Contact Methods
DAIKIN INDUSTRIES, LTD.
Head Office: Umeda Center Bldg., 2-4-12, Nakazaki-Nishi, Kita-ku, Osaka, 530-8323
Japan
★The printing may deviates from the real products, please refer to the real object when purchasing.
★Models, parameters and performance may change due to product improvement without further
notification. Please refer to the nameplate for detail.

Installation and Maintenance Manual

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IMM HTS/HTD/HTC

Installation and Maintenance Manual

Date: Oct. 2019

New part No.: Z8100190-13

Old part No.: Z8100190-12

Centrifugal Water Chiller

This Manual is applicable to following models and their derived and

HTS/HTD/HTC Water-cooled Chiller

Thanks for purchasing DAIKIN chiller.

The Manual specifies safety，installation and maintenance precautions.

Please read through the manual before installation and operation.

Engineered for Flexibility and Performance

III. WORKING PRINCIPLE AND TECHNICAL DATA............................................................3

Engineered for Flexibility and Performance 1

Maintenance and Inspection Schedule.............................................................................................56

Engineered for Flexibility and Performance 2

1.1 General Description

Engineered for Flexibility and Performance 3

II. Major Component Locations

Engineered for Flexibility and Performance 4

III. Working Principle and Technical Data

Engineered for Flexibility and Performance 5

Engineered for Flexibility and Performance 6

Connection Size (NPT) 1 1 1/2

Engineered for Flexibility and Performance 7

IV. About Safety

Engineered for Flexibility and Performance 9

4.3 Precautions (Remove and repair)

Engineered for Flexibility and Performance 10

V. Receiving and Handling

Engineered for Flexibility and Performance 11

Engineered for Flexibility and Performance 12

Engineered for Flexibility and Performance 13

Engineered for Flexibility and Performance 14

Spring isolator installation

Engineered for Flexibility and Performance 15

Fig. 6-3 079-087 chillers

Fig. 6-4 100-160 chillers

Table 6-2 floor type chillers

Engineered for Flexibility and Performance 16

Engineered for Flexibility and Performance 17

Chilled Water Pump

Engineered for Flexibility and Performance 18

Engineered for Flexibility and Performance 19

Fig. 6-6 Site connection diagram

Engineered for Flexibility and Performance 21

Fig. 6-7 Site connection diagram

Engineered for Flexibility and Performance 22

Cable wiring table

Copper wiring terminal maximum size（L×B，mm）

Engineered for Flexibility and Performance 24

Engineered for Flexibility and Performance 26

Fig.6-11 MicrotechV Box Grounding Fig.6-12 UPS Starter Grounding

E) UPS wiring precautions.

F) Wiring confirmation has been connected.

Engineered for Flexibility and Performance 27

VII Operation of OITS

Engineered for Flexibility and Performance 28

Engineered for Flexibility and Performance 29

Engineered for Flexibility and Performance 30

IGV control principle is as follows：

The module wiring diagram is shown in Fig.7-6