Installation, Operation, IOM 1359

and Maintenance Manual Group: Chiller

Part Number: IOM1359
Date: January 2024

Trailblazer®
Air-Cooled Scroll Chillers
Model AGZ, F-Vintage
30 to 245 Tons (100 to 860 kW)
R-32 Refrigerant
60 Hz
 Table of Contents

Table of Contents Circuit Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Circuit Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Hazard Identification Information . . . . . . . . . . . . . . 3
Touchscreen Controller . . . . . . . . . . . . . . . . . . . . . . 55
UL Compliance Statements . . . . . . . . . . . . . . . . . . 4
Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit/Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
General Description . . . . . . . . . . . . . . . . . . . . . . . . 5
Circuit 1/Circuit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operating Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Startup and Shutdown Procedures . . . . . . . . . . . . . 57
Lifting Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pre-Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Unit Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Startup Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Service Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Post Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Application Consideration . . . . . . . . . . . . . . . . . . . . 12
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . 12
Flow Switch Installation and Calibration . . . . . . . . 58
Water Flow Limitations . . . . . . . . . . . . . . . . . . . . . 13
Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pressure Drop Data . . . . . . . . . . . . . . . . . . . . . . . . . 16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Terminals . . . . . . . . . . . . . . . . . . . . . . . . 63
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . 18
Compressor Maintenance . . . . . . . . . . . . . . . . . . . 63
Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Unit Controller Operation . . . . . . . . . . . . . . . . . . . . . 22
All-Aluminum Condenser Coils . . . . . . . . . . . . . . . 64
General Description . . . . . . . . . . . . . . . . . . . . . . . 22
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Controller Inputs and Outputs . . . . . . . . . . . . . . . . 23
Liquid Line Solenoid Valve . . . . . . . . . . . . . . . . . . 65
Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
High Ambient Control Panel . . . . . . . . . . . . . . . . . 65
Unit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 65
Evaporator Pump Control . . . . . . . . . . . . . . . . . . . 30
Hot Gas Bypass (Optional) . . . . . . . . . . . . . . . . . . 66
Unit Capacity Overrides . . . . . . . . . . . . . . . . . . . . 32
Refrigerant Charging . . . . . . . . . . . . . . . . . . . . . . . 68
Circuit Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 33
R-32 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Compressor Control . . . . . . . . . . . . . . . . . . . . . . . 34
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . 70
Condenser Fan Control . . . . . . . . . . . . . . . . . . . . . 35
Competence of Personnel . . . . . . . . . . . . . . . . . . 71
Staging Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Staging Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Variable Speed Fan Control . . . . . . . . . . . . . . . . . 42
Pre-Start Checklist . . . . . . . . . . . . . . . . . . . . . . . . 78
EXV Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Warranty Registration Form . . . . . . . . . . . . . . . . . 79
Alarm and Events . . . . . . . . . . . . . . . . . . . . . . . . . 45
Limited Product Warranty . . . . . . . . . . . . . . . . . . . 84
List and Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
©2024 Daikin Applied, Minneapolis, MN. All rights reserved throughout the world.This document contains the most current product information as
of this printing. Daikin Applied Americas Inc. has the right to change the information, design, and construction of the product represented within the
document without prior notice. For the most up-to-date product information, please go to www.DaikinApplied.com.
™® Trailblazer, MicroTech, and Daikin Applied are trademarks or registered trademarks of Daikin Applied Americas Inc. The following are
trademarks or registered trademarks of their respective companies: BACnet from American Society of Heating, Refrigerating and Air-Conditioning
Engineers, Inc.; Echelon, LonWorks, LonMark, and LonTalk from Echelon Corporation; Modbus from Schneider Electric; and Windows from
Microsoft Corporation.

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 2 www.DaikinApplied.com

 Safety Information

Safety Information WARNING

This manual provides installation, operation, and maintenance Electric shock hazard. Improper handling of this equipment
information for Daikin Applied Trailblazer® AGZ-F air-cooled can cause personal injury or equipment damage. This
scroll chillers with a MicroTech® unit controller. equipment must be properly grounded. Connections to and
service of the MicroTech control panel must be performed only
NOTE: Installation and maintenance are to be performed
by personnel that are knowledgeable in the operation of the
only by licensed, if required by local codes and
regulations, or qualified personnel who are familiar equipment being controlled.
with local codes and regulations and are experienced
with this type of equipment. WARNING
Polyolester Oil, commonly known as POE oil is a synthetic
WARNING
oil used in many refrigeration systems, and may be present
This unit contains R-32, a class A2L in this Daikin Applied product. POE oil, if ever in contact
refrigerant that is flammable. This unit with PVC/CPVC, will coat the inside wall of PVC/CPVC
should only be installed, serviced, pipe causing environmental stress fractures. Although there
repaired, and disposed of by qualified is no PVC/CPVC piping in this product, please keep this in
personnel licensed or certified in their mind when selecting piping materials for your application, as
jurisdiction to work with R-32 refrigerant. system failure and property damage could result. Refer to the
Installation and maintenance must be pipe manufacturer’s recommendations to determine suitable
done in accordance with this manual. applications of the pipe.
Improper handling of this equipment
can cause equipment damage or
CAUTION
personal injury.
Be aware that R-32 refrigerant may not contain an odor. Place Static sensitive components. A static discharge while handling
in a well ventilated area to prevent accumulation of refrigerant. electronic circuit boards can cause damage to the components.
When installing the unit in a small room, take measures to keep Discharge any static electrical charge by touching the bare
the refrigerant concentration from exceeding allowable safety metal inside the control panel before performing any service
limits. Excessive refrigerant leaks, in the event of an accident work. Never unplug any cables, circuit board terminal blocks,
in a closed ambient space, can lead to oxygen deficiency or power plugs while power is applied to the panel.

Do not pierce or burn this unit.

Never use an open flame during service or repair. Never Hazard Identification Information
store in a room with continuously operating ignition sources
(for example: open flames, an operating gas appliance, or DANGER
and operating electric heater.), where there is ignitable dust Danger indicates a hazardous situation, which will result in
suspension in the air, or where volatile flammables such as death or serious injury if not avoided.
thinner or gasoline are handled.
Only use pipes, nuts, and tools intended for exclusive use WARNING
with R-32 refrigerant in compliance with national codes Warning indicates a potentially hazardous situations, which
(ASHRAE15 or IRC). can result in property damage, personal injury, or death if not
Do not mix air or gas other than R-32 in the refrigerant system. If avoided.
air enters the refrigerant system, an excessively high pressure
results, which may cause equipment damage or injury. CAUTION
For more information, consult “R-32 Guidelines” on page 68. Caution indicates a potentially hazardous situations, which
can result in minor injury or equipment damage if not avoided.
DANGER
LOCKOUT/TAGOUT all power sources prior to service, NOTICE
pressurizing, de-pressuring, or powering down the unit. Notice indicates practices not related to physical injury.
Failure to follow this warning exactly can result in serious
injury or death. Disconnect electrical power before servicing
the equipment. More than one disconnect may be required NOTE: Indicates important details or clarifying statements for
information presented.
to denergize the unit. Be sure to read and understand the
installation, operation, and service instructions within this
manual.

www.DaikinApplied.com 3 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Safety Information

UL Compliance Statements gas (25 % maximum) is confirmed.

• Ensure that contamination of different refrigerants does
• All maintenance staff and others working in the local area
not occur when using charging equipment.
shall be instructed on the nature of work being carried
out. Work in confined spaces shall be avoided. • Ensure that contamination of different refrigerants does
not occur when using charging equipment.
• Ensure that the leak detection equipment being used is
suitable for use with all applicable refrigerants, i. e. non- • Hoses or lines shall be as short as possible to minimize
sparking, adequately sealed or intrinsically safe. the amount of refrigerant contained in them.
• If any hot work is to be conducted on the refrigerating • Cylinders shall be kept in an appropriate position
equipment or any associated parts, appropriate fire according to the instructions.
extinguishing equipment shall be available to hand and • Ensure that the REFRIGERATING SYSTEM is earthed
Have a dry powder or CO2 fire extinguisher adjacent to prior to charging the system with refrigerant.
the charging area. • Label the system when charging is complete (if not
• Prior to work taking place, the area around the equipment already).
is to be surveyed to make sure that there are no • Prior to recharging the system, it shall be pressure-tested
flammable hazards or ignition risks and “No Smoking” with the appropriate purging gas.
signs shall be displayed. • After charging a follow up leak test shall be carried out
• Where electrical components are being changed, they prior to leaving the site.
shall be fit for the purpose and to the correct specification. • Ensure that the correct number of cylinders for holding
If an indirect refrigerating circuit is being used, the the total system charge is available.
secondary circuit shall be checked for the presence of
• Cylinders shall be complete with pressure-relief valve and
refrigerant.
associated shut-off valves in good working order.
• Marking to the equipment continues to be visible and
• Empty recovery cylinders are evacuated and, if possible,
legible. Markings and signs that are illegible shall be
cooled before recovery occurs.
corrected.
• The recovery equipment shall be in good working order
• Refrigerating pipe or components are installed in a
with a set of instructions concerning the equipment that
position where they are unlikely to be exposed to any
is at hand and shall be suitable for the recovery of the
substance which may corrode refrigerant containing
flammable refrigerant.
components, unless the components are constructed of
materials which are inherently resistant to being corroded • If in doubt, the manufacturer should be consulted. In
or are suitably protected against being so corroded. addition, a set of calibrated weighing scales shall be
available and in good working order. Hoses shall be
• If the fault cannot be corrected immediately but it is
complete with leak-free disconnect couplings and in good
necessary to continue operation, an adequate temporary
condition.
solution shall be used. This shall be reported to the owner
of the equipment so all parties are advised. • If compressors or compressor oils are to be removed,
ensure that they have been evacuated to an acceptable
• No live electrical components nor live wiring are exposed
level to make certain that flammable refrigerant does not
while charging, or recovering or purging the system.
remain within the lubricant.
• Ensure continuity of earth bonding.
• For Installation in Locations Not Accessible to General
• Check that cabling will not be subject to wear, corrosion, Public.
excessive pressure, vibration, sharp edges or any other
• Unit not to be used by persons (including children) with
adverse environmental effects.
reduced physical, sensory or mental capabilities, or lack
• Inspections shall take into account the effects of aging or of experience and knowledge, unless they have been
continual vibration from sources such as compressors or given supervision or instruction.
fans.
• Children shall not be allowed to play on or with unit.
• If repairs are required to sealed electrical components;
• If unit is permanently connected to water main; hose sets
the sealed electrical components shall be replaced.
are not to be used.
• If repairs are required to intrinsically safe components;
• Maximum water side operating pressure for Unit is 435
the intrinsically safe components must be replaced.
psig.
• Electronic leak detectors may be used to detect
refrigerant leaks but, in the case of FLAMMABLE
REFRIGERANTS, the sensitivity may not be adequate,
or may need re-calibration. (Detection equipment shall be
calibrated in a refrigerant-free area).
• Leak detection equipment shall be set at a percentage of
the LFL of the refrigerant and shall be calibrated to the
refrigerant employed, and the appropriate percentage of

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 4 www.DaikinApplied.com

 Introduction

Introduction Unit Labels

Pictogram warning and informational labels may be present on
the unit. Consult the table below for reference.
General Description
Daikin Applied Trailblazer air-cooled water chillers are Label Description
complete, self-contained, automatic chillers designed for
outdoor installation only. Packaged units are completely
assembled, factory wired, charged, and tested.
WARNING - flammable refriger-
The electrical control center includes all equipment protection ant present
and operating controls necessary for dependable automatic
operation. Components housed in a centrally located, weather
resistant control panel with hinged and tool-locked doors.

Nomenclature
WARNING - flammable refrigerant
present

Read the technical manual for

service instructions

No. Description
1 A = Air-Cooled
2 G = Global WARNING - A2L low-burning
velocity refrigerant present
3 Z = Scroll Compressor
4 Number of Fans
5 Design Vintage
6 Compressor Code

Pressurized medium present

Ultraviolet (UV) radiation present

Read the technical manual for

instructions

www.DaikinApplied.com 5 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Installation

Installation Inspection
Check all items carefully against the bill of lading. Inspect
all units for damage upon arrival. Report shipping damage
Operating Limits and file a claim with the carrier. Check the unit nameplate
before unloading, making certain it matches with the power
Table 1: Operating/Standby Limits supply available. Daikin Applied is not responsible for physical
damage after the unit leaves the factory.
Maximum standby ambient temperature 130°F (54°C)
Maximum operating ambient temperature 105°F (41°C)
Maximum operating ambient temperature with Lifting Guidance
optional high ambient package (see information 125°F (52°C) Daikin Applied equipment is designed to withstand the loads of
under High Ambient Operation)
the lifting and rigging process resulting from ASME Standard
Minimum operating ambient temperature P30.1 - Planning for Load Handling Activities or equivalent.
32°F (0°C)
(standard control)
Lifting guidance is intended for installations of newly delivered
Minimum operating ambient temperature (with equipment. If moving previously installed equipment for re-
-4°F (-20°C)
optional low-ambient control)
location or disposal, consideration should be given to unit
40°F to 70°F condition. Equipment should also be drained as unit weight
Leaving chilled water temperature
(4°C to 21°C)
and center of gravity values do not reflect the addition of water
Leaving chilled fluid temperatures (with glycol) - for lifting.
Note that in cases of high ambient temperature,
the lowest leaving water temperature settings 15°F to 70°F
may be outside of the chiller operating (-9°C to 21°C)
DANGER
envelope; consult Daikin Tools to ensure chiller Improper rigging, lifting, or moving of a unit can result in unit
is capable of the required lift. damage, property damage, severe personal injury or death.
Operating chilled water delta-T range
6°F to 20°F See the as-designed, certified dimensioned drawings included
(3.3°C to 11.1°C) in the job submittal for the weights and center of gravity of the
Maximum evaporator operating inlet fluid
81°F (27°C)
unit. If the drawings are not available, consult the local Daikin
temperature Applied sales office for assistance.
Maximum evaporator non-operating inlet fluid
temperature
100°F (38°C) Installation is to be performed only by qualified personnel who
are familiar with local codes and regulations, and experienced
with this type of equipment. Lifting equipment and mechanisms
Nameplates must be determined by the Lifting Director per the current
version of ASME Standard P30.1 or equivalent and must be
The unit nameplate is located on the exterior of the Unit Power suited for the load capacity.
Panel. Both the Model No. and Serial No. are located on the
Daikin Applied is not a licensed nor certified rigging specialist.
unit nameplate; the Serial No. is unique to the unit. These
Therefore it is the customer’s responsibility to consult a
numbers should be used to identify the unit for service, parts,
certified rigging contractor to rig, lift, and move components
or warranty questions. This plate also has the unit refrigerant
and subcomponents properly and safely as needed.
charge and electrical ratings. Evaporator data plate is under
insulation and contains the serial number. Compressor CAUTION
nameplate is located on each compressor and gives pertinent
electrical information. Forklifts may not be used to lift or move Trailblazer units as
the method may result in unit damage.
WARNING
Installation is to be performed by qualified personnel who are CAUTION
familiar with local codes and regulations. When around sharp edges, wear appropriate Personal
Protective Equipment (PPE), such as gloves, protective
CAUTION clothing, foot wear, eye protection, etc. to prevent personal
injury.
When around sharp edges, wear appropriate Personal
Protective Equipment (PPE), such as gloves, protective
clothing, foot wear, eye protection etc. to prevent personal
injury.

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 6 www.DaikinApplied.com

 Installation

Lifting Brackets Figure 2: Illustration of Allowed Angle Label

Lifting bracket designs vary from product to product. Rules of
engagement with the lifting brackets are the same regardless
of the bracket type. For Trailblazer units, a typical lifting bracket
with 2ʺ (51 mm) diameter holes found on the sides of the unit
base are illustrated in Figure 1. See the as-designed certified
drawings for specific lifting points on this product model.
Engagement with each bracket is to be as close to vertical as
possible. The maximum allowable lift angle from the vertical
is 30° as shown in Figure 2. If the lift angle shifts beyond 30°
from vertical on any of the lift points, the lift shall not proceed
until a plan and rigging can be secured that will correct the
angle of lift.

WARNING
The lifting angle must not go beyond 30 degrees from vertical
or the unit can become unstable which may result in unit
damage, property damage, severe personal injury, or death.

Figure 1: Illustration of Lifting Bracket and Allowed Angle

for Lifting Lifting Equipment
Lifting equipment is supplied by the user or their designate.
This is typically selected around the unit certified information
of the equipment to be lifted and the available lifting equipment
planned to be at the site where the lift is to take place. It is the
responsibility of the Lifting Director to follow a standard practice
of lift planning and equipment selection, like that found in the
ASME P30 series of standards. Lifting plan and equipment
must ensure that the only contact with the unit is at the lifting
brackets. Straps, chains or spreader bars that are likely to be
used shall not come in contact with the unit.

CAUTION
Lifting mechanisms must not make contact with the unit
beyond the lifting bracket. Extreme care must be used when
rigging the unit to prevent damage to the control panels, unit
handles, unit piping, and unit frame.

Lifting Points
Lifting points are predetermined by design. When lifting,
all factory installed lifting brackets must be used. Figure 3
illustrates typical 8 point lifting configuration, with four lifting
points on each side of the unit. The unit must remain level
throughout the entire lifting event. Level is defined as one end
being no more than 0.25” per foot of unit length to the opposite
end.

WARNING
Be aware that the center of gravity may not necessarily be in
the geometric center of the unit. No additional items can be
added to a lift with the unit as it may affect the center of gravity
and cause unit damage, property damage, or severe personal
injury or death. Refer to as-designed, certified drawings for
weight, center of gravity location and details specific to unit
configuration.

www.DaikinApplied.com 7 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Installation

Figure 3: Lifting Points Locations 6. Long term storage in humid environments may cause
condensate corrosion on steel surfaces. Consider adding
a desiccant material to alleviate corrosion concerns.
When the unit is being tied down for transit, the maximum
allowable attachment angle from the vertical is 30 degrees in
the opposite direction of lifting. Shimming of the unit under the
lifting brackets or tie-down points must be used to ensure even
contact along the length of the base rail.

Long Term Storage

This information applies to new units being stored waiting for
startup or existing units that may be inoperative or in storage
for four months or more.
The chiller must be stored in a secure location and protected
from any damage or sources of corrosion while in storage. It
is recommended that a Daikin Applied service representative
perform a leak test and visual inspection for any damage or
unusual conditions affecting the unit on a minimum quarterly
WARNING
schedule, to be paid by the owner or contractor. Daikin Applied
After the unit is securely in place, remove the lifting brackets and install the will not be responsible for any refrigerant loss during the
wire guards. The guards must be in place prior to start up. Failure to do so storage time, for repairs to the unit during the storage period,
can result in damage to the unit or personal injury. or while moving the unit from the original location to a storage
facility and back to any new installation location. If there is
Figure 4: Lifting Brackets Removed and Guards Installed concern about the possibilities of damage and loss of charge
during storage, the customer can have the charge removed
and stored in recovery cylinders.

CAUTION
If the temperature of where the chiller is located is expected to
exceed 130°F (54.4°C), then the refrigerant must be removed.
It is necessary to observe some precautions during storage.
• Do not keep the machine near a heat source and/or open
flame.
• Humid environments may cause condensate corrosion on
steel surfaces. Consider adding a desiccant material to
alleviate corrosion concerns.
• For units previously installed, ensure water has been
drained from the unit or sufficient glycol has been added if
ambient temperature may be lower than 40°F (4.4°C).
For additional tasks required, contact a Daikin Applied service
Transit and Temporary Storage representative.
If the unit is stored for an intermediate period before installation
or moved to a different location, take these additional
precautions:
1. Support the unit well along the length of the base rail.
2. Level the unit (no twists or uneven ground surface).
3. Provide proper drainage around the unit to prevent
flooding of the equipment.
4. Provide adequate protection from vandalism, mechanical
contact, etc.
5. Securely close the doors and lock the handles.

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 8 www.DaikinApplied.com

 Installation

Unit Placement Service Clearance

Trailblazer units are for outdoor applications only and can be
mounted either on a roof or at ground level. Sides
It is highly recommended to provide a minimum of 8 feet (2.4
NOTICE meters) on one side to allow for coil replacement. A minimum
Outdoor installations are defined as open to the atmosphere of 4 feet (1.2 meters) of side clearance is required; however,
with no permanent walls within the defined clearance distance the unit performance may be derated.
and no roof is allowed above the unit.
Control Panel End
For roof mounted applications, install the unit on a steel
channel or I-beam frame to support the unit above the roof. Minimum of 4 feet (1.2 meters)
Spring isolators for roof applications are recommended. For
ground level applications, install the unit on a substantial base Opposite Control Panel End
that will not settle. Use a one-piece concrete slab with footings Minimum of 4 feet (1.2 meters)
extended below the frost line. Be sure the foundation is level
within 0.5” (13 mm) over its length and width. The foundation
Figure 6: Service Clearance
must be strong enough to support the unit weight. Drawings,
dimensional values, and other information may change
depending on options or configurations selected. Refer to the
as-built submittal drawings provided by a Daikin Applied sales
representative for configuration-specific details.
The addition of neoprene waffle pads (supplied by customer)
under the unit may allow water to drain from inside the frame,
which can act as a dam. Installation of optional spring or
rubber-in-shear isolators can also assist with drainage).

Mounting
The inside of the base rail is open to allow access for
securing mounting bolts, etc. Refer to the as-built submittal
drawings provided by a Daikin Applied sales representative for
configuration-specific details.
All compressor bolts, rubber grommets, and fasteners should
be left in place on the base plate as shown in Figure 5. None of
these fasteners are considered to be ‘temporary shipping bolts.
Operational Spacing Requirements
Sufficient clearance must be maintained between the unit
Figure 5: Compressor Base Plate Mounting and adjacent walls or other units to allow the required unit
air flow to reach the coils. Failure to do so will result in a
capacity reduction and an increase in power consumption.
No obstructions are allowed above the unit at any height. The
clearance requirements shown are a general guideline and
cannot account for all scenarios. Such factors as prevailing
winds, additional equipment within the space, design outdoor
air temperature, and numerous other factors may require more
clearance than what is shown. Additional clearances may be
required under certain circumstances.

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

www.DaikinApplied.com 9 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Installation

Case 1: Wall on One Side Table 3: Two Units, Side-by-Side

NOTE: Assumes a solid height wall taller than unit. Refer to Distance
Case 4 for partial wall openings. Between
No. of Fans 4 6 8 10 12 14
Two
Units
Table 2: Wall on One Side
% Capacity
0.0 1.0 2.0 2.5 NR NR
No. of Fans Clearance Reduct. Unit
4 ft
4-6 Fans 4 ft minimum clearance from any solid height % Power
0.0 1.4 3.0 3.6 NR NR
wall taller than unit Increase Unit
8 Fans 6 ft minimum clearance from any solid height % Capacity
0.0 0.5 1.2 2.0 NR NR
wall taller than unit. Refer to Case 4 for partial Reduct. Unit
5 ft
open wall % Power
0.0 0.7 1.7 3.0 NR NR
10-14 fans 8 ft minimum clearance from any solid height Increase Unit
wall taller than unit. Refer to Case 4 for partial % Capacity
open wall 0.0 0.0 0.5 1.4 2.5 3.0
Reduct. Unit
6 ft
% Power
Figure 7: Building or Wall on One Side of Unit 0.0 0.0 0.7 2.0 2.5 4.0
Increase Unit
% Capacity
0.0 0.0 0.0 0.7 2.0 2.5
Reduct. Unit
8 ft
% Power
0.0 0.0 0.0 1.0 3.0 3.5
Increase Unit
NR = Not recommended due to air recirculation and elevated
condenser pressure and elevated power input
NOTE: Distance between can only be reduced if the 8 ft (2.4
m) clearance is on the outside of the two units for coil
removal.

Case 3: Three Units, Side by Side

For outside units on each side of the middle unit - see case
2 above. Percentage of capacity reduction & percentage of
power increase for different spacing for the middle unit with a
unit on each side.

Figure 9: Three Units, Side-by-Side

Case 2: Two Units, Side-by-Side

Percentage capacity reduction & percentage of power increase
for different spacing between units.

Figure 8: Two Units, Side-by-Side

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 10 www.DaikinApplied.com

 Installation

Table 4: Three Units, Side-by-Side Case 5: Pit/Solid Wall Installation

Distance Percentage full load capacity reduction
Between
No. of Fans 4 6 8 10 12 14
Two
Units Table 6: Pit/Solid Wall Installation
% Capacity Height of Wall (ft)
1.0 NR NR NR NR NR
Reduct. Unit Up
4 ft No. of Distance 10 12 13 14
to 8
% Power Fans from Wall
2.0 NR NR NR NR NR
Increase Unit
4 4 ft 0.0% 1.4% 6.0% NA NA
% Capacity
0.0 1.0 NR NR NR NR 5 ft 0.0% 0.8% 3.2% 6.0% NA
Reduct. Unit
5 ft
% Power 6 ft 0.0% 0.0% 0.8% 1.6% 3.0%
0.0 2.0 NR NR NR NR
Increase Unit 6-8 < 5 ft NA NA NA NA NA
% Capacity 5 ft 0.5% 1.5% 6.0% NA NA
0.0 0.0 2.0 3.0 4.0 5.0
Reduct. Unit
6 ft 6 ft 0.0% 0.8% 3.2% 6.0% NA
% Power
0.0 0.0 3.0 4.5 6.0 7.5 8 ft 0.0% 0.0% 0.9% 1.6% 3.0%
Increase Unit
% Capacity 10 < 6 ft NA NA NA NA NA
0.0 0.0 1.4 2.0 3.0 4.0
Reduct. Unit 6 ft 0.5% 1.5% 6.0% NA NA
8 ft
% Power 8 ft 0.0% 0.8% 3.2% 6.0% NA
0.0 0.0 2.1 3.1 4.5 6.0
Increase Unit
10 ft 0.0% 0.0% 0.9% 1.6% 3.0%
NR = Not recommended due to air recirculation and elevated
condenser pressure and elevated power input 12-14 6 ft NA NA NA NA NA
6 ft 0.8% 1.8% 7.2% NA NA
Case 4: Open Screening Walls 8 ft 0.0% 1.0% 4.0% 7.2% NA
Percentage open wall area vs. distance in ft. from unit 10 ft 0.0% 0.0% 1.0% 1.9% 3.6%
NA = Not Allowed
Table 5: Three Units, Side-by-Side

Distance Figure 10: Pit/Solid Wall Installation

Between
No. of Fans 4 6 8 10 12 14
Two
Units
% Capacity
0.0 1.0 2.0 2.5 NR NR
Reduct. Unit
4 ft
% Power
0.0 1.4 3.0 3.6 NR NR
Increase Unit
% Capacity
0.0 0.5 1.2 2.0 NR NR
Reduct. Unit
5 ft
% Power
0.0 0.7 1.7 3.0 NR NR
Increase Unit
% Capacity
0.0 0.0 0.5 1.4 2.5 3.0
Reduct. Unit
6 ft
% Power
0.0 0.0 0.7 2.0 2.5 4.0
Increase Unit
% Capacity
0.0 0.0 0.0 0.7 2.0 2.5
Reduct. Unit
8 ft
% Power
0.0 0.0 0.0 1.0 3.0 3.5
Increase Unit
NR = Not recommended due to air recirculation and elevated
condenser pressure and elevated power input

www.DaikinApplied.com 11 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Application Consideration

Application Consideration Figure 11: Typical Piping, Brazed-Plate Evaporator

Chilled Water Piping

All evaporators and condensers have OGS-type grooved water
connections (adhering to Standard AWWA C606) or optional
flange connections. The installing contractor must provide
matching mechanical connections. PVC piping should not be
used. Be sure that water inlet and outlet connections match
certified drawings and nozzle markings.
Field-installed water piping to the chiller must include:
• A cleanable strainer installed at the water inlet to the NOTICE
evaporator to remove debris and impurities before they Welded pipe connections are not allowed between the
reach the evaporator, causing damage. The orientation strainer and evaporator due to the chance of slag entering the
of the strainer must me installed to allow removal of the evaporator. Evaporator may be oriented with connections on
screen for cleaning. a different side than shown.
• Adequate piping support to eliminate weight and strain on
the fittings and connections. Inlet Strainer Guidelines
• A water flow switch must be installed in the horizontal An inlet water strainer kit must be installed in the chilled water
piping of the supply (evaporator inlet) water line to avoid piping before the evaporator inlet. Several paths are available
evaporator freeze-up under low or no flow conditions. to meet this requirement:
The flow switch is supplied by the factory as an installed
component or a field-installed kit shipped along with the 1. A factory installed option.
unit. (See page 14 for more information.) 2. A field-installed kit shipped-loose with the unit that
• Piping for units with brazed-plate evaporators must have consists of:
a drain and vent connection provided in the bottom of • Y-type area strainer with 304 stainless steel perforated
the lower connection pipe and to the top of the upper basket, Victaulic pipe connections and strainer cap.
connection pipe respectively, see Figure 11. These
evaporators do not have drain or vent connections due to • Extension pipe with two Schrader fittings that can be
their construction. used for a pressure gauge and thermal dispersion flow
switch. The pipe provides sufficient clearance from the
• Water pressure gauge connection taps and gauges at evaporator for strainer basket removal.
the inlet and outlet connections of the evaporator for
measuring water pressure drop. • 0.5-inch blowdown valve
It is recommended that the field-installed water piping to the • Two grooved clamps
chiller include: Both are sized and with the pressure drop shown on page
16.
• Thermometers at the inlet and outlet connections of the
evaporator. 3. A field-supplied strainer that meets specification and
• Vibration eliminators in both the supply and return water installation requirements of the current Installation,
lines. Operation and Maintenance Manual available at
www.DaikinApplied.com.
• Insulated chilled water piping to reduce heat loss
and prevent condensation. For information on freeze
protection, see “Evaporator Freeze Protection” on page Table 7: Strainer Data
14. Strainer Size Maximum Factory Field Installed
• Isolation valves installed in the incoming and outgoing Perforation Installed Option
water piping to the evaporator Size Option
3.0 in 0.063 Y Y
4.0 in 0.063 Y Y
6.0 in 0.063 Y Y

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 12 www.DaikinApplied.com

 Application Consideration

Figure 12: Strainer Pressure Drop Variable Evaporator Flow

Reducing evaporator flow in proportion to load can reduce
system power consumption. The rate of flow change should be
a maximum of 10 percent of the flow per minute. For example,
if the maximum design flow is 200 gpm and it will be reduced to
a flow of 140 gpm, the change in flow is 60 gpm. Ten percent of
200 gpm equals 20 gpm change per minute, or a minimum of
three minutes to go from maximum to desired flow. The water
flow through the evaporator must remain between the minimum
and maximum values. If flow drops below the minimum
allowable, large reductions in heat transfer can occur. If the
flow exceeds the maximum rate, excessive pressure drop and
erosion can occur. See “Constant Evaporator Flow” on page
13 for set point information.

System Water Considerations

All chilled water systems need adequate time to recognize
a load change, respond to the change and stabilize to avoid
undesirable short cycling of the compressors or loss of
temperature control. In air conditioning systems, the potential
for short cycling usually exists when the building load falls
below the minimum chiller plant capacity or on close-coupled
Figure 13: Factory Installed Strainer systems with very small water volumes. Some of the things
the designer should consider when looking at water volume
are the minimum cooling load, the minimum chiller plant
capacity during the low load period and the desired cycle time
for the compressors. Assuming that there are no sudden load
changes and that the chiller plant has reasonable turndown,
a rule of thumb of “gallons of water volume equal to two to
three times the chilled water gpm flow rate” is often used. A
storage tank may have to be added to the system to reach the
recommended system volume. Refer to AG 31-003 for method
of calculating “Minimum Chilled Water Volume”.
The water quality provided by the owner/occupant/operator/
user to a chiller system should minimize corrosion, scale
buildup, erosion, and biological growth for optimum efficiency
of HVAC equipment without creating a hazard to operating
personnel or the environment. Strainers must be used to
protect the chiller systems from water-borne debris. Daikin
Applied will not be responsible for any water-borne debris
damage or water side damage to the chiller heat exchangers
due to improperly treated water.

Water Flow Limitations Water systems should be cleaned and flushed prior to chiller
installation. Water testing and treatment should be verified
during initial chiller installation/commissioning and maintained
Constant Evaporator Flow on a continuous basis by water treatment professionals (see
The evaporator flow rates and pressure drops shown on page Limited Product Warranty).
16 for various system designs. The maximum flow rate and
pressure drop are based on a 6°F temperature drop. Flow CAUTION
rates above the maximum values will result in unacceptable The improper use of detergents, chemicals, and additives
pressure drops and can cause excessive erosion, potentially in the chiller system water may adversely affect chiller
leading to failure. performance and potentially lead to repair costs not covered
The minimum flow and pressure drop is based on a full load by warranty. Any decision to use these products is at the
evaporator temperature drop of 20°F. Evaporator flow rates discretion of the owner/occupant/operator/user as such they
below the minimum values can result in laminar flow causing assume full liability/responsibility for any damage that may
low pressure alarms, scaling and poor temperature control. occur due to their use.

www.DaikinApplied.com 13 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Application Consideration

Evaporator Freeze Protection CAUTION

Evaporator freeze-up can be a concern in the application of Adding glycol or draining the system and flushing with an
air-cooled water chillers in areas experiencing below freezing adequate concentration of glycol are the recommended
temperatures. To protect against freeze-up, insulation and an methods of freeze protection. If the chiller does not have
electric heater are furnished with the evaporator. All models the ability to control the pumps and the water system is not
have an external plate heater and thermostat. These heaters drained or does not have adequate glycol in temperatures
help protect the evaporator down to -20°F (-29°C) ambient below freezing, catastrophic evaporator failure may occur.
air temperature. The evaporator heater cable is factory wired
Failure to allow pump control by the chiller may cause the
to the 115 volt control circuit transformer in the control box.
following problems:
A 115V power source for the heater and controls may also
be supplied from a separate power feed to maximize unit 1. If the chiller attempts to start without the building
protection if desired. Refer to the field wiring diagram for automation enabling the pump, the chiller will lock out on
additional information on supplying a separate 115V power the No Flow alarm and require manual reset.
feed. 2. If the chiller evaporator water temperature drops below
Operation of the heaters is automatic through the sensing the “Freeze setpoint” the chiller will attempt to start the
thermostat that energizes the evaporator heaters for protection water pumps to avoid evaporator freeze. If the chiller
against freeze-up. Unless the evaporator is drained in the does not have the ability to start the pumps, the chiller
winter or contains an adequate concentration of glycol, the will alarm due to lack of water flow.
disconnect switch to the evaporator heater must not be open. 3. If the chiller does not have the ability to control the
Although the evaporator is equipped with freeze protection, pumps and the water system is not to be drained in
it does not protect water piping external to the unit or the temperatures below freezing or contain glycol, the chiller
evaporator itself if there is a power failure or heater burnout, or may be subject to catastrophic evaporator failure due to
if the chiller is unable to control the chilled water pumps. Use freezing. The freeze rating of the evaporator is based on
one of the following recommendations for additional freeze the evaporator heater and pump operation. The external
protection: brazed plate heater itself may not be able to properly
protect the evaporator from freezing without circulation
1. If the unit will not be operated during the winter, drain the
of water.
evaporator and chilled water piping and flush with glycol.
2. Add a glycol solution to the chilled water system. Burst Flow Switch
protection should be approximately 10°F below minimum
design ambient temperature. All chillers require a chilled water flow switch to check that
there is adequate water flow through the evaporator and to
3. Insulate the exposed piping. shut the unit down if necessary to avoid evaporator freeze-up
4. Add thermostatically controlled heat by wrapping the under low or no flow conditions. A factory-included thermal
lines with heat tape. dispersion flow switch will be installed on packaged models.
When glycol is added to the water system for freeze protection, Installation should be per manufacturer’s instructions included
the refrigerant suction pressure will be lower, cooling with the switch. Flow switches should be calibrated to shut
performance less, and water side pressure drop greater. See off the unit when operated below the minimum listed flow rate
“Glycol Solutions” on page 15 for flow rate and pressure for the unit. Flow switch installation and calibration is further
drop adjustment factors. discussed on page 58.

Chilled Water Pump Figure 14: Flow Switch

It is important that the chilled water pumps be wired to, and
controlled by, the chiller’s microprocessor. When equipped
with the optional dual pump output, the chiller controller has
the ability to remotely send a signal to the pump relay to start
pump A or B, or automatically alternate the pump selection,
as well as enable standby operation. The controller will
energize the pump whenever at least one circuit on the chiller
is enabled to run, whether there is a call for cooling or not.
This helps ensure proper unit start-up sequence. The pump
will also be turned on when the water temperature goes below
the Freeze Setpoint for longer than a specified time to help
prevent evaporator freeze-up. See the Field Wiring Diagram for
connection points.

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 14 www.DaikinApplied.com

 Application Consideration

There is also a set of switch contacts on the switch that can Condenser Coil Options and Coating
be used for an indicator light or an alarm to indicate when a
“no flow” condition exists. Freeze protect any flow switch that Considerations
is installed outdoors. Differential pressure switches are not The standard coils on the Trailblazer chiller are an all aluminum
recommended for outdoor installation. They can freeze and not alloy microchannel design with a series of flat tubes containing
indicate a no-flow conditions. multiple, parallel flow microchannels layered between the
refrigerant manifolds. The microchannel coils are designed
Glycol Solutions to withstand 1000+ hour acidified synthetic sea water fog
(SWAAT) test (ASTM G85-02) at 120°F (49°C) with 0% fin loss
The use of glycol may impact system performance depending
and develop no leaks.
on its concentration and should be considered during initial
system design. When glycol is added to the chilled water Epoxy coating is a water-based extremely flexible and durable
system for freeze protection, recognize that the refrigerant polymer coating uniformly applied to all coil surfaces through
suction pressure will be lower, cooling performance less, a multi-step, submerged electrostatic coating process. Epoxy
and water side pressure drop will be higher. The reduction coated coils provide a 10,000+ hour salt spray resistance per
in performance depends upon the glycol concentration and ASTM B117-90, applied to both the coil and the coil headers.
temperature. The epoxy coated coils also receive a UV-resistant urethane
top-coat to provide superior resistance to degradation from
Test coolant with a clean, accurate glycol refractometer to
direct sunlight. This coil coating option provides the best overall
determine the freezing point.
protection against corrosive marine, industrial or combined
CAUTION atmospheric contamination to provide extended longevity.

The installed glycol level must align with the rated glycol
Table 9: Coil/Coating Selection Matrix
percentage indicated on the submitted chiller technical data
sheet. Failure to adhere to the rated glycol percentage may Combined
Non- Unpolluted
Coil Option Industrial3 Marine-
Corrosive1 Marine2
result in unit damage and loss of unit warranty. Industrial4
Standard +++ - - -
Microchannel
CAUTION Epoxy Coated +++ +++ +++ ++
Coils
Do not use an automotive-grade antifreeze. Industrial
grade glycols must be used. Automotive antifreeze contains NOTE: 1. Non-corrosive environments may be estimated
by the appearance of existing equipment in the
inhibitors which will cause plating on the copper tubes within
immediate area where the chiller is to be placed.
the chiller evaporator. The type and handling of glycol used
must be consistent with local codes. 2. Marine environments should take into
consideration proximity to the shore as well as
prevailing wind direction.
Low Ambient Operation
3. Industrial contaminants may be general or
Compressor staging is adaptively determined by system load, localized, based on the immediate source of
ambient air temperature, and other inputs to the MicroTech contamination (i.e. diesel fumes due to proximity to a
unit control. The standard minimum ambient temperature is loading dock).
32°F (0°C). A low ambient option with fan VFD allows operation 4. Combined marine-industrial are influenced by
down to -4°F (-20°C). The minimum ambient temperature proximity to shore, prevailing winds, general and local
is based on still conditions where the wind is not greater sources of contamination.
than 5 mph. Greater wind velocities will result in reduced
discharge pressure, increasing the minimum operating
ambient temperature. Field installed louvers are available and
recommended to help allow the chiller to operate effectively
down to the ambient temperature for which it was designed.

High Ambient Operation

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

www.DaikinApplied.com 15 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Pressure Drop Data

Pressure Drop Data

Evaporator Pressure Drop Data
Table 10: ACK240-DQ Data

Evaporator Evaporator Model Minimum Flow Rate Nominal Flow Rate Maximum Flow Rate
Part
GPM DP ft. l/s DP kPa GPM DP ft. l/s DP kPa GPM DP ft. l/s DP kPa
Number
332955701 ACK240DQ-58AH 36.0 1.3 2.3 4.0 72.0 7.2 4.5 21.6 144.0 32.7 9.1 97.9
332955702 ACK240DQ-66AH 42.0 1.6 2.6 4.7 84.0 7.8 5.3 23.4 168.0 34.4 10.6 102.8
332955703 ACK240DQ-78AH 54.0 2.2 3.4 6.6 108.0 9.7 6.8 29.0 216.0 40.7 13.6 121.6
332955704 ACK240DQ-86AH 60.0 2.4 3.8 7.2 120.0 10.0 7.6 30.0 240.0 41.1 15.1 122.9
332955705 ACK240DQ-98AH 66.0 2.5 4.2 7.4 132.0 9.6 8.3 28.8 264.0 38.0 16.7 113.6
332955706 ACK240DQ-106AH 72.0 2.7 4.5 8.0 144.0 10.0 9.1 29.8 288.0 38.5 18.2 114.9
332955707 ACK240DQ-114AH 66.0 2.1 4.2 6.4 132.0 7.5 8.3 22.5 264.0 28.1 16.7 84.0
332955708 ACK240DQ-122AH 78.0 2.7 4.9 8.1 156.0 9.3 9.8 27.7 312.0 33.9 19.7 101.4
332955710 ACK240DQ-138AH 84.0 2.8 5.3 8.4 168.0 8.9 10.6 26.5 336.0 30.7 21.2 91.9
332955711 ACK240DQ-142AH 90.0 3.1 5.7 9.2 180.0 9.6 11.4 28.7 360.0 33.1 22.7 98.9
332955712 ACK240DQ-154AH 96.0 3.2 6.1 9.6 192.0 9.6 12.1 28.8 360.0 28.5 22.7 85.1
332955713 ACK240DQ-170AH 108.0 3.6 6.8 10.9 216.0 10.3 13.6 30.8 360.0 24.0 22.7 71.6
332955714 ACK240DQ-194AH 120.0 4.0 7.6 11.8 240.0 10.5 15.1 31.3 360.0 19.5 22.7 58.3
332955715 ACK240DQ-210AH 138.0 4.6 8.7 13.8 276.0 11.8 17.4 35.4 360.0 17.5 22.7 52.3
NOTE: Exceeding max flow rates can cause erosion damage to the evaporator.
Each channel count has its own maximum flow rate, and the frame itself has an maximum flow rate of 360 GPM.

Table 11: ACK502-DQ Data

Evaporator Evaporator Model Minimum Flow Rate Nominal Flow Rate Maximum Flow Rate
Part
GPM DP ft. l/s DP kPa GPM DP ft. l/s DP kPa GPM DP ft. l/s DP kPa
Number
332956501 ACK502-DQ-162 150.0 2.9 9.5 8.7 300.0 11.2 18.9 33.4 501.0 30.7 31.6 91.7
332956503 ACK502-DQ-190 168.0 3.3 10.6 9.8 336.0 11.1 21.2 33.0 528.0 25.4 33.3 76.0
332956504 ACK502-DQ-206 192.0 4.0 12.1 11.8 384.0 12.6 24.2 37.8 528.0 22.3 33.3 66.6
332956505 ACK502-DQ-234 204.0 4.2 12.9 12.5 408.0 12.1 25.7 36.2 528.0 18.5 33.3 55.3
332956506 ACK502-DQ-254 216.0 4.5 13.6 13.4 432.0 12.2 27.3 36.6 528.0 16.7 33.3 50.0
NOTE: Exceeding max flow rates can cause erosion damage to the evaporator.
Each channel count has its own maximum flow rate, and the frame itself has an maximum flow rate of 360 GPM.

Table 12: ACH1000-DQ Data

Evaporator Evaporator Model Minimum Flow Rate Nominal Flow Rate Maximum Flow Rate
Part
GPM DP ft. l/s DP kPa GPM DP ft. l/s DP kPa GPM DP ft. l/s DP kPa
Number
332956402 ACH1000DQ-166AH 240.0 3.8 15.1 11.3 480.0 13.4 30.3 40.2 801.6 35.6 50.6 106.3
332956452
332956403 ACH1000DQ-178AH 264.0 4.0 16.7 12.0 528.0 14.2 33.3 42.4 881.0 37.3 55.6 111.4
332956453
332956404 ACH1000DQ-182AH 276.0 4.2 17.4 12.6 552.0 14.8 34.8 44.2 881.0 35.7 55.6 106.8
332956454
NOTE: Exceeding max flow rates can cause erosion damage to the evaporator.
Each channel count has its own maximum flow rate, and the frame itself has an maximum flow rate of 360 GPM.

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 Pressure Drop Data

Table 13: Strainer Pressure Drop (2.5in): P/N 331775460

and 335043702

Flow (gpm) Pressure Drop (ft)

40 0.3
60 0.7
100 2.0
150 4.3
300 16.1

Table 14: Strainer Pressure Drop (3in): P/N 335043703 and

331775463

Flow (gpm) Pressure Drop (ft)

50 0.3
100 1.0
200 3.5
300 8.1
400 16.2

Table 15: Strainer Pressure Drop (4in): P/N 335043704 and

331775465

Flow (gpm) Pressure Drop (ft)

100 0.4
200 1.4
300 2.8
400 5.1
500 7.8
600 11.5
700 16.1

Table 16: Strainer Pressure Drop (6in): 335043706

Flow (gpm) Pressure Drop (ft)

200 0.3
300 0.7
400 1.3
500 1.9
600 2.7
700 3.7
800 4.6

www.DaikinApplied.com 17 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Electrical Data

Electrical Data Power wiring connections to the chiller may be done with
either copper or aluminum wiring, provided the wire size and
count fit in the chiller lugs provided. All wiring must be done in
accordance with applicable local and national codes, including
Electrical Connection NECA/AA 10402012, Standard for Installing Aluminum Building
Trailblazer units can be ordered with either standard multi-point Wire and Cable (ANSI). Wiring within the unit is sized in
power or optional single point power connections and with accordance with the NEC®. Refer to the unit nameplate and
various disconnect and circuit breaker options. Wiring within the unit selection report for the correct electrical ratings.
the unit is sized in accordance with the NEC®. 1. The control transformer is furnished and no separate
NOTICE 115V power is required. For both single and multi-point
power connections, the control transformer is in circuit
Wiring, fuse, and wire size must be in accordance with the
#1 with control power wired from there to circuit #2. In
National Electrical Code® (NEC). The voltage to these units
multi-point power, disconnecting power to circuit #1
must be within ±10% of nameplate voltage (415V units must
disconnects control power to the unit.
have voltage within -13% and +6% of nameplate voltage) and
the voltage unbalance between phases must not exceed 2%. 2. Wire sizing supplied to the control panel shall be in
Since a 2% voltage unbalance will cause a current unbalance accordance with field wiring diagram
of 6 to 10 times the voltage unbalance per the current version 3. Single-point power supply requires a single disconnect
of the NEMA MG-1 Standard, it is most important that the to supply electrical power to the unit. This power supply
unbalance between phases be kept at a minimum. must either be fused or use a circuit breaker.
4. All field wire lug range values given unit selection report
Table 17: Power Connection Availability
apply to 75°C rated wire per NEC.
Comp. 5. Must be electrically grounded according to national and
Power Disc. Panel High Short Circuit
Circuit
Connection Swt. Current Rating local electrical codes.
Breakers
Std. Single Point Std. Std. Opt. CAUTION
Opt. Multi-Point Opt. Opt. Opt. A static discharge while handling circuit boards can cause
damage to components. Use a static strap before performing
Required field wiring varies depending on unit configuration.
any service work. Never unplug cables, circuit board terminal
See wiring diagram information. Voltage limitations are:
blocks, or power plugs while power is applied to the panel.
1. Voltage must be within 10 percent of nameplate rating.
2. Voltage imbalance not to exceed 2%. Since a 2% Panel High Short Circuit Current Rating
voltage imbalance can cause a current imbalance of 6 The AGZ F control panels are designed with High Short Circuit
to 10 times the voltage imbalance per the NEMA MG-1 Capacity (HSCCR) ratings, these ratings can vary by size and
Standard, it is important that the imbalance between voltage. Please consult the unit data plate or submittal data for
phases be kept at a minimum. the value.
DANGER
Qualified, licensed electricians must perform wiring. Electrical
shock hazard exists that can cause severe injury or death.

DANGER
LOCKOUT/TAGOUT all power sources prior to starting,
pressurizing, de-pressuring, or powering down the Chiller.
Disconnect electrical power before servicing the equipment,
including condenser fan motors or compressors. More than
one disconnect may be required to de-energize the unit.
Failure to follow this warning exactly can result in serious
injury or death. Be sure to read and understand the installation,
operation, and service instructions within this manual.

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 18 www.DaikinApplied.com

 Electrical Data

Use with On-Site Generators

Switching from site grid power to generator power and vice
versa requires that the chiller must either be powered down
or the power must be off for more than five seconds to avoid
sending out of phase voltage to the chiller. A properly installed,
fully synchronized Automatic Transfer Switch must be used to
transfer power if the chiller is running under load.

Generator Sizing

WARNING
Generator must be sized by an electrical engineer familiar
with generator applications.

Transfer Back to Grid Power

Proper transfer from stand-by generator power back to grid
power is essential to avoid chiller damage and must be used to
ensure proper function of the unit.

WARNING
Stop the chiller before transferring supply power from the
generator back to the utility power grid. Transferring power
while the chiller is running can cause severe chiller damage.
The necessary procedure for reconnecting power from the
generator back to the utility grid is as follows:
1. Set the generator to always run five minutes longer than
the unit start-to-start timer, which can be set from two to
sixty minutes, while keeping the chiller powered by the
generator until the fully synchronized Automatic Transfer
Switch properly hands over chiller power from the site.
2. Configure the transfer switch provided with the
generator to automatically shut down the chiller before
transfer is made. The automatic shut-off function can
be accomplished through a BAS interface or with the
“remote on/off” wiring connection shown in the field
wiring diagrams.
A start signal can be given anytime after the stop signal since
the start-to-start timer will be in effect.

www.DaikinApplied.com 19 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Electrical Data

Field Wiring
Figure 15: Field Wiring for Single Point

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 20 www.DaikinApplied.com

 Electrical Data

Figure 16: Field Wiring for Multi-Point

www.DaikinApplied.com 21 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Unit Controller Operation

Unit Controller Operation System Architecture

The overall controls architecture uses the following:

General Description • One MicroTech® unit controller

• One iMX8 PC
The MicroTech unit controller’s design not only permits
• One touch screen HMI
the chiller to run more efficiently, but also can simplify
troubleshooting if a system failure occurs. Every MicroTech • I/O extension modules as needed depending on the
unit controller is programmed and tested prior to shipment to configuration of the unit
facilitate start-up. • Communications interface(s) as needed based on
installed options
The controller menu structure is separated into three distinct
categories that provide the operator or service technician with The touch screen HMI and the iMX8 Linux PC will connect
a full description of: to the unit controller via ethernet. Communication interface
modules and I/O extensions will connect to the unit controller
1. current unit status via Modbus protocol.
2. control parameters
3. alarms
Security protection prevents unauthorized changing of the
setpoints and control parameters.
MicroTech unit control continuously performs self-diagnostic
checks, monitoring system temperatures, pressures and
protection devices, and will automatically shut down a
compressor or the entire unit should a fault occur. The cause
of the shutdown will be retained in memory and can be easily
displayed in plain English for operator review. The MicroTech
chiller controller will also retain and display the date/time the
fault occurred. In addition to displaying alarm diagnostics, the
MicroTech chiller controller also provides the operator with a
warning of limit (pre-alarm) conditions.

Figure 17: System Architecture

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 Unit Controller Operation

Controller Inputs and Outputs Table 20: Digital Outputs

# Description Output Off Output On
Unit Controller N01 Alarm Indicator Alarm Not Active Alarm Active
N02 Fan Contactor Fan(s) Off Fan(s) On
(K101)
Table 18: Analog Inputs
N03 Fan Contactor Fan(s) Off Fan(s) On
# Description Signal Type (K102)
U1 Transformer Temperature NTC 10k Thermistor N04 Compressor #1 Compressor Off Compressor On
(TX1T)(OPT for TX01) (CMK1)
U4 Outside Ambient NTC 10k Thermistor N05 Compressor #3 Compressor Off Compressor On
Temperature (OAT1) (CMK3)
U7 LWT Reset (LWR1) 4-20 mA Current N06 See Table 21 and Table 22 Below
U8 Demand Limit (DML1) 4-20 mA Current N07 Fan Contactor Fan(s) Off Fan(s) On
(K201)
Table 19: Digital Inputs N08 Fan Contactor Fan(s) Off Fan(s) On
(K202)
# Description Signal Off Signal On N09 Compressor #2 Compressor Off Compressor On
ID1 Unit Switch Unit Disable Unit Enable (CMK2)
ID2 Motor Protect Relay Fault No Fault N010 Compressor #4 Compressor Off Compressor On
Circuit 1 (MP01) (CMK4)
ID3 Motor Protect Relay Fault No Fault N011 See Table 21 and Table 22 Below
Circuit 2 (MP02) N012 Evaporator Water Pump Off Pump On
ID4 High Press Switch Fault No Fault Pump 1
Circuit 1 (HPR1) N013 Evaporator Water Pump Off Pump On
ID5 High Press Switch Fault No Fault Pump 2
Circuit 2 (HPR2) NOTE: Digital outputs N06 and N011 are dependent on
ID6 Transformer High Fault No Fault how the unit is configured. There are two options as
Temperature Switch outlined in Table 21 and Table 22 below.
(TX1R)(OPT for TX01)
ID7 Evaporator Flow No Flow Flow Table 21: Digital Outputs (Less than 6 Compressors)
Switch
ID8 Phase Voltage Monitor Fault No Fault # Description Output Off Output On
Circuit 1 (PVM1)
N06 Fan Contactor (K103) Fans Off Fans On
ID9 Phase Voltage Monitor Fault No Fault
Circuit 2 (PVM1) N011 Fan Contactor (K203) Fans Off Fans On

ID10 Ground Fault Circuit 1 Fault No Fault

(GFM1) (OPT) Table 22: Digital Outputs (6 Compressors)
ID11 Ground Fault Circuit 2 Fault No Fault
# Description Output Off Output On
(GFM2) (OPT)
ID12 External Alarm/Event External Fault No External N06 Compressor #5 Compressor Off Compressor On
Fault (CMK5)
ID13 Double Set Point/Mode Use alternate mode or LWT N011 Compressor #6 Compressor Off Compressor On
Switch set point. See sections on Unit (CMK6)
Mode Selection and LWT Target.
ID14 Remote Switch Remote Remote Table 23: Expansion Valve Outputs
Disable Enable
# Description Signal Output
J27 Circuit 1 EEV (EXV1) Four Wire Stepper Motor Signal
J28 Circuit 2 EEV (EXV2) Four Wire Stepper Motor Signal

www.DaikinApplied.com 23 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Unit Controller Operation

Expansion Module (Sensor Box) EXV Information

NOTICE
Table 24: Analog Inputs
The values below are determined based on user entered
# Description Signal Type EXV type. Current unit design and software supports only one
Ratiometric 0.5-4.5 valve type at this time resulting in the default EXV values being
U1 Circuit 1 Suction Pressure (SCP1)
Vdc appropriate
Ratiometric 0.5-4.5
U2 Circuit 2 Suction Pressure (SCP2)
Vdc Table 27: Stepper Motor Driver Configuration
Circuit 1 Suction Temperature
U4 NTC 10k Thermistor Parameter Value Unit
(SCT1)
Circuit 2 Suction Temperature Total Steps 600 steps
U3 NTC 10k Thermistor
(SCT2) Movement Speed 160 steps/sec
Circuit 1 Discharge Pressure Ratiometric 0.5-4.5 Move Current 800 mA
U5
(DCP1) Vdc
Hold Current 160 mA
Circuit 2 Discharge Pressure Ratiometric 0.5-4.5
U6 Duty Cycle 50 %
(DCP2) Vdc
Entering Evap. Fluid Temperature Full Close Steps 600 steps
U7 NTC 10k Thermistor
(EEWT) Extra Open Enable False n/a
Leaving Evap. Fluid Temperature Extra Close Enable True n/a
U8 NTC 10k Thermistor
(ELWT)
Circuit 1 Discharge Temperature
U9
(DCT1)
NTC 10k Thermistor
Set Points
Circuit 2 Discharge Temperature
U10
(DCT2)
NTC 10k Thermistor Set points are initially set to the values in the Default column,
and can be adjusted to any value in the Range column.
Set points are stored in permanent memory. Basic unit
Table 25: Digital Outputs
configuration set points will require the unit to be off in order
Description Output Off Output On to make a change and then require rebooting the controller in
Liquid Line Solenoid order to apply a change. If an option is not included on the unit,
N01 Solenoid Off Solenoid On the respective set point may not be visible. Data and settings
Circuit 1 (LLS1)
Hot Gas Bypass that only apply to a specific operation mode will only be visible
N02 Solenoid Off Solenoid On if that mode is selected.
Circuit 1 (SV1)
Liquid Line Solenoid
N03 Solenoid Off Solenoid On
Circuit 2 (LLS2) Table 28: Unit Level Set Point Defaults and Ranges
Hot Gas Bypass Description Default Range
N04 Solenoid Off Solenoid On
Circuit 2 (SV2) Basic Unit Configuration
Unit Model Not Set AGZ002 – AGZ014
Expansion Module (Main Box) Fan Configuration Not Set Not Set, Packaged
Valid 8 Character Code –
Compressor Code Not Set
Table 26: Digital Outputs Item Detail
208V, 230V, 380V, 400V,
Nominal Voltage Not Set
# Description Output Off Output On 460V, 575V
Evaporator Glycol No No, Yes
N01 Fan Contactor (K103) Fan(s) Off Fan(s) On
Cool, Cool/Ice, Ice (see note
N02 Fan Contactor (K104) Fan(s) Off Fan(s) On Available Modes Cool
below table)
N03 Fan Contactor (K203) Fan(s) Off Fan(s) On Ground Fault
No No, Yes
N04 Fan Contactor (K204) Fan(s) Off Fan(s) On Protection
Design Leaving Fluid
44.0F 15F – 70F
Temperature
Power Connection
Single Point Single Point, Multi Point
Configuration
Mode/Enabling
Unit Enable Enable Disable, Enable
Control source Local Local, Remote, Network
Unit Test Mode Off Off, On
Staging and Capacity Control
7°C See Dynamic Set Point
Cool LWT 1
(44.6°F) Ranges
7°C See Dynamic Set Point
Cool LWT 2
(44.6°F) Ranges

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 24 www.DaikinApplied.com

 Unit Controller Operation

Description Default Range Description Default Range

4.4°C -9.5 to 4.4 °C (14.9 to 39.9 High Condenser 3550.8 KPA 3241 to 4206 KPA (470 to
Ice LWT
(39.9°F) °F) Pressure Hold (515 PSI) 610 PSI)
5.6°C High Condenser 4137 KPA 3241 to 4206 KPA (470 to
Startup Delta T 0.6 to 8.3 °C (1.1 to 14.9 °F)
(10.1°F) Pressure Unload (600 PSI) 610 PSI)
0.3°C High Condenser 4206 KPA 3310 to 4275 KPA (480 to
Shut Down Delta T 0.3 to 1.7 °C (0.5 to 3.1 °F)
(0.5°F) Pressure Fault (610 PSI) 620 PSI)
Stage Up Delay 240 sec 120 to 480 sec High Discharge 121 °C 93.3 to 149°C (200 to
Stage Down Delay 30 sec 20 to 60 sec Temperature Fault (250°F) 300°F)
0.6°C/min 0.1 to 2.7°C/min (0.2 to High Transformer 65.6 °C 54.4 to 104.4°C (130 to 220
Max Pulldown Rate Temperature Unload (150°F) °F)
(1.1°F/min) 4.9°F/min)
Evaporator Pump Control Low OAT Start Time 165 sec 150 to 240 sec
Evap Pump Control #1 Only, #2 Only, Auto, #1 Network Communication Configuration
#1 Only
Configuration Primary, #2 Primary Lon Module
0 seconds 0 to 6553.4 seconds
Evap Recirc Timer 90 15 to 300 seconds Maximum Send Time
Evap Pump 1 Run Lon Module
0 0 to 999999 hours 0 seconds 0 to 6553.4 seconds
Hours Minimum Send Time
Evap Pump 2 Run Lon Module Receive
0 0 to 999999 hours 0 seconds 0 to 6553.4 seconds
Hours Heartbeat
Expansion Valve Manual Settings - The parameters below can BACnet Module Dev
be changed to override the automatic calculations. These setpoints 0 0 to 4194302
Instance
should only be changed if in a non-nominal condition and the
BACnet Module Unit
automatic calculations are not sufficient. English Metric, English
Support
EXV Manual Preo­
0.0 % 0.0 to 60.0 % BACnet Module
pen Done Done, False, True
Reset Out of Service
EXV Manual Stage
0.0 % 0.0 to 25.0 % BACnet IP Module
Up Bump Off Off, On
DHCP
EXV Manual Stage
0.0 % 0.0 to 25.0 % BACnet IP Module 000.000.000.000 to
Down Bump
Power Conservation and Limits Network Address 999.999.999.999
LWT Reset Enable Disable Disable, Enable BACnet IP Module 000.000.000.000 to
Network Mask 999.999.999.999
Demand Limit
Disable Disable, Enable BACnet IP Module 000.000.000.000 to
Enable
Network Gateway 999.999.999.999
Unit Sensor Offsets
Evap LWT Sensor The following apply to both BACnet MSTP and Modbus,
0°C (0°F) -5.0 to 5.0 °C (-9.0 to 9.0 °F) depending on the selected protocol.
Offset
Evap EWT Sensor Module Address 1 0 to 127
0°C (0°F) -5.0 to 5.0 °C (-9.0 to 9.0 °F)
Offset Module Baud Rate 38400 9600, 19200, 38400, 76800
OAT Sensor Offset 0°C (0°F) -5.0 to 5.0 °C (-9.0 to 9.0 °F) Module Max Master 0 0 to 127
Transformer Module Max Info
Temperature Sensor 0°C (0°F) -5.0 to 5.0 °C (-9.0 to 9.0 °F) 0 0 to 255
Frame
Offset Module Parity Even Even, Odd, None
Alarm and Limit Settings - Units
Module Stop bits 1 0 to 2
Evaporator Water 2.2°C See Dynamic Set Point
Freeze (36°F) Ranges BAS Control Inputs
Evaporator Flow Network Unit Enable Disable Disable, Enable
5 sec 5 to 15 sec Network Mode
Loss Delay Cool Cool, Ice
Evaporator Command
3 min 1 to 10 min Network Cool Set 7°C See Dynamic Set Point
Recirculate Timeout
External Fault Point (44.6°F) Ranges
None None, Event, Alarm Network Ice Set 4.39°C -9.5 to 4.4 °C (14.9 to 39.9
Configuration
1.7°C See Dynamic Set Point Point (39.9°F) °F)
Low Ambient Lockout Network Capacity
(35.1°F) Ranges 100% 0 to 100%
Low OAT Lockout Lockout & Lockout & Stop, Lockout Limit
Configuration Stop Only, Disabled Network Alarm Clear
Normal Normal, Clear Alarm
Alarm and Limit Settings - Circuits Command
Low Evap Pressure 696.4 kPa See Dynamic Set Point
Hold (103 PSI) Ranges
Low Evap Pressure 689.5 kPa See Dynamic Set Point
Unload (102 PSI) Ranges
Low Evaporator 151.7 kPa 138 to 207 KPA (20 to 30
Pressure Fault (22 PSI) PSI)
Evaporator Maximum 1310 kPa 979 to 1379 KPA (142 to
Operating Pressure (190 PSI) 200 PSI)

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 Unit Controller Operation

Dynamic Set Point Ranges Description Default Range

Table 29 to Table 32 provide settings that have different ranges EXV Control Mode Auto Auto, Manual
of adjustment based on other settings. Manual EXV Setpoint
Matches Current
5 to 100 %
Automatic Setpoint

Table 29: Cool LWT 1 and Cool LWT2 Set Point Ranges Sensor Offsets
Suction Pressure -100 to 100 kPa
Evaporator Unit 0 kPa (0 PSI)
Range Sensor Offset (-14.5 to 14.5 PSI)
Glycol Vintage
Discharge Pressure -100 to 100 kPa
No F vintage 4.4 to 21.1°C (39.9 to 70°F) 0 kPa (0 PSI)
Sensor Offset (-14.5 to 14.5 PSI)
Yes F vintage -9.5 to 21.1°C (14.9 to 70°F) Suction Temperature -5.0 to 5.0 °C
0°C (0°F)
Sensor Offset (-9.0 to 9.0 °F)
Table 30: Evaporator Water Freeze Discharge
-5.0 to 5.0 °C
Temperature Sensor 0°C (0°F)
Evaporator Glycol Range (-9.0 to 9.0 °F)
Offset
No 2.2 to 5.6°C (36 to 42.1°F)
Yes -28.89 to 5.6°C (-20 to 42.1°F)
Unit Function
Table 31: Low Ambient Lockout
The calculations in this section are used in unit level control
Condenser Fan Configuration Range logic or in control logic across all circuits.
All Single Speed (AF) 0 to 15.6°C (32 to 60.1°F)
First Fan or All Fan Variable
Evaporator Delta T
Speed (DC, DD, DE, DF, DG, -23.3 to 15.6°C (-9.9 to 60.1°F) The evaporator water delta T is calculated as entering water
DH, DV, HA, HB)
temperature minus leaving water temperature.

Table 32: Low Evaporator Pressure

Available Mode Range

Selection
No 620.5 to 827.4 KPA (90 to 120 PSI)
LWT Slope
Yes 317 to 827.4 KPA (46 to 120 PSI) LWT slope is calculated such that the slope represents the
estimated change in LWT over a time frame of one minute.
Circuit Level Set Points
The settings in this section all exist for each individual circuit.
Pulldown Rate
The slope value calculated above will be a negative value
Table 33: Set Points for Individual Circuits as the water temperature is dropping. A pulldown rate is
calculated by inverting the slope value and limiting to a
Description Default Range minimum value of 0°F/min.
Circuit and Compressor Enable
Circuit Enable Enable Disable, Enable LWT Error
Compressor 1 Enable LWT error is calculated as:
Auto Auto, Off
(Circuit 1 Only)
Compressor 3 Enable
Auto Auto, Off
(Circuit 1 Only)
Compressor 5 Enable
Auto Auto, Off
(Circuit 1 Only)
Unit Capacity
Compressor 2 Enable
Auto Auto, Off Unit capacity calculations are based on the nominal
(Circuit 2 Only)
Compressor 4 Enable
horsepower of the running compressors in relation to the total
Auto Auto, Off nominal horsepower of all compressors.
(Circuit 2 Only)
Compressor 6 Enable
Auto Auto, Off
(Circuit 2 Only)
Condenser EXV Control
Condenser Target
Auto Auto, Manual
Mode
Manual Condenser 21.1 to 48.9 °C
37.8 °C (100 °F)
Target (70 to 120 °F)
2.8 to 11.1 °C (5
SSH Target 5.6 °C (10 °F)
to 20 °F)

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 26 www.DaikinApplied.com

 Unit Controller Operation

Capacity Staging Deadbands Using the predicted capacity change for staging up, the
resulting change in leaving water temperature is predicted.
The staging deadbands the band in which unit capacity will
not be increased or decreased. They are based off a relation
of the evaporator temperature delta, the unit capacity, and
the capacity change of staging up or down a compressor. The Using the change in leaving water temperature, the stage up
largest compressor available for stage up or stage down is control band is calculated.
used in the following calculations for a conservative estimate.
The stage up and stage down deadbands are each determined
from a three-part calculation, then limited to stay within defined
boundaries of the range:
Stage Down Deadband
To calculate the stage down deadband, first the largest
compressor available for stage down is determined. With that
information, the percent change if this compressor were to
The stage up deadband is the measure of how far the leaving stage down is calculated.
water temperature be must above the target to trigger a stage
up in capacity.
The stage down deadband is the measure of how far the
Using the predicted capacity change for staging down, the
leaving water temperature be must below the target to trigger a
resulting change in leaving water temperature is predicted.
stage down in capacity.
The result of the first two equations will be a negative value,
reflecting a decrease in capacity.
Figure 18: Capacity Staging Deadbands

Using the change in leaving water temperature, the stage down

control band is calculated. The sign is flipped so the stage
down control band is a positive value.

Start Up Temperature

Shut Down Temperature

No. Description
1 Leaving Water Temperature Unit Enable
2 Stage Up Control Band
Enabling and disabling the chiller is accomplished using set
3 Stage Down Control Band points and inputs to the chiller. The Unit Switch input and
4 LWT Target + Stage Down Control Band the Unit Enable HMI Set Point are both required to be On/
5 LWT Target Enable for the unit to be enabled when the control source is
6 LWT Target + Stage Up Control Band
set to ‘Local’. If the control source is set to ‘Remote’, the Unit
Switch and Remote Switch inputs are both required to be On/
Stage Up Deadband Enable for the unit to be enabled. If the control source is set to
‘Network’, the Unit Switch input and BAS Enable set point must
To calculate the stage up deadband, first the largest both be On/Enable for the unit to be enabled.
compressor available for stage up is determined. With that
information, the percent change if this compressor were to
stage up is calculated.

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 Unit Controller Operation

Unit is enabled according to the following table: Figure 19: Transitions between these states are shown in
the following diagram.
Control Unit BAS Unit
Source Unit Enable Remote Enable Enable/
Set Switch HMI Set Switch Set Disable
Point Point Point State
- Off - - - Disable
- Disable - - Disable
Local
On Enable - - Enable
- - Off - Disable
Remote
On - On - Enable
- - - Disable Disable
Network
On - - Enable Enable

Unit Mode Selection

The operating mode of the unit is determined by set points and
inputs to the chiller. The Available Modes set point determines
what modes of operation can be used. The Control Source
set point determines where a command to change modes will
come from. T1 – Off to Start
The Mode Switch digital input switches between cool mode All of the following are required:
and ice mode if they are both available and the control source
is set to ‘Local’. The BAS mode request switches between cool • Unit Enable = On
mode and ice mode if they are both available and the control • No Unit Alarms active
source is set to ‘Network’. • If Unit Mode = Ice then Ice Delay is not active
Unit Mode is selected according to the following table: • There is at least one compressor available to start
• Low Ambient Lockout is not active
Table 34: Unit Mode Settings • Unit configuration settings are valid
Available Control T2 – Start to Auto
Mode BAS Mode
Modes Set Source Set Unit Mode
Switch Command
Point Point All of the following are required:
Cool - - - Cool • Evaporator flow is seen and recirculated
Local/ Off - Cool
Remote On - Ice T3 - Auto to Shut Down
Cool/Ice
- Cool Cool Any of the following are required:
Network
- Ice Ice • Unit Enable = Off
Ice - - - Ice • Unit Mode = Ice AND LWT target is reached
• Low Ambient Lockout is active
Unit States
• A Unit Fault is present
The unit will always be in one of three states:
Off – Unit is not enabled to run T4 – Shut Down to Alarm
Auto – Unit is enabled to run All of the following are required:

Pumpdown – Packaged units with microchannel coils will • A Unit Fault is present
not do a pumpdown; however, the pumpdown state will exist
T5 – Start to Shut Down
for units with microchannel coils and remote evaporator. So
if the conditions for the Auto to Pumpdown transition occur, Any of the following are required:
the unit state will transition from Auto to Pumpdown and • A Unit Fault is present
then immediately to Off.
• Unit Enable = Off

T6 – Off to Alarm
All of the following are required:
• A Unit Fault is present

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 Unit Controller Operation

T7 – Alarm to Off If OAT drops below the low ambient lockout set point and
any circuits are running, then those circuits will be allowed
All of the following are required:
to remain running, and the unit will not enter the low ambient
• No Unit Faults are present lockout condition. Circuits that are not running will enter a
circuit level lockout condition when OAT drops below the
T8 – Shut Down to Off lockout set point. This condition will clear at the circuit level
All of the following are required: when OAT rises to the lockout set point plus 2.5°C (4.5°F).
• No Unit Faults are present If the OAT is below the low ambient lockout set point, the OAT
sensor fault is not active, and neither circuit is running, low
T9 – Off to Test ambient lockout is triggered. The unit will go directly into the
off state and will remain in the off state until the lockout has
All of the following are required:
cleared. This condition will clear when OAT rises to the lockout
• No Unit Faults are present set point plus 2.5°C (4.5°F).
• Unit Enable = Off
• Test Mode = True Disabled Option
When the chiller is configured to disable low ambient lockout,
T10 – Test to Shut Down the unit will not enter the low ambient lockout condition or shut
Any of the following are required: down any running circuits regardless of the OAT.
• A Unit Fault is present
BAS Annunciation
• Unit Enable = On
Low Ambient Lockout is not an alarm, but it can be
• Test Mode = False
annunciated to the BAS as if it is one. When the Low OAT
Lockout BAS Alert setpoint is set to On and the low ambient
Low Ambient Lockout lockout is active, the following alarm will trigger:
The operation of the chiller in response to OAT dropping below
the Low OAT Lockout set point is configurable if the chiller has Table 35: Low OAT Lockout
variable speed condenser fans. In that case, there are three
options: Alarm Low OAT Lockout

• Lockout and Stop – Chiller will shut down and lockout. Type Problem
• Lockout only – Chiller does not shut down running Displayed Text Message Module Module ID Payload
circuits, will lock out circuits that are off. Code Type

• Disabled – Chiller does not shut down or lock out. Alarm Parts 65 1 0 0

For chillers without condenser fan VFD’s, there is no Alarm Code 1090584576
configuration, and the chiller will always operate according to Trigger Trigger conditions are defined in the sections
the first option shown above. Descriptions of the operation for above
each option are in the following sections. Low ambient lockout Action Taken: No Action
logic resides on the PC. Reset Clearing conditions are defined in the section
above
Lockout and Stop Operation
When the chiller is configured for lockout and stop, it will
operate as described in this section.
If the OAT drops below the low ambient lockout set point
and the OAT sensor fault is not active, low ambient lockout
is triggered. The unit will perform a normal shutdown if any
circuits are running. Once all circuits shut off, the unit will
remain in the off state until the lockout has cleared. This
condition will clear when OAT rises to the lockout set point plus
2.5°C (4.5°F).

Lockout Only Operation

When the chiller is configured for lockout only, it will operate as
described in this section.

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 Unit Controller Operation

Unit Status Figure 20: Transitions between these states are shown in
the following diagram.
Unit Status is displayed to indicate the general operating
condition of the unit. The following table lists the text displayed
for each unit status and the conditions that enable each status.
If more than one status is enabled at the same time, the
highest numbered status overrides the others and is displayed.

Table 36: Unit Status

# Status Conditions
0 None There is an initialization error
1 Auto Unit State = Auto
Off:Low OAT Unit State = Off and low ambient lockout
5
Lockout is active
Off: All Cir Unit State = Off and both circuits
6
Disabled unavailable
Auto:All Cir Unit State = Auto and both circuits
Disabled unavailable
7 Off:Alarm Unit State = Off and Unit Alarm active
Unit State = Off, Control Source = Local,
8 Off:HMI Disable
and Local Enable = Disable
Off:Remote Unit State = Off, Control Source =
T1 – Off to Start
9
Switch Remote, and Remote Switch is open Requires any of the following
Unit State = Off, Control Source =
10 Off:BAS Disable
Network, and BAS Enable = false • Unit state = Auto
11 Off:Unit Switch Unit State = Off and Unit Switch = Disable • Freeze protection started
12 Off:Test Mode Unit State = Off and Unit Mode = Test
Auto:Wait For Unit State = Auto, no circuits running, and
T2 – Start to Run
13
load LWT is less than startup temp Requires the following
Auto:Evap Unit State = Auto and Evaporator State =
14 • Flow ok for time longer than evaporator recirculate time
Recirculate Start
Auto:Wait For Unit State = Auto, Evaporator State = set point
15
Flow Start, and Flow Switch is open
16 Shutdown Unit State = Shutdown
T3 – Run to Off
Unit State = Auto, max pulldown rate has Requires all of the following
17 Auto:Max PDR
been met or exceeded
• Unit state is Off
Auto:Unit Cap Unit State = Auto, unit capacity limit has
18 • Freeze protection not active
Limit been met or exceeded
Auto:High Amb Unit State = Auto and high ambient
19
Limit capacity limit is active T4 – Start to Off
Off:Invalid The selected unit configuration is not Requires all of the following
24
Config valid.
• Unit state is Off
• Freeze protection not active
Evaporator Pump Control
T5 – Run to Start
For control of the evaporator pumps, three evaporator pump
control states should be used: Requires flow switch input off for time longer than the Flow
Loss Delay set point.
Off - No pump on.
Start – Pump is on, water loop is being recirculated.
Run – Pump is on, water loop has been recirculated and
circuits can start if needed.

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 Unit Controller Operation

Freeze Protection LWT Target

To protect the evaporator from freezing, the evaporator The LWT Target varies based on various settings and inputs. A
pump will be started to circulate water through the loop as base LWT Target is selected, and a reset can be used to offset
a last resort. Other countermeasures should avoid water the target to a higher value when the chiller is operating in Cool
temperatures dropping to a dangerous level, but, if need be, mode. In Ice mode, no reset can be applied.
this freeze protection function will be activated. The base LWT target is selected as shown in the following
Freeze protection should start if all of the following are true: table:
• LWT ≤ Evap Freeze set point for at least three seconds
Table 38: LWT Target
• LWT sensor fault isn’t active
• Evaporator Flow Loss alarm is not active Available Control
Mode BAS Mode Base LWT
Modes Set Source Set
Freeze protection should end when any of the following are Point Point
Switch Command Target
true:
Cool LWT 1
Off -
• [LWT ≥ 1.11°C + Evap Freeze set point OR LWT sensor Local/ Set Point
fault is active] and pump has been in start or run state for Remote Cool LWT 2
Cool On -
at least 15 minutes Set Point
• Evaporator Flow Loss alarm is active Network - -
BAS Cool
Set Point
Pump Selection Off -
Cool LWT 1
Local/ Set Point
The pump output used will be determined by the Pump Remote Ice LWT
Control Mode set point. This setting allows the following On -
Set Point
configurations: Cool/Ice
BAS Cool
- Cool
Set Point
Table 37: Pump Selection Network
BAS Ice
- Ice
Set Point
Pump Selection Description
Mode Local/ Ice LWT
- -
Remote Set Point
Pump 1 Primary Pump 1 is used normally, with pump 2 as a Ice
BAS Ice
backup Network - -
Set Point
Pump 2 Primary Pump 2 is used normally, with pump 1 as a
backup
Leaving Water Temperature (LWT) Reset
Pump Load The primary pump is the one with the least run
Balancing hours, the other is used as a backup Leaving water reset raises the leaving water temperature set-
Pump 1 Only Pump 1 will always be used
point when the building load is at less-than-design conditions.
Producing warmer chilled water lessens the burden on the
Pump 2 Only Pump 2 will always be used compressors, which means that the chiller is more efficient.
The base LWT target may be reset if LWT reset is enabled via
Primary/Standby Pump Staging the setpoint. When the setpoint is set to off, no leaving water
The pump designated as primary will start first. If the reset will happen and the leaving water setpoint will remain the
evaporator state is start for a time greater than the recirculate same.
timeout set point and there is no flow, then the primary pump
The reset amount is adjusted based on the 4 to 20 mA reset
will shut off and the standby pump will start. When the
input. Reset is 0° if the reset signal is less than or equal to
evaporator is in the run state, if flow is lost for more than half of
4 mA. Reset is 5.56°C (10.0°F) if the reset signal equals or
the Flow Loss Delay set point value, the primary pump will shut
exceeds 20 mA. The amount of reset will vary linearly between
off and the standby pump will start. Once the standby pump
these extremes if the reset signal is between 4 mA and 20 mA.
is started, the flow loss alarm logic will apply if flow cannot be
established in the evaporator start state, or if flow is lost in the When the reset amount increases, the Active LWT Target is
evaporator run state. changed at a rate of 0.1°C every 10 seconds. When the active
reset decreases, the Active LWT Target is changed all at once.
Pump Load Balancing After the reset is applied, the LWT target can never exceed a
If auto pump control is selected, the primary/standby logic value of 70°F for F vintage.
above is still used. When the evaporator is not in the run state,
the run hours of the pumps will be compared. The pump with
the least hours will be designated as the primary at this time.

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 Unit Controller Operation

Unit Capacity Control Staging Down a Compressor

Capacity control is responsible for the overall output of the Requirements for staging up:
chiller. Compressors are staged to meet the active evaporator • Water Delta < Stage Down Dead Band
leaving fluid temperature target.
• Stage Down Timer has Expired
Compressor Staging Stage Down Delay
The compressors will stage until the leaving water temperature
A minimum amount of time, defined by the Stage Down
reaches its setpoint within a dead band. Once the unit is
Delay set point, should pass after a capacity change before a
enabled, if the water delta is sufficient for start, capacity control
compressor can be staged off again.
will stage up a compressor, triggering the corresponding circuit
to start. Capacity control will continue to stage compressors However, if the LWT drops below the Shut Down Temperature
on with a stage up delay after each to meet the leaving fluid the stage down delay is ignored and the unit will shut down
target. Before a compressor can stage on, the pulldown rate is immediately.
checked to make sure staging up will not result in a pulldown
rate higher than the max setpoint. Choosing compressor to stage down
In general, compressors with more run hours will normally stop
Staging Up a Compressor first. When selecting the next compressor to turn off, first each
Requirements for staging up: circuit is evaluated. The circuit that has more running capacity
is chosen. This is measured by taking the sum of the nominal
• LWT > Stage Up Temperature
horsepower of each compressor that is currently running. If
• Pulldown Rate < Max Pulldown Rate both circuits are equal, circuit 1 is chosen.
• Stage Up Delay Timer has Expired (see exception below) The running compressor with the most run hours on the
• If a transformer is present, the temperature is more than chosen circuit will be staged down. If a compressor has an
10°F below the unload setpoint active start-stop timer, it will be marked as un-stoppable until
• The staging circuit has a discharge pressure less than the the start-stop timer is expired. If multiple compressors are
High Condenser Pressure Hold setpoint equal, the compressor with the lowest ID number is chosen.
• The resulting capacity will not exceed the demand limit

Stage Up Delay Unit Capacity Overrides

A minimum amount of time, defined by the Stage Up Delay Unit capacity limits can be used to limit total unit capacity in
set point, should pass after a capacity change before a Cool mode only. Multiple limits may be active at any time, and
compressor can be staged on again. the lowest limit is always used in the unit capacity control.

This delay should only apply when at least one compressor

is running. If the first compressor starts and quickly shuts off
Demand Limit
for some reason, another compressor may start without this The maximum unit capacity can be limited by a 4 to 20 mA
minimum time passing. signal on the Demand Limit analog input. This function is
only enabled if the Demand Limit set point is set to ON. The
Choosing compressor to stage up maximum unit capacity stage is determined as to not exceed
the calculated max capacity reflected demand limit.
In general, compressors with fewer starts will normally start
first. When selecting the next compressor to turn on, first each
circuit is evaluated. The circuit that has more available capacity
Network Limit
to start is chosen. This is measured by taking the sum of the The maximum unit capacity can be limited by a network signal.
nominal horsepower of each compressor available for start. If This function is only enabled if the control source is set to
both circuits are equal, circuit 1 is chosen. network. The maximum unit capacity stage is based on the
network limit value received from the BAS. The compressors
The available compressor with the least starts on the chosen
are staged as to not exceed the calculated max capacity.
circuit will be staged up. If a compressor is already running,
is disabled, or has an active start-start timer it will be marked
as un-available. In addition, if the resulting capacity from a Maximum LWT Pulldown Rate
stage up is over the demand limit (if active), that compressor The maximum rate at which the leaving water temperature can
will be marked as un-available. Capacity predictions are based drop will be limited by the Maximum Pulldown Rate set point,
on nominal horsepower, so larger compressors may be over only when the unit mode is Cool.
the demand limit but a smaller sized compressor on the same
If the rate exceeds this set point, no more compressors will
circuit may be available to start. If multiple compressors are
be started until the pulldown rate is less than the set point.
equal, the compressor with the lowest ID number is chosen.
Running compressors will not be stopped as a result of
exceeding the maximum pulldown rate.

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 Unit Controller Operation

High Ambient Limit Figure 21: Circuit State Transitions

On units configured with single point power connections, the

maximum load current could be exceeded at high ambient
temperatures.
If the power connection is single point and the OAT rises to
46.67°C (116°F), the high ambient limit becomes active. This
limit is removed when the OAT drops back down to 45.56°C
(114°F).
When the limit is active, the unit is allowed to run all but one
compressor. So, it will inhibit the unit from loading if all but
one compressor is on, and it will shut down a compressor if all
compressors are running.

Sound Reduction
On AGZ-F chillers, sound reduction is built into the fan code
which is input in the unit commissioning sequence. The
condenser control section contains information about rpm
T1 – Off to Start
ranges corresponding to the codes. Only the fan code the unit
was configured for should be used. All of the following are required:
• Circuit Enable = Enable
Test Mode • No Circuit Alarms active
Test mode is a variation of manual control that is not meant to • There is at least one compressor available to start
make cold water, but to test individual components. Test mode • Unit State = Auto
is useful in situations like opening the EXVs and solenoids
manually to allow for pump down. In test mode, compressors T2 – Start to Run
will “bump” when started, so they will turn themselves off after
a few seconds with no additional action. All of the following are required:
• The EXV preopen procedure has finished
• The first compressor to start is running
Circuit Functions
T3 - Run to Shut Down
Table 39: Circuit States Any of the following are required:
State Description • Unit Enable = Off
Off Circuit is off. EXV is at 0.2%, solenoids are closed • Circuit Enable = Disable
and no fans or compressors running. • A Circuit Fault is present
Start EXV is going through the preopen sequence. • There are no compressors running on the circuit
Run Circuit is running with at least one compressor.
Shut Down Circuit is going through shut down procedures. Can
T4 – Shut Down to Alarm
transition to Off or Alarm. All of the following are required:
Alarm Circuit fault is active. • A Circuit Fault is present

T5 – Start to Shut Down

Any of the following are required:
• Unit Enable = Off
• Circuit Enable = Disable
• A Circuit Fault is present

T6 – Off to Alarm
All of the following are required:
A Circuit Fault is present

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 Unit Controller Operation

T7 – Alarm to Off Compressor Control

All of the following are required: The AGZ Compressor class controls the compressors within
• No Circuit Faults are present the circuit it is instantiated.

T8 – Shut Down to Off Compressor State

All of the following are required:
State Description
• No Circuit Faults are present Off Compressor is off.

Circuit Status Start Compressor contactor is closed, and the

compressor is starting.
The displayed circuit status should be determined by the Run Compressor is running.
conditions in the following table. If more than one status
Shut Down Compressor contactor is opened, and the
is enabled at the same time the highest numbered status compressor is stopping.
overrides the others and is displayed.
Alarm Compressor is on for a duration of three seconds
# Status Conditions then turns itself off, for testing.

0 None There is an initialization error

Figure 22: Compressor State Transitions
1 Off:Ready Circuit is ready to start when
needed.
2 Off:Cycle Circuit is off and cannot start
Timers due to active cycle timer on all
compressors.
3 Off:All Comp Circuit is off and cannot start due to
Disable all compressors being disabled.
4 Off:Keypad Circuit is off and cannot start due to
Disable circuit enable set point.
5 Off:Circuit Circuit is off and circuit switch is off.
Switch
6 Off:Alarm Circuit is off and cannot start due to
T1 – Off to Start
active circuit alarm.
All of the following are required:
7 Off:Test Mode Circuit is in test mode.
8 Preopen Circuit is in preopen state. • Compressor Enable = Enable
• Start-Start timer expired
9 Run:Pumpdown Circuit is in pumpdown state.
• Capacity control initiates start
10 Run:Normal Circuit is in run state and running
normally. T2 – Start to Run
11 Run:Evap Circuit is running and cannot load All of the following are required:
Press Low due to low evaporator pressure.
• Ten second start timer expires
12 Run:Cond Circuit is running and cannot load
Press High due to high condenser pressure. • Contactor is closed

T3 - Run to Shut Down

Any of the following are required:
• Compressor Enable = Disable
• Capacity control initiates shut down

T4 – Start to Shut Down

Any of the following are required:
• Compressor Enable = Disable
• Capacity control initiates shut down

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 Unit Controller Operation

T5 – Shut Down to Off Condenser Fan Control

All of the following are required: Condenser fan control will activate and deactivate fans as
• Contactor is opened needed any time the circuit is the start or run state. All fans
will be off when the circuit is in the off or alarm state. There
T6 – Off to Bump are special cases when the fans will be on in the circuit start
All of the following are required: state. Condenser fan digital outputs will be turned on or off
immediately for condenser stage changes.
• Unit State = Test
The condenser is configured in the unit commissioning
• Compressor bump initiated from the HMI sequence from the Unit Model and the Fan Code.
T7 – Bump to Shut Down
Condenser State
All of the following are required:
State Description
• Three second bump timer expires
Off All fans are off.
Compressor Types Start Condenser is starting.
The AGZ-F compressors are single speed scrolls. The Run Condenser is running, staging fans to target the
compressors can be different sizes, which are reflected in the condenser setpoint.
table below. Shut Down All fans are turned off.

Table 40: Compressor Types Figure 23: Condenser State Transitions

Compressor Code Nominal Horsepower
T1 – Off to Start
D 7.5
All of the following are required:
F 9.0
• Circuit State = Start
G 10
H 12 T2 – Start to Run
J 13 Any of the following are required:
L 16 • Circuit State = Run
P 22 • Outdoor Air Temperature > 80°F
S 27
U 40
T3 - Run to Shut Down
V 43 All of the following are required:
N No Compressor • Circuit State is not Start
These individual compressor codes make up the unit • Circuit State is not Run
compressor code, an eight-letter representation of which
compressors are on the unit. For example, VVSNSSSN.
T4 – Start to Shut Down
All of the following are required:
• Circuit State is not Start
• Circuit State is not Run

T5 – Shut Down to Off

All of the following are required:
• Commands to shut down fans sent

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 Unit Controller Operation

Condenser Types Condenser Stages

There are three main categories of condenser configurations. Condenser staging on each refrigerant circuit will use up to 4
digital outputs for control of condenser fans. When equipped
All On/Off Fans (AF) with variable speed (ECM) condenser fans, the speed signal(s)
sent to the fans(s) via Modbus starts and stops the fan or fans.
The AF configuration contains only on/off fans. The fans
The variable speed (ECM) fans do not use digital outputs.
are AC induction type and are controlled via digital outputs
to contactors in the unit control box. In AF condenser The tables in the following sections show the output states for
configurations with a more than four fans, the fans are put each stage of condenser control with all the supported unit
in groups and controlled by the four digital outputs. When configurations.
groups of two or three stage down, single, or double fan
groups stage to compensate, so every sequential stage F Vintage Models - No ECM Fans (AF)
changes the total condenser output by a difference of one fan.
The AF configuration is only designed to run at outdoor air Table 43: 2 Fans - AF
temperatures of greater than 32°F.
Circuit 1
First Fan ECM (DV) Description Output Contractor Fans Stage 1
Fan Output 1 UC NO2 K101 101 On
The DV configuration contains one variable speed ECM fan,
Circuit 2
and the rest are on/off induction fans. The DV fans ramp
Description Output Contractor Fans Stage 1
up and down as the on/off fans stage to smooth out the
transitions. Fan Output 1 UC NO7 K201 201 On

Table 41: First Fan ECM Table 44: 4 Fans - AF

Circuit 1
Type Description Minimum Maximum Horsepower
Speed Speed Stage
Description Output Contractor Fans
1 2
DV DC Fan 300 rpm 850 rpm 2 hp
Motors Fan Output 1 UC NO2 K101 101 On On
Fan Output 2 UC NO3 K102 102 On
All ECM Fans (H[X]) Circuit 2
Stage
H[X] represents a category of all ECM fans, there are multiple Description Output Contractor Fans
1 2
configurations within this category, represented by the variable
Fan Output 1 UC NO7 K201 201 On On
[X].
Fan Output 2 UC NO8 K202 202 On

Table 42: All ECM Fans

Table 45: 6 Fans - AF
Type Description Minimum Maximum Horsepower
Speed Speed Circuit 1
Stage
HA High Static DC 300 rpm 950 rpm 3 hp Description Output Contractor Fans
Fan Motors 1 2 3 4

HB High Static DC 300 rpm 900 rpm 3 hp Fan Output 1 UC NO2 K101 101 On On On On
Fan Motors Fan Output 3 UC NO5 K103 102 On On
DC DC Fan Motors 300 rpm 850 rpm 2 hp Fan Output 2 UC NO3 K102 103 On On
DD DC Fan Motors 300 rpm 800 rpm 2 hp
Fan Output 3 UC NO6 K103 104 On On
DE DC Fan Motors 300 rpm 750 rpm 2 hp
Circuit 2
DF DC Fan Motors 300 rpm 700 rpm 2 hp Stage
Description Output Contractor Fans
DG DC Fan Motors 300 rpm 650 rpm 2 hp 1 2 3 4
DH DC Fan Motors 300 rpm 600 rpm 2 hp Fan Output 1 UC NO7 K201 201 On On
Fan Output 2 UC NO8 K202 202 On

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 Unit Controller Operation

Table 46: 8 Fans - AF Table 48: 10 Fans - AF - 6 Compressors

Circuit 1 Circuit 1
Stage Stage
Description Output Contractor Fans Description Output Contractor Fans
1 2 3 4 1 2 3 4 5 6

Fan Output 1 UC NO2 K101 101 On On On On Fan Output 1 UC NO2 K101 101 On On On On

Fan Output 3 UC NO6 K103 102 On On Fan Output 3 UE2 NO1 K103 102 On On On

Fan Output 2 UC NO3 K102 103 On On Fan Output 2 UC NO3 K102 103 On On On On

Fan Output 3 UC NO6 K103 104 On On Fan Output 3 UE2 NO1 K103 104 On On On

Circuit 2 Fan Output 2 UC NO3 K102 105 On On On On

Stage
Description Output Contractor Fans Fan Output 3 UE2 NO1 K103 106 On On On
1 2 3 4
Circuit 2
Fan Output 1 UC NO7 K201 201 On On On On
Stage
Description Output Contractor Fans
Fan Output 3 UC NO11 K203 202 On On 1 2 3 4 5 6

Fan Output 2 UC NO8 K202 203 On On Fan Output 1 UC NO7 K201 201 On On On On

Fan Output 3 UC NO11 K203 204 On On Fan Output 3 UC NO11 K203 202 On On

Fan Output 2 UC NO8 K202 203 On On

Table 47: 10 Fans - AF - 4 Compressors Fan Output 3 UC NO11 K203 204 On On
Circuit 1
Stage Table 49: 12 Fans - AF - 4 Compressors
Description Output Contractor Fans
1 2 3 4 5 6
Circuit 1
Fan Output 1 UC NO2 K101 101 On On On On
Stage
Description Output Contractor Fans
Fan Output 3 UC NO6 K103 102 On On On 1 2 3 4 5 6

Fan Output 2 UC NO3 K102 103 On On On On Fan Output 1 UC NO2 K101 101 On On On On

Fan Output 3 UC NO6 K103 104 On On On Fan Output 3 UC NO6 K103 102 On On On

Fan Output 2 UC NO3 K102 105 On On On On Fan Output 2 UC NO3 K102 103 On On On On

Fan Output 3 UC NO6 K103 106 On On On Fan Output 3 UC NO6 K103 104 On On On

Circuit 2 Fan Output 2 UC NO3 K102 105 On On On On

Stage
Description Output Contractor Fans Fan Output 3 UC NO6 K103 106 On On On
1 2 3 4 5 6
Circuit 2
Fan Output 1 UC NO7 K201 201 On On On On
Stage
Description Output Contractor Fans
Fan Output 3 UC NO11 K203 202 On On 1 2 3 4 5 6

Fan Output 2 UC NO8 K202 203 On On Fan Output 1 UC NO7 K201 201 On On On On

Fan Output 3 UC NO11 K203 204 On On Fan Output 3 UC NO11 K203 202 On On On

Fan Output 2 UC NO8 K202 203 On On On On

Fan Output 3 UC NO11 K203 204 On On On

Fan Output 2 UC NO8 K202 205 On On On On

Fan Output 3 UC NO11 K203 206 On On On

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 Unit Controller Operation

Table 50: 12 Fans - AF - 6 Compressors F Vintage Model - First Fan ECM (DV)
Circuit 1
Stage Table 52: 2 Fans - DV
Description Output Contractor Fans
1 2 3 4 5 6
Circuit 1
Fan Output 1 UC NO2 K101 101 On On On On Description Output Contractor Fans Stage 1
Fan Output 3 UE2 NO1 K103 102 On On On Speed Signal 1 Modbus n/a 101 On
Circuit 2
Fan Output 2 UC NO3 K102 103 On On On On
Description Output Contractor Fans Stage 1
Fan Output 3 UE2 NO1 K103 104 On On On Speed Signal 1 Modbus n/a 201 On
Fan Output 2 UC NO3 K102 105 On On On On

Fan Output 3 UE2 NO1 K103 106 On On On

Table 53: 4 Fans - DV
Circuit 2 Circuit 1
Stage Stage
Description Output Contractor Fans Description Output Contractor Fans
1 2 3 4 5 6 1 2
Fan Output 1 UC NO7 K201 201 On On On On Speed Signal 1 Modbus n/a 101 On On
Fan Output 2 UC NO2 K101 102 On
Fan Output 3 UE2 NO4 K203 202 On On On
Circuit 2
Fan Output 2 UC NO8 K202 203 On On On On Stage
Description Output Contractor Fans
Fan Output 3 UE2 NO4 K203 204 On On On 1 2
Speed Signal 1 Modbus n/a 201 On On
Fan Output 2 UC NO8 K202 205 On On On On
Fan Output 2 UC NO7 K201 202 On
Fan Output 3 UE2 NO4 K203 206 On On On

Table 54: 6 Fans - DV

Table 51: 14 Fans - AF
Circuit 1
Circuit 1 Stage
Stage
Description Output Contractor Fans
Description Output
Con-
Fans
1 2 3 4
tractor 1 2 3 4 5 6 7 8
Speed Signal 1 Modbus n/a 101 On On On On
Fan Output 1 UC NO2 K101 101 On On On On On
Fan Output 3 UC NO3 K102 102 On On
Fan Output 3 UE2 NO1 K103 102 On On On On On
Fan Output 2 UC NO2 K101 103 On On
Fan Output 2 UC NO3 K102 103 On On On On On On
Fan Output 3 UC NO3 K102 104 On On
Fan Output 3 UE2 NO1 K103 104 On On On On On
Circuit 2
Fan Output 2 UC NO3 K102 105 On On On On On On Stage
Description Output Contractor Fans
Fan Output 3 UE2 NO1 K103 106 On On On On On 1 2 3 4

Circuit 2 Speed Signal 1 Modbus n/a 201 On On

Con- Stage Fan Output 2 UC NO7 K201 202 On

Description Output Fans
tractor 1 2 3 4 5 6 7 8

Fan Output 1 UC NO7 K201 201 On On On On

Fan Output 3 UE2 NO4 K203 202 On On On

Fan Output 2 UC NO8 K202 203 On On On On

Fan Output 3 UE2 NO4 K203 204 On On On

Fan Output 2 UC NO8 K202 205 On On On On

Fan Output 3 UE2 NO4 K203 206 On On On

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 Unit Controller Operation

Table 55: 8 Fans - DV Table 57: 10 Fans - DV - 6 Compressors

Circuit 1 Circuit 1
Stage Stage
Description Output Contractor Fans Description Output Contractor Fans
1 2 3 4 1 2 3 4 5 6

Speed Signal 1 Modbus n/a 101 On On On On Speed Signal 1 Modbus n/a 101 On On On On On On

Fan Output 3 UC NO3 K102 102 On On Fan Output 4 UE2 NO1 K103 102 On On

Fan Output 2 UC NO2 K101 103 On On Fan Output 2 NO2 K101 103 On On On

Fan Output 3 UC NO3 K102 104 On On Fan Output 4 UE2 NO1 K103 104 On On

Circuit 2 Fan Output 3 NO3 K102 105 On On On On

Stage
Description Output Contractor Fans Fan Output 3 NO3 K102 106 On On On On
1 2 3 4
Circuit 2
Speed Signal 1 Modbus n/a 201 On On On On
Stage
Description Output Contractor Fans
Fan Output 3 UC NO8 K202 202 On On 1 2 3 4 5 6

Fan Output 2 UC NO7 K201 203 On On Speed Signal 1 Modbus n/a 201 On On On On

Fan Output 3 UC NO8 K202 204 On On Fan Output 3 UC NO8 K202 202 On On

Fan Output 2 UC NO7 K201 203 On On

Table 56: 10 Fans - DV - 4 Compressors Fan Output 3 UC NO8 K202 204 On On
Circuit 1
Stage Table 58: 12 Fans - DV - 4 Compressors
Description Output Contractor Fans
1 2 3 4 5 6
Circuit 1
Speed Signal 1 Modbus n/a 101 On On On On On
Stage
Description Output Contractor Fans
Fan Output 4 NO6 K103 102 On On On 1 2 3 4 5 6

Fan Output 2 NO2 K101 103 On On On Speed Signal 1 Modbus n/a 101 On On On On On On

Fan Output 4 NO6 K103 104 On On On Fan Output 3 UC NO6 K103 102 On On

Fan Output 3 NO3 K102 105 On On On On Fan Output 2 UC NO3 K101 103 On On On

Fan Output 3 NO3 K102 106 On On On Fan Output 3 UC NO6 K103 104 On On

Circuit 2 Fan Output 2 UC NO3 K102 105 On On On On

Stage
Description Output Contractor Fans Fan Output 3 UC NO6 K102 106 On On On On
1 2 3 4 5 6
Circuit 2
Speed Signal 1 Modbus n/a 201 On On On On
Stage
Description Output Contractor Fans
Fan Output 3 NO8 K202 202 On On 1 2 3 4 5 6

Fan Output 2 NO7 K201 203 On On Speed Signal 1 Modbus n/a 201 On On On On On On

Fan Output 3 NO8 K202 204 On On Fan Output 3 UC NO11 K203 202 On On On On

Fan Output 2 UC NO8 K201 203 On On On

Fan Output 3 UC NO11 K203 204 On On On On

Fan Output 2 UC NO8 K202 205 On On

Fan Output 3 UC NO11 K202 206 On On

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 Unit Controller Operation

Table 59: 12 Fans - DV - 6 Compressors Condenser Target

Circuit 1 The condenser target varies for the type of condenser. The
Description Output Contractor Fans
Stage controlled variable that the condenser is targeting is the
1 2 3 4 5 6 saturated condenser temperature. The controlled device in
Speed Signal 1 Modbus n/a 101 On On On On On On this case is condenser output, with the controlled agent being
refrigerant in the condenser.
Fan Output 3 UE2 NO1 K103 102 On On
For all configurations in all conditions, the condenser target
Fan Output 2 UC NO3 K101 103 On On On
is 100°F for the first 60 seconds after starting the condenser.
Fan Output 3 UE2 NO1 K103 104 On On This has two purposes. For low ambient conditions, the circuit
Fan Output 2 UC NO3 K102 105 On On On On must build suction head pressure to achieve a successful low
ambient start. During this process, if a condenser fan stages
Fan Output 3 UE2 NO1 K102 106 On On On On
up, it will knock the suction pressure down making it more
Circuit 2 difficult to successfully start. At low ambient, the condenser
Stage target is often well below 100°F on startup (see below
Description Output Contractor Fans
1 2 3 4 5 6 sections). Setting the target to 100°F forces the condenser
Speed Signal 1 Modbus n/a 201 On On On On On On fans to wait longer than they would otherwise wait before
staging up. At high ambient, the condenser target is often well
Fan Output 3 UE2 NO4 K203 202 On On On On
above 100°F (see below sections). With a high target, the fans
Fan Output 2 UC NO8 K201 203 On On On may wait too long to stage up. In other words, the discharge
Fan Output 3 UE2 NO4 K203 204 On On On On
pressure might rise to a fault level before the condenser
saturated temperature reaches a value where the fans would
Fan Output 2 UC NO8 K202 205 On On stage up. Once the 60 second timer is complete, the target
Fan Output 3 UE2 NO4 K202 206 On On goes right to the value calculated as outlined in the sections
below.
Table 60: 14 Fans - DV
Condenser Target for AF Configurations
Circuit 1
Stage
(Fantrol)
Con-
Description Output Fans
tractor 1 2 3 4 5 6 7 8 The condenser target for AF configurations is selected based
Speed Signal 1 Modbus n/a 101 On On On On On On ON On on circuit capacity using the condenser target set points. Since
the AF configuration has a lower resolution for targeting a
Fan Output 5 UE2 NO2 K104 102 On On On On
setpoint, more conservative targets are used. There are set
Fan Output 2 UC NO2 K101 103 On On On On points that establish the condenser target for part load and
100% capacity.
Fan Output 5 UE2 NO2 K104 104 On On On On

Fan Output 3 UC NO3 K102 105 On On On On On On Load Range

Fan Output 4 UE2 NO1 K103 106 On On Part Load 90.0°F

Full Load 100.0°F
Fan Output 3 UC NO3 K102 107 On On On On On On

Fan Output 4 UE2 NO1 K103 108 On On

A minimum condenser target will also be enforced. This
minimum will be calculated based on the saturated evaporator
Circuit 2
temperature and is designed to keep the compressors within
Stage
Description Output
Con-
Fans their envelopes.
tractor 1 2 3 4 5 6 7 8
The 20°F is added as a buffer to make sure that even if the
Speed Signal 1 Modbus n/a 201 On On On On On On
Tc overshoots below the target, the compressor is not in
Fan Output 3 UE2 NO4 K203 202 On On On On danger of leaving the envelope. The condenser target takes
Fan Output 2 UC NO7 K201 203 On On On the maximum value of the two, the target and the lower bound
Tc. This makes it so the target Tc is never outside of the
Fan Output 3 UE2 NO4 K203 204 On On On On
compressor envelope.
Fan Output 2 UC NO8 K202 205 On On

Fan Output 3 UC NO8 K202 206 On On

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 Unit Controller Operation

Condenser Target for DV and H[X] Staging Up

Configurations (Variable Speed)
The condenser target for DV and H[X] configurations is
Regular State Up Logic
selected based on circuit capacity, outdoor air temperature, The first fan will not start until the circuit is in the run state and
and the compressor envelope for the most conservative the stage up error has accumulated past the limit. The only
compressor in the product line. The primary target is calculated exception to this is a high ambient start (special stage up case
from a curve developed for maximizing efficiency of the form: #1).
When the saturated condenser temperature is above the target
plus the active deadband, stage up error is accumulated.

Where Optimum Tccircuit x is in Fahrenheit, outdoor air The Stage Up Error Step is added to a Stage Up Accumulator
temperature is in Fahrenheit, and nominal capacity is in once every 5 seconds, only if the Saturated Condenser
nominal horsepower calculated: Refrigerant Temperature is not falling. When Stage Up Error
Accumulator is greater than the Stage Up Limit the fan stage
is increased by one stage if the stage up timer has expired. If
the chiller is in a low ambient condition the low ambient staging
conditions must be satisfied (see low ambient starts and
Simultaneously, using the compressor envelope of the most staging section.
conservative compressor in the product line, a minimum bound
for the condenser target is calculated: Outdoor Air < 20 20-50 50-80 80-110 >110
Temperature (°F)
Stage Up 5.0 5.0 5.0 5.0 5.0
Deadband (°F)
The 20°F is added as a buffer to make sure that even if the Stage Down 30.0 23.0 29.8 19.8 15.0
Tc overshoots below the target, the compressor is not in Deadband (°F)
danger of leaving the envelope. The condenser target takes The only exception to the above table is if there are no fans
the maximum value of the two, the optimum Tc and the lower running on a circuit (circuit just started).
bound Tc. This makes it so the target Tc is never outside of the
compressor envelope. Outdoor Air All
Temperature (°F)
The calculated condenser target is capped at a high bound of
Stage Up 1.0
133°F. A 133°F saturated condenser temperature correlates
Deadband (°F)
to a discharge pressure of about 509.4 PSI (gauge). If the
discharge pressure is higher than 515 PSI (gauge), the circuit Stage Down 1.0
Deadband (°F)
will not have room to start another compressor. When looking
to stage up a compressor, capacity control monitors discharge
pressure and will not stage up that circuit is the pressure is High Ambient Starts
higher than 515 PSI. This cap makes it so the condenser fans When a circuit is called to start, if the saturated condenser
will ramp to 100% output to keep the discharge pressure below temperature is greater than 90°F before the preopen
515 PSI to allow more compressors to start. sequence, a high ambient start is initiated.

AF and DV
In an AF or DV high ambient start, the goal is to have the first
one or two fans on the circuit running at maximum capacity
before the compressor is turned on. In the high ambient start
logic, the stage up accumulation term is overridden and set to
the limit value, triggering an immediate stage up. By triggering
a regular stage up by maxing out the stage up accumulator,
the logic evaluates if a “skipping first stage” case should be
utilized (see section below). In most cases this results in the
condenser skipping the first stage. Another feature of the
high ambient start is that the PID output to the ECM fans (if
applicable) is overridden and set to the maximum value. By
setting the fan output to the maximum before the compressor
starts, the fans have time to ramp up in time to curb the
discharge pressure rise. If the outdoor air temperature is
greater that 105°F, all fans are staged up immediately.

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 Unit Controller Operation

H[X] Additional Stage Up Triggers

In an H[X] high ambient start, the goal is to turn all available • Trigger 1: If the stage up timer has not expired but:
ECM fans on. This allows the fans to skip staging up — The saturated condenser temperature is greater than
individually and go directly to their most efficient stage for 134°F
high ambient. If the outdoor air temperature is greater than — The saturated condenser temperature is rising
105°F, the fan speed setpoint is set to the maximum speed.
— 5 seconds have passed since the previous stage up
Otherwise, the fan speed is set to the minimum speed. In
the latter case, once at minimum speed the fans can ramp
up together to the max speed if needed to hit the condenser
target.
Staging Down

Low Ambient Starts and Staging Regular State Up Logic

When the saturated condenser refrigerant temperature is
On units with ECM fans (DV and H[X]), if the ambient
below the target minus the active deadband, stage down error
temperature is less than 50°F when the first fan is staged on,
is accumulated.
the speed command is held at the minimum for 5 seconds
after staging the first fan on. This mitigates windup in the PID
integrator term as the fan ramps up to its minimum speed. The Stage Down Error Step is added to Stage Down
Since there is a delay in condenser temperature change Accumulator once every 5 seconds. When the Stage Down
between when the fan is activated and when it has ramped up Error Accumulator is greater than the Stage Down Limit the fan
to speed, the PID loop sees this as a need to increase output, stage is decreased by one stage if the stage down timer has
the condenser output could overshoot the target and cause an expired.
unnecessary drop in suction pressure.
When a stage down occurs or the saturated temperature rises
Another low ambient consideration on units with AF and DV back above the target minus the Stage Down dead band, the
configurations is when a sequential compressor starts and Stage Down Error Accumulator is reset to zero.
the saturated condenser temperature increases, the regular
stage up logic may call an additional on/off fan to stage up. The stage down timer is 60 seconds divided by the number of
This additional fan is often too much condenser output at fans on the circuit. The stage down deadband and limit do not
low temperatures and causes a compressor to stage down vary with conditions:
on low suction pressure unloading. Units with the AF and DV Outdoor Air Temperature (°F) All
configurations at ambient temperatures under 30F with at least
Stage Down Deadband (°F) 5.0
one fan already running must wait to stage up until the output
term of the PID loop is greater than 90%. This allows extra Stage Down Limit (°F) 6.0
time before staging up an additional fan to bring the condenser
temperature back to the target area at the current stage. Even
if the condenser configuration is AF, the PID loop still runs in Variable Speed Fan Control
the background, so this logic still holds true. Condenser configurations of DV and H[X] have variable speed
fan control.
Skipping First Stage
• Case 1: If the circuit has 4 or more fans and OAT is at Speed Setpoint Calculations
least 21.11°C (70°F) when the first condenser stage
The speed command is calculated using a PID loop targeting
would normally be started.
the condenser saturated temperature target. The control loop
• Case 2: If the circuit has an H[X] configuration and OAT is monitors condenser temperature slope, and if the temperature
at least 10° (50°F) when the first condenser stage would is moving toward the target at a fast enough rate, the PID loop
normally be started. will be frozen to allow the change in temperature to stabilize
• Case 3: If the circuit has a DV configuration and OAT is at before changing fan speed again. If a circuit has more than
least 65°F when the first condenser stage would normally one variable speed fan, all variable speed fans on the circuit
be started. are run at the same speed.
• Case 4: If the circuit has an AF configuration and OAT
is at least 100°F when the first condenser stage would Staging Compensation
normally be started.
To create a smoother transition when the condenser stages up,
the speed command compensates by slowing down initially.
This is accomplished by setting the speed command to the
minimum speed when a fan is stages up, and the maximum
speed when a fan is staged down. After the fan speed is
changed the PID loop takes over again.

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 Unit Controller Operation

EXV Control T4 – SSH Control to MOP Control

EXV control has three distinct run time modes. Under normal All of the following are required:
conditions, the EXV targets SSH. When the evaporator • Evaporator Pressure > (Evaporator Maximum Operating
pressure is too low for the condition, the EXV switches to Pressure Setpoint – 10.0 PSI)
Pressure Control where it targets a higher pressure. If the
evaporator pressure is too high for the condition, for example T5 – MOP Control to SSH Control
high LWT, the EXV targets just below the maximum operating All of the following are required:
pressure of the evaporator to avoid a dangerous condition.
In SSH mode blends into the other two modes for a smooth • Evaporator Pressure < (Evaporator Maximum Operating
transition between states. Pressure Setpoint – 10.0 PSI)
• Two minute maximum operating pressure control timer
Table 61: EXV Control States has expired

EXV Control Description T6 – SSH Control to Pressure Control

State
All of the following are required:
Closed EXV is closing or in the closed position
• Evaporator Pressure < (Evaporator Pressure Control
Preopen EXV is opening prior to compressor start
Target – 25.0 PSI)
Static Start EXV constricts flow 5% less than preopen
• One minute suction superheat control timer has expired
position to build a liquid seal
Pressure Control EXV is controlling to evaporator pressure T7 – Pressure Control to SSH Control
target in low pressure situation
All of the following are required:
MOP Control EXV is controlling to evaporator MOP target in
high pressure situation • Evaporator Pressure > Evaporator Pressure Hold
SSH Control EXV is controlling to suction superheat target Setpoint
in a normal situation • Thirty second pressure control timer has expired
• The slope of the evaporator delta T is within plus or minus
Figure 24: EXV Control Transitions two degrees per minute
• Or Any of the following are required:
• Suction Superheat < 5°F

T8 – Pressure Control to MOP Control

All of the following are required:
• Evaporator Pressure > Evaporator Pressure Hold
Setpoint
• Evaporator Pressure > (Evaporator Maximum Operating
Pressure Setpoint – 10.0 PSI)

T1 – Closed to Preopen T9 – SSH Control to Closed

All of the following are required: All of the following are required:

• Circuit State = Start • Circuit State is not Start

• Circuit State is not Run
T2 – Preopen to Static Start
Any of the following are required:
T10 – Pressure Control to Closed
All of the following are required:
• Liquid Line Solenoid = Engaged
• EXV Position = Preopen Position • Circuit State is not Start
• Ten second Preopen timer has expired • Circuit State is not Run

T3 – Static Start to SSH Control T11 – MOP Control to Closed

All of the following are required: All of the following are required:

• EXV Position = Preopen Position – 5.0 % • Circuit State is not Start

• Fifteen second Static Start timer has expired • Circuit State is not Run

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 Unit Controller Operation

Control Error Calculations Figure 26: EXV Control Modes

Regardless of the EXV control state, control error calculations

are made for Pressure Control, SSH Control, and MOP
Control. The error equation is as follows:

Pressure Control Target

The pressure control target setpoint is dynamic and depends
on leaving water temperature. Bounds: high range: 65°F, 180
PSI low range: 32°F, 93 PSI.

Figure 25: Pressure Control Target Figure 27: Close uop of Blended Region

Maximum Operating Pressure Control NOTICE

Target Blended transitions between EXV modes help with stability.
The maximum operating pressure control target is always the
maximum operating pressure setpoint – 10 PSI. Liquid Line Solenoid
The liquid line solenoid is activated when the circuit state is in
Suction Superheat Control Target either the START or RUN states. This output should be off at all
The suction superheat control target is set via the HMI by the other times.
end user/technician. Valid targets are around 5°F to 15°F.
Hot Gas Bypass Solenoid
Position Change Calculations A hot gas bypass solenoid is only activated when there
Regardless of the EXV control state, position change is one compressor running on the entire unit. The circuit
calculations are made for Pressure Control, SSH Control, and that is running activates its hot gas bypass solenoid. The
MOP Control. The current EXV control state determines which hot gas bypass solenoid is only activated if the leaving
position change is applied. water temperature is two degrees above the leaving water
temperature target or less. If additional compressors are
The control states, Pressure Control, SSH Control, and MOP
staged on or the chiller is shut off the hot gas bypass valve will
Control, each have their own independent PID loops. The
immediately deactivate.
output of these loops is calculated every program cycle for use
in control state transitions. In addition to proportional, integral,
and derivative gains, there are a couple of additional features Capacity Overrides - Limit of Operation
to increase stability. There is a small SSH dead band to allow The following conditions shall override automatic capacity
the SSH to settle close to the setpoint in the case of the EXV control as described. These overrides keep the circuit from
resolution being too large to match the target precisely under entering a condition in which it is not designed to run.
the circumstances. For SSH and pressure control, there is a
slope locking feature that will lock the EXV in position while Low Evaporator Pressure
the measured value is moving towards the setpoint at a certain
rate. This helps prevent unstable overshoot. Below is an If the Low Evaporator Pressure Hold or Low Evaporator
illustration showing the EXV control modes. Pressure Unload events are triggered, the circuit capacity may
be limited or reduced.

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 Unit Controller Operation

High Condenser Pressure Alarms

If the High Condenser Pressure Unload event is triggered, the
circuit capacity may be limited or reduced. Unit Alarms Summary
This table lists all the unit alarms. For further details about
each alarm, see the following sections. For details on auto
Alarm and Events clear see the section below.

Alarm Digital Output Table 62: Unit Alarm Summary

The alarm digital output will be operated based on active alarm
scenarios as shown in the table below.
No. Unit Alarm Type Action Manual
Clear
State Scenario
1 Unit PVM/GFP Fault Unit Controller
Off No alarms preventing the chiller or an individual circuit Fault Shutdown HMI or
from running BAS
On A fault is preventing the chiller or either circuit from 2 Evaporator Flow Fault Unit Controller
running Loss Shutdown HMI or
BAS

List and Logs 3 Evaporator Water

Freeze Protect
Fault Unit
Shutdown
Controller
HMI or
BAS
Active Alarms List 4 Evaporator LWT Fault Unit Controller
Sensor Fault Shutdown HMI or
All alarms appear in the active alarm list while active. This BAS
active alarm list is accessed by pressing the alarm icon at the
5 Evaporator EWT Warning None n/a
top right of the HMI. The alarm icon will flash when there are Sensor Fault
alarms active. The alarm list will display the six highest priority
alarms. The format of the entries in this list is found in the User 6 OAT Sensor Fault Fault Unit Controller
Shutdown HMI or
Interface section of this document where the layout and format BAS
of the screens is specified.
7 External Alarm Warning Unit n/a
Shutdown
Alarm Log 8 Evaporator Pump Problem Backup Controller
All alarms are added to the alarm log when triggered. This #1 Failure pump is HMI or
alarm log will be found on the ‘Alarm Log’ screen. This log can used BAS
be downloaded as a CSV file through the ‘Trend’ page. 9 Evaporator Pump Problem Backup Controller
#2 Failure pump is HMI or
The format of the entries in this list is found in the User used BAS
Interface section of this document where the layout and format 10 External Event Fault Unit Controller
of the screens is specified. Shutdown HMI or
BAS
Event Log 11 Bad Demand Warning Demand n/a
Limit Input Limit
The event log should be set up and behave in a way similar to Ignored
the alarm log.
12 Bad LWT Reset Warning LWT Reset n/a
Sort order should be based on time and date, most recent Input Ignored
first in the log. All events will be added to the event log when 13 Transformer Fault Unit Controller
triggered. Overtemperature Shutdown HMI or
Fault BAS
14 Transformer Problem Transformer Controller
Temp Sensor Unload HMI or
Error Ignored BAS
15 Peripheral Fault Unit Controller
Module Comm Shutdown HMI or
Failure BAS

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 Unit Controller Operation

Circuit Alarm Summary Alarm Detail Explanation

This table lists all the circuit alarms, which will exist for each Details for each alarm are listed in a table format as shown
circuit. For further details about each alarm, see the following below. The table below briefly explains each row in the tables.
sections.
Alarm Description of Alarm
Table 64: Circuit Alarm Summary Type Category the alarm should be configured as per the
GCP (fault/problem/warning).
Display Text to be displayed on HMI in the alarm lists.
No. Unit Alarm Type Action Manual Text
Clear
Alarm Alarm message parts that should be generated for the
1 Circuit PVM/GFP Fault Circuit Controller Parts alarm per the GCP.
Fault Shutdown HMI or
BAS Message Module Module ID Payload
Code Type
2 Low Evaporator Fault Circuit Controller
Pressure Shutdown HMI or GCP Reference ID Corre- Additional
BAS Alarm Table sponding to Alarm
Index Below Module Type Information
3 High Condenser Fault Circuit Controller
Pressure Shutdown HMI or Alarm Alarm code that should be generated for the alarm per
BAS Code the GCP.

5 Mechanical High Fault Circuit Controller Trigger Conditions required to trigger the alarm.
Pressure Switch Shutdown HMI or Action Actions that should be taken when the alarm triggers.
BAS Taken
6 Motor Protection Fault Circuit n/a Reset Conditions required for clearing. Method for clearing
Fault Shutdown defined in the auto clear section below.
7 Low OAT Restart Fault Circuit Controller
Fault Shutdown HMI or Module Type Information
BAS
# Module Associated Module IDs Associated Payloads
8 No Pressure Fault Circuit n/a Type
Change After Start Shutdown
1 Unit “0”: Unit “0”: “None”
9 Evaporator Fault Circuit Controller
3 Fans “11”: Fan 1 on Circuit 1, “0”: “Modbus Communication Error”,
Pressure Sensor Shutdown HMI or “12”: Fan 2 on Circuit 1, “1”: “Short Circuit Fault”,
Fault BAS “13”: Fan 3 on Circuit 1, “2”: “Motor Stalled Fault”,
“14”: Fan 4 on Circuit 1, “3”: “Module NTC Fault”,
10 Condenser Fault Circuit Controller “15”: Fan 5 on Circuit 1, “4”: “Module Over Temp Fault”,
Pressure Sensor Shutdown HMI or “16”: Fan 6 on Circuit 1, “5”: “Bus Over Voltage Fault”,
Fault BAS “17”: Fan 7 on Circuit 1, “6”: “Bus Low Voltage Fault”,
“18”: Fan 8 on Circuit 1, “7”: “Output Phase Lost Fault”,
11 Suction Fault Circuit Controller “21”: Fan 1 on Circuit 2, “8”: “Input Phase Lost Fault”,
“22”: Fan 2 on Circuit 2, “9”: “Overload Fault”,
Temperature Shutdown HMI or “23”: Fan 3 on Circuit 2, “10”: “Comm Fail Fault”,
Sensor Fault BAS “24”: Fan 4 on Circuit 2, “11”: “Bus Unbalance Fault”,
“25”: Fan 5 on Circuit 2, “12”: “AC Low Fault”,
12 Discharge Fault Circuit n/a “26”: Fan 6 on Circuit 2 “13”: “AC High Fault”,
Temperature Shutdown “14”: “External Fault”,
“15”: “EEPROM Fault”,
Sensor Fault “16”: “Inner Comm Fault”,
“17”: “Ambient Over Temp Shutdown Fault”,
13 High Discharge Fault Circuit n/a “18”: “Ambient NTC Fault”,
Temperature Shutdown “19”: “Ext NTC Error Fault”,
“20”: “Current Sample Fault”,
14 EEXV Module Fault Circuit Controller “21”: “EEPROM Warning”,
Comm Failure Shutdown HMI or “22”: “Over Temp Fast Down Warning”,
BAS “23”: “Over Temp Slow Down Warning”,
“24”: “Over Temp Limit Warning”,
15 DC Fan Fault Problem Ignore Controller “25”: “Analog Input Warning”,
“26”: “Overload Warning”,
Affected Fan HMI or “27”: “Comm Fail Warning”,
BAS “28”: “Over Temp Fast Down Warning”,
“29”: “Ambient Over Temp Warning”,
“30”: “Fan Fail Warning”,
“31”: “Ext NTC Error Warning”

4 cpCOe “1”: Expansion Module – “0”: “None”

Expan- Sensor Box (UE01)
sion
Module

5 Sensor “0”: Unit, “0”: “None”

“1”: Circuit 1,
“2”: Circuit 2

6 EXV “0”: Dual EXV Driver, “0”: “None”

“1”: Circuit 1 EXV,
“2”: Circuit 2 EXV

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 Unit Controller Operation

# Module Associated Module IDs Associated Payloads Evaporator Water Freeze Protect
Type

7 BAS Ex- “0”: Expansion Module – “0”: “None” Alarm Evaporator Water Freez Protect
pansion Main Box (UE02)
Module Type Fault
8 Circuit “1”: Circuit 1, “0”: “None”, Displayed Evaporator Water Freeze Protect
“2”: Circuit 2 “1”: “Ground Fault Monitor”, Text
“2”: “Phase Voltage Monitor”
Alarm Message Module Module Payload
Parts Code Type ID
PVM/GFP Fault
151 1 0 0
Alarm PVM/GFP Fault
Alarm 2533425152
Type Fault Code
Displayed PVM/GFP Fault Trigger [Evaporator LWT drops below evaporator freeze
Text protect set point and LWT sensor fault is not active]
for a time longer than the evaporator recirculation
Alarm Message Module Module Payload time set point
Parts Code Type ID
Action Shutdown all circuits and lock out unit from running
228 1 0 1 Taken
Alarm 3825270785 Reset Alarm trigger no longer exists – Cannot be auto
Code cleared
Trigger Alarm is trigged if all of the following are true for at
least one second: Evaporator LWT Sensor Fault
-Power Configuration = Single Point
Alarm Evaporator LWT Sensor Fault
-PVM/GFP Input #1 is off
Type Warning
Action Shutdown all circuits and lock out unit from running
Taken Displayed Evaporator LWT Sensor Fault
Text
Reset Reset when input is on for at least 5 seconds or if
Power Configuration = Multi Point. Alarm Message Module Module Payload
Parts Code Type ID
Evaporator Flow Loss 162 5 0 0
Alarm 2718236672
Alarm Evaporator Flow Loss
Code
Type Fault
Trigger Trigger any time sensor status is other than “10”
Displayed Evaporator Flow Loss and UC01 communication with UE01 module is OK,
Text for at least one second.
Alarm Message Module Module Payload Action Shutdown all circuits and lock out unit from running
Parts Code Type ID Taken
150 1 0 0 Reset Sensor status returns to “10”
Alarm 2516647936
Code Evaporator EWT Sensor Fault
Trigger 1: Evaporator Pump State = Run AND Evaporator Alarm Evaporator EWT Sensor Fault
Flow input is off for time > Flow Proof Set Point AND
at least one compressor running Type Warning
2: Evaporator Pump State = Start for time greater Displayed Evaporator Water Freeze Protect
than Recirc Timeout Set Point and all pumps have Text
been tried and Evaporator Flow input is off
Alarm Message Module Module Payload
Action Shutdown all circuits and lock out unit from running Parts Code Type ID
Taken
2 5 0 0
Reset Alarm trigger no longer exists
Alarm 33882112
Code
Trigger Trigger any time sensor status is other than “10”
and UC01 communication with UE01 module is OK,
for at least one second.
Action Ignore sensor value in applicable calculations
Taken
Reset Sensor status returns to “10”

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 Unit Controller Operation

OAT Sensor Fault Evaporator Pump #2 Failure

Alarm OAT Sensor Fault Alarm Evaporator Pump #2 Failure
Type Warning Type Fault
Displayed OAT Sensor Fault Displayed Evaporator Pump #2 Failure
Text Text
Alarm Message Module Module Payload Alarm Message Module Module Payload
Parts Code Type ID Parts Code Type ID
128 5 0 0 81 1 0 0
Alarm 2147811328 Alarm 1375797248
Code Code
Trigger Trigger any time sensor status is other than “10” Trigger Unit is configured with primary and backup pumps,
and UC01 communication with UE01 module is OK, pump #2 is running, and the pump control logic
for at least one second. switches to pump #1
Action Shutdown all circuits and lock out unit from running Action Backup pump is used
Taken Taken
Reset Sensor status returns to “10” Reset This alarm can be cleared manually via the
controller HMI or BAS command
External Alarm
External Event
Alarm External Alarm
Alarm External Event
Type Fault
Type Fault
Displayed External Alarm
Text Displayed External Event
Text
Alarm Message Module Module Payload
Parts Code Type ID Alarm Message Module Module Payload
Parts Code Type ID
194 1 0 0
13 1 0 0
Alarm 3254845440
Code Alarm 218169344
Code
Trigger External Alarm/Event input is off for at least 5
seconds and external fault input is configured as a Trigger External Alarm/Event input is off for at least 5
fault. seconds and external fault input is configured as a
warning.
Action Shutdown all circuits and lock out unit from running
Taken Action None
Taken
Reset Alarm trigger no longer exists

Evaporator Pump #1 Failure Bad Demand Limit Input

Alarm Bad Demand Limit Input
Alarm Evaporator Pump #1 Failure
Type Warning
Type Fault
Displayed Bad Demand Limit Input
Displayed Evaporator Pump #1 Failure
Text
Text
Alarm Message Module Module Payload
Alarm Message Module Module Payload
Parts Code Type ID
Parts Code Type ID
9 1 0 0
81 1 0 0
Alarm 151060480
Alarm 1359020032
Code
Code
Trigger Demand limit input out of range and Demand Limit
Trigger Unit is configured with primary and backup pumps,
set point is set to On. For this alarm out of range is
pump #1 is running, and the pump control logic
considered to be a signal less than 3mA or more
switches to pump #2
than 21mA.
Action Backup pump is used
Action Demand limit function and signal are ignored
Taken
Taken
Reset This alarm can be cleared manually via the
Reset Demand Limit set point is set to Off or demand limit
controller HMI or BAS command
input back in range for 5 seconds.

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 Unit Controller Operation

Bad LWT Reset Input Transformer Temperature Sensor Error

Alarm Transformer Temperature Sensor Error
Alarm Bad LWT Reset Input
Type Fault
Type Warning
Displayed Transformer Temperature Sensor Error
Displayed Bad LWT Reset Input
Text
Text
Alarm Message Module Module Payload
Alarm Message Module Module Payload
Parts Code Type ID
Parts Code Type ID
246 5 0 0
8 1 0 0
Alarm 4127522816
Alarm 134283264
Code
Code
Trigger The unit is configured with a transformer and
Trigger LWT Reset is enabled and LWT reset input out of
the sensor status is other than “10” and UC01
range. For this alarm out of range is considered to
communication with UE01 module is OK, for at least
be a signal less than 3mA or more than 21mA.
one second.
Action LWT reset signal and function are ignored
Action Ignore transformer unload logic
Taken
Taken
Reset LWT Reset Type set point is not 4-20mA or LWT
Reset: Sensor status returns to “10”, or the unit is
reset input back in range for 5 seconds.
reconfigured to not have a transformer

Low OAT Lockout Peripheral Module Comm Failure

Alarm Low OAT Lockout Alarm Peripheral Module Comm Failure
Type Warning Type Fault
Displayed Low OAT Lockout Displayed Peripheral Module Comm Failure
Text Text
Alarm Message Module Module Payload Alarm Message Module Module Payload
Parts Code Type ID Parts Code Type ID
65 1 0 0 188 4,6,7 0 0
Alarm 1090584576 Alarm Expansion Module – Sensor Box: 3154380800
Code Code
Expansion Module – Main Box: 3154575360
Trigger Low OAT Lockout is active and BAS Alert setpoint Dual EXV Driver: 3154509824
is enabled.
Trigger Modbus communication is lost with any of the above
Action Specified in Low OAT Lockout Section modules, only if applicable to current configuration
Taken
Action Shutdown all circuits and lock out unit from running
Reset Alarm trigger no longer exists Taken
Reset Alarm trigger no longer exists, or the unit is
Transformer Overtemperature Fault reconfigured to not the affected module
Alarm Transformer Overtemperature Fault
Type Fault
Displayed Transformer Overtemperature Fault
Text
Alarm Message Module Module Payload
Parts Code Type ID
247 1 0 0
Alarm 4144037888
Code
Trigger The unit is configured with a transformer and the
transformer over-temperature input is off
Action Shutdown all circuits and lock out unit from running
Taken
Reset Alarm trigger no longer exists, or the unit is
reconfigured to not have a transformer

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 Unit Controller Operation

Circuit Alarms Low Evaporator Pressure

Alarm Low Evaporator Pressure
PVM/FFP Fault
Type Fault
Alarm PVM/FFP Fault Displayed Low Evaporator Pressure
Type Fault Text
Displayed PVM/FFP Fault Alarm Message Module Module Payload
Text Parts Code Type ID
Alarm Message Module Module Payload 153 8 1,2 0
Parts Code Type ID Alarm Circuit 1: 2567439360
228 8 1,2 1,2 Code
Circuit 2: 2567440384
Alarm Circuit 1 GFM: 3825730561 Trigger This alarm should trigger when Freeze time
Code is exceeded, Low Ambient Start is not active,
Circuit 2 GFM: 3825731585
and Circuit State = Run. It should also trigger if
Circuit 1 PVM: 3825730562 [Evaporator Pressure < Low Evaporator Pressure
Circuit 2 PVM: 3825731586 Fault setpoint and Circuit State = Run] for longer
than one second.
Trigger [Power Configuration = Multi Point and PVM/GFP
input is off] for longer than one second Freezestat logic allows the circuit to run for varying
times at low pressures. The lower the pressure, the
Action Shutdown circuit and lock circuit out from running shorter the time the compressor can run. This time
Taken is calculated as follows:
Reset PVM/GFP input is on for at least 5 seconds or if Freeze error = Low Evaporator Pressure Unload –
Power Configuration = Single Point Evaporator Pressure
Freeze time =
Mechanical High Pressure Switch
For units equipped with shell and tube type
Alarm Mechanical High Pressure Switch evaporator:

Type Fault 80 –(freeze error/6.895), limited to a range of

40 to 80 seconds For units with plate frame type
Displayed Mechanical High Pressure Switch evaporator:
Text 60 – (freeze error/6.895), limited to a range of
Alarm Message Module Module Payload
20 to 60 seconds
Parts Code Type ID When the evaporator pressure goes below the
Low Evaporator Pressure Unload set point, a timer
166 8 1,2 0
starts. If this timer exceeds the freeze time, then a
Alarm Circuit 1: 2785543168 freezestat trip occurs. If the evaporator pressure
Code rises to the unload set point or higher, and the
Circuit 2: 2785544192 freeze time has not been exceeded, the timer will
Trigger Mechanical High Pressure switch input is off for reset.
longer than one second The alarm cannot trigger if the evaporator pressure
Action Shutdown circuit and lock circuit out from running sensor fault is active.
Taken Action Shutdown circuit and lock circuit out from running
Reset Alarm trigger no longer exists– Cannot be auto Taken
cleared Reset Evaporator Pressure > Low Evaporator Pressure
Fault setpoint

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 Unit Controller Operation

High Condenser Pressure Low OAT Restart Fault

Alarm High Condenser Pressure Alarm Low OAT Restart Fault
Type Fault Type Fault
Displayed High Condenser Pressure Displayed Low OAT Restart Fault
Text Text
Alarm Message Module Module Payload Alarm Message Module Module Payload
Parts Code Type ID Parts Code Type ID
145 8 1,2 0 161 8 1,2 0
Alarm Circuit 1: 2433221632 Alarm Circuit 1: 2701657088
Code Code
Circuit 2: 2433222656 Circuit 2: 2701658112
Trigger Condenser Pressure > High Condenser Pressure Trigger Circuit has failed three low OAT start attempts
Fault setpoint for longer than one second
Action Shutdown circuit and lock circuit out from running
Action Shutdown circuit and lock circuit out from running Taken
Taken
Reset This alarm can be cleared manually via the
Reset If the Condenser Pressure < High Condenser controller HMI or via BAS command, or auto cleared
Pressure Fault setpoint as outlined in the section below

High Discharge Temperature No Pressure Change After Startup

Alarm High Discharge Temperature Alarm No Pressure Change After Start
Type Fault Type Fault
Displayed High Discharge Temperature Displayed No Pressure Change After Start
Text Text
Alarm Message Module Module Payload Alarm Message Module Module Payload
Parts Code Type ID Parts Code Type ID
148 8 1,2 0 189 8 1,2 0
Alarm Circuit 1: 2483553280 Alarm Circuit 1: 3171419136
Code Code
Circuit 2: 2483554304 Circuit 2: 3171420160
Trigger Discharge Temperature > High Discharge Trigger After start of compressor, at least a 7 KPA (1 PSI)
Temperature Fault setpoint for longer than one drop in evaporator pressure OR 35 KPA (5.1 PSI)
second increase in condenser pressure has not occurred
after 30 seconds.
Action Shutdown circuit and lock circuit out from running
Taken Action Shutdown circuit and lock circuit out from running
Taken
Reset If the Discharge Temperature < High Discharge
Temperature Fault setpoint Reset This alarm can be cleared manually via the
controller HMI or via BAS command, or auto cleared
as outlined in the section below.
Motor Protection Fault
Alarm Motor Protection Fault Low Suction SH Fault
Type Fault
Alarm Evaporator Pressure Sensor Fault
Displayed Motor Protection Fault
Text Type Fault
Alarm Message Module Module Payload Displayed Evaporator Pressure Sensor Fault
Parts Code Type ID Text
133 8 1,2 0 Alarm Message Module Module Payload
Parts Code Type ID
Alarm Circuit 1: 2231895040
Code 8 1,2 0
Circuit 2: 2231896064
Alarm
Trigger [Motor Protection input is off and power up start
Code
delay is not active] for longer than one second
Trigger SSH < 3F for 5 minutes consecutive.
Action Shutdown circuit and lock circuit out from running
Taken Action Shutdown circuit and lock circuit out from running
Taken for 30 minutes
Reset Motor Protection input is on
Reset This alarm can be cleared manually via the
controller HMI or via BAS command, or auto cleared
as outlined in the section below once the 30-minute
timer has expired

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 Unit Controller Operation

Low Condenser Sat. Temperature Condenser Pressure Sensor Fault

Alarm Condenser Pressure Sensor Fault
Alarm Low Condenser Sat. Temperature
Type Fault
Type Fault
Displayed Condenser Pressure Sensor Fault
Displayed Low Condenser Sat. Temperature
Text
Text
Alarm Message Module Module Payload
Alarm Message Module Module Payload
Parts Code Type ID
Parts Code Type ID
142 5 1,2 0
155 8 1,2 0
Alarm Circuit 1: 2382693376
Alarm Circuit 1:
Code
Code Circuit 2: 2382694400
Circuit 2:
Trigger Trigger any time sensor status is other than “10”
Trigger Condenser Sat. Temperature is less than the limit
and UC01 communication with UE01 module is OK,
for 5 consecutive minutes, where the limit
for at least one second
is defined as:
Action Shutdown circuit and lock circuit out from running
Evaporator Sat. Evaporator Sat. Taken
Temperature <= 30°F Temperature > 30°F
Reset Sensor status returns to “10”
Limit = 50°F Limit = (1.2 * Evaporator
Sat. Temperature) +
11.6 (all in °F)
Discharge Temperature Sensor Fault
Action Shutdown circuit and lock circuit out from running Alarm Discharge Temperature Sensor Fault
Taken for 60 minutes
Type Fault
Reset This alarm can be cleared manually via the
Displayed Discharge Temperature Sensor Fault
controller HMI or via BAS command, or auto cleared
Text
as outlined in the section below once the 60-minute
timer has expired Alarm Message Module Module Payload
Parts Code Type ID
Evaporator Pressure Sensor Fault 147 5 1,2 0

Alarm Evaporator Pressure Sensor Fault Alarm Circuit 1: 2466579456

Code
Type Fault Circuit 2: 2466580480

Displayed Evaporator Pressure Sensor Fault Trigger Trigger any time sensor status is other than “10”
Text and UC01 communication with UE01 module is OK,
for at least one second.
Alarm Message Module Module Payload
Parts Code Type ID Action Shutdown circuit and lock circuit out from running
Taken
155 5 1,2 0
Reset Sensor status returns to “10”
Alarm Circuit 1: 2600797184
Code
Circuit 2: 2600798208 Suction Temperature Sensor Fault
Trigger Trigger any time sensor status is other than “10”
Alarm Suction Temperature Sensor Fault
and UC01 communication with UE01 module is OK,
for at least one second Type
Action Shutdown circuit and lock circuit out from running Displayed Suction Temperature Sensor Fault
Taken Text
Reset Sensor status returns to “10” Alarm Message Module Module Payload
Parts Code Type ID

Alarm Circuit 1: 3070559232

Code
Circuit 2: 3070560256
Trigger Trigger any time sensor status is other than “10”
and UC01 communication with UE01 module is OK,
for at least one second
Action Shutdown circuit and lock circuit out from running
Taken
Reset Sensor status returns to “10”

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 Unit Controller Operation

Evaporator EXV Module Communication Faults Events

Alarm Evaporator EXV Module Communications Fault The following table lists all the events. For further details about
Type Fault each event, see the following sections.
Displayed Evap EXV Module Communications Fault
Text Table 65: Events
Alarm Message Module Module Payload Event Text for Selection Level Action
Parts Code Type ID Set Point
32 6 1,2 0 Low Evaporator Low Pressure Hold Circuit Inhibit
Alarm Circuit 1: 537265152 Pressure Hold capacity
Code increase
Circuit 2: 537266176
Low Evaporator Low Pressure Circuit Reduce
Trigger Trigger any time EXV connection status is false and Pressure Unload Unload capacity
UC01 communication with Dual EXV Driver module
is OK, for at least one second. High Condenser High Pressure Circuit Reduce
Pressure Unload Unload capacity
Action Shutdown circuit and lock circuit out from running
Taken
Reset Sensor status returns to good
Event Detail Explanation
Event Description of the event
DC Fan Fault
Displayed Text to be displayed in the event log
Alarm DC Fan Fault Text

Type Problem Trigger Conditions required to trigger the event

Displayed DC Fan Fault Action Taken Action that should be taken when the event
Text triggers and while active

Alarm Message Module Module Payload Reset Conditions for the event to reset
Parts Code Type ID
33 3 See
Module
See
Module Circuit Events
Type Type
Table Table
The events in this section exist for both circuit one and circuit
Above Above two.
Alarm Generated on a case-by-case basis
Code Low Evaporator Pressure - Hold
Trigger Triggered when a DC fan reports an alarm Alarm Low Evaporator Pressure - Hold
Action Ignore affected fan in condenser staging logic Displayed Cn Low Evap Pr Hold
Taken Text
Reset DC fan reports alarm is cleared Trigger This event is triggered if all of the following are true:
• circuit state = Run
Auto Clearing Alarms • evaporator pressure <= Low Evaporator
Alarm auto-clearing only occurs if there are no alarms present Pressure - Hold set point
that cannot be auto cleared. Alarms that cannot be auto • circuit is not currently in a low OAT start
cleared are noted in the alarm descriptions above.
• it has been at least 30 seconds since a
The auto clearing process is equivalent to if the user manually compressor has started on the circuit.
cleared the alarms from the HMI or sent the clear alarms
Action Inhibit starting of additional compressors on the
command via the BAS system. Taken circuit
A successful auto-clear means all alarms have been cleared. Reset While still running, the event will be reset if
evaporator pressure > Low Evaporator Pressure
The first successful auto-clear starts an hour-long timer, while Hold SP + 90 KPA(13 PSI). The event is also reset if
the timer is active, no more than 3 successful auto-clears can the circuit is no longer in the run state.
occur. After the third successful auto-clear, there will be no
more attempts until the timer expires.

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 Unit Controller Operation

Low Evaporator Pressure - Unload

Alarm Low Evaporator Pressure - Unload
Displayed Cn Low Evap Pr Unld
Text
Trigger This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the
circuit
• evaporator pressure <= Low Evaporator
Pressure - Unload set point for a time greater
than half of the current freezestat time
• circuit is not currently in a low OAT start
• it has been at least 30 seconds since a
compressor has started on the circuit.
Action Stage off one compressor on the circuit every 10
Taken seconds while evaporator pressure is less than the
unload set point, except the last one
Reset While still running, the event will be reset if
evaporator pressure > Low Evaporator Pressure
Hold SP + 90 KPA(13 PSI). The event is also reset if
the circuit is no longer in the run state

High Condenser Pressure - Unload

Alarm High Condenser Pressure – Unload
Displayed Cn High Cond Pr Unld
Text
Trigger This event is triggered if all of the following are true:
• circuit state = Run
• more than one compressor is running on the
circuit
• condenser pressure > High Condenser
Pressure – Unload set point
Action Stage off one compressor on the circuit every 10
Taken seconds while condenser pressure is higher than
the unload set point, except the last one. Inhibit
staging more compressors on until the condition
resets
Reset While still running, the event will be reset if
condenser pressure <= High Condenser Pressure
Unload SP – 862 KPA(125 PSI). The event is also
reset if the circuit is no longer in the run state

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 Touchscreen Controller

Touchscreen Controller Entering an invalid password has the same effect as not
entering a password.
Once a valid password has been entered, the controller
Home Screen allows further changes and access without requiring the user
to enter a password until either the password timer expires
or a different password is entered. The default value for this
Figure 28: Home Screen
password timer is 10 minutes.

Navigation Menu
Figure 30: Navigation Menu

When power is applied to the control circuit, the controller

screen will be active. Tap the touchscreen to display the Home
screen. From the home screen you can see the status of the
unit as well as key temperature readings.
Press the Home Screen icon at the top of the screen to return
Tap the Navigation Menu icon in the upper left corner of the
to this page at any time.
display screen to access the Navigation Menu.

Login Screen From the Navigation Menu you can select the following
options:
Figure 29: Login Screen • Unit
• Circuit 1
• Circuit 2
• Trends
• Configuration
• Maintenance
To close the Navigation Menu, tap the “X” in the upper right
corner of the display screen.

There are 4 levels of access for the user interface:

• No password
• Operator level - 5321
• Technician/Manager level - 2526
• Daikin Applied service technician level

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 Touchscreen Controller

Unit/Setpoints Configuration
The Unit Home screen displays important information about the
unit, including the active setpoint, entering water temperature, Figure 33: Configuration Screen
startup temperature, and more.

Figure 31: Unit Home Screen

Use the Configuration screen to properly setup and configure

the unit. From the Configuration screen you can perform the
following actions:
From the Unit screen you can view and modify the following
settings: • Commission Unit
• Setpoints • Fan Addressing
• Evaporator Pumps • Update Software
• Freeze Protection • Configure BAS
• Power Conservation • Setup SiteLine

Circuit 1/Circuit 2 Maintenance

From the Circuit 1 and Circuit 2 screens you can view key
information for each circuit and access the following settings: Figure 34: Maintenance Screen

• Setpoints
• Compressors
• Condenser Fans

Figure 32: Circuit Screen

Navigate to the Maintenance screen to view maintenance

information about the unit, such as model number, last
maintenance date, next scheduled maintenance date, and to
access test mode.

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 Startup and Shutdown Procedures

Startup and Shutdown Startup Electrical Check Out

Procedures WARNING
Electrical power must be applied to the compressor crankcase
heaters 24 hours before starting unit to eliminate refrigerant
Pre-Startup from the oil.
Inspect the chiller to ensure no components became loose or 1. Open all electrical disconnects and check all power
damaged during shipping or installation including leak test and wiring connections. Start at the power block and
wiring check. Complete the pre-start checklist on page 78 systematically check all connections through all
and return to Daikin Applied prior to startup date. components to and including the compressor terminals.
These should be checked again after 3 months of
CAUTION
operation and at least yearly thereafter.
Repeated manual clearing of alarms without resolving the
cause of the alarm may damage the chiller, impact the unit’s 2. Check all control wiring by pulling on the wire at
operational performance, and may affect the chiller’s warranty. connections and tighten all screw connections. Check
plug-in relays for proper seating and to insure retaining
clips are installed.
CAUTION
3. Apply power to the unit. The panel Alarm Light will stay
Dyes used for refrigerant leak detection are not tested or
on until S1 is closed. Ignore the Alarm Light for the check
recommended for use in Daikin Applied chillers. Use of these
out period. If you have the optional Alarm Bell, you may
products may damage and/or degrade the performance of the
wish to disconnect it.
equipment and will void the manufacturer warranty.
4. Check at the power block or disconnect for the proper
Startup Checkout voltage between phases. Check power for proper
phasing using a phase sequence meter before starting
1. Verify chilled water piping requirements from page 49 are unit.
met.
5. Check for 120 Vac at the control transformer and at TB-2
2. Check the pump operation and vent all air from the terminal #1 and the neutral block (NB).
system.
6. Check between TB-2 terminal #7 and NB for 120 Vac
3. Circulate evaporator water, checking for proper system supply for transformer #2.
pressure and evaporator pressure drop. Compare the
pressure drop to the evaporator water pressure drop 7. Check between TB-2 terminal #2 and NB for 120 Vac
curve. control voltage. This supplies the compressor crank case
heaters.
4. Flush System and clean all water strainers before placing
the chiller into service. 8. Check between TB-3 terminal #17 and #27 for 24 Vac
control voltage.
5. Check water treatment and proper glycol percentage by
volume, if used.
6. Check all exposed brazed joints for evidence of leaks. Startup Steps
Joints may have been damaged during shipping or when Refer to the MicroTech unit controller information on page 22
the unit was installed. to become familiar with unit operation before starting the chiller.
7. Check that all refrigerant valves are either opened or There should be adequate building load (at least 50 percent
closed as required for proper operation of the chiller. of the unit full load capacity) and stable conditions to properly
8. A thorough leak test must be done using an electronic check the operation of the chiller refrigerant circuits.
leak detector. Check all valve stem packing for leaks. Be prepared to record all operating parameters required by
Replace all refrigerant valve caps and tighten. the “Compressorized Equipment Warranty Form”. Return
9. Check all refrigerant lines to insure that they will not this information within 10 working days to Daikin Applied as
vibrate against each other or against other chiller instructed on the form to obtain full warranty benefits.
components and are properly supported. • Verify chilled water flow rate.
10. Check all connections and all refrigerant threaded • Calibrate thermal dispersion flow switch, see instructions
connectors. on page 58
11. Look for any signs of refrigerant leaks around the • Verify remote start / stop or time clock (if installed) has
condenser coils and for damage during shipping or requested the chiller to start.
installation. • Set the chilled water setpoint to the required temperature.
12. Connect refrigerant service gauges to each refrigerant (The system water temperature must be greater than the
circuit before starting unit. total of the leaving water temperature setpoint plus one-

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 Startup and Shutdown Procedures

half the control band plus the startup delta-T before the
MicroTech controller will stage on cooling.)
Shutdown
• Set the Evap Delta T based on a percent of unit nominal Temporary Shutdown
flow and the Start Delta T as a starting point. Delta-
T=Tons x 24 / gpm 1. Use the LED Enable button on the Main control box door
to disable the unit.
• Check the controller setpoints to be sure that factory
defaults are appropriate. 2. Turn off chilled water pump. Chilled water pump to
operate while compressors are pumping down.
Table 66: Unit Enable Button Light Legend 3. To start the chiller after a temporary shutdown, follow the
Light Activity Unit Status Description
startup instructions.

Off Not Enabled or No Power

Extended Shutdown
Slow Pulse (3 Second Period) Enable and Not Running
1. Front seat both condenser liquid line service valves.
On Running 2. Use the LED Enable button on the Main control box door
On with Fast Pulse (1 Second Running with Alarm to disable the unit.
On, 1 Second Double Pulse)
3. Front seat both refrigerant circuit discharge valves (if
Fast Pulse Not Running with Alarm applicable).
4. If chilled water system is not drained, maintain power to
Post Startup the evaporator heater to prevent freezing. Maintain heat
tracing on the chilled water lines.
After the chiller has been operating for a period of time and has
become stable, check the following: 5. Drain evaporator and water piping and flush with glycol
to prevent freezing.
• Compressor oil level.
6. If electrical power to the unit is on, the compressor
• Refrigerant sight glass for flashing.
crankcase heaters will keep the liquid refrigerant out of
• Rotation of condenser fans. the compressor oil. This will minimize startup time when
• Complete the “Equipment Warranty Registration Form,” putting the unit back into service. The evaporator heater
found at the end of this manual, within 10 days of start- will be able to function.
up in order to comply with the terms of Daikin Applied
7. If electrical power is off, make provisions to power the
Limited Product Warranty.
evaporator heater (if chilled water system is not drained
or is filled with suitable glycol). Tag all opened electrical
disconnect switches to warn against startup before the
refrigerant valves are in the correct operating position.
To start the chiller after an extended shutdown, follow the pre-
startup and startup instructions.

Flow Switch Installation and

Calibration
A thermal dispersion flow switch uses heat to determine
flow and therefore must be calibrated during system startup.
A thermal dispersion flow switch can be an acceptable
replacement for paddle type flow switches and differential
pressure switches but care must be taken regarding wiring.
The thermal dispersion flow switch supplied by Daikin Applied,
shown in Figure 35, comes as a 2 part unit consisting of a flow
switch and an adapter labeled E40242 by the supplier.

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 Startup and Shutdown Procedures

Figure 35: Thermal Dispersion Flow Switch and Adapter If the flow sensor is to be mounted away from the unit, the
sensor should be mounted on the wall of the inlet pipe of
evaporator, or in a run of straight pipe that allows 5 to 10 pipe
diameters prior to the sensor and 3 to 5 pipe diameters of
straight pipe after the sensor. Flow switch is placed in inlet pipe
to reflect flow entering the evaporator.

Figure 37: Mount in Direction of Flow

NOTICE
Flow switch MUST be calibrated before chiller operation. Failure to
properly calibrate the switch may result in severe chiller damage and/or
void warranty.

Mounting
It is important that the flow switch be mounted so that the
Figure 36 highlights the position of the electrical connector and
probe is sufficiently inserted into the fluid stream. Figure 38
indentation ‘mark’ on flow switch.
illustrates the recommended orientation of the sensor. It may
not be mounted directly on top or directly on the bottom of a
Figure 36: Flow Switch Details horizontal pipe.

NOTICE
DO NOT alter or relocate factory installed flow switch. If issues exist,
contact Chiller Technical Response at TechResponse@DaikinApplied.com.

Figure 38: Remote Mounting Guidelines for Flow Switch

No. Descriptions
1 Electrical Connector
2 Indentation

It is required that the flow switch be mounted such that the

electrical connection and indentation ‘mark’ are pointed in the
direction of flow as shown in Figure 37.

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 Startup and Shutdown Procedures

Table 67: Flow Volume Calculation

US GPM at the velocities indicated below

Inside GPM
Pipe Pipe Default adjustment
Size Diameter per '+' or '-'
(inch) (inch) 20 cm/sec 30 cm/sec 50 cm/sec 75 cm/sec 100 cm/sec 150 cm/sec 200 cm/sec 250 cm/sec 300cm/sec key input
2 2.06 6.86 10.3 17.2 25.7 34.3 51.5 68.6 85.8 102.9 1.72

2.5 2.46 9.79 14.7 24.5 36.7 49.0 73.4 97.9 122.4 146.9 2.42

3 3.07 15.1 22.7 37.8 56.7 75.6 113.4 151.2 189.0 226.8 3.78

3.5 3.55 20.2 30.3 50.6 75.8 101.1 151.7 202.2 252.8 303.3 5.06

4 4.03 26.0 39.1 65.1 97.7 130.2 195.3 260.4 325.5 390.5 6.51

5 5.05 40.9 61.4 102.3 153.5 204.6 306.9 409.2 511.5 613.7 10.2

6 6.07 59.1 88.6 147.7 221.6 295.5 443.2 590.9 738.7 886.3 14.8

8 7.98 102.3 153.5 255.8 383.7 511.6 767.5 1023.3 1279.1 1534.7 25.6

10 10.02 161.3 241.9 403.2 604.8 806.5 1209.7 1612.9 2016.2 2419.1 39.0

12 11.94 229.0 343.4 572.4 858.6 1144.7 1717.1 2289.5 2861.9 3433.8 57.2

14 13.13 276.8 415.2 692.0 1037.9 1383.9 2075.9 2767.8 3459.8 4151.3 69.2

16 15.00 361.5 542.2 903.6 1355.5 1807.3 2710.9 3614.6 4518.2 5421.2 90.4

18 16.88 457.5 686.3 1143.8 1715.7 2287.6 3431.4 4575.2 5719.0 6862.1 114.4

20 18.81 572.4 853.0 1421.6 2132.4 2843.2 4264.8 5686.4 7108.0 8528.6 142.2

Flow Switch Adapter Step 1: Adjust flow through the evaporator to the minimum
If needed, the adapter is threaded into the pipe wall using desired operating gpm. Maintain this flow throughout the setup
pipe sealant appropriate for the application. The flow sensor procedure.
is mounted onto the adapter using silicone grease. Carefully Step 2: Once steady state minimum desired operating flow is
apply lubricant to the inside threads and o-ring so temperature obtained, perform the ‘Teach’ function on the flow switch. The
probe does not become coated with lubricant or pipe thread ‘Teach’ function is initiated by holding down the minus ‘-’ button
sealant. Torque the adapter/sensor connection to 18.5 ft/lbs. on the face of the flow switch for 15 seconds. During this 15
second period, LEDs ‘0’ and ‘9’ will be lit green. Once the
Wiring ‘Teach’ function is completed, the outer LEDs will flash green
Refer to wiring diagram in the unit control panel. as shown in Figure 39.

Either AC or DC is used to power the flow switch. The unit

Figure 39: Automatic Teach of Setpoint
controller’s digital input is a DC signal which is supplied
through the switch output of the flow switch for flow indication.
It is required that the AC and DC commons of power be
separated. Contact Chiller Technical Response for alternate
wiring scenarios.

Flow Switch Setup

The flow switch comes from the factory set at a default velocity
of 20cm/s. This value is typically well below the minimum water
flow specified for the unit’s evaporator and condenser so field
adjustment is required for adequate low flow protection. Table
67 shows the calculated gallons per minute (gpm) for Schedule
40 steel pipe for various fluid velocities from 15 cm/s to 60
cm/s. The flow switch has a range of adjustment from 3 cm/s to
300 cm/s.

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 Startup and Shutdown Procedures

Step 3: After the ‘Teach’ function is completed and the outer Figure 41: Upper Range of Minimum Flow
LEDs flashed, the flow switch will indicate a new set point
based upon the current flow which should still be at the steady
state minimum desired operating flow. Figure 40 shows a
typical display for this condition. All LEDs to the left of the
SP LED are lit green. The SP LED is lit RED (or may toggle
amber) which indicates that the flow switch is OPEN. Typically,
an increase in fluid flow is between 15% to 30% above the
‘Teach’ function flow is required for the SP LED to turn AMBER
and the flow switch to CLOSE indicating acceptable flow.

Figure 40: Teach Adjustment Complete

Step 5: Once the SP is set, it is recommended that the

sensor be locked to avoid inadvertent readjustment. This
can be performed by pressing both the ‘+’ and ‘-’ buttons
simultaneously for 10 seconds. The indication goes out
momentarily indicating the unit is locked. To unlock, the same
procedure is performed to toggle to unlocked.
NOTE: 1. The LED window display on flow switch represents
a velocity range of 50 cm/s. The window centers on
the set point (SP). For example, if the SP was set to
200 cm/s, then the LED labeled ‘0’ would represent
a velocity of 180 cm/s when lit and the LED labeled 9
In Step 3, the ‘Teach’ function re-adjusted the flow switch set would represent a velocity of 230 cm/s when lit.
point (SP) while flow was at the minimum desired operating 2. Each LED represents 5 cm/s, or two presses of the
flow. The chiller will not operate at this flow because the ‘+’ or ‘-’ buttons.
flow switch is OPEN after performing the ‘Teach’ function. 3. When power is initially applied to the flow switch,
The benefit of the ‘Teach’ function is to quickly set the set all green LEDs light and go out step by step. During
point within the desired operating range. Additional ‘manual’ this time, the output is closed. The unit is in the
adjustment of set point is required in order to allow for chiller operating mode.
operation at this minimum flow. The ‘+’ and ‘-’ buttons on the 4. When making manual adjustments to the set point
face of the flow switch allow for the manual adjustment of the (SP), if no button is pressed for 2 seconds, the unit
SP. Pressing the ‘+’ button reduces the flow set point while returns to the operating mode with the newly set
pressing the ‘-’ button increases the flow set point. Each button value.
press, ‘+’ or ‘-‘, changes the flow set point by 2.5 cm/s. Flow below display range: The SP LED will be lit red and
Step 4: Press the ‘+’ button until LED ‘9’ begins to flash, as the leftmost LED will be flashing green. For example, if the SP
shown in Figure 41. Opening of flow switch should now occur was set to 200 cm/s, the flashing labeled ‘0’ would indicate that
at approximately 80% to 90% of minimum flow. the flow was below 180 cm/s. This would be shown if no flow
through chiller or lowered than desired flow.

www.DaikinApplied.com 61 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Startup and Shutdown Procedures

Figure 42: Display for Flow Below Range

Flow above display range: The SP LED will be lit amber, all
LEDs to the left and right of the SP LED with be green with the
rightmost LED flashing green. For example, if the SP was set
to 200 cm/s, the flashing LED labeled ‘9’ would indicate that
the flow was above 230 cm/s. This may be a normal display
depending on range by which flow varies through chiller.

Figure 43: Display for Flow Above Range

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 Unit Maintenance

Unit Maintenance Compressor Maintenance

The scroll compressors are fully hermetic and require standard
maintenance practices:
General • Check oil level monthly
On initial start-up and periodically during operation, it will • Inspect electrical connections annually
be necessary to perform certain routine service checks.
Among these are checking the liquid line sight glasses, taking • Test oil annually
condensing and suction pressure readings, and checking
Crankcase Heaters
to see that the unit has normal superheat and subcooling
readings. A recommended maintenance schedule is located at The scroll compressors are equipped with externally mounted
the end of this section. band heaters located at the oil sump level. The function of
the heater is to keep the temperature in the crankcase high
enough to prevent refrigerant from migrating to the crankcase
Electrical Terminals and condensing in the oil during off-cycle.
Prior to attempting any service on the control center, study the Power must be supplied to the heaters 24 hours before starting
wiring diagram furnished with the unit so that you understand the compressors.
the operation of the unit.

DANGER Lubrication
LOCKOUT/TAGOUT all power sources prior to starting, No routine lubrication is required on AGZ units. The fan motor
pressurizing, de-pressuring, or powering down the Chiller. bearings are permanently lubricated and no further lubrication
Disconnect electrical power before servicing the equipment. is required. Excessive fan motor bearing noise is an indication
Failure to follow this warning exactly can result in serious of a potential bearing failure.
injury or death.
POE type oil is used for compressor lubrication. Further details
DANGER and warnings are listed on page 67.
The panel is always energized even if the system switch is off. WARNING
If it is necessary to de-energize the complete panel, including
POE oil must be handled carefully using proper protective
crankcase heaters, pull the main unit disconnect. More than
equipment (gloves, eye protection, etc.). The oil must not come
one disconnect may be required to de-energize the unit.
in contact with certain polymers (e.g. PVC), as it may absorb
Failure to do so may result in serious injury or death.
moisture from this material. Daikin Applied recommends
against the use of PVC and CPVC piping for chilled water
WARNING systems. Also, do not use oil or refrigerant additives in the
Electrical Shock Hazard. Before servicing or inspecting system.
the equipment, disconnect power to the unit. The internal
capacitor remains charged after power is turned off. Wait at
least the amount of time specified on the drive before touching
any components. Failure to do can result in property damage,
personal injury, or death.

WARNING
Warranty may be affected if wiring is not in accordance
with specifications. A blown fuse or tripped protector may
indicate a short, ground fault, or overload. Before replacing
fuse or restarting compressor, the trouble must be found and
corrected. It is important to have a qualified control panel
electrician service this panel. Unqualified tampering with the
controls can cause serious damage to equipment and void
the warranty.

CAUTION
Periodically check electrical terminals for tightness and tighten
as required. Always use a back-up wrench when tightening
electrical terminals.

www.DaikinApplied.com 63 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Unit Maintenance

All-Aluminum Condenser Coils Periodic Clean Water Rinse

The condenser coils are an all-aluminum design including A monthly clean water rinse is recommended for all coils
the connections, microchannel, fins (an oven brazing process according to Table 73. Coils should be rinsed with water at a
brazes the fins to the microchannel flat tube), and headers lower pressure such as from a hose. Pressure washers are not
(see Figure 44), which eliminates the possibility of corrosion recommended as the higher pressure may damage the fins.
normally found between dissimilar metals of standard coils. Regular water rinsing of epoxy coated coils that are applied in
During the condensing process, refrigerant in the coil passes coastal or industrial environments will help to remove chlorides,
through the microchannel flat tubes, resulting in higher dirt and debris. An elevated water temperature (not to exceed
efficiency heat transfer from the refrigerant to the airstream. In 130ºF) will reduce surface tension, increasing the ability to
the unlikely occurrence of a coil leak, contact Daikin Applied to remove chlorides and dirt.
receive a replacement coil module.
Table 68: Coil Cleaning Guidelines
Figure 44: Microchannel Coil Cross Section Coating Option Recommended Rinsing Required Cleaning
Aluminum Coil Monthly with low N/A
Only pressure water only
Epoxy Coated Monthly with low Quarterly with approved
Coil pressure water only - cleaner, Chloride Remover is
max 130°F required - max 130°F

Cleaning Epoxy Coated Coils

The following cleaning procedures are recommended as part
of the routine maintenance activities for epoxy coated coils.
Documented routine cleaning of epoxy coated coils is required
to maintain warranty coverage.

Routine Quarterly Cleaning of Epoxy Coated

Coil Surfaces
Quarterly cleaning is essential to extend the life of an epoxy
coated coil and shall be part of the unit’s regularly scheduled
maintenance procedures. Failure to clean epoxy coated coils
will void the warranty and may result in reduced efficiency and
durability in the environment.
For routine quarterly cleaning, first clean the coil with a coil
Cleaning Microchannel Aluminum Coils cleaner (see Table 74). After cleaning the coils with a cleaning
Maintenance consists primarily of the routine removal of dirt agent, use the chloride remover to remove soluble salts and
and debris from the outside surface of the fins. revitalize the unit.

WARNING Recommended Coil Cleaning Agents

Prior to cleaning the coils, turn off and lock out the main power
The following cleaning agents, used in accordance with the
switch to the unit and open all access panels. Failure to do
manufacturer’s directions on the container for proper mixing
can result in property damage, personal injury, or death.
and cleaning, has been approved for use on epoxy coated
coils to remove mold, mildew, dust, soot, greasy residue, lint
Remove Surface Loaded Fibers and other particulates:
Surface loaded fibers or dirt should be removed prior to water
rinse to prevent further restriction of airflow. If unable to back Table 69: Epoxy Coated Coil Recommended Cleaning
wash the side of the coil opposite that of the coils entering air Agents
side, then surface loaded fibers or dirt should be removed with
Chemical Type Cleaning Agent
a vacuum cleaner. If a vacuum cleaner is not available, a soft
Coil Cleaner Enviro-Coil Concentrate
non-metallic bristle brush may be used. In either case, the tool
should be applied in the direction of the fins. Coil surfaces can Coil Cleaner GulfCoat™
be easily damaged (fin edges bent over) if the tool is applied Chloride Remover CHLOR*RID®
across the fins.
Chloride remover should be used to remove soluble salts from
NOTE: Use of a water stream, such as a hose, against a epoxy coated coils, but the directions must be followed closely.
surface loaded coil will drive the fibers and dirt into This product is intended to remove chlorides and sulfates and
the coil. This will make cleaning efforts more difficult. not intended for use as a degreaser. Any grease or oil film
Surface loaded fibers must be completely removed should first be removed with the approved cleaning agent.
prior to using low velocity clean water rinse.

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 Unit Maintenance

1. Remove Barrier - Soluble salts adhere themselves

to the substrate. For the effective use of this product,
Liquid Line Solenoid Valve
the product must be able to come in contact with the The liquid line solenoid valves that shut off refrigerant flow
salts. These salts may be beneath any soils, grease or in the event of a power failure do not normally require any
dirt; therefore, these barriers must be removed prior to maintenance.
application of this product. As in all surface preparation,
the best work yields the best results.
2. Apply chloride remove directly onto the substrate.
High Ambient Control Panel
Sufficient product must be applied uniformly across the This option consists of an exhaust fan with rain hood, two inlet
substrate to thoroughly wet out surface with no areas screens with filters, necessary controls and wiring to allow
missed. This may be accomplished by use of a pump- operation to 125°F (52°C). The components can be factory or
up sprayer. The method does not matter, as long as the field installed as a kit.
entire area to be cleaned is wetted. After the substrate • It must be supplied on units operating at ambient
has been thoroughly wetted, the salts will be soluble and temperatures of 105°F (40.6°C) and above.
is now only necessary to rinse them off.
• It is automatically included on units with fan VFD (low
3. Rinse - It is highly recommended that a hose be used ambient option).
as a pressure washer will damage the fins. The water to • Check inlet filters periodically and clean as required.
be used for the rinse is recommended to be of potable Verify that the fan is operational.
quality, though a lesser quality of water may be used if a
small amount of chloride remover is added.
System Adjustment
Harsh Chemical and Acid Cleaners
To maintain peak performance at full load operation, the
Harsh chemicals, household bleach or acid cleaners should not system superheat and liquid subcooling may require
be used to clean outdoor epoxy coated coils. These cleaners adjustment. Read the following subsections closely to
can be very difficult to rinse out of the coil and can accelerate determine if adjustment is required.
corrosion and attack the epoxy coating. If there is dirt below
the surface of the coil, use the recommended coil cleaners as Liquid Line Sight Glass and Subcooling
described above.
The refrigerant sight glasses should be observed periodically. A
High Velocity Water or Compressed Air clear glass of liquid indicates that there is subcooled refrigerant
charge in the system. Bubbling refrigerant in the sight glass,
High velocity water or compressed air may damage the coil fins during stable run conditions, may indicate that the system can
and must only be used at a pressure lower than 100 psig and be short of refrigerant charge. However, it is not unusual to
130°F to prevent fin and/or coil damage. Nozzles must have see bubbles in the sight glass during changing load conditions.
a diffuse pattern, as a concentrated jet may damage the fins. Refrigerant gas flashing in the sight glass could also indicate
Never use a pressure washer for coil cleaning. The force of the an excessive pressure drop in the liquid line, possibly due to a
water or air jet may bend the fin edges and increase airside clogged filter-drier or a restriction elsewhere in the liquid line.
pressure drop. Reduced unit performance or nuisance unit
shutdowns may occur. If the unit is at steady full load operation and bubbles are
visible in the sight glass, then check liquid subcooling. If
subcooling is low, add charge to clear the sight glass. Once
Evaporator the subcooler is filled, extra charge will not lower the liquid
temperature and does not help system capacity or efficiency.
On AGZ-F models, the evaporator is a compact, high efficiency, If subcooling is normal (15 to 20 degrees F at full load) and
dual circuit, brazed plate-to-plate type heat exchanger flashing is visible in the sight glass, check the pressure drop
consisting of parallel stainless steel plates. The evaporator across the filter-drier.
is protected with an electric resistance heater and insulated
with 3/4” (19mm) thick closed-cell polyurethane insulation. An element inside the sight glass indicates the moisture
This combination provides freeze protection down to -20°F condition corresponding to a given element color. Immediately
(-29°C) ambient air temperature. Evaporators are designed after the system has been opened for service, the element may
and constructed according to, and listed by, Underwriters indicate a wet condition. If the sight glass does not indicate
Laboratories (UL). Other than cleaning and testing, no service a dry condition after about 12 hours of operation, the circuit
work should be required on the evaporator. should be pumped down and the filter-drier changed or verify
moisture content by performing an acid test on compressor oil.

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 Unit Maintenance

Expansion Valve The pressure regulating valve is factory set to begin opening
at 110 psig with R-32 and can be changed by adjusting the
The expansion valve’s function is to keep the evaporator pressure setting. To raise the pressure setting, remove the cap
supplied with the proper amount of refrigerant to satisfy the and turn the adjustment screw clockwise. To lower the setting,
load conditions. Before adjusting superheat, check that unit turn the screw counterclockwise. Do not force the adjustment
charge is correct and liquid line sight glass is full with no beyond the range it is designed for as this will damage the
bubbles and that the circuit is operating under stable, full load adjustment assembly. The regulating valve opening point
conditions. can be determined by slowly reducing the system load while
Electronic Expansion Valve - For suction superheat targets, observing the suction pressure. When the bypass valve starts
see “Circuit Level Set Points” on page 26. to open, the refrigerant line on the evaporator side of the valve
will begin to feel warm to the touch.
Filter-Driers A solenoid valve is located ahead of the bypass valve and is
Replace the filter-drier any time excessive pressure drop is controlled by the MicroTech controller. It is active when only the
read across the filter-drier and/or when bubbles occur in the first stage of cooling on a circuit is active.
sight glass with normal subcooling. The filter-drier should also
be changed if the moisture indicating liquid line sight glass
WARNING
indicates excess moisture in the system. When performing valve checkout procedure, the hot gas
line may become hot enough in a short period of time to
Any residual particles from the condenser tubing, compressor
cause personal injury. Be sure to read and understand the
and miscellaneous components are swept by the refrigerant
installation, operation, and service instructions within this
into the liquid line and are caught by the filter-drier.
manual.
A condenser liquid line service valve is provided for isolating
A field installed HGBP kit can be added to units already
the charge in the condenser, but also serves as the point from
installed. If a 120-V version of the kit is ordered, the solenoid
which the liquid line can be pumped out. With the line free of
valve comes with a DIN connector and has to be wired. The
refrigerant, the filter-drier core(s) can be easily replaced.
wiring should be two 14 AWG wires, one red and one white to
AGZ-F units come equipped with replaceable core filter driers. be run in conduit. Field to wire:
The core assembly of the replaceable core drier consists of a
• Circuit 1 Red to NO2 on UE01 and white to SPL1 (splice
filter core held tightly in the shell in a manner that allows full
connector)
flow without bypass.
• Circuit 2 Red to NO4 on UE01 and white to SPL1 (splice
connector)
Hot Gas Bypass (Optional)
NOTE: PIPING SHOWN FOR ONE SYSTEM OF UNIT. UNITS AGZ140-180E PACKAGE CHILLER
HAVE TWO INDEPENDENT SYSTEMS.
DIN connection size is 1/2 in. NPTF for conduit fitting. Required
MICROCHANNEL ALUMINUM COIL

334549802 0D
wire, conduit fittings, and conduit to be supplied by the field.
CONDENSER
ASSEMBLY

The hot gas bypass (HGBP) option allows the system to

operate at lower loads without excessive on/off compressor
AIR AIR SCHRADER AIR
FLOW FLOW VALVE FLOW

cycling. HGBP is required to be on both refrigerant circuits Figure 45: HGBP Portion of Refrigerant Schematic
SUCTION
TRANSDUCER
(WL1, WL2)

because of the lead / lag feature of the controller. HGBP allows

HOTGAS CHARGING
SHUT-OFF VALVE
AIR AIR SUCTION SHUT-OFF
FLOW FLOW VALVE SUCTION BALL VALVE WITH

passage of discharge gas into the evaporator inlet (between

TEMP. SENSOR SCHRADER VALVE
DISCHARGE
(ST1, ST2) (OPTION)
DISCHARGE HIGH PRESSURE
DISCHARGE
TRANSDUCER SWITCH

the electronic expansion valve and the evaporator) which

SOLENOID
SCHRADER (WH1, WH2)
VALVE
VALVE

generates a false load to supplement the actual chilled water

LIQUID LINE
CHECK VALVE

or air handler load.

SCROLL
DISCHARGE OUTSIDE AIR COMPRESSOR SUCTION
SHUT-OFF VALVE TEMPERATURE
WITH SCHRADER
(TANDEM OR TRIO) TUBING
(WAA) DISCHARGE
VALVE LOCATED ON

NOTE: The hot gas bypass valve should not generate a CONDENSER RAIL TUBING

100% false load. For glycol applications, HGBP may OIL SIGHT OIL
HEATER

not have full range of setting or turn down.

GLASS FUSIBLE
CHARGING
PLUG
VALVE

ENTERING WATER
TEMPERATURE
LIQUID SENSOR WYE STRAINER REQUIRED
TUBING (FACTORY OR FIELD
INSTALLED)
HOT GAS SOLENOID HGBP
ACCESS BYPASS TUBING VALVE VALVE
FITTING
(OPTIONAL) WATER
SCHRADER IN
VALVE
LEAVING WATER
LIQUID TEMP. SENSOR
SHUT-OFF
VALVE
WATER
OUT

FILTER SCHRADER SOLENOID SCHRADER SIGHT ELECTRICAL FLOW SENSOR PLATE TYPE
DRIER VALVE VALVE VALVE GLASS EXPANSION VALVE (OPTIONAL) EVAPORATOR
(REPLACEABLE CORE)

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 Unit Maintenance

Table 70: Planned Maintenance Schedule POE Lubricants

Polyolester (POE) oil is used for compressor lubrication. This
type of oil is extremely hydroscopic which means it will quickly

Quarterly
Monthly
Operation

(Note 1)

(Note 2)
Weekly

Annual
absorb moisture if exposed to air and may form acids that can
be harmful to the chiller. Avoid prolonged exposure of POE oil
General to the atmosphere to prevent this problem.
Complete unit log and review (Note 3) X It is important that only the manufacturer’s recommended oils
Visually inspect unit for loose or be used. Acceptable POE oil types are:
X
damaged components
Inspect thermal insulation for integrity X • Danfoss POE lubricant 1855L
Clean and paint as required X
Electrical
WARNING
Check terminals for tightness, X POE oil must be handled carefully using proper protective
tighten as necessary
equipment (gloves, eye protection, etc.) The oil must not come
Clean control panel interior X
in contact with certain polymers (e.g. PVC), as it may absorb
Visually inspect components for
signs of overheating X moisture from this material. Daikin Applied recommends
Verify compressor heater operation X against the use of PVC and CPVC piping for chilled water
Test and calibrate equipment systems. Also, do not use oil or refrigerant additives in the
X
protection and operating controls system.
Verify solenoid plug(s) tightness and X
gasket integrity
Refrigeration
WARNING
Leak test X Polyolester Oil, commonly known as POE oil is a synthetic
Check sight glasses for clear flow X oil used in many refrigeration systems, and is present in this
Check filter-drier pressure drop X Daikin Applied product. POE oil, if ever in contact with PVC/
Perform compressor vibration test X CPVC, will coat the inside wall of PVC/CPVC pipe causing
Acid test oil sample X environmental stress fractures. Although there is no PVC/
Condenser (air-cooled) CPVC piping in this product, please keep this in mind when
Rinse condenser coils (Note 5) X selecting piping materials for your application, as system
Clean epoxy coated condenser coils X
failure and property damage could result. Refer to the pipe
(Note 5)
manufacturer’s recommendations to determine suitable
Check fan blades for tightness on
shaft (Note 6) X applications of the pipe.
Check fans for loose rivets and X
cracks Procedure Notes
Check coil fins for damage X
• Use only new sealed metal containers of oil to insure
Notes: quality.
1. Monthly operations include all weekly operations. • Buy smaller containers to prevent waste and
2. Annual (or spring start-up) operations includes all weekly contamination.
and monthly operations. • Use only filter driers designed for POE and check
pressure drops frequently.
3. Log readings can be taken daily for a higher level of unit
observation. • Test for acid and color at least annually. Change filter
driers if acid or high moisture (> 200 ppm) is indicated (<
4. Never Megohm motors while they are in a vacuum to 100 ppm typical).
avoid damage to the motor.
• Evacuate to 500 microns and hold test to insure systems
5. Coil rinsing and cleaning can be required more frequently are dry.
in areas with a high level of airborne particles.
6. When cleaning condenser coils, be sure fan motors are Control and Alarm Settings
electrically locked out. The software that controls the operation of the unit is factory-
set for operation with R-32.

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 Unit Maintenance

Refrigerant Charging If subcooling is low, add charge to clear the sight glass. Once
the subcooler is filled, extra charge will not lower the liquid
temperature and does not help system capacity or efficiency.
CAUTION
If subcooling is normal (15 to 20° F at full load) and flashing is
When moving refrigerant to/from the chiller using an auxiliary
visible in the sight glass, check the pressure drop across the
tank, a grounding strap must be used. An electrical charge
filter-drier.
builds when halo-carbon refrigerant travels in a rubber
hose. A grounding strap must be used between the auxiliary Overcharging of refrigerant will raise the compressor discharge
refrigerant tank and the end sheet of the chiller (earth ground), pressure due to filling of the condenser tubes with excess
which will safely take the charge to the ground. Damage to refrigerant.
sensitive electronic components could occur if this procedure
is not followed. Service
If a unit is low on refrigerant, you must first determine the Special tools will be required due to higher refrigerant
cause before attempting to recharge the unit. Locate and repair pressures with R-32. Oil-less/hp recovery units, hp recovery
any refrigerant leaks. Soap works well to show bubbles at cylinders (DOT approved w/525# relief), gauge manifold 30”-
medium size leaks but electronic leak detectors are needed to 250 psi low/0-800 psi high, hoses w/800 psi working & 4,000
locate small leaks. psi burst.
Charging or check valves should always be used on charging All filter driers and replacement components must be rated for
hoses to limit refrigerant loss and prevent frostbite. Ball valve POE oils and for the refrigerant pressure
type recommended. Charge to 80-85% of normal charge
Brazed connections only. No StayBrite or solder connections
before starting the compressors.
(solder should never be used with any refrigerant). K or L type
refrigeration tubing only. Use nitrogen purge. Higher R-32
Charging procedure pressures and smaller molecule size make workmanship more
The units are factory-charged with R-32. Use the following critical.
procedure if recharging in the field is necessary. Cooling the recovery cylinder will speed recovery and lessen
The charge can be added at any load condition between stress on recovery equipment.
25 to 100 percent load per circuit, but at least two fans per
refrigerant circuit should be operating if possible.
Evaporator waterflow MUST be established while charging the
unit.
• Start the system and observe operation.
• Trim the charge to the recommended liquid line sub-
cooling (approximately 15-20°F typical at full load).
• Use standard charging procedures (liquid only) to top off
the charge.
• Check the sight glass to be sure there is no refrigerant
flashing.
With outdoor temperatures above 60°F (15.6°C), all condenser
fans should be operating and the liquid line temperature
should be within 15°F to 20°F (8.3°C to 11.1°C) of the outdoor
air temperature. At 25-50% load, the liquid line temperature
should be within 5°F (2.8°C) of outdoor air temperature with all
fans on. At 75-100% load the liquid line temperature should be
within 10°F (5.6°C) of outdoor air temperature with all fans on.
If the unit is at steady full load operation and bubbles are
visible in the sight glass, then check liquid subcooling. The
AGZ units have a condenser coil design with approximately
15% of the coil tubes located in a subcooler section of the coil
to achieve liquid cooling to within 15 to 20°F (8.3 to11.1°C)
of the outdoor air temperature when all condenser fans are
operating. Subcooling should be checked at full load with 70°F
(21.1°C) ambient temperature or higher, stable conditions, and
all fans running. Liquid line subcooling at the liquid shut-off
valve should be between 15 and 20°F at full load.

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 R-32 Guidelines

R-32 Guidelines Maintenance

• Portable equipment shall be repaired outside or in a
workshop specially equipped for servicing units with
WARNING FLAMMABLE REFRIGERANTS.
This unit contains R-32, a class A2L refrigerant • Ensure sufficient ventilation at the repair place.
that is flammable. This unit should only be
• Be aware that malfunction of the equipment may be
installed, serviced, repaired, and disposed of
caused by refrigerant loss and a refrigerant leak is
by qualified personnel licensed or certified in
possible.
their jurisdiction to work with R-32 refrigerant.
Installation and maintenance must be done • Discharge capacitors in a way that won’t cause any
in accordance with this manual. Improper spark. The standard procedure to short circuit the
handling of this equipment can cause capacitor terminals usually creates sparks.
equipment damage or personal injury. • Reassemble sealed enclosures accurately. If seals are
Be aware that R-32 refrigerant may not contain an odor. Place worn, replace them.
in a well ventilated area to prevent accumulation of refrigerant. • Check safety equipment before putting into service.
When installing the unit in a small room, take measures to keep
the refrigerant concentration from exceeding allowable safety Repair
limits. Excessive refrigerant leaks, in the event of an accident
• Portable equipment shall be repaired outside or in a
in a closed ambient space, can lead to oxygen deficiency.
workshop specially equipped for servicing units with
Do not pierce or burn this unit. FLAMMABLE REFRIGERANTS.
Never use an open flame during service or repair. Never • Ensure sufficient ventilation at the repair place.
store in a room with continuously operating ignition sources • Be aware that malfunction of the equipment may be
(for example: open flames, an operating gas appliance, or caused by refrigerant loss and a refrigerant leak is
and operating electric heater.), where there is ignitable dust possible.
suspension in the air, or where volatile flammables such as • Discharge capacitors in a way that won’t cause any
thinner or gasoline are handled. spark.
Only use pipes, nuts, and tools intended for exclusive use • When brazing is required, the following procedures shall
with R-32 refrigerant in compliance with national codes be carried out in the right order:
(ASHRAE15 or IRC). — Remove the refrigerant. If the recovery is not required
Do not mix air or gas other than R-32 in the refrigerant system. If by national regulations, drain the refrigerant to the
air enters the refrigerant system, an excessively high pressure outside. Take care that the drained refrigerant will not
results, which may cause equipment damage or injury. cause any danger. In doubt, one person should guard
the outlet. Take special care that drained refrigerant
Do not use means to accelerate the defrosting process or to
will not float back into the building.
clean, other than those recommended by the manufacturer.
— Evacuate the refrigerant circuit.
The unit shall be stored in a room without continuously
operating ignition sources (for example: open flames, an — Remove parts to be replaced by cutting, not by flame.
operating gas appliance or an operating electric heater. — Purge the braze point with nitrogen during the brazing
procedure.
Maintaining and servicing R-32 refrigerant should only
be performed as recommended by this manual and by — Carry out a leak test before charging with refrigerant.
personnel licensed or certified in their jurisdiction to handle • Reassemble sealed enclosures accurately. If seals are
A2L refrigerants. Dismantling the unit and treatment of worn, replace them.
the refrigerant, oil, and additional parts must be done in • Check safety equipment before putting into service.
accordance with the relevant local, state, and national
regulations. Lubrication
Only use tools meant for use on R-32 refrigerant, such as R-32 should be used only with polyolester (POE) oil. The HFC
a gauge manifold, charge hose, gas leak detector, reverse refrigerant components in R-32 will not be compatible with
flow check valve, refrigerant charge base, vacuum gauge, or mineral oil or alkylbenzene lubricants. R-32 systems will be
refrigerant recovery equipment. charged with the OEM recommended lubricant, ready for use
with R-32.

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 R-32 Guidelines

Leak Detection Decommissioning

NEVER use the following when attempting to detect R-32 • If the safety is affected when the equipment is put out of
refrigerant leaks: service, the REFRIGERANT CHARGE shall be removed
before decommissioning.
• A halide torch (or any other detector using a naked flame)
• Ensure sufficient ventilation at the equipment location.
• Substances containing chlorine
• Be aware that malfunction of the equipment may be
• Electronic leak detection
caused by refrigerant loss and a refrigerant leak is
possible.
Pressure Testing and Refrigerant
• Discharge capacitors in a way that won’t cause any
Evacuation spark.
• Make sure that air or any matter other than R-32 • Remove the refrigerant. If the recovery is not required by
refrigerant does not get into the refrigeration cycle. national regulations, drain the refrigerant to the outside.
• If refrigerant gas leaks occur, ventilate the room as soon Take care that the drained refrigerant will not cause any
as possible. danger. In doubt, one person should guard the outlet.
• R-32 should always be recovered and never released Take special care that drained refrigerant will not float
directly into the environment. back into the building.
• Only use tools meant for use on R-32 refrigerant (such
as a gauge manifold, charging hose, or vacuum pump
Recovery
adapter). When removing refrigerant from a system, either for servicing
or decommissioning, it is recommended good practice that all
refrigerants are removed safely. When transferring refrigerant
Handling and Storage into cylinders, ensure that only appropriate refrigerant recovery
cylinders are employed. Ensure that the correct number of
Precautions for Safe Handling cylinders for holding the total system charge is available.
All cylinders to be used are designated for the recovered
Waste air is to be released into the atmosphere only via
refrigerant and labelled for that refrigerant (i. e. special
suitable separators. Open and handle receptacle with care.
cylinders for the recovery of refrigerant). Cylinders shall be
complete with pressure-relief valve and associated shut-off
Fire and Explosion Protection valves in good working order. Empty recovery cylinders are
Information evacuated and, if possible, cooled before recovery occurs.
Keep ignition sources away. Do not smoke. Protect against The recovery equipment shall be in good working order with
electrostatic charges. a set of instructions concerning the equipment that is at
hand and shall be suitable for the recovery of all appropriate
Conditions for Safe Storage refrigerants including, when applicable, FLAMMABLE
REFRIGERANTS. In addition, a set of calibrated weighing
• Requirements to be met by storerooms and receptacles: scales shall be available and in good working order. Hoses
— Store only in unopened original receptacles shall be complete with leak-free disconnect couplings and in
— Store in a cool and dry location good condition. Before using the recovery machine, check that
• Further information about storage conditions: it is in satisfactory working order, has been properly maintained
and that any associated electrical components are sealed to
— Keep container tightly sealed
prevent ignition in the event of a refrigerant release. Consult
— Store in cool, dry conditions in well sealed receptacle manufacturer if in doubt.
— Protect from heat and direct sunlight
The recovered refrigerant shall be returned to the refrigerant
• Maximum storage temperature: 40°C supplier in the correct recovery cylinder, and the relevant waste
transfer note arranged. Do not mix refrigerants in recovery
Commissioning units and especially not in cylinders.
• Ensure that the floor area is sufficient for the If compressors or compressor oils are to be removed, ensure
REFRIGERANT CHARGE or that the ventilation duct is that they have been evacuated to an acceptable level to make
assembled in a correct manner. certain that FLAMMABLE REFRIGERANT does not remain
• Connect the pipes and carry out a leak test before within the lubricant. The evacuation process shall be carried
charging with refrigerant. out prior to returning the compressor to the suppliers. Only
• Check safety equipment before putting into service. electric heating to the compressor body shall be employed to
accelerate this process. When oil is drained from a system, it
shall be carried out safely.

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 R-32 Guidelines

Disposal • Information about potential ignition sources, especially

those that are not obvious, such as lighters, light
• Waste treatment method recommendation: switches, vacuum cleaners, electric heaters.
— Must be specially treated adhering to official • Information about the different safety concepts:
regulations
— Unventilated: Safety of the appliance does not
— Incineration in an adequate incinerator is depend on ventilation of the housing. Switching off the
recommended appliance or opening of the housing has no significant
— Uncleaned packaging disposal must be made effect on the safety. Nevertheless, it is possible
according to official regulations that leaking refrigerant may accumulate inside the
• Ensure sufficient ventilation at the working place enclosure and flammable atmosphere will be released
• Remove the refrigerant. If the recovery is not required by when the enclosure is opened.
national regulations, drain the refrigerant to the outside. — Ventilated enclosure: Safety of the appliance
Take care that the drained refrigerant will not cause any depends on ventilation of the housing. Switching
danger. In doubt, one person should guard the outlet. off the appliance or opening of the enclosure has a
Take special care that drained refrigerant will not float significant effect on the safety. Care should be taken
back into the building to ensure sufficient ventilation before.
• Evacuate the refrigerant circuit — Ventilated room: Safety of the appliance depends on
• Purge the refrigerant circuit with nitrogen for 5 minutes the ventilation of the room. Switching off the appliance
or opening of the housing has no significant effect on
• Evacuate again the safety. The ventilation of the room shall not be
• Cut out the compressor and drain the oil switched off during repair procedures.
• Information about refrigerant detectors:
Competence of Personnel — Principle of function, including influences on the
operation.
Information of procedures additional to usual information for
— Procedures, how to repair, check or replace a
refrigerating appliance installation, repair, maintenance and
refrigerant detector or parts of it in a safe way.
decommission procedures is required when an appliance with
flammable refrigerants is affected. — Procedures, how to disable a refrigerant detector in
case of repair work on the refrigerant carrying parts.
The training of these procedures is carried out by national
training organizations or manufacturers that are accredited to • Information about the concept of sealed components and
teach the relevant national competency standards that may sealed enclosures according to IEC 60079-15:2010.
be set in legislation. The achieved competence should be • Information about the correct working procedures:
documented by a certificate. — Commissioning
i. Ensure that the floor area is sufficient for the
WARNING
refrigerant charge or that the ventilation duct is
Service on this equipment is to be performed by qualified assembled in a correct manner.
refrigeration personnel familiar with equipment operation,
ii. Connect the pipes and carry out a leak test before
maintenance, correct servicing procedures, and the safety
charging with refrigerant.
hazards inherent in this work. Causes for repeated tripping
of equipment protection controls must be investigated and iii. Check safety equipment before putting into service.
corrected. Disconnect all power before doing any service — Maintenance
inside the unit. If refrigerant leaks from the unit, there is a
potential danger of suffocation since refrigerant will displace iv. Portable equipment shall be repaired outside or in a
the air in the immediate area. Servicing this equipment must workshop specially equipped for servicing units with
comply with the requirements of all applicable industry related flammable refrigerants.
published standards and local, state and federal, statutes, v. Ensure sufficient ventilation at the repair place.
regulations and codes in regards to refrigerant reclamation
vi. Be aware that malfunction of the equipment may be
and venting. Avoid exposing refrigerant to an open flame or
caused by refrigerant loss and a refrigerant leak is
other ignition source.
possible.

Information and Training vii. Discharge capacitors in a way that won’t cause any
spark. The standard procedure to short circuit the
The training should include the substance of capacitor terminals usually creates sparks.
the following viii. Reassemble sealed enclosures accurately. If seals are
worn, replace them.
• Information about the explosion potential of flammable
refrigerants to show that flammables may be dangerous ix. Check safety equipment before putting into service.
when handled without care. — Repair

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 R-32 Guidelines

i. Portable equipment shall be repaired outside or in a Information on Servicing

workshop specially equipped for servicing units with
flammable refrigerants. Checks to the area
ii. Ensure sufficient ventilation at the repair place. Prior to beginning work on systems containing FLAMMABLE
iii. Be aware that malfunction of the equipment may be REFRIGERANTS, safety checks are necessary to ensure that
caused by refrigerant loss and a refrigerant leak is the risk of ignition is minimized
possible.
Work procedure
iv. Discharge capacitors in a way that won’t cause any
spark. Work shall be undertaken under a controlled procedure so as
to minimize the risk of a flammable gas or vapor being present
v. When brazing is required, the following procedures
while the work is being performed.
shall be carried out in the right order:
• Remove the refrigerant. If the recovery is not required by General work area
national regulations, drain the refrigerant to the outside.
All maintenance staff and others working in the local area shall
Take care that the drained refrigerant will not cause any
be instructed on the nature of work being carried out. Work in
danger. In doubt, one person should guard the outlet.
confined spaces shall be avoided.
Take special care that drained refrigerant will not float
back into the building.
Checking for presence of refrigerant
• Evacuate the refrigerant circuit.
The area shall be checked with an appropriate refrigerant
• Remove parts to be replaced by cutting, not by flame. detector prior to and during work, to ensure the technician is
• Purge the braze point with nitrogen during the brazing aware of potentially toxic or flammable atmospheres. Ensure
procedure. that the leak detection equipment being used is suitable for use
• Carry out a leak test before charging with refrigerant. with all applicable refrigerants, i. e. non-sparking, adequately
vi. Reassemble sealed enclosures accurately. If seals are sealed or intrinsically safe.
worn, replace them.
Presence of fire extinguisher
vii. Check safety equipment before putting into service.
If any hot work is to be conducted on the refrigerating
— Decommissioning equipment or any associated parts, appropriate fire
i. If the safety is affected when the equipment is putted extinguishing equipment shall be available to hand. Have a dry
out of service, the refrigerant charge shall be removed powder or CO2 fire extinguisher adjacent to the charging area.
before decommissioning.
ii. Ensure sufficient ventilation at the equipment location. No ignition sources
iii. Be aware that malfunction of the equipment may be No person carrying out work in relation to a REFRIGERATING
caused by refrigerant loss and a refrigerant leak is SYSTEM which involves exposing any pipe work shall use any
possible. sources of ignition in such a manner that it may lead to the
risk of fire or explosion. All possible ignition sources, including
iv. Discharge capacitors in a way that won’t cause any cigarette smoking, should be kept sufficiently far away from
spark. the site of installation, repairing, removing and disposal, during
v. Remove the refrigerant. If the recovery is not required which refrigerant can possibly be released to the surrounding
by national regulations, drain the refrigerant to the space. Prior to work taking place, the area around the
outside. Take care that the drained refrigerant will not equipment is to be surveyed to make sure that there are no
cause any danger. In doubt, one person should guard flammable hazards or ignition risks. “No Smoking” signs shall
the outlet. Take special care that drained refrigerant be displayed.
will not float back into the building.
Ventilated area
— Disposal
i. Ensure sufficient ventilation at the working place. Ensure that the area is in the open or that it is adequately
ventilated before breaking into the system or conducting any
ii. Remove the refrigerant. If the recovery is not required hot work. A degree of ventilation shall continue during the
by national regulations, drain the refrigerant to the period that the work is carried out. The ventilation should
outside. Take care that the drained refrigerant will not safely disperse any released refrigerant and preferably expel it
cause any danger. In doubt, one person should guard externally into the atmosphere.
the outlet. Take special care that drained refrigerant
will not float back into the building.

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 R-32 Guidelines

Checks to the refrigerating equipment etc.

Where electrical components are being changed, they shall be • Ensure that the apparatus is mounted securely.
fit for the purpose and to the correct specification. At all times • Ensure that seals or sealing materials have not degraded
the manufacturer’s maintenance and service guidelines shall to the point that they no longer serve the purpose of
be followed. If in doubt, consult the manufacturer’s technical preventing the ingress of flammable atmospheres.
department for assistance. Replacement parts shall be in accordance with the
manufacturer’s specifications.
The following checks shall be applied to installations using
FLAMMABLE REFRIGERANTS: Repair to intrinsically safe components
• the actual REFRIGERANT CHARGE is in accordance • Do not apply any permanent inductive or capacitance
with the room size within which the refrigerant containing loads to the circuit without ensuring that this will not
parts are installed; exceed the permissible voltage and current permitted for
• the ventilation machinery and outlets are operating the equipment in use.
adequately and are not obstructed; • Intrinsically safe components are the only types that can
• if an indirect refrigerating circuit is being used, the be worked on while live in the presence of a flammable
secondary circuit shall be checked for the presence of atmosphere. The test apparatus shall be at the correct
refrigerant; rating.
• marking to the equipment continues to be visible and • Replace components only with parts specified by the
legible. Markings that are illegible shall be corrected; manufacturer. Other parts may result in the ignition of
• refrigerating pipe or components are installed in a refrigerant in the atmosphere from a leak.
position where they are unlikely to be exposed to any NOTE: The use of silicon sealant can inhibit the effectiveness
substance which may corrode refrigerant containing of some types of leak detection equipment.
components, unless the components are constructed of Intrinsically safe components do not have to be
materials which are inherently resistant to being corroded isolated prior to working on them.
or are suitably protected against being so corroded.
Cabling
Checks to electrical devices • Check that cabling will not be subject to wear, corrosion,
Repair and maintenance to electrical components shall include excessive pressure, vibration, sharp edges or any other
initial safety checks and component inspection procedures. If adverse environmental effects. The check shall also take
a fault exists that could compromise safety, then no electrical into account the effects of aging or continual vibration
supply shall be connected to the circuit until it is satisfactorily from sources such as compressors or fans.
dealt with. If the fault cannot be corrected immediately but it
is necessary to continue operation, an adequate temporary Detection of flammable refrigerants
solution shall be used. This shall be reported to the owner of • Under no circumstances shall potential sources of ignition
the equipment so all parties are advised. be used in the searching for or detection of refrigerant
Initial safety checks shall include: leaks. A halide torch (or any other detector using a naked
flame) shall not be used.
• that capacitors are discharged: this shall be done in a
• The following leak detection methods are deemed
safe manner to avoid possibility of sparking;
acceptable for all refrigerant systems.
• that no live electrical components and wiring are exposed
• Electronic leak detectors may be used to detect
while charging, recovering or purging the system;
refrigerant leaks
• that there is continuity of earth bonding.
• REFRIGERANTS, the sensitivity may not be adequate,
Repairs to sealed components or may need re-calibration. (Detection equipment shall
be calibrated in a refrigerant-free area.) Ensure that
• During repairs to sealed components, all electrical the detector is not a potential source of ignition and
supplies shall be disconnected from the equipment being is suitable for the refrigerant used. Leak detection
worked upon prior to any removal of sealed covers, etc. If equipment shall be set at a percentage of the LFL of
it is absolutely necessary to have an electrical supply to the refrigerant and shall be calibrated to the refrigerant
equipment during servicing, then a permanently operating employed, and the appropriate percentage of gas (25 %
form of leak detection shall be located at the most critical maximum) is confirmed.
point to warn of a potentially hazardous situation.
• Leak detection fluids are also suitable for use with most
• Particular attention shall be paid to the following to ensure refrigerants but the use of detergents containing chlorine
that by working on electrical components, the casing is shall be avoided as the chlorine may react with the
not altered in such a way that the level of protection is refrigerant and corrode the copper pipe-work.
affected. This shall include damage to cables, excessive
number of connections, terminals not made to original
specification, damage to seals, incorrect fitting of glands,

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 R-32 Guidelines

NOTE: Examples of leak detection fluids are Charging procedures

— bubble method In addition to conventional charging procedures, the following
— fluorescent method agents. requirements shall be followed.
• If a leak is suspected, all open flames shall be removed/ • Ensure that contamination of different refrigerants does
extinguished. not occur when using charging equipment.
• If a leakage of refrigerant is found which requires brazing, • Hoses or lines shall be as short as possible to minimise
all of the refrigerant shall be recovered from the system, the amount of refrigerant contained in them.
or isolated (by means of shut off valves) in a part of the • Cylinders shall be kept in an appropriate position
system remote from the leak. Removal of refrigerant shall according to the instructions.
be according to instructions above.
• Ensure that the REFRIGERATING SYSTEM is earthed
Removal and evacuation prior to charging the system with refrigerant.
• Label the system when charging is complete (if not
• When breaking into the refrigerant circuit to make repairs,
already).
or for any other purpose, conventional procedures
shall be used. However, for flammable refrigerants • Extreme care shall be taken not to overfill the
it is important that best practice be followed, since REFRIGERATING SYSTEM.
flammability is a consideration. • Prior to recharging the system, it shall be pressure-
• The following procedure shall be adhered to: tested with the appropriate purging gas. The system shall
be leak-tested on completion of charging but prior to
i. safely remove refrigerant following local and national
commissioning. A follow up leak test shall be carried out
regulations;
prior to leaving the site.
ii. purge the circuit with inert gas;
iii. evacuate;
Decommissioning
Before carrying out this procedure, it is essential that the
iv. purge with inert gas;
technician is completely familiar with the equipment and all its
v. open the circuit by cutting or brazing. detail.
• The refrigerant charge shall be recovered into the correct It is recommended good practice that all refrigerants are
recovery cylinders if venting is not allowed by local and recovered safely.
national codes. For appliances containing flammable
Prior to the task being carried out, an oil and refrigerant sample
refrigerants, the system shall be purged with oxygen-
shall be taken in case analysis is required prior to re-use of
free nitrogen to render the appliance safe for flammable
recovered refrigerant.
refrigerants. This process might need to be repeated
several times. It is essential that electrical power is available before the task
• Compressed air or oxygen shall not be used for purging is commenced.
refrigerant systems. A. Become familiar with the equipment and its operation.
• For appliances containing flammable refrigerants, B. Isolate system electrically.
refrigerants purging shall be achieved by breaking the
vacuum in the system with oxygen-free nitrogen and C. Before attempting the procedure, ensure that
continuing to fill until the working pressure is achieved, — mechanical handling equipment is available, if
then venting to atmosphere, and finally pulling down to a required, for handling refrigerant cylinders;
vacuum. — all personal protective equipment is available and
• When the final oxygen-free nitrogen charge is used, the being used correctly;
system shall be vented down to atmospheric pressure to — the recovery process is supervised at all times by a
enable work to take place. competent person;
• Ensure that the outlet for the vacuum pump is not close — recovery equipment and cylinders conform to the
to any potential ignition sources and that ventilation is appropriate standards.
available.
D. Pump down refrigerant system, if possible.
E. If a vacuum is not possible, make a manifold so that
refrigerant can be removed from various parts of the
system.
F. Make sure that cylinder is situated on the scale before
recovery takes place.
G. Start the recovery machine and operate in accordance
with instructions.

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 R-32 Guidelines

H. Do not overfill cylinders (no more than 80 % volume • The recovered refrigerant shall be returned to the
liquid charge. refrigerant supplier in the correct recovery cylinder,
and the relevant waste transfer note arranged. Do not
I. Do not exceed the maximum working pressure of the
mix refrigerants in recovery units and especially not in
cylinder, even temporarily.
cylinders.
J. When the cylinders have been filled correctly and the • If compressors or compressor oils are to be removed,
process completed, make sure that the cylinders and ensure that they have been evacuated to an acceptable
the equipment are removed from site promptly and all level to make certain that FLAMMABLE REFRIGERANT
isolation valves on the equipment are closed off. does not remain within the lubricant. The evacuation
K. When the cylinders have been filled correctly and the process shall be carried out prior to returning the
process completed, make sure that the cylinders and compressor to the suppliers. Only electric heating to the
the equipment are removed from site promptly and all compressor body shall be employed to accelerate this
isolation valves on the equipment are closed off. process. When oil is drained from a system, it shall be
carried out safely.
Equipment shall be labelled stating that it has been de-
commissioned and emptied of refrigerant. This label should be
dated and signed.
For appliances containing FLAMMABLE REFRIGERANTS,
ensure that there are labels on the equipment stating the
equipment contains FLAMMABLE REFRIGERANT.

Labeling
Equipment shall be labelled stating that it has been de-
commissioned and emptied of refrigerant. The label shall be
dated and signed. For appliances containing FLAMMABLE
REFRIGERANTS, ensure that there are labels on the
equipment stating the equipment contains FLAMMABLE
REFRIGERANT.

Recovery
• When removing refrigerant from a system, either for
servicing or decommissioning, it is recommended good
practice that all refrigerants are removed safely.
• When transferring refrigerant into cylinders, ensure
that only appropriate refrigerant recovery cylinders are
employed. Ensure that the correct number of cylinders for
holding the total system charge is available. All cylinders
to be used are designated for the recovered refrigerant
and labelled for that refrigerant (i. e. special cylinders for
the recovery of refrigerant). Cylinders shall be complete
with pressure-relief valve and associated shut-off valves
in good working order. Empty recovery cylinders are
evacuated and, if possible, cooled before recovery
occurs.
• The recovery equipment shall be in good working order
with a set of instructions concerning the equipmenthat
is at hand and shall be suitable for the recovery of all
appropriate refrigerants including, when applicable,
FLAMMABLE REFRIGERANTS. In addition, a set of
calibrated weighing scales shall be availableand in good
working order. Hoses shall be complete with leak-free
disconnect couplings and in good condition. Before using
the recovery machine, check that it is in satisfactory
working order, has been properly maintained and that any
associated electrical components are sealed to prevent
ignition in the event of a refrigerant release. Consult
manufacturer if in doubt.

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 Troubleshooting

Troubleshooting
PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS
1. Main or compressor disconnect switch open 1. Close switch.
2. Fuse blown; circuit breakers open 2. Check electrical circuits and motor windings for shorts or grounds.
Investigate for possible overloading. Check for loose or corroded
connections. Replace fuse or reset breakers after fault cause is corrected
3. Thermal overloads tripped 3. Overloads are auto-reset. Check voltages, cycle times and mechanical
operations. Allow time for auto-reset

Compressor Will Not 4. Defective contactor or coil 4. Replace

Run
5. System shutdown by equipment protection devices 5. Determine type and cause of shutdown and correct it before restarting
equipment
6. No cooling required 6. None. Wait until unit calls for cooling
7. Liquid line solenoid will not open 7. Repair or replace solenoid. Check wiring
8. Motor electrical trouble 8. Check motor for opens, shorts, or burnout
9. Loose wiring 9. Check all wire junctions. Tighten all terminal screws
1. Low lift, inverted start 1. Control issues or condenser fan VFDs needed
2. Compressor running in reverse 2. Check unit and compressor for correct phasing
Compressor Noisy 3. Improper piping or support on suction or discharge 3. Relocate, add, or remove hangers
Or Vibrating
4. Worn compressor isolator bushing 4. Replace
5. Compressor mechanical failure 5. Replace
1. Noncondensables in system 1. Extract noncondensables with approved procedures or replace charge
2. Circuit overcharged with refrigerant 2. Remove excess, check liquid subcooling
3. Optional discharge shutoff valve not open 3. Open valve
High Discharge 4. Condenser fan control wiring not correct 4. Correct wiring
Pressure
5. Fan not running 5. Check electrical circuit and fan motor
6. Dirty condenser coil 6. Clean coil
7. Air recirculation 7. Correct
1. Rapid load swings 1. Stabilize load
2. Lack of refrigerant 2. Check for leaks, repair, add charge. Check liquid sight glass
3. Fouled liquid line filter drier 3. Check pressure drop across filter drier. Replace
4. Expansion valve malfunctioning 4. Repair or replace and adjust for proper superheat
Low Suction
Pressure 5. Condensing temperature too low 5. Check means for regulating condenser temperature
6. Compressors not staging properly 6. See corrective steps - Compressor Staging Intervals Too Low
7. Insufficient water flow 7. Correct flow
8. Excess or wrong oil used 8. Recover or change oil
9. Evaporator dirty 9. Back flush or clean chemically

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 Troubleshooting

PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

1. Defective capacity control 1. Replace
Compressor Will Not 2. Faulty sensor or wiring 2. Replace
Stage Up
3. Stages not set for application 3. Adjust controller setting for application
1. Control band not set properly 1. Adjust controller settings for application
2. Faulty water temperature sensor 2. Replace
3. Insufficient water flow 3. Correct flow
Compressor Staging
Intervals Too Short 4. Rapid temperature or flow swings 4. Stabilize load
5. Oversized equipment 5. Evaluate equipment selection
6. Chiller enabled with no load/Light Loads 6. Evaluate BAS sequence and settings. Evaluate need for HGBP or thermal
inertia
1. Oil hang-up in remote piping 1. Review refrigerant piping and correct
2. Low oil level 2. Verify superheat, add oil
3. Loose fitting on oil line 3. Repair
4. Level too high with compressor operating 4. Confirm correct superheat, remove oil
5. Insufficient water flow - Level too high 5. Correct flow, verify superheat
Compressor Oil Level
Too High Or Too Low 6. Excessive liquid in crankcase - Level too high 6. Check crankcase heater. Check liquid line solenoid valve operation
7. Short cycling 7. Stabilize load or correct control settings for application.
8. HGBP valve oversize or improperly set-up 8. replace or adjust HGBP valve
9. Expansion valve operation or selection 9. Confirm superheat at minimum and maximum load conditions
10. Compressor mechanical issues 10. Replace compressor
11. Wrong oil for application 11. Verify
1. Voltage imbalance or out of range 1. Correct power supply
Motor Overload Relays 2. Defective or grounded wiring in motor 2. Replace compressor
or Circuit Breakers
Open 3. Loose power wiring or burnt contactors 3. Check all connections and tighten, replace contactors
4. High condenser temperature 4. See corrective steps for High Discharge Pressure
1. Operating beyond design conditions 1. Correct so conditions are within allowable limits
2. Discharge valve not open 2. Open valve

Compressor Thermal 3. Short cycling 3. Stabilize load or correct control settings for application
Protection Switch Open 4. Voltage range or imbalance 4. Check and correct
5. High superheat 5. Adjust to correct superheat
6. Compressor mechanical failure 6. Replace compressor

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 Appendix

Appendix
Pre-Start Checklist
Pre-Start Checklist – Scroll Compressor Chillers
Must be completed, signed, and provided to Daikin Applied sales office at least 2 weeks prior to requested start date.
Job Name
Installation Location
Customer Order Number
Model Number(s)
G.O. Number(s)
Chilled Water Piping and Condenser Water Piping for Water-cooled Chiller Yes No N/A Initials
Piping Complete
Water strainer(s) installed in piping per IOM requirements
Chilled Water System – flushed, filled, and vented; Water treatment in place
Condenser Water System (incl. cooling tower) - flushed, filled, vented; Water treatment
in place (applicable for water-cooled systems)
Pumps installed and operational (rotation checked, strainers cleaned)
Water system operated and tested; flow meets unit design requirements
Flow switch(es) - installed, wired, and ready for calibration during startup
Air vent installed on evaporator chilled water inlet piping
Glycol at design % (if applicable)
Electrical Yes No N/A Initials
Building controls operational (3-way valves, face/bypass dampers, bypass valves, etc.)
*Power leads connected to power block or optional disconnect
Power leads have been checked for proper phasing and voltage
All interlock wiring complete and compliant with Daikin Applied specifications
Power applied at least 24 hours before startup
Crankcase heaters must operate for 24+ hours before startup to maximize separation
Chiller components (EXV Sensors Transducers) installed and wired properly
*Wiring complies with National Electrical Code and local codes (See Notes)
Remote EXV wired with shielded cable
Miscellaneous Yes No N/A Initials
Unit control switches all off
Remote Evaporator / Condenser Piping factory reviewed
All refrigerant components/piping leak tested, evacuated and charged
Thermometers, wells, gauges, control, etc., installed
Minimum system load of 80% capacity available for testing/adjusting controls
SiteLineTM cloud-connected controls included and needs to be commissioned
Document Attached: Technical Breakdown from Selection Software
Document Attached: Final Order Acknowledgement
Document Attached: Remote piping approval
Notes: The most common problems delaying start-up and affecting unit reliability are:
1. Field installed compressor motor power supply leads too small. Questions: Contact the local Daikin Aplied sales representative*. State size, number
and type of conductors and conduits installed:
a. From Power supply to chiller
* Refer to NFPA 70-2017, Article 440.35
2. Remote Evaporator piping incomplete or incorrect. Provide approved piping diagrams.
3. Items on this list incorrectly acknowledged resulting in delayed start and possible extra expenses incurred by return trips.
Contractor Representative Daikin Applied Sales Representative
Signed: Signed:
Name: Name:
Company: Company:
Date: Date:
Phone/Email: Phone/Email:

©2023 Daikin Applied Form SF-18002 19 June 2023

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 78 www.DaikinApplied.com
 Appendix

Warranty Registration Form

New Chiller Start-Up Form - Warranty Registration
AGZ and AMZ Scroll Compressor Chillers
This form must be completely filled out and returned to Daikin Applied (Warranty Department) within ten (10) days of start-up in
order to comply with the terms of the Daikin Limited Product Warranty.
Complete and mail to: Daikin Applied, Attn: Warranty Department, PO Box 2510, Staunton, VA 20042-2510
Or email to: stn.wty_startup_regi@DaikinApplied.com

JOB INFORMATION

Job Name: Daikin G.O.:

Startup Date: No. of Units at Site: Daikin S.O.:
Installation Notes: Purchasing Contractor Information:

UNIT INFORMATION

Unit Model No.: Serial No.:

Component Model Number Serial Number

Compressor 1:
Compressor 2:
Compressor 3:
Compressor 4:
Compressor 5:
Compressor 6:
Benshaw/DRC Control Box M/M#: Benshaw/DRC Control Box S/N#:
Before beginning, confirm that items on the Pre-Start Checklist have been completed and initial:
Note Discrepancies here or on Page 6:

www.DaikinApplied.com 1 SF-20001 AGZ/AMZ Warranty Registration Startup Form

www.DaikinApplied.com 79 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Appendix

PRE START-UP CHECKLIST

Pre Start-Up Checklist, All NO checks require an explanation under “Description”
Please check YES or NO

Is the unit free of visible shipping damage, corrosion, or paint problems? Yes No N/A
Is unit level and isolators installed? Yes No N/A
Does the unit meet all location, installation and service clearances per IOM Bulletin? Yes No N/A
Are all fan fastener nuts on the fans tights? Yes No N/A
Does electrical service correspond to unit nameplate? Yes No N/A
Nameplate: Volts: Hertz: Phase:
Has electrical service been checked for proper phasing at each circuit power terminal block? Yes No N/A
Has unit been properly grounded and all field wiring confirmed to unit electrical specifications? Yes No N/A
Has a fused disconnect and fuses or breaker been sized per product manual and installed per Yes No N/A
local code?
Number of Conduits: Number of Wires: Wire Size:
Are all electrical power connections tight? Yes No N/A
Has power been applied for 24 hours prior to start-up? Yes No N/A
Does all field wiring conform to unit electrical specifications? Yes No N/A
Are all service and liquid line valves per the IOMM in correct position? Yes No N/A
Water Strainer installed? Brazed Plate Evaporator 0.063” (1.6mm) or smaller perforations Yes No N/A
Has a flow switch been installed per the IOM manual? Yes No N/A
Has the chilled water circuit been cleaned, flushed, and water treatment confirmed? Yes No N/A
Does the chiller water piping conform to the IOM manual? Yes No N/A
Are fans properly aligned and turn freely? Yes No N/A
Is wind impingement against the air-cooled condenser a consideration? Yes No N/A
Are the condenser coils coated? Yes No N/A

Description of unit location with respect to building structures. Include measured distances.

REFRIGERANT PIPING FOR REMOTE EVAPORATOR APPLICATIONS

Reviewed and confirmed piping is per the approved SF-99006 form submitted to the factory? Yes No N/A
Has all field piping been leak tested at 150 psig (690 kPA)? Yes No N/A
Has system been properly evacuated and charged? Yes No N/A
Refrigerant: Circuit 1: lbs. Circuit 2: lbs.
Is a liquid line filter-drier installed in each circuit? Yes No N/A
Is a liquid line solenoid installed correctly in each circuit? Yes No N/A
Is the suction temperature sensor properly installed? Yes No N/A
SF-20001 AGZ/AMZ Warranty Registration Startup Form 2 www.DaikinApplied.com

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 80 www.DaikinApplied.com

 Appendix

DESIGN CONTROLS
CHILLER
Water Pressure Drop: psig (kPa) Ft. (kPa) gpm (lps)
Water Temperatures: Entering: °F (°C) Leaving: °F (°C)

CONDENSER
Design Ambient Temperatures: Entering: °F (°C) Leaving: °F (°C)
Minimum Ambient Temperatures: Entering: °F (°C) Leaving: °F (°C)

START-UP
Does unit start and perform per sequence of operation as stated in the IOM Manual? Yes No
Do condenser fans rotate in the proper directions? Yes No
MICROTECH STATUS CHECK
Each Reading Must be Verified with Field Provided Instruments of Known Accuracy
Water Temperatures MicroTech Verification
Leaving Evaporator: °F (°C) °F (°C)
Entering Evaporator: °F (°C) °F (°C)
Circuit #1 Refrigerant Pressures
Evaporator: psig (kPa) psig (kPa)
Liquid Lines Pressure: psig (kPa)
Condenser Pressure: psig (kPa) psig (kPa)
Circuit #2 Refrigerant Pressures
Evaporator: psig (kPa) psig (kPa)
Liquid Lines Pressure: psig (kPa)
Condenser Pressure: psig (kPa) psig (kPa)
Circuit #1 Refrigerant Temperatures
Saturated Evaporator Temperature: °F (°C) °F (°C)
Suction Line Temperature: °F (°C) °F (°C)
Suction Superheat: °F (°C) °F (°C)
Saturated Condenser Temperature: °F (°C) °F (°C)
Liquid Line Temperature: °F (°C)
Subcooling: °F (°C)
Discharge Temperature: °F (°C)
Circuit #2 Refrigerant Temperatures:
Saturated Evaporator Temperature: °F (°C) °F (°C)
Suction Line Temperature: °F (°C) °F (°C)
Suction Superheat: °F (°C) °F (°C)
Saturated Condenser Temperature: °F (°C) °F (°C)
Liquid Line Temperature: °F (°C)
Subcooling: °F (°C)
Discharge Temperature: °F (°C)
Ambient Air Temperature: °F (°C) °F (°C)
www.DaikinApplied.com 3 SF-20001 AGZ/AMZ Warranty Registration Startup Form

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 Appendix

NON-MICROTECH READINGS
Water Pressure Drop: (ft) (psig) (gpm)*
NOTE: Actual DP ft ÷ Design DP ft = √ x Design GPM = Actual GPM
Does the system contain glycol? Yes No
Percentage by weight: or by volume: Glycol Type:
If the chilled water system include glycol, have the freeze protection, low pressure devices and settings
been adjusted for the actual job requirements? Detail these settings on page 8 - Remarks section Yes No

NOTE: See operation manual for low temperature on ice bank applications.

Unit Voltage Across Each Phase: L1-L2: V L2-L3: V L1-L3: V

Unit Current Per Phase: L1 amps: V L2 amps: V L3 amps: V

Compressor Current Per Phase: Compressor #1: V L1 amps: V L2 amps: V L3 amps: V
Compressor #2: V L1 amps: V L2 amps: V L3 amps: V
Compressor #3: V L1 amps: V L2 amps: V L3 amps: V
Compressor #4: V L1 amps: V L2 amps: V L3 amps: V
Compressor #5: V L1 amps: V L2 amps: V L3 amps: V
Compressor #6: V L1 amps: V L2 amps: V L3 amps: V

MICROTECH SETPOINTS
ALARM SETPOINTS MUST BE VERIFIED WITH INSTRUMENTS OF KNOWN ACCURACY

Leaving Evaporator: °F (°C) Low Pressure Hold: psig (kPa)

Reset Leaving: °F (°C) Low Pressure Unload: psig (kPa)
Reset Signal: ma Evaporator Water Freeze: psig (kPa)
Reset Option: High Pressure Cut-Out: psig (kPa)
Maximum Chilled Water Reset: °F (°C) Unit Type:
Return Setpoint: °F (°C) Number of Compressors:
Maximum Pulldown: °F (°C) Number of Stages:
Evaporator Full Load Delta T: °F (°C) Number of Fan Stages:
Evap Recirc Timer: sec. Software Version:
Start-to-stop Delay: min.
Stop-to-stop Delay: min.
Stage Up Delay: sec.
Stage Down Delay: sec.

SF-20001 AGZ/AMZ Warranty Registration Startup Form 4 www.DaikinApplied.com

IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER 82 www.DaikinApplied.com
 Appendix

SITELINE (IF APPLICABLE)

Gateway Serial Number(s): MAC Address:
ICCID: Confirm ethernet cable connection: Yes No N/A
Confirm hardware is installed and wired:
Connected from two antennas to CELL MAIN and CELL DIV ports on gateway (Cellular installation) or
one antenna to WiFi/BT port on gateway (Wi-Fi installation) or LAN switch to Eth0 port on gateway
(LAN installation) Yes No N/A
Confirm Ethernet cable connected between Eth1 port on gateway and Equipment unit controller (TIP
port on MT3) Yes No N/A
Configure Wi-Fi or LAN Settings (if applicable) (Refer IM1332 Appendix A):
Wi-Fi settings configured in gateway Yes No N/A
LAN settings configured in gateway Yes No N/A
Record Signal Strength from Gateway User Interface (should be in Good or Excellent range):
Confirm cloud connectivity:
Call Controls Technical Response Center (TRC) at (866) 462-7829 to confirm data transfer: Yes No N/A
Submit Commissioning Procedure in SiteLine User Interface Yes No N/A
Has SiteLine been explained to end user? Yes No N/A
Have operator instructions been provided to end user? Yes No N/A
Hours of training:
If the answer to any of the above is “no,” explain:

SUMMARY & SIGNATURES

Are all control lines secure to prevent excess vibration and wear? Yes No
Are all gauges shut off, valve caps, and packings tight after startup? Yes No
Has the chiller been leak tested? Detail refrigerant leaks and repairs below Yes No
Refrigerant Leaks:

Repairs Made:

Items not installed per IOM Manual and/or recommended corrective actions:

Print Name Signature

Mechanical Contractor Signature: Date:
Electrical Contractor Signature: Date:
Customer Signature: Date:
Technician Signature: Date:
Daikin Applied Service Manager Review: Date:
www.DaikinApplied.com 5 SF-20001 AGZ/AMZ Warranty Registration Startup Form

www.DaikinApplied.com 83 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

 Appendix

IVS SENSORLESS PUMP COMMISSIONING CHECK SHEET

FOR PUMP PACKAGE UNITS ONLY

Project Name:
Building Address:
Contractor Name:
Site Contact Name: Site Contact Number:
Your Company: Your Name:
Pump Model: Pump Tag Number:
Pump Serial: Sales Order Number:
NOTE: For independent sensorless operation, go to Section 1. For independent external sensor operation, go to Section 2. For external
controller, go to Section 3.

SECTION 1 - SENSORLESS STARTUP PROCEDURE

Complete
1. Open up and bleed pump seal flush line to verify no air has travelled into seal / seal lines
2. Change parameter 0-20 (default value is option 1601 – “Reference [Unit]”) to option 1850 “Sensorless Readout”
to display Sensorless flow readout on the top left corner of screen
3. Change parameter 0-22 (default value is option 1610 – “Power [kW]”) to option 1654 “Feedback 1 [Unit]” to
display Sensorless pressure readout on the top right corner of screen
4. Open the discharge valve and set the pump to the design duty speed and record the VFD Sensorless pressure and
flow readout (include units). This is what the actual system flow and head are.
SENSORLESS PRESSURE =
SENSORLESS FLOW =
5. Ramp the pump up or down to achieve the design flow. Record the VFD sensorless flow and pressure –this will be
your new setpoint.
SENSORLESS PRESSURE =
SENSORLESS FLOW =
6. Set parameter 20-21 to the Sensorless Pressure readout taken in previous step
7. Set parameter 22-89 to the Sensorless Flow readout taken in previous step
8. Set parameter 22-87 to a value that is 40% of the value in 20-21. You have now readjusted the quadratic control
curve to match actual site conditions.
9. Change parameter 0-20 back to the default value of option 1601 – “Reference [Unit]”
10. Change parameter 0-22 back to the default value of option 1610 – “Power [kW]”
11. Put the VFD into AUTO mode. The pump will ramp up to get to the setpoint pressure and as the demand in the
system decreases, the setpoint will also decrease to ride the control curve down to the minimum pressure set in
parameter 22-87. As demand increases, it will ride back up the control curve to full design setpoint.

www.DaikinApplied.com 84 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

SF-20001 AGZ/AMZ Warranty Registration Startup Form 6 www.DaikinApplied.com
 Appendix

Limited Product Warranty

DAIKIN APPLIED AMERICAS INC.

LIMITED PRODUCT WARRANTY
(United States and Canada)

WARRANTY
Daikin Applied Americas Inc. dba Daikin Applied (“Company”) warrants to contractor, purchaser and any owner of the product
(collectively “Owner”) that, subject to the exclusions set forth below Company, at its option, will repair or replace defective parts in
the event any product manufactured by Company, including products sold under the brand name Daikin and used in the United States
or Canada, proves defective in material or workmanship within twelve (12) months from initial startup or eighteen (18) months from
the date shipped by Company, whichever occurs first. Authorized replacement parts are warranted for the remainder of the original
warranty. All shipments of such parts will be made FOB factory, freight prepaid and allowed. Company reserves the right to select
carrier and method of shipment. In addition, Company provides labor to repair or replace warranty parts during Company normal
working hours on products with rotary screw compressors or centrifugal compressors. Warranty labor is not provided for any other
products.

Company must receive the Registration and Startup Forms for products containing motor compressors and/or furnaces within ten (10)
days of original product startup, or the ship date and the startup date will be deemed the same for determining the commencement
of the warranty period and this warranty shall expire twelve (12) months from that date. For additional consideration, Company will
provide an extended warranty(ies) on certain products or components thereof. The terms of the extended warranty(ies) are shown on
a separate extended warranty statement.

No person (including any agent, sales representative, dealer or distributor) has the authority to expand the Company’s obligation
beyond the terms of this express warranty or to state that the performance of the product is other than that published by Company.

EXCLUSIONS
1. If free warranty labor is available as set forth above, such free labor does not include diagnostic visits, inspections, travel time and
related expenses, or unusual access time or costs required by product location.
2. Refrigerants, fluids, oils and expendable items such as filters are not covered by this warranty.
3. This warranty shall not apply to products or parts : (a) that have been opened, disassembled, repaired, or altered, in each case by
anyone other than Company or its authorized service representative; (b) that have been subjected to misuse, abuse, negligence,
accidents, damage, or abnormal use or service; (c) that have not been properly maintained; (d) that have been operated or
installed, or have had startup performed, in each case in a manner contrary to Company's printed instructions; (e) that have been
exposed, directly or indirectly, to a corrosive atmosphere or material such as, but not limited to, chlorine, fluorine, fertilizers,
waste water, urine, rust, salt, sulfur, ozone, or other chemicals, contaminants, minerals, or corrosive agents; (f) that were
manufactured or furnished by others and/or are not an integral part of a product manufactured by Company; or (g) for which
Company has not been paid in full.
4. This warranty shall not apply to products with rotary screw compressors or centrifugal compressors if such products have not
been started, or if such startup has not been performed, by a Daikin Applied or Company authorized service representative.

SOLE REMEDY AND LIMITATION OF LIABILITY

THIS WARRANTY CONSTITUTES THE SOLE WARRANTY MADE BY COMPANY. COMPANY'S LIABILITY TO OWNER AND OWNER’S
SOLE REMEDY UNDER THIS WARRANTY SHALL NOT EXCEED THE LESSER OF: (i) THE COST OF REPAIRING OR REPLACING
DEFECTIVE PRODUCTS; AND (ii) THE ORIGINAL PURCHASE PRICE ACTUALLY PAID FOR THE PRODUCTS. COMPANY MAKES NO
REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, REGARDING PREVENTION OF MOLD/MOULD, FUNGUS, BACTERIA,
MICROBIAL GROWTH, OR ANY OTHER CONTAMINATES. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES,
INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE,
AND NON-INFRINGEMENT, WHICH ARE HEREBY DISCLAIMED. IN NO EVENT AND UNDER NO CIRCUMSTANCE SHALL COMPANY
BE LIABLE TO OWNER OR ANY THIRD PARTY FOR INCIDENTAL, INDIRECT, SPECIAL, CONTINGENT, CONSEQUENTIAL, DELAY OR
LIQUIDATED DAMAGES FOR ANY REASON, ARISING FROM ANY CAUSE WHATSOEVER, WHETHER THE THEORY FOR RECOVERY IS
BASED IN LAW OR IN EQUITY, OR IS UNDER A THEORY OF BREACH CONTRACT OR WARRANTY, NEGLIGENCE, STRICT LIABILITY,
OR OTHERWISE. THE TERM “CONSEQUENTIAL DAMAGE” INCLUDES, WITHOUT LIMITATION, THOSE DAMAGES ARISING FROM
BUSINESS INTERRUPTION OR ECONOMIC LOSS, SUCH AS LOSS OF ANTICIPATED PROFITS, REVENUE, PRODUCTION, USE,
REPUTATION, DATA OR CROPS.

ASSISTANCE
To obtain assistance or information regarding this warranty, please contact your local sales representative or a Daikin Applied office.

Form No. 933-430285Y-01-A (11/2023)

www.DaikinApplied.com 85 IOM 1359 • TRAILBLAZER AIR-COOLED SCROLL CHILLER

Daikin Applied Training and Development

Now that you have made an investment in modern, efficient Daikin Applied equipment, its care should
be a high priority. For training information on all Daikin Applied HVAC products, please visit us at www.
DaikinApplied.com and click on Training, or call 540-248-9646 and ask for the Training Department.

Warranty

All Daikin Applied equipment is sold pursuant to its standard terms and conditions of sale, including
Limited Product Warranty. Consult your local Daikin Applied representative for warranty details. To find
your local Daikin Applied representative, go to www.DaikinApplied.com.

Aftermarket Services

To find your local parts office, visit www.DaikinApplied.com or call 800-37PARTS (800-377-2787).
To find your local service office, visit www.DaikinApplied.com or call 800-432-1342.

This document contains the most current product information as of this printing. For the most up-to-
date product information, please go to www.DaikinApplied.com.

Products manufactured in an ISO Certified Facility.

IOM 1359 (01/2024) ©2024 Daikin Applied | (800) 432–1342 | www.DaikinApplied.com