Related Manuals for AIREDALE UCFC160D-6/2
Summary of Contents for AIREDALE UCFC160D-6/2
- Page 1 I N S T A L L A T I O N , O P E R A T I N G & M A I N T E N A N C E M A N U A L Ultima Compact FreeCool Free-Cooling Chiller 75 –...
- Page 2 To further protect your investment in Airedale products, we have introduced Airedale Service, who can provide full commissioning services, comprehensive maintenance packages and service cover 24 hours a day, 365 days a year (UK mainland). For a free quotation contact Airedale Service or your local Sales Engineer.
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Page 3: Table Of Contents
Chillers ULTIMA COMPACT FREECOOL Contents GENERAL STATEMENT WARRANTY GENERAL DESCRIPTION Unit Identification Standard Features Optional Extras – Energy Saving Optional Extras – General INSTALLATION DATA Dimensions Point Loadings, Weights & Centre of Gravity (C of G) Unit lifting Anti Vibration Mounting Positioning Water System Standard Recommended Installation... -
Page 4: General Statement
CAUTION Service and maintenance of Airedale equipment should only be carried out by Technically trained competent personnel. CAUTION When working with any air conditioning units ensure that the electrical isolator is switched off prior to servicing or repair work and that there is no power to any part of the equipment. -
Page 5: Warranty
Installation & Maintenance manual provided, during the Warranty Period. In the event of a problem being reported, Airedale will cover the full cost of rectification (excluding costs for any specialist access or lifting equipment) if warranty is valid under these conditions. -
Page 6: General Description
Example UCFC75DQ-2/1 INTRODUCTION The Airedale range of Ultima Compact FreeCool air cooled liquid chillers covers the cooling capacity range 75kW to 450kW in 45 model sizes incorporating Standard D, Quiet DQ and Super Quiet DSQ variations. Attention has been placed on maximising the unit’s cooling and energy performance while keeping the sound, vibration levels and footprint to an absolute minimum. -
Page 7: General Description
Chillers ULTIMA COMPACT FREECOOL General Description STANDARD FEATURES With all the features of the Standard range, the Quiet and Super Quiet chillers are available with additional features: Quiet Chiller - DQ • Fan speed reduced to 750 rpm Super Quiet Chiller - •... -
Page 8: Optional Extras - Energy Saving
Epoxy Coated Condenser Coils • Coil Guards • Sequence Control CAUTION It is only possible to set up sequencing following completion of interconnecting communication wiring. Airedale Service can arrange Sequence setup on request. • BMS Interface Card • Dual Pressure Relief Valve •... -
Page 9: Installation Data
1340 UCFC100DSQ-3/1 1730 1440 UCFC125DSQ-4/1 2200 1690 UCFC150DSQ-4/1 2250 1670 Have only 4 fixing and 4 point loadings. Based on standard unit, for units fitted with pump options, please contact Airedale. Chillers Installation & Maintenance : 903-132 TM E 06/05/A... - Page 10 ULTIMA COMPACT FREECOOL Chillers Installation Data DIMENSIONS DOUBLE ROW FANS - /2 UCFC160 - UCFC450 Electric Control Panels Mains Electric Isolators Mains Cable Entry 20mm Ø Mounting Holes Optional Plenum Extension Water Flange Connections: UCFC160-250 DN80 PN16 UCFC275-450 DN100 PN16 Emergency Stop 1100 2200...
- Page 11 1100 3390 UCFC400DSQ-16/2 5290 1100 3390 UCFC450DSQ-16/2 5380 1100 3380 Have only 4 fixing and 4 point loadings. Based on standard unit, for units fitted with pump options, please contact Airedale. Chillers Installation & Maintenance : 903-132 TM E 06/05/A...
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Page 12: Unit Lifting
Lift the unit slowly and evenly. • If the unit is dropped, it should immediately be checked for damage and reported to Airedale Service. CAUTION Only use lifting points provided. The unit should be lifted from the base and where possible, with all packing and protection in position. - Page 13 CAUTION Do not connect any services until all anti vibration mounts have been fully adjusted. Airedale International Air Conditioning Ltd Leeds Road, Rawdon, Leeds. LS19 6JY England Tel: + 44 (0) 113 239 1000 Fax: + 44 (0) 113 250 7219...
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Page 14: Anti Vibration Mounting
Chillers ULTIMA COMPACT FREECOOL Installation Data ANTI VIBRATION MOUNTING - OPTIONAL Spring Type (CLS) High deflection steel spring Spring pressure plate Height adjusting nut Locking nut Load bearing supports Load bearing top plate High frequency isolation pad 10 dia holding down bolt holes High frequency isolation grommets 10 Steel spring location rings 11 Transportation/restraining bolts... -
Page 15: Positioning
ULTIMA COMPACT FREECOOL Chillers Installation Data POSITIONING The installation position should be selected with the following points in mind: • Position on a stable and even base, levelled to ensure that the compressor operates correctly • Levelling should be to +/- 5mm •... -
Page 16: Water System
Chillers ULTIMA COMPACT FREECOOL Installation Data WATER SYSTEM Chilled water pipework and ancillary components must be installed in accordance with: • National and Local Water supply company standards • The manufacturer's instructions are followed when fitting ancillary components • The system liquid is treated to prevent corrosion and algae forming •... -
Page 17: Water System
ULTIMA COMPACT FREECOOL Chillers Installation Data WATER SYSTEM Pump Statement When installing circulating water pumps or equipment containing them, the following rules should be applied: • Ensure the system is filled with liquid then vented and the pump primed with water before running the pump. - Page 18 For minimum system volume refer to the Technical Manual. Based on 12/7°C water temperature and 30°C ambient with a 20% Ethylene Glycol Water Concentration. Figures based on D Model, for DQ & DSQ details, please contact Airedale. Chillers Installation & Maintenance : 903-132 TM E 06/05/A...
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Page 19: Glycol Data
ULTIMA COMPACT FREECOOL Chillers Installation Data GLYCOL DATA CAUTION All free-cooling units should use minimum 20% glycol concentration. Ethylene Glycol Nominal Correction Factors Glycol in System / Freezing Point ºC 20% / -9°C 30% / -15°C 40% / -23°C Cooling Duty 1.00 0.98 0.96... -
Page 20: Interconnecting Wiring
Chillers ULTIMA COMPACT FREECOOL Installation Data INTERCONNECTING WIRING No Pumps " " Mains incoming supply 400V/3PH/50Hz " " " Separate Permanent Supply 230V/1PH/50Hz " " External Trace Heater Connections 240V/500W max. " (1) Evaporator Remote Pump Interlock 24VAC " UCFC75 - 450 Unit Remote On/Off 24VAC "... - Page 21 ULTIMA COMPACT FREECOOL Chillers Installation Data ELECTRICAL DATA UCFC75D-2/1 UCFC100D-2/1 UCFC125D-3/1 UCFC150D-3/1 UCFC160D-6/2 Unit Data Nominal Run Amps (1) A Maximum Start Amps (2) A Permanent Supply 230 V 1 PH 50 Hz Mains Supply 400 V 3 PH 50 Hz...
- Page 22 Chillers ULTIMA COMPACT FREECOOL Installation Data ELECTRICAL DATA UCFC180D-6/2 UCFC200D-6/2 UCFC225D-6/2 UCFC250D-8/2 UCFC275D-8/2 Unit Data Nominal Run Amps (1) A Maximum Start Amps (2) A Permanent Supply 230 V 1 PH 50 Hz Mains Supply 400 V 3 PH 50 Hz Rec Permanent Fuse Size Rec Mains Fuse Size Max Permanent Incoming Cable...
- Page 23 ULTIMA COMPACT FREECOOL Chillers Installation Data ELECTRICAL DATA UCFC300D-8/2 UCFC330D-10/2 UCFC360D-10/2 UCFC400D-12/2 UCFC450D-12/2 Unit Data Nominal Run Amps (1) A Maximum Start Amps (2) A Permanent Supply 230 V 1 PH 50 Hz Mains Supply 400 V 3 PH 50 Hz Rec Permanent Fuse Size Rec Mains Fuse Size Max Permanent Incoming Cable...
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Page 24: Controls
ULTIMA COMPACT FREECOOL Controls CONTROL SCHEME Airedale recognises that all chiller applications are different but fall mainly into 2 application categories; Variable Supply Temperature and Constant Supply Temperature. FEATURES The onboard microprocessor has the capability of satisfying either control requirement as illustrated below. -
Page 25: Operation
ULTIMA COMPACT FREECOOL Chillers Controls GENERAL microprocessor controller offers powerful analogue and digital control to meet a wide range of monitoring and control features including a real time clock and DESCRIPTION Industry standard communication port and network connections. The controller’s inbuilt display is used for viewing the unit operating status and making adjustments to control parameters by allowing the operator access to a series of display pages. -
Page 26: Setting Up
The units leave the factory set, however follow the Navigation instructions if necessary. Time Zones The programme provides 3 On/Off periods per day, 7 days per week. The unit is factory set for continuous operation. Technical Support For further details, please contact Airedale. Chillers Installation & Maintenance : 903-132 TM E 06/05/A... -
Page 27: Viewing Unit Operating Status
ULTIMA COMPACT FREECOOL Chillers Controls VIEWING UNIT OPERATING STATUS Status Menu Allows access to view operating status of Digital and Analogue Inputs and Outputs. Using the Navigation instructions, the following Sub-Menus shown in sequence can be accessed: Tandem Compressor Units Trio Compressor Units Digital Inputs Phase Rotation or MCCB Status... -
Page 28: Alarms
To reset or delete the alarms displayed in the alarm screen, simply press again. COMMON ALARMS Outlined below is a selection of Common Alarms, a full list is available, please contact Airedale. Phase Rotation or MCCB A normally closed contact. When Phase Rotation is incorrect all controller outputs are de-activated. -
Page 29: Commissioning Data
Refer to Technical Manual - Performance Data - Capacity Data Minimum leaving water temperature °C Maximum return water temperature °C +20°C Temperatures lower than those stated can be obtained with additional glycol. For conditions outside those quoted, please refer to Airedale. MECHANICAL DATA Oil & Refrigerant Charges UCFC75D-2/1 UCFC100D-2/1... -
Page 30: Waterside Pressure Drops
Chillers ULTIMA COMPACT FREECOOL Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) CAUTION Constant water flow MUST be maintained. Variable water volume is NOT recommended and may invalidate warranty. Use the formula below to calculate the External Head Available: Total Pump Head Available Chiller Pressure Drop External Head Available... - Page 31 ULTIMA COMPACT FREECOOL Chillers Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) CAUTION Constant water flow MUST be maintained. Variable water volume is NOT recommended and may invalidate warranty. UCFC160D - UCFC450D 450D 330-360D 400D 250D 225D 300D 200D 275D 160-180D WATERFLOW (l/s)
- Page 32 Chillers ULTIMA COMPACT FREECOOL Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) CAUTION Constant water flow MUST be maintained. Variable water volume is NOT recommended and may invalidate warranty. UCFC160DSQ - 330DSQ-360DSQ UCFC450DSQ 450DSQ 400DSQ 250DSQ 225DSQ 300DSQ 200DSQ 275DSQ 160DSQ-180DSQ WATERFLOW (l/s)
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Page 33: Pump Packages
ULTIMA COMPACT FREECOOL Chillers Commissioning Data PUMP PACKAGES Single Head Pump or Run/Standby WATERFLOW (l/s) WATERFLOW (l/s) WATERFLOW (l/s) Single Head Pump or Run / Standby Pump Standard Larger UCFC75 UCFC100 Curve UCFC125 UCFC150 UCFC160-450 Chillers Installation & Maintenance : 903-132 IM E 06/05/A... - Page 34 Chillers ULTIMA COMPACT FREECOOL Commissioning Data PUMP PACKAGES Twin Head Pump WATERFLOW (l/s) WATERFLOW (l/s) Twin Head Pump Standard Larger UCFC75 UCFC100 Curve UCFC125 UCFC150 UCFC160-450 Chillers Installation & Maintenance : 903-132 TM E 06/05/A...
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Page 35: Operational Sequence
ULTIMA COMPACT FREECOOL Chillers Commissioning Data OPERATIONAL SEQUENCE Refrigerant Charge Check for the presence of a refrigerant charge in the condenser side. Sump Heater The mains supply to the sump (oil) heater should be switched on at least 8 hours prior to compressor starting to avoid refrigerant migration. -
Page 36: Commissioning Procedure
Chillers ULTIMA COMPACT FREECOOL Commissioning Procedure GENERAL To be read in conjunction with the commissioning sheets provided, items highlighted should be recorded. CAUTION Please ensure all documents have been completed correctly and return to Technical Support immediately to validate warranty. PRE COMMISSIONING CHECKLIST CAUTION ALL work MUST be carried out by Technically Trained competent personnel. - Page 37 ULTIMA COMPACT FREECOOL Chillers Commissioning Procedure PRE COMMISSIONING CHECKLIST (CONT..) • Check that each circuit trips on low pressure. The alarm should appear within 3 minutes. • The alarm will be recognised at the display circuit trip, to clear the alarms refer Alarm Handling CAUTION Prior to the chiller compressors being allowed to start, the Water Flow Fail and...
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Page 38: Commissioning Checklist
Chillers ULTIMA COMPACT FREECOOL Commissioning Procedure COMMISSIONING The following should be carried out with a load on the system, otherwise the unit is likely to short cycle. The following tests are to be carried out on 1 circuit at a time. CHECKLIST •... -
Page 39: Maintenance
FABRIC Visually inspect the unit for general wear and tear, treat Rust should be inhibited, primed and touched up metalwork. with matching paint (available from Airedale or your Distributor). Visually inspect pipe and pipework insulation. Repair/rectify as necessary. Clean evaporator water strainer. -
Page 40: Compressor Maintenance
Chillers ULTIMA COMPACT FREECOOL Maintenance GENERAL MAINTENANCE (CONT..) 6 MONTHS ACTION NOTES Repeat 3 month checks plus the following: SYSTEM Check evaporator trace heating and low ambient thermostat Remember to re-cap the Schraeder are set to activate at 4.0ºC. connections! 12 MONTHS ACTION NOTES... - Page 41 Discharge Line Ball Valve 20 Compressor Compartment Discharge Shraeder Connection 21 Evaporator, Waterside & Optional Pump Compartment HP Switch 22 Water Inlet Flange Connection 3a Head Pressure Control Solenoid Valve Set (behind panel) 23 Water Outlet Flange Connection Compressor Electrical Terminal Box 24 Mains Panel Oil Level Sight Glass 25 Door Interlocking isolator...
- Page 42 1,2,3 9,10 12,13,14 19/19a...
- Page 43 ULTIMA COMPACT FREECOOL Chillers Notes: Chillers Installation & Maintenance : 903-132 IM E 06/05/A...
- Page 44 Chillers ULTIMA COMPACT FREECOOL Notes: Chillers Installation & Maintenance : 903-132 TM E 06/05/A...
- Page 45 Head Office: Airedale International Air Conditioning Ltd Leeds Road Rawdon Leeds LS19 6JY United Kingdom Tel: +44 (0) 113 239 1000 Fax: +44 (0) 113 250 7219 e-mail: enquiries@airedale.com website: www.airedale.com PART NO: ISSUE DATE 903-132 IM E 01/06/05...
- Page 46 Airedale Departmental Contact Details: CUSTOMER SERVICES For further assistance, please e-mail: enquiries@airedale.com or telephone: Customer Services UK Sales Enquiries + 44 (0) 113 238 7789 uk.sales@airedale.com International Enquiries + 44 (0) 113 239 1000 enquiries@airedale.com Spares Hot Line + 44 (0) 113 238 7878 spares@airedale.com...