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AIREDALE TurboChill TCC Series Technical Manual

Air cooled and freecoolbchillers, r513a spray evaporator
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TurboChill™
Air Cooled (TCC) and FreeCool (TCF) Chiller
200kW to 1650kW
R513A
Spray Evaporator
Technical Manual

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Summary of Contents for AIREDALE TurboChill TCC Series

  • Page 1 TurboChill™ Air Cooled (TCC) and FreeCool (TCF) Chiller 200kW to 1650kW R513A Spray Evaporator Technical Manual...

  • Page 2: Warranty, Commissioning & Maintenance

    Airedale Ltd. endeavours to ensure that the information in this document is correct and fairly stated, but none of the statements are to be relied upon as a statement or representation of fact. Airedale Ltd. does not accept liability for any error or omission, or for any reliance placed on the information contained in this document.

  • Page 3: Warranty

    All Airedale products or parts (non consumable) supplied for installation within the UK mainland and commissioned by an Airedale engineer, carry a full Parts & Labour warranty for a period of 12 months from the date of commissioning or 18 months from the date of despatch, whichever is the sooner.

  • Page 4: Health And Safety

    IMPORTANT The information contained in this manual is critical to the correct operation and maintenance of the unit and should be read by all persons responsible for the installation, commissioning and maintenance of this Airedale unit. Safety The equipment has been designed and manufactured to meet international safety standards but, like any mechanical / electrical equipment, care must be taken if you are to obtain the best results.
  • Page 5 Chillers TurboChill™ R513A Air Cooled and FreeCool Protective Personal Equipment Airedale recommends that personal protective equipment is used whilst installing, maintaining and commissioning equipment. Manual Handling Some operations when servicing or maintaining the unit may require additional assistance with regards to manual handling.

  • Page 6: Environmental Considerations

    Chillers Environmental Considerations Freeze Protection Airedale recommends the following actions to help protect the unit during low temperature operation. This also includes the units subject to low ambient temperatures. Units with supply water temperatures below +5°C Glycol is recommended when a supply water temperature of +5°C or below is required or when static water can be exposed to freezing temperatures.

  • Page 7: Table Of Contents

    Chillers TurboChill™ R513A Air Cooled and FreeCool Contents Warranty, Commissioning & Maintenance ChillerGuard™ Customer Services Warranty Health and Safety Safety Pressure Equipment Directive Environmental Considerations Nomenclature Unit Overview Unit Components Refrigeration Turbocor Compressor Condenser Electrical Condenser Fans Waterside Controls Mechanical Design Features &...
  • Page 8 TurboChill™ R513A Air Cooled and FreeCool Chillers Contents Hydronic Data Evaporator Pressure Drop - 100% Water Evaporator Pressure Drop - 20% Ethylene Glycol Strainer Pressure Drop - 100% Water Strainer Pressure Drop - 20% Ethylene Glycol Installation Data Air Cooled Masses & Centre of Gravity (C of G) Freecool Masses &...
  • Page 9 Chillers TurboChill™ R513A Air Cooled and FreeCool Intentionally Blank Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 10: Nomenclature

    Evaporator Code Introduction The Airedale range of TurboChill air cooled and Freecool liquid chillers uses the technologically superior centrifugal Turbocor compressors. Designed to cover the high capacity range between 200kW and 1650kW. Each model is individually selected to provide the optimum solution for each application by offering maximum flexibility and matching customer requirements in terms of: ●...
  • Page 11 Chillers TurboChill™ R513A Air Cooled and FreeCool Construction The base shall be fabricated from galvanised steel to ensure a rigid, durable, weatherproof construction. Unit panels shall be manufactured from galvanised sheet steel coated with epoxy baked powder paint to provide a durable and weatherproof finish.

  • Page 12: Unit Overview

    TurboChill™ R513A Air Cooled and FreeCool Chillers Unit Overview Airflow ● EC Condenser Fans ● AC Condenser Fans ● High Airflow EC Condenser Fans ● No Discharge Plenum ● 300mm Fan Discharge Plenum ● 500mm Extended Height Fan Discharge Plenum Electrical Panel ●...
  • Page 13 Chillers TurboChill™ R513A Air Cooled and FreeCool Coils ● Epoxy Coated Microchannel Condenser Coils ● RTPF FreeCooling Coils Waterside ● Differential Pressure Sensor ● Flow Switch ● Pump Interlock ● Water Filter ● Various Pump Options ● Immersion Heater ● Grooved and Clamped Type Connections Refrigeration ●...

  • Page 14: Unit Components

    TurboChill™ R513A Air Cooled and FreeCool Chillers Unit Components Refrigeration Refrigeration ● ● Compressors - Turbocor centrifugal ● ● Dual maintainable pressure relief valves ● ● Microchannel epoxy coated condensing coils ● RTPF free cooling coils ○ Epoxy coated RTPF free cooling coils ●...
  • Page 15 Two immersion heater(s) and thermostat protect the evaporator against freeze up in ambient temperatures down to -20°C. (in compliance with Airedale freeze protection policy). Connections for external trace heating rated at 230V/500W is available. Compressors and evaporator shall be mounted on a rigid galvanised heavy duty sub frame.

  • Page 16: Turbocor Compressor

    TurboChill™ R513A Air Cooled and FreeCool Chillers Turbocor Compressor Each installed compressor comes with the following components: ● Suction and discharge shut off valves. ● Discharge non-return valve. ● Line reactor (for removing additional impedance harmonics and voltage spikes in the ac waveform). ●...

  • Page 17: Condenser

    Chillers TurboChill™ R513A Air Cooled and FreeCool Condenser Large surface area microchannel coil(s) (ideally positioned to optimise airflow and heat transfer) shall be manufactured as a “V-block” arrangement. This microchannel “V-block” arrangement has a lower airside pressure drop than a traditional round tube plate fin heat exchanger making the fans run more efficiently.

  • Page 18: Electrical

    TurboChill™ R513A Air Cooled and FreeCool Chillers Electrical Fans Controls Speed Controllers (AC Fans) Circuit 1 Compressors 1 & 2 Bus-bar Chamber Circuit 2 Pumps Compressors 3 & 4 Controls and Electrical ● ● Leak detection on circuits containing >500 tonnes equivalent CO ●...
  • Page 19 Chillers TurboChill™ R513A Air Cooled and FreeCool 3 Phase Single Point Isolaton Single point isolation shall be fitted as a standard feature. Ultracap Power Backup The Ultracap module is a standard feature utilising the latest Ultra Capacitor technology in external backup device for the EVD Evolution drivers and pCO controllers.

  • Page 20: Condenser Fans

    TurboChill™ R513A Air Cooled and FreeCool Chillers Condenser Fans Fans ● ● 800 mm diameter EC axial fans ○ ○ 800 mm diameter AC axial fans ○ ○ 800 mm diameter High Airflow EC fans* ● ○ – Standard features Optional features Feature not available * High airflow EC fans are not available with the X type units.

  • Page 21: Waterside

    Chillers TurboChill™ R513A Air Cooled and FreeCool Waterside Strainer Grooved Connection Pump(s) Inverter housing Return Supply Waterside – ● Free Cooling Coil ● ● Evaporator immersion heaters ○ ● Internal water filter** ○ ○ Pump hydronic options** ● ● Grooved and clamped type connections ○...
  • Page 22 Flanged Connections Flanged connections shall be fitted to the unit upon request. (excluding TCC evaporator only hydronic options). Please contact Airedale. Pump Vibration Eliminator Bellows shall be fitted to the pumps (>11kW) to reduce any vibration through the system pipework.
  • Page 23 Chillers TurboChill™ R513A Air Cooled and FreeCool Pump Options A variety of pump options to suit a wide range of applications are available: Factory fitted in line as a single pump or run / standby configuration with multiple pump sizes to tailor exact customer requirements in terms of flow and additional head.
  • Page 24 Water Connections Water inlet and outlet connections shall be of a grooved and clamped type construction. Optional flanged connections shall be available on request (excluding TCC evaporator only), please consult Airedale. Water connection to evaporator only (air cooled only) Water inlet and outlet connections shall terminate directly on the evaporator.

  • Page 25: Controls

    Chillers TurboChill™ R513A Air Cooled and FreeCool Controls The microprocessor controller shall offer powerful analogue and digital control to meet a wide range of monitoring and control features including a real time clock and Industry standard communication port and network connections. The controller’s inbuilt display shall be 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 Up to 6 units can be sequenced. Included within this package is a site visit by an Airedale control specialist to set up multiple unit sequence control. The chiller sequence manager is supplied as a separate control panel to be mounted remotely in an indoor location, such as a plant room.
  • Page 27 Compressor Reduced Start Delay Compressor fast start functionality shall be avaliable for applications that require minimum downtime following 3 phase power failure. This is subject to a compressor UPS being fitted onto the L4 permanent supply. Please contact Airedale. Password Protection CAUTION The control system integrity shall be maintained by restricting access with a password PIN number.
  • Page 28 BMS system configuration by others. Enables units to be interfaced with most BMS, factory fitted, please contact Airedale. A wide range of protocols shall be accommodated through the use of interface devices. Available as a standard option are: ModBus / Jbus, Carel, Trend, SNMP, LonWorks, Metasys and BACnet. Also available shall be Airedale’s own supervisory plug-in BMS card pCOWEB.

  • Page 29: Mechanical

    Chillers TurboChill™ R513A Air Cooled and FreeCool Mechanical Mechanical ● ● Lifting lugs ● ● Base - plain galvanised steel ● ● Panels - galvanised sheet steel with epoxy powder paint ● ● No discharge plenum ○ ○ 300mm height fan discharge plenum ○...
  • Page 30 TurboChill™ R513A Air Cooled and FreeCool Chillers No Discharge Plenum No discharge plenum is fitted as standard. Discharge Air Plenum - Condenser Fan Factory fitted and constructed from galvanised sheet steel coated with epoxy baked powder paint, this plenum shall direct discharge air vertically which reduces air re-circulation and provides a degree of acoustic reduction in the horizontal plane.

  • Page 31: Design Features & Information

    Chillers TurboChill™ R513A Air Cooled and FreeCool Design Features & Information Specific Heat Capacity (SHC) % Ethylene Glycol Concentration Specific Heat Capacity (kJ/kgK) 4.190 4.115 3.901 3.686 3.474 % Propylene Glycol Concentration Specific Heat Capacity (kJ/kgK) 4.190 4.139 4.033 3.903 3.749 (1) Data quoted for water/glycol solutions at a nominal temperature of 10°C.
  • Page 32 TurboChill™ R513A Air Cooled and FreeCool Chillers Design Features & Information Operating Limits Standard Unit Minimum ambient air DB -20°C* Maximum ambient air DB at full load operation 35°C Max ambient air DB (subject to chiller model selected) 40°C Minimum supply water temperature 5°C Maximum return water temperature 26°C**...

  • Page 33: Performance Effects Of Glycol

    Glycol Data For a given percentage of glycol in the system there are correction factors that need to be applied, the following tables should be used as a guide only. For accurate glycol selections please contact Airedale. CAUTION The source data must be based upon 100% water for the correction factors to be valid.

  • Page 34: Measurement Of Sound Data

    TurboChill™ R513A Air Cooled and FreeCool Chillers Design Features & Information Measurement of Sound Data All sound data quoted has been measured in the third-octave band limited values, using a Real Time Analyser calibrated sound intensity meter in accordance with BS EN ISO9614 Part 1:2009. The Global sound data quoted is valid for noise emitted in the horizontal plane in all directions.

  • Page 35: Pressure Relief Valve Discharge Piping

    Chillers TurboChill™ R513A Air Cooled and FreeCool Design Features & Information Pressure Relief Valve Discharge Piping Considerations must be made when designing pipework for PRV venting. This must be designed in accordance to EN378-3 Section 5.8 Piping and ducting. ● Caution must be taken to ensure excessive pressure drop in the pipework is avoided. ●...

  • Page 36: Water Systems And Recommended Flow Schemes

    TurboChill™ R513A Air Cooled and FreeCool Chillers Installation Data Water Systems and Recommended Flow Schemes The recommended requirements to allow commissioning to be carried out correctly are: ● The inclusion of binder points adjacent to the flow and return connections, to allow temperature and pressure readings.
  • Page 37 Chillers TurboChill™ R513A Air Cooled and FreeCool Installation Data Standard Air Cooled Circuit Incorporating: ● 20 Mesh Water Filter. ● Differential Pressure Transducer. ● Shut off Valves. Chiller Technical Manual 7525371 V1.3.0_06_2019...
  • Page 38 TurboChill™ R513A Air Cooled and FreeCool Chillers Installation Data Standard Free Cool Circuit Incorporating: ● Double regulating valve. ● Mixing valve. ● 20 mesh water filter. ● Differential pressure transducer. Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 39: Technical Data - Tcc

    (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 40 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 41 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 42 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 43 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 44 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 45 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 46 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 47 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 48 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 49: Sound Data

    (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 13/7°C at 35°C ambient. (3) Based on a unit with a 300mm plenum, for other configurations please see Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 50 (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 13/7°C at 35°C ambient. (3) Based on a unit with a 300mm plenum, for other configurations please see Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 51 (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 13/7°C at 35°C ambient. (3) Based on a unit with a 300mm plenum, for other configurations please see Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 52 (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 13/7°C at 35°C ambient. (3) Based on a unit with a 300mm plenum, for other configurations please see Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 53: Technical Data -Tcf

    (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 54 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 55 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 56 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 57 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 58 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 59 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 60 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 61 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 62 (8) For minimum system water volume calculation, refer to Design Features & Information - Minimum System Water Volume Calculations. (9) Based on full load conditions and EC fans. Pump electrical data is available from Airedale upon request. Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 63: Sound Data

    (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 16/10°C at 35°C ambient. (3) Based on unit with a 300mm plenum, for units fitted with optional extras, please contact Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 64 (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 16/10°C at 35°C ambient. (3) Based on unit with a 300mm plenum, for units fitted with optional extras, please contact Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 65 (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 16/10°C at 35°C ambient. (3) Based on unit with a 300mm plenum, for units fitted with optional extras, please contact Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 66 (1) dB(A) is the overall sound level, measured on the A scale. (2) All sound data measured at nominal conditions: Water in/out 16/10°C at 35°C ambient. (3) Based on unit with a 300mm plenum, for units fitted with optional extras, please contact Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 67: Evaporator Pressure Drop - 100% Water

    Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Hydronic Data Evaporator Pressure Drop - 100% Water Flow Rate (l/s) 37 38 Flow Rate (l/s) Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 68: Evaporator Pressure Drop - 20% Ethylene Glycol

    TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Hydronic Data Evaporator Pressure Drop - 20% Ethylene Glycol Flow Rate (l/s) 37 38 Flow Rate (l/s) Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 69: Strainer Pressure Drop - 100% Water

    Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Hydronic Data Strainer Pressure Drop - 100% Water 4" 6" 5" 8" 80 100 120 140 160 180 200 220 240 260 280 300 320 Flow Rate (l/s) Strainer Pressure Drop - 20% Ethylene Glycol 4"...

  • Page 70: Installation Data

    TCC24R18S-40 8910 9160 4850 1160 TCC24R20S-40 9860 10110 5540 1160 TCC24R22L-41 11360 11680 6380 1150 TCC24R24L-41 11990 12310 6630 1150 Above refers to standard unit water configurations of evaporator only, contact Airedale for other options. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 71 TCC24X18S-40 8910 9160 4850 1160 TCC24X20S-40 9860 10110 5540 1160 TCC24X22L-41 11360 11680 6380 1150 TCC24X24L-41 11990 12310 6630 1150 Above refers to standard unit water configurations of evaporator only, contact Airedale for other options. Chiller Technical Manual 7525371 V1.3.0_06_2019...

  • Page 72: Freecool Masses & Centre Of Gravity (C Of G)

    14040 5050 1070 TCF24R20S-52 13780 15390 5740 1060 TCF24R22L-41 14800 16530 6570 1060 TCF24R24L-41 15800 17730 6840 1050 Above refers to standard unit water configurations of no pump, no bypass, contact Airedale for other options. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 73 14040 5050 1070 TCF24X20S-52 13780 15390 5740 1060 TCF24X22L-41 14800 16530 6570 1060 TCF24X24L-41 15800 17730 6840 1050 Above refers to standard unit water configurations of no pump, no bypass, contact Airedale for other options. Chiller Technical Manual 7525371 V1.3.0_06_2019...

  • Page 74: Point Loadings

    TCC24R20S-40 870 TCC24R22L-41 970 1035 1020 1085 1080 980 TCC24R24L-41 1040 985 1030 1020 945 1115 1085 1140 1125 1030 925 Above refers to standard unit water configurations of evaporator only, contact Airedale for other options. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 75 TCC24X20S-40 870 TCC24X22L-41 970 1035 1020 1085 1080 980 TCC24X24L-41 1040 985 1030 1020 945 1115 1085 1140 1125 1030 925 Above refers to standard unit water configurations of evaporator only, contact Airedale for other options. Chiller Technical Manual 7525371 V1.3.0_06_2019...
  • Page 76 1280 1300 1400 1435 1315 1210 TCF24R24L-41 1425 1475 1620 1715 1605 1425 1385 1400 1490 1515 1405 1265 Above refers to standard unit water configurations of no pump, no bypass, contact Airedale, for other options. Chiller Technical Manual 9635376 V1.3.0_06_2019...
  • Page 77 1280 1300 1400 1435 1315 1210 TCF24X24L-41 1425 1475 1620 1715 1605 1425 1385 1400 1490 1515 1405 1265 Above refers to standard unit water configurations of no pump, no bypass, contact Airedale, for other options. Chiller Technical Manual 7525371 V1.3.0_06_2019...

  • Page 78: Unit Lifting

    ● Use the appropriate spreader bars/lifting slings with the holes/lugs provided. ● Lift the unit slowly and evenly. ● If the unit is dropped, it should immediately be checked for damage and reported to Airedale. ● Allow free space abovethe fans to prevent air recirculation.
  • Page 79 Chillers TurboChill™ R513A Air Cooled and FreeCool Installation Data Lifting Dimensions 8 Point 2300 ≥60° ≥60° Lifting Single Circuit Machines Dual Circuit Machines Number of Fans A (mm) B (mm) A (mm) B (mm) Size 3600 1536 3600 1490 4500 1536 4500 1536...

  • Page 80: Dimensions

    TurboChill™ R513A Air Cooled and FreeCool Chillers Installation Data Dimensions Contact Airedale for detailed general arrangement drawings. Number of Fans 4 Fan 2200 2800 2626 6 Fan 2200 2800 3758 8 Fan 2200 2800 4890 10 Fan 2200 2800 6022...

  • Page 81: Positioning

    Chillers TurboChill™ R513A Air Cooled and FreeCool 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 ± 1°. ●...

  • Page 82: Anti Vibration Mounting (Optional)

    TurboChill™ R513A Air Cooled and FreeCool Chillers Installation Data Anti Vibration Mounting (Optional) Spring Type Each mount is coloured to indicate the different loads, refer to instructions supplied for correct allocation. Dimensions A(1) TCC / TCF Units Unloaded dimension Components Locating screw.
  • Page 83 Chillers TurboChill™ R513A Air Cooled and FreeCool Anti Vibration Mount location to Unit and Plinth The Anti Vibration mount is larger than the unit base. Consideration must be made with regard to steelwork / concrete plinth sizes. Full information is available on the approved General Arrangement drawings. The base of the unit is open. Considerations must be made for service and maintenance requirements if the unit is installed on a gantry.

  • Page 84: Interconnecting Wiring

     IMPORTANT (1) Must be directly wired to the chiller to validate warranty. This system has been designed to be connected to a TN type distribution system. For alternate IMPORTANT distribution type systems, contact Airedale. Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 85: Plan Termination

    Chillers TurboChill™ R513A Air Cooled and FreeCool pLAN termination Customer Side RxTx - RxTx + RxTx - RxTx + Panel Side The plugged termination ensures that the connections are made simultaniously. Failure to attached CAUTION the cables this way may cause damage to the controller. Chiller Technical Manual 7525371 V1.3.0_06_2019...

  • Page 86: Power Quality & Harmonics

    TurboChill™ R513A Air Cooled and FreeCool Chillers Power Quality & Harmonics Variable speed drives are now common place due to their efficiency and versatility. Not ignoring these facts, care must be taken when installing VSD technology into new and existing installations. This is due to the effect the introduction of such technology may have on line harmonics of a buildings electrical system.

  • Page 87: Pre Start Checks

    Chillers TurboChill™ R513A Air Cooled and FreeCool Pre Start Checks ALL work must be carried out by technically trained competent personnel. CAUTION The equipment contains live electrical and moving parts, Isolate prior to maintenance or repair work. Water Flow Make sure that you have the correct water flow rate before turning the unit on. (Refer to commissioning documentation). CAUTION If the unit is operated without water flow the unit will be damaged.

  • Page 88: Pco5+ Built In Display And Keypad

    TurboChill™ R513A Air Cooled and FreeCool Chillers pCO5+ Built In Display and Keypad The in-built display is equipped with LCD display (8 rows x 22 columns) with 6 buttons. ALARM - Red LED indicates ENTER -Selects menus & alarm present moves cursor to adjustable fields green LED Display...

  • Page 89: Unit Operation

    Chillers TurboChill™ R513A Air Cooled and FreeCool Unit Operation The unit must not be started unless the pre start checks have been carried out. Restarting the Unit To turn the unit on press the key to enter the program menu. Using the keys select the Unit On/Off option and press When...

  • Page 90: Changing The Setpoint

    TurboChill™ R513A Air Cooled and FreeCool Chillers Changing the Setpoint To change the set point of the unit from the main screen press the button. Use the to scroll to the set point option as shown below and press The following screen will be shown: Using the button scroll to the password screen.

  • Page 91: Enabling Pumps

    Chillers TurboChill™ R513A Air Cooled and FreeCool Enabling Pumps Pump Start-Up Use the start-up guide for the general setting of the pump controller including the setting of the correct direction of rotation. The start-up guide will be started the first time when the controller is connected to a supply voltage. It can be restarted in the menu under GENERAL.

  • Page 92: Maintenance

    TurboChill™ R513A Air Cooled and FreeCool Chillers Operational Maintenance checks Owners Responsibility To ensure that the chiller can be maintained correctly ensure the following requirements are met. Maintain a safe working environment around the chiller, free from obstructions and debris. The unit shall follow the maintenance schedule below as a minimum.

  • Page 93: Electrical Inspection

    RS232 serial interface lead and connect the RS485 output to the fan. ● Tx += RS A ● Tx - = RS B (Except high airflow fans where interogation is via a separate module available from Airedale). Chiller Technical Manual 9635376 V1.3.0_06_2019...

  • Page 94: Refrigeration

    TurboChill™ R513A Air Cooled and FreeCool Chillers Maintenance Refrigeration Task Frequency 3 Mths 12 Mths 60 Mths Compare the following and compare results with commissioning records: ● Suction, liquid and discharge pressures. Refrigeration system temperatures, suction, liquid and ● discharge. Record superheat and sub cooling temperatures. Refrigeration Check each circuit sight glass for dryness and bubbles for ●...

  • Page 95: Waterside

    Water Strainer A water strainer must be fitted to the inlet side of the chiller evaporator. Failure to do so may result in severe damage and will void the AIREDALE warranty. Water Flow Rate Check that the design water flow rate is available to the unit. If not available do not turn unit on.

  • Page 96: Controls

    TurboChill™ R513A Air Cooled and FreeCool Chillers Maintenance Controls Task Frequency 3 Mths 12 Mths 60 Mths Controls Change controller battery. ● The controller will keep the strategy for a short period of time with no battery. Service Tools/Test Equipment Safety Equipment ●...

  • Page 97: System

    Chillers TurboChill™ R513A Air Cooled and FreeCool Maintenance System Task Frequency 3 Mths 12 Mths 60 Mths Check the following against the commissioning records: System Record operating conditions. ● Water on / off temperatures. ● Water pressure drop. ● Unit Operation Checks Record the following operating conditions of the unit at stable conditions: ●...

  • Page 98: Appendix - Ecodesign

    TurboChill™ R513A Air Cooled and FreeCool Chillers Appendix - Ecodesign SEPR (Seasonal Energy Performance Ratio) ● Type of condensing - Air cooled standard EC fans. ● Refrigerant fluid - R513A. ● Operating temperature - +7°C (Outlet water). ● Operating control - Variable. ●...

  • Page 99: Ecodesign - Tcc (R)

    Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign - TCC (R) Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 225725.0 228639.0 230439.2 398835.0 431715.9 458705.0 Rated Refrigerant Capacity P 1,3,5...
  • Page 100 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 446773.4 461494.0 603525.1 655931.0 748662.9 805644.8 Rated Refrigerant Capacity P 1,3,5 434.6...
  • Page 101 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 898157.4 434508.5 447371.7 624598.3 708139.8 760294.8 Rated Refrigerant Capacity P 1,3,5 789.4...
  • Page 102 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 846146.7 629562.2 635727.4 654331.4 703169.8 836964.3 Rated Refrigerant Capacity P 1,3,5 789.4...
  • Page 103 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 840947.9 899114.6 776991.8 803670.7 1103881.6 1103834.3 Rated Refrigerant Capacity P 1,3,5 834.5...

  • Page 104: Ecodesign - Tcc (X)

    TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign - TCC (X) Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 178259.6 182601.0 183150.9 284972.7 278552.0 283663.7 Rated Refrigerant Capacity P 1,3,5...
  • Page 105 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 320369.0 329502.8 568971.9 543872.4 556588.5 582656.9 Rated Refrigerant Capacity P 1,3,5 354.7...
  • Page 106 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 631255.7 318661.1 327229.9 534144.3 546165.4 571148.9 Rated Refrigerant Capacity P 1,3,5 679.5...
  • Page 107 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 614928.1 533885.6 534471.3 539260.9 560669.2 712933.8 Rated Refrigerant Capacity P 1,3,5 679.5...
  • Page 108 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 711919.0 738675.3 622726.2 645485.5 986649.9 998180.5 Rated Refrigerant Capacity P 1,3,5 759.6...

  • Page 109: Ecodesign - Tcf (R)

    Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign - TCF (R) Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 223034.9 235657.7 354220.6 379081.4 358036.4 477315.2 Rated Refrigerant Capacity P 1,3,5...
  • Page 110 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 533642.4 431580.2 623165.1 665818.2 692623.7 745577.1 Rated Refrigerant Capacity P 1,3,5 469.3...
  • Page 111 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 423050.5 610452.7 624593.7 636256.4 724208.4 624118.6 Rated Refrigerant Capacity P 1,3,5 459.3...
  • Page 112 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 614714.1 630570.9 663157.4 809605.4 809692.6 852856.7 Rated Refrigerant Capacity P 1,3,5 679.2...
  • Page 113 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) Annual Electricity Consumption kWh/a 865091.5 975598.6 1019513.5 Rated Refrigerant Capacity P 1,3,5 859.2 1034.1 1089.1 Rated Power Input D 270.9 359.5...

  • Page 114: Ecodesign - Tcf (X)

    TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign - TCF (X) Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 204241.6 187417.1 299740.8 289720.1 282025.4 332587.1 Rated Refrigerant Capacity P 1,3,5...
  • Page 115 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 411916.0 440634.3 592699.0 576023.6 592199.4 626942.0 Rated Refrigerant Capacity P 1,3,5 419.4...
  • Page 116 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 361465.9 579286.7 612521.5 577857.4 604849.3 588414.9 Rated Refrigerant Capacity P 1,3,5 419.4...
  • Page 117 Chillers TurboChill™ R513A Air Cooled and FreeCool Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) (2021) (2021) (2021) Annual Electricity Consumption kWh/a 585402.2 587669.5 589366.8 771450.0 764325.8 754769.1 Rated Refrigerant Capacity P 1,3,5 654.2...
  • Page 118 TurboChill™ R513A Air Cooled and FreeCool Chillers Technical Data Ecodesign Notes: Units SEPR 1,3,5 Tier 2 Tier 2 Tier 2 SEPR Tier (2021) (2021) (2021) Annual Electricity Consumption kWh/a 786395.2 880205.0 929162.9 Rated Refrigerant Capacity P 1,3,5 814.2 954.1 999.1 Rated Power Input D 259.4 356.2...
  • Page 119 All Airedale products or parts (non consumable) supplied for installation within the UK mainland and commissioned by an Airedale engineer, carry a full Parts & Labour warranty for a period of 12 months from the date of commissioning or 18 months from the date of despatch, whichever is the sooner.
  • Page 120 TurboChill™ R513A Air Cooled and FreeCool Chillers Chiller Technical Manual 9635376 V1.0.0_01_2019...
  • Page 121 Chillers TurboChill™ R513A Air Cooled and FreeCool Chiller Technical Manual 9635376 V1.0.0_01_2019...
  • Page 122 Head Offi ce Airedale International Air Conditioning Ltd Leeds Road Rawdon Leeds LS19 6JY Tel: +44 (0) 113 2391000 Fax:+44 (0) 113 2507219 E-mail enquiries@airedale.com Web www.airedale.com TM_TURBOCHILL_TCC_TCF_R513A_9635376_09_2019...

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