Related Manuals for AIREDALE Ultima Compact FreeCool Series
Summary of Contents for AIREDALE Ultima Compact FreeCool Series
- Page 1 COVER Ultima Compact FreeCool Free Cooling Chiller 75 kW - 450 kW R407C INSTALLATION & MAINTENANCE...
- Page 2 Any spare part supplied by Airedale under warranty shall be warranted for the unexpired period of the warranty or 3 months from delivery, whichever period is the longer.
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Page 3: Table Of Contents
Chillers ULTIMA COMPACT FREECOOL CONTENT S Contents General Statement ........................4 Warranty ..........................5 General Description ....................... 6 Unit Identification ........................6 Standard Features ......................... 7 Optional Extras General ...................... 8 Installation Data ........................9 Dimensions ..........................9 Weights, Point Loadings & Centre of Gravity (C of G) ............11 Unit Lifting .......................... -
Page 4: General Statement
A full hazard data sheet in accordance with COSHH regulations is available should this be required. SPARES For ease of identification when ordering spares or contacting Airedale about your unit, please quote the unit type, unit serial number and the date of manufacture, which can be found on the unit serial plate. -
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. keeping the footprint to an absolute minimum. -
Page 7: Standard Features
Chillers ULTIMA COMPACT FREECOOL General Description STANDARD FEATURES Standard Chiller The Standard Ultima Compact FreeCool chiller comes complete with: Microprocessor Control with BMS capability Condenser Coil & integral Free Cooling Coil Assembly Plate Evaporator Evaporator Pad Heater Multiple Scroll Compressors Dual Independent Refrigeration Circuits Intelligent Head Pressure Control Compressor Enclosures... -
Page 8: Optional Extras General
Chiller Sequence Manager CAUTION It is only possible to set up sequencing following completion of interconnecting communication wiring. Airedale Service can arrange Sequence setup on request. Factory Fitted Extended Discharge Air Plenum - Condenser Fan Corrosion Resistant Coated Coils... -
Page 9: Installation Data
Chillers ULTIMA COMPACT FREECOOL Installation Data DIMENSIONS IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. Single Row Fans - /1 UCFC75 - UCFC150 Electric Control Panels Mains Electric Isolators Mains Cable Entry 20mm Ø... - Page 10 ULTIMA COMPACT FREECOOL Chillers Installation Data DIMENSIONS IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. Double Row Fans - /2 UCFC160 - UCFC450 Electric Control Panels Mains Electric Isolators Mains Cable Entry 20mm Ø...
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Page 11: Weights, Point Loadings & Centre Of Gravity (C Of G)
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. Operating weight includes refrigerant charge and system water volume. Chillers Installation & Maintenance : 6259584 02/2013... - Page 12 5560 1100 3330 Have only 6 fixing and 6 point loadings. Based on standard unit, for units fitted with pump options, please contact Airedale. Operating weight includes refrigerant charge and system water volume. Chillers Installation & Maintenance : 6259584 02/2013...
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Page 13: Unit Lifting
Chains/slings MUST NOT interfere with the casing or fan assembly to avoid damage Lift the unit slowly and evenly IMPORTANT If the unit is dropped, it should immediately be checked for damage and reported to Airedale. LIFTING DIMENSIONS 2 FANS /1 Row 1900... -
Page 14: Anti Vibration Mounting (Optional)
ULTIMA COMPACT FREECOOL Chillers Installation Data ANTI VIBRATION MOUNTING (OPTIONAL) Spring Type Each mount is coloured to indicate the different loads, refer to AV selection sheet supplied separately for correct allocation. Dimensions A (1) FØ UCFC 75 UCFC 160 - 450 Unloaded dimension 2 spring type 4 spring type... -
Page 15: Positioning
Chillers ULTIMA COMPACT 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 +/- 5mm Where vibration transmission to the building structure is possible, fit spring anti- vibration mounts and flexible water connections Observe airflow and maintenance clearances... -
Page 16: Water System
ULTIMA COMPACT FREECOOL Chillers 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 water is treated to prevent corrosion and algae forming Glycol required as standard, with the correction concentration to suit the lowest ambient the equipment will experience The schematic is referred to as a guide to ancillary recommendations... - Page 17 Chillers ULTIMA COMPACT FREECOOL Installation Data WATER SYSTEM Component 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 Recommended temperature and pressure readings Requirements A flow switch or equivalent, fitted adjacent to the water outlet side of the Chiller A water-flow commissioning valve set fitted to the system...
- Page 18 ULTIMA COMPACT FREECOOL Chillers Installation Data WATER SYSTEM Pressure Testing When all the pipework has been connected in the system, proceed as follows: Ensure all shut off and control valves are fully open Pressurise system to the operating pressure, hold for 1 hour (a gradual fall in pressure shown on the gauge indicates a leak) Leaks should be found and repaired and the unit pressure tested for a further hour When the pressure remains at the operating pressure for 1 hour, the system can be...
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Page 19: Water System General Specification
For minimum system volume calculation method, refer to Technical Manual. Based on 12/7°C water temperature and 35°C ambient with a 20% Ethylene Glycol Water Concentration. Based on D Model, for DQ & DSQ details, please contact Airedale. Chillers Installation & Maintenance : 6259584 02/2013... -
Page 20: Glycol Data
ULTIMA COMPACT FREECOOL Chillers Installation Data GLYCOL DATA For a given percentage of glycol in the system there are correction factors that need to be applied, the following tables can be used as a guide. 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... -
Page 21: Electrical
Chillers ULTIMA COMPACT FREECOOL Installation Data ELECTRICAL General As standard the equipment is designed for 400V, 3 phase, 3 wire 50Hz and a separate permanent 230V, 1 phase, 50Hz supply, to all relevant IEE regulations, British standards and IEC requirements The control voltage to the interlocks is 24V, always size the low voltage interlock and protection cabling for a maximum voltage drop of 2V Avoid large voltage drops on cable runs, particularly low voltage wiring... -
Page 22: Interconnecting Wiring
ULTIMA COMPACT FREECOOL Chillers Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. INTERCONNECTING WIRING No Pumps Mains incoming supply 400V / 3PH / 50Hz Separate Permanent Supply 230V / 1PH +N / 50Hz External Trace Heater Connections 230V/500W max. -
Page 23: Electrical Data
Chillers ULTIMA COMPACT FREECOOL Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. ELECTRICAL DATA UCFC75D-2/1 UCFC100D-2/1 UCFC125D-3/1 UCFC150D-3/1 UCFC160D-6/2 Unit Data Nominal Run Amps Maximum Start Amps Rec Mains Fuse Size Mains Supply 400V / 3PH / 50 Hz Max Mains Incoming Cable Size... - Page 24 ULTIMA COMPACT FREECOOL Chillers Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. ELECTRICAL DATA UCFC75DQ-2/1 UCFC100DQ-3/1 UCFC125DQ-3/1 UCFC150DQ-4/1 UCFC160DQ-6/2 ALL DATA AS D MODEL EXCEPT: Fan & Motor - Per Fan Quantity Full Load Amps 1.15...
- Page 25 Chillers ULTIMA COMPACT FREECOOL Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. ELECTRICAL DATA UCFC180D-6/2 UCFC200D-6/2 UCFC225D-6/2 UCFC250D-8/2 UCFC275D-8/2 Unit Data Nominal Run Amps Maximum Start Amps Rec Mains Fuse Size Mains Supply 400V / 3PH / 50 Hz Max Mains Incoming Cable Size...
- Page 26 ULTIMA COMPACT FREECOOL Chillers Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. ELECTRICAL DATA UCFC180DQ-6/2 UCFC200DQ-6/2 UCFC225DQ-8/2 UCFC250DQ-8/2 UCFC275DQ-10/2 ALL DATA AS D MODEL EXCEPT: Fan & Motor - Per Fan Quantity Full Load Amps 1.15...
- Page 27 Chillers ULTIMA COMPACT FREECOOL Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. ELECTRICAL DATA UCFC300D-8/2 UCFC330D-10/2 UCFC360D-10/2 UCFC400D-12/2 UCFC450D-12/2 Unit Data Nominal Run Amps Maximum Start Amps Rec Mains Fuse Size Mains Supply 400V / 3PH / 50 Hz Max Mains Incoming Cable Size...
- Page 28 ULTIMA COMPACT FREECOOL Chillers Installation Data IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation. ELECTRICAL DATA UCFC300DQ-10/2 UCFC330DQ-12/2 UCFC360DQ-12/2 UCFC400DQ-14/2 UCFC450DQ-14/2 ALL DATA AS D MODEL EXCEPT: Fan & Motor - Per Fan Quantity Full Load Amps 1.15...
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Page 29: Controls
ULTIMA COMPACT FREECOOL Controls TEMPERATURE Airedale recognises that all chiller applications are different but fall mainly into 2 application categories; Variable Supply Temperature and Constant Supply Temperature. CONTROL The onboard microprocessor has the capability of satisfying either control requirement as illustrated below. -
Page 30: General Description
ULTIMA COMPACT FREECOOL Chillers Controls GENERAL The microprocessor controller offers powerful analogue and digital control to meet a wide range of monitoring and control features including a real time clock and Industry standard DESCRIPTION communication port and network connections. adjustments to control parameters by allowing the operator access to a series of display pages. -
Page 31: Setting Up
Real Time Clock 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 : 6259584 02/2013... -
Page 32: 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 33: 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 34: 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. OIL & REFRIGERANT CHARGES UCFC75D-2/1 UCFC100D-2/1 UCFC125D-3/1... -
Page 35: Waterside Pressure Drops
125D/DQ/DSQ 75D/DQ/DSQ Waterflow (l/s) UCFC150 150D/DQ/DSQ Waterflow (l/s) Chiller pressure drop refers to standard unit only. For pump options, please contact Airedale. For glycol solutions, please refer to Data, on page 20. Glycol Chillers Installation & Maintenance : 6259584 02/2013... - Page 36 250DQ 225DQ 300DQ 200DQ 275DQ 160DQ-180DQ Waterflow (l/s) Chiller pressure drop refers to standard unit only. For pump options, please contact Airedale. For glycol solutions, please refer to Glycol Data, on page 20. Chillers Installation & Maintenance : 6259584 02/2013...
- Page 37 250DSQ 225DSQ 300DSQ 200DSQ 275DSQ 160DSQ-180DSQ WATERFLOW (l/s) Chiller pressure drop refers to standard unit only. For pump options, please contact Airedale. For glycol solutions, please refer to Glycol Data, on page 20. Chillers Installation & Maintenance : 6259584 02/2013...
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Page 38: 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 UCFC125 Curve UCFC150 UCFC160 - UCFC450 Chillers Installation & Maintenance : 6259584 02/2013... - Page 39 Chillers ULTIMA COMPACT FREECOOL Commissioning Data PUMP PACKAGES Twin Head Pump Waterflow (l/s) Waterflow (l/s) Twin Head Pump Standard Larger UCFC75 UCFC100 UCFC125 Curve UCFC150 UCFC160 - UCFC450 Chillers Installation & Maintenance : 6259584 02/2013...
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Page 40: Operational Sequence
ULTIMA COMPACT FREECOOL Chillers Commissioning Data OPERATIONAL SEQUENCE Refrigerant Charge Check for the presence of a refrigerant charge in the condenser side. Compressor Oil Heater The mains supply to the oil heater should be switched on at least 8 hours prior to compressor starting to avoid refrigerant migration. -
Page 41: Commissioning Procedure
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 Airedale Technical Support immediately to validate warranty. PRE COMMISSIONING CHECKLIST ALL work MUST be carried out by technically trained competent personnel. - Page 42 ULTIMA COMPACT FREECOOL Chillers Commissioning Procedure PRE COMMISSIONING CHECKLIST 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 , on page 33 Alarm Handling Prior to the chiller compressors being allowed to start, the Water Flow Fail and CAUTION...
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Page 43: 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 Switch the door interlocking MCCB to the ON position but again only on the circuit which is to be tested... -
Page 44: 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 45: Compressor Maintenance
Chillers ULTIMA COMPACT FREECOOL Maintenance GENERAL MAINTENANCE 6 MONTHS ACTION NOTES Repeat 3 month checks plus the following: SYSTEM Check evaporator heater and low ambient thermostat are Remember to re-cap the Schrader set to activate at 4.0ºC. connections! 12 MONTHS ACTION NOTES Repeat 6 month checks plus the following:... -
Page 46: Parts Identification
ULTIMA COMPACT FREECOOL Chillers Parts Identification For ease of identification when ordering spares or contacting Airedale about your unit, SPARES please quote the unit type, unit serial number and the date of manufacture, which can be found on the unit serial plate. - Page 47 Chillers ULTIMA COMPACT FREECOOL Parts Identification Chillers Installation & Maintenance : 6259584 02/2013...
- Page 48 W here to Fin d U s 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 LITER ATUR E ORDER COD E...
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