Related Manuals for AIREDALE Ultima FreeCool
Summary of Contents for AIREDALE Ultima FreeCool
- Page 1 INSTALLATION, OPERATING & MAINTENANCE MANUAL Ultima FreeCool Free-Cooling Chiller 200 – 750 kW...
- 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 FREECOOL Contents GENERAL STATEMENT Safety WARRANTY GENERAL DESCRIPTION Unit Identification Standard Features Optional Extras - Energy Saving Optional Extras - General INSTALLATION DATA Dimensions Point Loading & Centre of Gravity Weights Unit Lifting Anti Vibration Mounting Positioning Water System Data... -
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 UFC200D-8 INTRODUCTION The Airedale range of Ultima FreeCool air cooled liquid chillers covers the cooling capacity range 200kW to 750kW in 39 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 Chillers ULTIMA FREECOOL General Description STANDARD FEATURES Refrigeration Each refrigeration circuit is supplied with the following: • Full operating charge of R407C • Liquid injection oil cooling circuit fitted to each compressor as standard with filter, sight glass, strainer and non-return valve •...
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Page 8: Optional Extras - Energy Saving
ULTIMA FREECOOL Chillers General Description OPTIONAL EXTRAS - ENERGY SAVING Power Factor Correction When applied to the motors of each compressor, the compressor power factor is controlled to a minimum operating value of 0.95 at the full operating capacity. This satisfies many supply authorities that may impose surcharges on equipment with power factor less than 0.95. -
Page 9: Installation Data
Chillers ULTIMA FREECOOL Installation Data DIMENSIONS C of G2 20mm Ø Mounting Holes Water Connections UFC200 - 400 = DN100 PN16 UFC450 - 650 = DN125 PN16 UFC700 - 750 = DN150 PN16 Mains Electric Isolator Mains Cable Entry Controls... -
Page 10: Point Loading & Centre Of Gravity
ULTIMA FREECOOL Chillers Installation Data DIMENSIONS (CONT.) DSQ Models UFC200DSQ-8 4945 1850 1850 UFC225DSQ-8 4945 1850 1850 UFC250DSQ-8 4945 1850 1850 UFC275DSQ-10 5795 1550 1450 1550 UFC300DSQ-10 5795 1550 1450 1550 UFC350DSQ-14 7670 1100 1725 1920 1830 UFC400DSQ-14 7670 1100... -
Page 11: Weights
Chillers ULTIMA FREECOOL Installation Data WEIGHTS STANDARD D UFC200D-8 UFC225D-8 UFC250D-8 UFC275D-8 UFC300D-8 Weight - Machine 3340 3360 3380 3480 3670 Weight - Operating 3940 3960 3980 4070 4310 QUIET DQ UFC200DQ-8 UFC225DQ-8 UFC250DQ-8 UFC275DQ-8 UFC300DQ-8 Weight - Machine 3270... -
Page 12: Unit Lifting
ULTIMA FREECOOL Chillers Installation Data UNIT LIFTING • Employ lifting specialists. • Local codes and regulations relating to the lifting of this type of equipment should be observed. • Use the appropriate spreader bars/lifting slings with the holes/lugs provided. Attach lifting chains to the 4 lifting lugs provided, each chain must be capable of •... - 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 FREECOOL Installation Data ANTI VIBRATION Locate and secure mount using bolting down holes provided in base plate. Ensure mounts are located in line with the chiller base. MOUNTING If applicable remove compressor enclosure covers to allow access to AV fixing CLS Type (Optional) points on the chiller base. -
Page 15: Positioning
ULTIMA 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 Data
CAUTION The unit water connections are NOT designed to support external pipework, pipework should be supported during installation. CAUTION No liability for externally connected pipework will be regarded by Airedale International Air Conditioning Ltd. STANDARD RECOMMENDED INSTALLATION CAUTION The following installation recommendations should be adhered to. Failure to do this could invalidate the chiller warranty. - Page 17 To prevent air locking in the system it is advisable to fill the systems from the lowest point, ie drain point on pipework. Auto air vents are fitted, Airedale strongly recommends an auto pressurisation unit be fitted to the system.
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Page 18: Glycol Data
Chillers ULTIMA FREECOOL 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... -
Page 19: Electrical Data
ULTIMA FREECOOL Chillers Installation Data ELECTRICAL DATA 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. - Page 20 Chillers ULTIMA FREECOOL Installation Data INTERCONNECTING WIRING No Pumps Mains incoming supply 400V/3PH/50Hz " " " " Separate Permanent Supply 230V/1PH/50Hz " " " External Trace Heating Connections 240V/500W max " (1)Evaporator Pump Interlock 24VAC " UFC200 – UFC750 Unit Remote On/Off 24VAC "...
- Page 21 Motor Rating 0.70 0.70 0.70 0.70 0.70 OPTIONAL EXTRAS - Fitted to standard D models - for data on DQ & DSQ please refer to Airedale. Power Factor Correction Nominal Run Amps Maximum Start Amps Recommended Mains Fuse Compressor Nominal...
- Page 22 Motor Rating 0.70 0.70 0.70 0.70 0.70 OPTIONAL EXTRAS - Fitted to standard D models - for data on DQ & DSQ please refer to Airedale. Power Factor Correction Nominal Run Amps Maximum Start Amps Recommended Mains Fuse Compressor Nominal...
- Page 23 2.10 2.10 Motor Rating 0.70 0.70 0.70 OPTIONAL EXTRAS - Fitted to standard D models - for data on DQ & DSQ please refer to Airedale. Power Factor Correction Nominal Run Amps Maximum Start Amps Recommended Mains Fuse Compressor Nominal...
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Page 24: Controls
ULTIMA 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 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 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 and visual alarm by allowing the operator access to a series of display pages. -
Page 26: Setting Up
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 Manual : 903-125 IM E 05/04/A... -
Page 27: Viewing Unit Operating Status
ULTIMA 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: Digital Inputs Analogue Inputs... -
Page 28: Alarms
Chillers ULTIMA FREECOOL Controls ALARMS The controller logs and allows viewing of the last 100 conditions recorded in descending chronological order. 1 3 / 0 5 / 0 2 1 1 : 3 2 E v e n t n u m b e r... -
Page 29: Commissioning Data
Maximum Ambient Air DB °C Refer to Technical Manual - Performance Data Minimum Leaving Water Temperature °C +5°C Maximum Return Water Temperature °C +20°C For conditions outside those quoted, please refer to Airedale. MECHANICAL DATA Oil & Refrigerant Charges STANDARD D UFC200D-8 UFC225D-8... -
Page 30: Waterside Pressure Drops
Chillers ULTIMA FREECOOL Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) Standard – D Models 450-500 575-650 700 750 200-275 WATERFLOW (l/s) Quiet– DQ Models 575-650 450-500 200-275 300 WATERFLOW (l/s) Chillers Installation & Maintenance Manual : 903-125 IM E 05/04/A... - Page 31 ULTIMA FREECOOL Chillers Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) Super Quiet– DSQ Models 450-500 575 & 700 200-250 275 300 WATERFLOW (l/s) For glycol solutions, please refer to Glycol Data. Chillers Installation & Maintenance Manual : 903-125 IM E 05/04/A...
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Page 32: Electrical Data
Chillers ULTIMA FREECOOL Commissioning Data ELECTRICAL DATA CLIENTS INCOMING Compressor Start-Up SUPPLY 400/3/50 Information POWER FACTOR CORRECTION CLOSED TRANSITION START OPTIONAL EXTRA OPTIONAL EXTRA POWER POWER FACTOR FACTOR CORRECTION CORRECTION PRR1 CAPACITOR CAPACITOR PHASE COMPRESSOR ROTATION RELAY Starting Sequence (Star- Delta Starting) 5 Sec ±... - Page 33 ULTIMA FREECOOL Chillers Commissioning Data ELECTRICAL DATA Capacity Control The following staggered timings are recommended on compressor start-up: 100% 75 Sec ± 5 180 Sec ± 10 • 12% load (starting position) should be used only at start-up, never as a stage of capacity control.
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Page 34: 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 Airedale Service immediately to validate warranty. PRE COMMISSIONING CHECKLIST CAUTION ALL work MUST be carried out by Technically Trained competent personnel. - Page 35 ULTIMA FREECOOL Chillers Commissioning Procedure PRE COMMISSIONING CHECKLIST (CONT..) Waterflow • Drive the 3-way valve fully open by raising the return water temperature above the ambient and measure the pressure drop across the free cooling coils. Commissioning • Lower the return water temperature to below the ambient to close the valve fully.
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Page 36: Commissioning Checklist
Chillers ULTIMA 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. -
Page 37: 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 water strainer. -
Page 38: Compressor Maintenance
Chillers ULTIMA FREECOOL Maintenance GENERAL MAINTENANCE 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... -
Page 39: Unit Schematic
ULTIMA FREECOOL Chillers Maintenance UNIT SCHEMATIC OPTIONS SINGLE PUMP (a) EXPANSION VESSEL & INJECTION PUMP (f) TWIN HEADED PUMP (b) EXPANSION VESSEL RUN & STANDBY PUMP (c) FREE COOLING COIL PRESSURE RELIEF VALVE 3bar INJECTION PUMP OPTIONA FLUSHING BYPASS LOOP (d) - Page 40 Chillers ULTIMA FREECOOL Notes: Chillers Installation & Maintenance Manual : 903-125 IM E 05/04/A...
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Page 41: Parts Identification
Chillers Parts Identification 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. A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our Spares department on request. - Page 42 Chillers ULTIMA FREECOOL Parts Identification Pump Bus bar Chamber 3 phase Mains Incoming Evaporator Door Interlocking isolator Fan and Motor Assemblies Star Delta Contactors Free Cooling Condensing Coils Closed Transition Connection Compressor Feet/Resilient Pads Power Factor Correction Unloading Solenoid Valves...
- Page 43 ULTIMA FREECOOL Chillers Notes: Chillers Installation & Maintenance Manual : 903-125 IM E 05/04/A...
- Page 44 Chillers ULTIMA FREECOOL Notes: Chillers Installation & Maintenance Manual : 903-125 IM E 05/04/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 903-125 IM E 01/05/04...
- 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...
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