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AIREDALE Ultima Remote Air Cooled Installation, Operating And Maintenance Manual

Air cooled chiller 75kw - 450kw
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INSTALLATION, OPERATING &
MAINTENANCE MANUAL
Ultima Remote Air Cooled
Air Cooled Chiller
75kW - 450kW

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Summary of Contents for AIREDALE Ultima Remote Air Cooled

  • Page 1 INSTALLATION, OPERATING & MAINTENANCE MANUAL Ultima Remote Air Cooled Air Cooled Chiller 75kW - 450kW...
  • 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 our Airedale Service or your local Sales Engineer.

  • Page 3: Table Of Contents

    Chillers ULTIMA REMOTE AIR COOLED Contents GENERAL STATEMENT WARRANTY GENERAL DESCRIPTION Unit Identification Introduction Standard Features Optional Extras – Energy Saving Optional Extras – General INSTALLATION DATA Dimensions Point Loadings, Weights & Centre of Gravity (C of G) Unit Lifting...

  • Page 4: General Statement

    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. Service and maintenance of Airedale equipment should only be carried out CAUTION by Technically trained competent personnel.

  • 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 URAC250DQ INTRODUCTION The Airedale range of Ultima Remote Air Cooled liquid chillers covers the nominal 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 performance while keeping the sound and vibration levels and footprint to an absolute minimum.

  • Page 7: Optional Extras - Energy Saving

    Chillers ULTIMA REMOTE AIR COOLED General Description STANDARD FEATURES Refrigeration Each refrigeration circuit is supplied with the following:  Holding charge of nitrogen  Electronic expansion valve  Liquid line ball valve  Discharge line ball valve  Large capacity filter drier with replaceable cores ...

  • Page 8: Optional Extras - General

    Water Filter  Factory Fitted 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

    Chillers ULTIMA REMOTE AIR COOLED Installation Data DIMENSIONS Water Connections - Victualic Type C of G2 URAC 75 - 200 65mm URAC 225 - 450 80mm 20mm Ø Mounting Holes Refrigeration Mains Electric Connections Isolator (Refer to Mechanical Data) Controls...

  • Page 10: Point Loadings, Weights & Centre Of Gravity (C Of G)

    ULTIMA REMOTE AIR COOLED Chillers Installation Data POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G) Operating Model D Weight C of G1 (mm) C of G2 (mm) URAC75D URAC100D URAC125D URAC150D 1190 URAC175D 1290 URAC200D 1380 URAC225D 1450...

  • Page 11: Unit Lifting

    Chillers ULTIMA REMOTE AIR COOLED 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 lifting eye bolts/lifting lugs provided.  Attach lifting chains to the 4 lifting eye bolts/lifting lugs provided, each chain and eye bolt must be capable of lifting the whole chiller.

  • Page 12: Anti Vibration Mounting - Optional

    ULTIMA REMOTE AIR COOLED Chillers Installation Data ANTI VIBRATION MOUNTING - OPTIONAL COMPONENTS: Locating Screw Retaining Nut & Washer Levelling Screw Levelling Lock Nut Retaining Studs Upper Retaining Nuts Lower Retaining Nuts Spring assembly Pressure Plate Top Plate Bolting-down holes DIMENSIONS: FØ...

  • Page 13: Positioning

    Chillers ULTIMA REMOTE AIR COOLED 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 14: Refrigeration System

    When installation is complete, fill the system with dry nitrogen to the required PED pressure, (Airedale recommends 27/40 bar ). Record the pressure over a period of time. If there is any reduction in pressure, trace the leak and repair before conducting a further pressure test.

  • Page 15: Pipework Installation - Good Practices

    Chillers ULTIMA REMOTE AIR COOLED Installation Data PIPEWORK INSTALLATION - GOOD PRACTICES Oil Traps For long vertical rises in discharge lines, it is essential that oil traps are located every 6m to ensure proper oil movement / entrapment. In addition there should be an oil trap at the exit of the chiller before a vertical riser is applied (see example below).

  • Page 16: Water System

    ULTIMA REMOTE AIR COOLED Chillers Installation Data WATER SYSTEM 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.
  • Page 17 Chillers ULTIMA REMOTE AIR COOLED 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).

  • Page 18: Glycol Data

    ULTIMA REMOTE AIR COOLED Chillers Installation Data GLYCOL DATA 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. Ethylene Glycol Nominal Correction Factors Glycol in System / Freezing Point ºC...

  • Page 19: Electrical Data

    Chillers ULTIMA REMOTE AIR COOLED 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: Electrical Data

    ULTIMA REMOTE AIR COOLED Chillers Installation Data ELECTRICAL DATA URAC75 URAC100 URAC125 URAC150 URAC175 Unit Data Nominal Run Amps Maximum Start Amps Permanent Supply 230V 1PH 50Hz Mains Supply 400V 3PH 50Hz Rec Permanent Fuse Size Rec Mains Fuse Size Max Permanent Incoming Cable mm²...
  • Page 21 Chillers ULTIMA REMOTE AIR COOLED Installation Data ELECTRICAL DATA URAC200 URAC225 UWC240 URAC250 UWC270 Unit Data Nominal Run Amps Maximum Start Amps Permanent Supply 230V 1PH 50Hz Mains Supply 400V 3PH 50Hz Rec Permanent Fuse Size Rec Mains Fuse Size Max Permanent Incoming Cable mm²...
  • Page 22 ULTIMA REMOTE AIR COOLED Chillers Installation Data ELECTRICAL DATA URAC300 URAC330 URAC360 URAC400 URAC450 Unit Data Nominal Run Amps Maximum Start Amps Permanent Supply 230V 1PH 50Hz Mains Supply 400V 3PH 50Hz Rec Permanent Fuse Size Rec Mains Fuse Size Max Permanent Incoming Cable mm²...

  • Page 23: Controls

    ULTIMA REMOTE AIR COOLED - 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 24: Operation

    ULTIMA REMOTE AIR COOLED 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 communication port and network connections.

  • Page 25: 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 : 6259535 IM E 02/2013...

  • Page 26: Viewing Unit Operating Status

    ULTIMA REMOTE AIR COOLED 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...

  • Page 27: Alarms

    Chillers ULTIMA REMOTE AIR COOLED - 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...

  • Page 28: Commissioning Data

    Minimum Leaving Water Temperature °C +6°C Maximum Return Water Temperature °C +20°C Temperatures lower than those stated can be obtained with the addition of glycol. For conditions outside those quoted, please refer to Airedale. MECHANICAL DATA Oil & Refrigerant Charges URAC75 URAC100...

  • Page 29: Waterside Pressure Drops

    Chillers ULTIMA REMOTE AIR COOLED Commissioning Data WATERSIDE PRESSURE DROPS CAUTION Constant water flow MUST be maintained. Variable water volume is NOT recommended. UWC75 – UWC250 URAC75-100 (Except UWC240) URAC125 URA175 URAC150 URAC200 URAC250 URAC225 WATERFLOW (l/s) URAC240 – URAC450...

  • Page 30: Operational Sequence

    ULTIMA REMOTE AIR COOLED Chillers Commissioning Data OPERATIONAL SEQUENCE Refrigerant Charge Check for the presence of a refrigerant charge in the condenser side. Crankcase Heater (If The mains supply to the crankcase (oil) heater should be switched on at least 8 hours prior to compressor starting to avoid refrigerant migration.

  • Page 31: Commissioning Procedure

    Commissioning Procedure GENERAL To be read in conjunction with the commissioning sheets provided, items highlighted should be recorded. Please ensure all documents have been completed correctly and return to Airedale CAUTION Service immediately to validate warranty. PRE COMMISSIONING CHECKLIST ALL work MUST be carried out by Technically Trained competent personnel.
  • Page 32 ULTIMA REMOTE AIR COOLED 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 ...

  • Page 33: Commissioning Checklist

    Chillers ULTIMA REMOTE AIR COOLED 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 34: 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 35: Compressor Maintenance

    Chillers ULTIMA REMOTE AIR COOLED 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.

  • Page 36: 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 37 Chillers ULTIMA REMOTE AIR COOLED Notes: Chillers Installation & Maintenance : 6259535 IM E 02/2013...
  • Page 38 ULTIMA REMOTE AIR COOLED Chillers Notes: Chillers Installation & Maintenance : 6259535 IM E 02/2013...
  • Page 39 Chillers ULTIMA REMOTE AIR COOLED Notes: Chillers Installation & Maintenance : 6259535 IM E 02/2013...
  • Page 40 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 PART NO:...

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