COVER Ultima Compact FreeCool Free Cooling Chiller 75 kW - 450 kW R407C INSTALLATION & MAINTENANCE
ULTIMA COMPACT FREECOOL Chillers AB OUT AIR ED AL E About Airedale Products & Customer Services WARRANTY All AIAC products or parts (non consumable) supplied for installation within the UK mainland and commissioned by an AIAC 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.
Chillers ULTIMA COMPACT FREECOOL CONTENT S Contents General Statement .................................................................................................................. 4 Warranty .................................................................................................................................. 5 General Description ............................................................................................................... 6 Unit Identification ..........................
ULTIMA COMPACT FREECOOL Chillers General Statement 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.
Chillers ULTIMA COMPACT FREECOOL Warranty GENERAL To be read in conjunction with Airedale International Air Conditioning Ltd standard Conditions of Sale and any related quotation. The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty for a period of 12 months from the date of commissioning or 18 months from the date of despatch, which ever is the sooner. Commissioning must be carried out by Airedale or an approved Airedale company.
ULTIMA COMPACT FREECOOL Chillers General Description UNIT IDENTIFICATION INTRODUCTION ULTIMA COMPACT FREE COOLING CHILLER UCFC Ultima Compact FreeCool 75 - 450 Model Size (Expressed as Nominal Cooling in kW) D- Double Circuit - Standard Chiller DQ- Double Circuit - Quiet Chiller DSQ- Double Circuit - Super Quiet Chiller 2 - 16 Number of Fans /1 or /2 Single or Double Row of Fans Example UCFC75DQ-2/1 The Airedale range of Ultima Compact FreeCool air cooled liquid chillers covers the cooli
Chillers ULTIMA COMPACT FREECOOL General Description STANDARD FEATURES Standard Chiller -D 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 Electronic Expansion Valve (EEV) 3 way modulating valve to c
ULTIMA COMPACT FREECOOL Chillers General Description OPTIONAL EXTRAS – GENERAL Loose Item Factory Fitted Extended Discharge Air Plenum - Condenser Fan Corrosion Resistant Coated Coils Coil Guards Power Factor Correction BMS Interface Card Single Pressure Relief Valve (UCFC75 - 450) Dual Pressure Relief Valve (UCFC180 - 450) R407C Leak Detection System Electronic Soft Start Flushing Bypass Kit In Line Pump Packages including Flushing Bypass Kit Evaporator Differen
Chillers ULTIMA COMPACT FREECOOL Installation Data DIMENSIONS The following information is for general guidance; refer to the certified drawings provided for installation.
ULTIMA COMPACT FREECOOL Chillers Installation Data DIMENSIONS IMPORTANT The following information is for general guidance; refer to the certified drawings provided for installation.
Chillers ULTIMA COMPACT FREECOOL Installation Data WEIGHTS, POINT LOADINGS & CENTRE OF GRAVITY (C OF G) Single Row Fans - /1 UCFC75 - UCFC150 1 2 Model D UCFC75D-2/1 UCFC100D-2/1 UCFC125D-3/1 UCFC150D-3/1 Model DQ UCFC75DQ-2/1 UCFC100DQ-3/1 UCFC125DQ-3/1 UCFC150DQ-4/1 Model DSQ UCFC75DSQ-2/1 UCFC100DSQ-3/1 UCFC125DSQ-4/1 UCFC150DSQ-4/1 (1) (2) (3) = C of G P1 P3 P5 P2 P4 P6 kg kg kg kg P1 365 380 405 410 P2 365 380 385 410 P3 (1) (1) 255 255 P4 (1) (1) 245 255 P5 295 305 240 250 P6 295
ULTIMA COMPACT FREECOOL Chillers Installation Data WEIGHTS, POINT LOADINGS & CENTRE OF GRAVITY (C OF G) Double Row Fans - /2 UCFC160 - UCFC450 1 2 Model D UCFC160D-6/2 UCFC180D-6/2 UCFC200D-6/2 UCFC225D-6/2 UCFC250D-8/2 UCFC275D-8/2 UCFC300D-8/2 UCFC330D-10/2 UCFC360D-10/2 UCFC400D-12/2 UCFC450D-12/2 Model DQ UCFC160DQ-6/2 UCFC180DQ-6/2 UCFC200DQ-6/2 UCFC225DQ-8/2 UCFC250DQ-8/2 UCFC275DQ-10/2 UCFC300DQ-10/2 UCFC330DQ-12/2 UCFC360DQ-12/2 UCFC400DQ-14/2 UCFC450DQ-14/2 Model DSQ UCFC160DSQ-8/2 UCFC180DS
Chillers ULTIMA COMPACT FREECOOL 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 (provided by others) with the holes/lugs provided Attach individual lifting chains to each of the lifting eye bolts/lifting lugs provided; each individual chain must be capable of lifting the whole unit Do not use 1 chain between 2 lifting points to avoid load
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.
Chillers ULTIMA COMPACT FREECOOL Installation Data POSITIONING CAUTION 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 antivibration mounts and flexible water connections Observe airflow and maintenance clearances Pipework and electrical connections are readily
ULTIMA COMPACT FREECOOL Chillers Installation Data WATER SYSTEM CAUTION 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 referre
Chillers ULTIMA COMPACT FREECOOL Installation Data WATER SYSTEM Component Recommended Requirements 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 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 In multiple chiller installations, 1 commissioning valv
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 c
Chillers ULTIMA COMPACT FREECOOL Installation Data WATER SYSTEM – GENERAL SPECIFICATION Connections Water Inlet / Outlet Water Drain / Bleed in Water System Min. System Water Volume (1) l Max. System Press Bar OPTIONAL EXTRAS - ALL MODELS Water Pump (2) & (3) Single Head or Run/Standby Nom External Head - Standard kPa Nom External Head - Larger kPa Twin Head Nom External Head - Standard kPa Nom External Head - Larger kPa Connections Water Inlet / Outlet Water Drain / Bleed in Water System Min.
ULTIMA COMPACT FREECOOL Chillers Installation 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. GLYCOL DATA CAUTION All free cooling units should use minimum 20% glycol concentration. Ethylene Glycol Nominal Correction Factors Glycol in System / Freezing Point ºC Cooling Duty Input Power Catalogue Data x by: Water Flow Pressure Drop 20% / -9°C 1.00 1.00 1.00 1.00 30% / -15°C 0.98 0.98 1.09 1.
Chillers ULTIMA COMPACT FREECOOL Installation Data ELECTRICAL General CAUTION 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 A fused and is
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 UCFC 75 - 450 L1 L2 L3 E Mains incoming supply 400V / 3PH / 50Hz L4 N1 E Separate Permanent Supply 230V / 1PH +N / 50Hz 2 N External Trace Heater Connections 230V/500W max.
Chillers ULTIMA COMPACT FREECOOL Installation Data The following information is for general guidance; refer to the certified drawings provided for installation.
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 2 1.15 2.10 0.68 3 1.15 2.10 0.68 3 1.15 2.10 0.68 4 1.15 2.10 0.68 6 1.15 2.10 0.70 UCFC75DSQ-2/1 UCFC100DSQ-3/1 UCFC125DSQ-4/1 UCFC150DSQ-4/1 UCFC160DSQ-8/2 2 0.83 1.50 0.32 3 0.83 1.50 0.32 4 0.83 1.50 0.32 4 0.83 1.50 0.32 8 0.
Chillers ULTIMA COMPACT FREECOOL Installation Data The following information is for general guidance; refer to the certified drawings provided for installation.
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 6 1.15 2.10 0.70 6 1.15 2.10 0.70 8 1.15 2.10 0.70 8 1.15 2.10 0.70 10 1.15 2.10 0.70 UCFC180DSQ-8/2 UCFC200DSQ-8/2 UCFC225DSQ-10/2 UCFC250DSQ-10/2 UCFC275DSQ-12/2 8 0.83 1.50 0.32 8 0.83 1.50 0.32 10 0.83 1.50 0.32 10 0.83 1.50 0.
Chillers ULTIMA COMPACT FREECOOL Installation Data The following information is for general guidance; refer to the certified drawings provided for installation.
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 10 1.15 2.10 0.70 12 1.15 2.10 0.70 12 1.15 2.10 0.70 14 1.15 2.10 0.70 14 1.15 2.10 0.70 UCFC300DSQ-12/2 UCFC330DSQ-16/2 UCFC360DSQ-16/2 UCFC400DSQ-16/2 UCFC450DSQ-16/2 12 0.83 1.50 0.32 16 0.83 1.50 0.32 16 0.83 1.50 0.
Chillers ULTIMA COMPACT FREECOOL Controls TEMPERATURE CONTROL Airedale recognises that all chiller applications are different but fall mainly into 2 application categories; Variable Supply Temperature and Constant Supply Temperature. The onboard microprocessor has the capability of satisfying either control requirement as illustrated below.
ULTIMA COMPACT FREECOOL Chillers Controls GENERAL DESCRIPTION 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. 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.
Chillers ULTIMA COMPACT FREECOOL Controls OPERATION Standard Operating Page The Operating Page will appear and remain present following start up of the controller as illustrated: The following Menus can be accessed from the Operating Page, it is recommended that the display is always returned to the Operating Page by using the Password Protection Esc key To guard against unauthorised adjustments, a password is required to gain access to certain menus as defined below.
ULTIMA COMPACT FREECOOL Chillers Controls VIEWING UNIT OPERATING STATUS Status Menu Allows access to view operating status of Digital and Analogue Inputs and Outputs.
Chillers ULTIMA COMPACT FREECOOL Controls ALARMS The controller logs and allows viewing of the last 100 conditions recorded in descending chronological order. 1 2 3 Alarm Handling 1 A Red LED behind the Alarm alarms, simply press the 2 1 2 5 3 4 5 Alarm Label Alarm Status: Alarm Active or Alarm Cleared Time of Alarm Alarm Log Date of Alarm key will light in the event of an alarm. To view the key and the keys to scroll through.
ULTIMA COMPACT FREECOOL Chillers Commissioning Data OPERATING LIMITS Unit With Electronic Fan Speed HP Control (-20°C) Minimum Ambient air DB °C -20°C Refer to Technical Manual - Performance Data - Capacity Data Maximum Ambient air DB °C Minimum leaving water temperature °C +6C Maximum return water temperature °C +20°C 1 2 Temperatures lower than those stated can be obtained with additional glycol. For conditions outside those quoted, please refer to Airedale.
Chillers ULTIMA COMPACT FREECOOL Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) CAUTION Full design water flow MUST be maintained at all times. Variable water volume is NOT recommended and will invalidate warranty. Use the formula below to calculate the External Head Available: - Total Pump Head Available Chiller Pressure Drop = External Head Available = 153 kPa Example: UCFC125D-3/1 6.
ULTIMA COMPACT FREECOOL Chillers Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) CAUTION Full design water flow MUST be maintained at all times. Variable water volume is NOT recommended and will invalidate warranty.
Chillers ULTIMA COMPACT FREECOOL Commissioning Data WATERSIDE PRESSURE DROPS (20% Ethylene Glycol Concentration) CAUTION Full design water flow MUST be maintained at all times. Variable water volume is NOT recommended and will invalidate warranty.
ULTIMA COMPACT FREECOOL Chillers Commissioning Data PUMP PACKAGES 325 Total Pump Head Available (kPa) Single Head Pump or Run/Standby 6 300 275 250 5 225 200 2 6 10 14 18 22 26 30 34 Waterflow (l/s) Total Pump Head Available (kPa) 450 400 4 350 300 3 250 200 1 2 3 4 5 6 7 8 9 10 11 12 9 10 11 12 Waterflow (l/s) Total Pump Head Available (kPa) 350 2 300 1 250 200 150 100 1 2 3 4 5 6 7 8 Waterflow (l/s) UCFC75 UCFC100 UCFC125 UCFC150 UCFC160 - UCFC450 3
Chillers ULTIMA COMPACT FREECOOL Commissioning Data PUMP PACKAGES Twin Head Pump Total Pump Head Available (kPa) 350 6 300 250 5 200 150 0 5 10 15 20 25 30 35 Waterflow (l/s) Total Pump Head Available (kPa) 350 4 300 3 2 250 1 200 150 1 2 3 4 5 6 7 8 9 Waterflow (l/s) UCFC75 UCFC100 UCFC125 UCFC150 UCFC160 - UCFC450 Curve Twin Head Pump Standard 1 1 1 2 5 Larger 2 3 3 4 6 Chillers Installation & Maintenance : 6259584 02/2013 39
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.
Chillers ULTIMA COMPACT FREECOOL Commissioning Procedure To be read in conjunction with the commissioning sheets provided, items highlighted should be recorded. GENERAL CAUTION Please ensure all documents have been completed correctly and return to Airedale Technical Support immediately to validate warranty. PRE COMMISSIONING CHECKLIST CAUTION ALL work MUST be carried out by technically trained competent personnel.
ULTIMA COMPACT FREECOOL Chillers Commissioning Procedure PRE COMMISSIONING CHECKLIST CAUTION 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 to Alarm Handling, on page 33 Prior to the chiller compressors being allowed to start, the Water Flow Fail and Pump Interlock features MUST both be proven to work correctly.
Chillers ULTIMA COMPACT FREECOOL Commissioning Procedure COMMISSIONING CHECKLIST 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.
ULTIMA COMPACT FREECOOL Chillers Maintenance CAUTION ALL work MUST be carried out by technically trained competent personnel. WARNING The equipment contains live electrical and moving parts, ISOLATE prior to maintenance or repair work. WARNING Power Factor Correction - Optional Extra Allow Discharge time and short circuit the capacitor before handling! This applies to any flying leads directly attached to the capacitor terminals.
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 set to activate at 4.0ºC. Remember to re-cap the Schrader connections! 12 MONTHS ACTION NOTES Repeat 6 month checks plus the following: SYSTEM Check safety devices cut out the compressor at the correct settings. REFRIGERATION Check glycol concentration if appropriate. Adjust as necessary.
Chillers Discharge Line Ball Valve Discharge Schrader Connection HP Switch Head Pressure Control Solenoid Valve Set (behind panel) Compressor Electrical Terminal Box Oil Level Sight Glass Compressor Oil Heater Liquid Line Filter Drier Electronic Expansion Valve Liquid Line Sight Glass Liquid Line Discharge Thermostat Switch Low Pressure Switch Suction Pressure Transducer Suction Port Oil Drain Point Compressor Feet/Resilient Mounts Water Inlet Sensor Evaporator Isolating valves for maintenance Free Cooling
28 33 4 18 18b 39 40 Chillers Installation & Maintenance : 6259584 02/2013 38 47 ULTIMA COMPACT FREECOOL 36 Chillers 24 Parts Identification 29 15 16 22 23 18c 19/19a17 32 4 34 25 26 27 6 5 3a 7 8 9,10 11 37 21 18a 20 35 3a 4 12,13,14 30 31 1,2,3 3a
W here to Fin d U s Head Office: Airedale International Air Conditioning Ltd Leeds Road Rawdon Leeds LS19 6JY United Kingdom Tel: Fax: e-mail: website: LITER ATUR E ORDER COD E PART NO: 6259584 (IM E) A B V1.2.0 DATE 09/2008 01/2010 02/2013 +44 (0) 113 239 1000 +44 (0) 113 250 7219 enquiries@airedale.com www.airedale.
