AIREDALE TurboChill TCC1 Series, Installation Manual

Page 1: ...COVER R134a Air Cooled Chiller 500 kW 1100 kW TurboChill INSTALLATION MANUAL ...

Page 2: ...iant and incorporates a full parts and labour warranty for the first 12 months ChillerGuard packages can be tailored to include specific call out times and extended cover to meet your business needs CHILLERGUARD SERVICE PLAN UK Mainland For customers outside the UK our international distributors trained by Airedale would be pleased to offer service on Airedale units SPARES A spares list for 1 3 an...

Page 3: ...al Data 10 Installation Data 12 Weights Point Loadings Centre of Gravity C of G 12 Unit Lifting 14 Anti Vibration Mounting Optional 15 Anti Vibration Mounting Optional Allocation 16 Positioning 18 Airflow Maintenance Clearances 18 Water System 19 Grooved Clamped Type Connection 19 Standard Recommended Installation 20 Glycol Data 22 Waterside Pressure Drop kPa 23 Electrical 24 Electrical Data 25 In...

Page 4: ...nce work on this equipment should be undertaken by competent and trained personnel in accordance with local relevant standards and codes of practice 5 The refrigerant used in this range of products is classified under the COSHH regulations as an irritant with set Occupational Exposure Levels OEL for consideration if this plant is installed in confined or poorly ventilated areas CAUTION 6 A full ha...

Page 5: ...icial order on Airedale for the replacement part including site labour if required Airedale will acknowledge this order with detailed prices for components travel and labour rates Should warranty be accepted following inspection of the faulty component a credit note will be issued against the invoice raised in line with the acknowledgement Should warranty be refused the invoice raised against the ...

Page 6: ...olution for each application by offering maximum flexibility and matching customer requirements in terms of Capacity EER ESEER Sound Levels Quiet TTC 95 and Super Quiet 70 Footprint Pressure Drop Commercial considerations REFRIGERANTS The range has been designed and optimised for operation with ozone benign R134a refrigerant Airedale certify that the equipment detailed in this manual conforms with...

Page 7: ...frigeration Circuit Acoustically Lined compressor enclosure Electronic Expansion Valve EEV Intelligent Head Pressure Control Electronically Commutated EC Sickle Bladed fans with Long Bellmouth Pressure Relief Valves Per Compressor Grooved water connections counter pipe assembly Features Connections for External Trace Heating 230V 500W available Turbocor centrifugal compressor supplied with as stan...

Page 8: ...atherproof electrical power and controls panel is situated at the end of the unit and contains Individual mains power isolator for each compressor Separate door locking electrical isolation for fan mains compartment Dedicated bus bar chamber for connection of incoming 3 phase and earth mains power supply refer to Interconnecting Wiring on page 25 Emergency Stop fitted to compressor mains compartme...

Page 9: ...nication wiring Airedale Service can arrange sequence setup on request UK Mainland Corrosion Resistant Coated Coils Coil Guards Discharge Air Plenum Condenser Fan Extended Discharge Air Plenum Condenser Fan Maintainable Dual Pressure Relief Valve R134a Leak Detection System Evaporator Differential Pressure Sensor Remote Setpoint Adjust Factory Fitted BMS Interface Card Chillerguard Maintenance 1 F...

Page 10: ...ensional Data IMPORTANT The following information is for general guidance please refer to the certified drawings provided for installation M L C 510 2100 50 50 D E H F J 7 9 9 G K A 1 B 90 90 5 2 3 4 746 6 6 8 11 10 3100 2600 9 Grooved Water Connections DN200 PN16 219 1mm ...

Page 11: ... 1400 2325 600 3305 3210 TCC1xD216Xxx mm 2600 2200 9100 500 2875 1400 1400 2325 600 3305 3210 TCC1xB118Xxx mm 2600 2200 10100 500 3000 1400 1400 3000 800 3730 2360 TCC1xB218Xxx mm 2600 2200 10100 500 3000 1400 1400 3000 800 3730 2360 TCC1xC118Xxx mm 2600 2200 10100 500 3000 1400 1400 3000 800 3455 2910 TCC1xD118Xxx mm 2600 2200 10100 500 3000 1400 1400 3000 800 3305 3210 TCC1xD218Xxx mm 2600 2200 ...

Page 12: ... 755 725 755 525 1070 4600 TTC12B220Xxx 7590 715 465 770 725 770 465 715 465 695 660 695 465 1070 4970 TTC12C110Xxx 6010 835 825 810 640 815 745 760 585 1060 2710 TTC12C112Xxx 6380 670 720 705 785 420 670 645 640 710 420 1060 3240 TTC12C114Xxx 6700 700 785 735 785 450 700 710 675 710 450 1070 3650 TTC12C116Xxx 7020 735 800 770 830 485 735 740 705 750 485 1070 4400 TTC12C118Xxx 7340 765 845 800 845...

Page 13: ... 890 835 870 510 790 800 755 790 510 1060 4350 TTC13D218Xxx 7910 885 925 865 900 540 820 830 785 820 540 1060 4550 TTC13D220Xxx 8240 725 615 835 780 835 475 725 525 760 715 760 475 1060 4950 TTC14B112Xxx 7430 870 790 790 845 620 790 710 710 765 540 1040 3250 TTC14B114Xxx 7830 910 860 830 860 660 830 775 750 775 580 1050 3680 TTC14B116Xxx 8170 885 925 865 890 725 845 820 780 810 625 1050 4480 TTC14...

Page 14: ... Lifting eye bolt lug dimension 40mm Do not use 1 chain between 2 lifting points to avoid load shift IMPORTANT Only use lifting points provided Chains slings MUST NOT interfere with the casing or fan assembly to avoid damage Lift the unit slowly and evenly If the unit is dropped it should immediately be checked for damage and reported to Airedale LIFTING DIMENSIONS 8 10 Fan A1 C B 2300 12 20 Fan A...

Page 15: ...access to mount fixing holes in the unit base 4 Lock the upper retaining nuts 6a to the underside of the top plate 9 before a load is applied 5 Remove retaining nut and washer 2 lower the unit onto the mounts and replace retaining nut and washer Installation 6 Beginning with the mount with the largest deflection adjust the height of each mount using the levelling screw 3 CAUTION Mountings must be ...

Page 16: ...GE PLAIN BLACK ORANGE BLACK ORANGE ORANGE ORANGE BLACK TTC12C110Xxx PLAIN PLAIN PLAIN ORANGE PLAIN PLAIN PLAIN ORANGE TTC12C112Xxx ORANGE ORANGE ORANGE PLAIN RED ORANGE ORANGE ORANGE ORANGE RED TTC12C114Xxx ORANGE PLAIN PLAIN PLAIN BLACK ORANGE ORANGE ORANGE ORANGE BLACK TTC12C116Xxx PLAIN PLAIN PLAIN PLAIN BLACK PLAIN PLAIN ORANGE PLAIN BLACK TTC12C118Xxx PLAIN PLAIN PLAIN PLAIN BLACK PLAIN PLAIN...

Page 17: ... PLAIN PLAIN BLACK PLAIN PLAIN PLAIN PLAIN BLACK TTC13D220Xxx ORANGE ORANGE PLAIN PLAIN PLAIN BLACK ORANGE BLACK PLAIN ORANGE PLAIN BLACK TTC14B112Xxx PLAIN PLAIN PLAIN PLAIN ORANGE PLAIN ORANGE ORANGE PLAIN BLACK TTC14B114Xxx PLAIN PLAIN PLAIN PLAIN ORANGE PLAIN PLAIN PLAIN PLAIN BLACK TTC14B116Xxx PLAIN PLAIN PLAIN PLAIN ORANGE PLAIN PLAIN PLAIN PLAIN ORANGE TTC14B118Xxx YELLOW YELLOW PLAIN YELL...

Page 18: ... readily accessible Where multiple units are installed due care should be taken to avoid the discharge air from each unit adversely affecting other units in the vicinity Within a side enclosed installation the fan MUST be higher than the enclosing structure Increase airflow and maintenance clearances for side enclosed or multiple unit applications Ensure there are no obstructions directly above th...

Page 19: ...nections are NOT designed to support external pipework pipework MUST be supported separately 1 Place Grooved Ends Together 2 Locate Rubber Gasket Note that an expansion gap of 5mm is shown here The gasket should be checked for compatability and damage prior to installation A thin coat of sealing lubricant should be applied to both the inside and outside mating surfaces Slip the gasket fully onto o...

Page 20: ...the flow proving device is critical if the chiller warranty is to be valid Following components are fitted within the chiller unit as standard Temperature Sensors Drain Point Auto Air Vent WATER SYSTEM 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 readi...

Page 21: ...m can safely be operating at a maximum of 10bar 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 Pressure Testing W...

Page 22: ...Example At 100 Water Output 800 kW Compressor Input 250 5 kW Flow Rate 38 2 Pressure Drop 37 5 kPa Ambient 35 C Inlet Fluid Temp 7 C Outlet Fluid Temp 12 C 5 C ΔT To 20 Ethylene Glycol 100 Water Multiplier Corrected Figures Output kW 800 0 x 0 97 776 0 kW Compressor Input kW 250 5 x 0 98 245 5 kW Water Flow l s 38 2 x 1 02 38 9 l s Pressure Drop kPa 37 5 x 1 20 45 0 kPa Waste glycol needs to be ha...

Page 23: ...l design water flow MUST be maintained at all times Variable water volume is NOT recommended and will invalidate warranty Refer to the unit nomenclature to identify the Evaporator Code TTC1x XX xxXxx 140 130 120 110 100 90 80 70 60 50 40 30 20 Waterside Pressure Drop kPa 10 0 15 20 25 30 35 40 45 50 55 60 65 70 Waterflow l s ...

Page 24: ...ltage interlock and protection cabling for a maximum voltage drop of 2V General Avoid large voltage drops on cable runs particularly low voltage wiring CAUTION The Emergency Stop MUST NOT be used to stop the chiller other than in the event of an emergency A fused and isolated electrical supply of the appropriate phase frequency and voltage should be installed Wires should be capable of carrying th...

Page 25: ...85 Nominal Run Amps 1 A 135 Start Amps A 2 Type Of Start Digital Electronic Soft Start 1 Based on Full Load Condition 35 C Ambient INTERCONNECTING WIRING L1 Í L2 Í L3 Í E Í Mains incoming supply 400V 3PH 50Hz L4 Í N1 Í E Í Separate Permanent Supply 230V 1PH 50Hz 11 Î External Trace Heating Connections N Î 230V 500W max 502 Î 507 Í 1 Remote Pump Interlock 24VAC 502 Î 505 Í 1 Evaporator Pump Water F...

Page 26: ...TURBOCHILL Chillers Chillers 26 Installation Manual 6703052 05 2008 Notes ...

Page 27: ...Chillers TURBOCHILL Chillers Installation Manual 6703052 05 2008 27 Notes ...

Page 28: ... 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 LITERATURE ORDER CODE PART NO ISSUE 6703052 IM E 05 2008 ...