AIREDALE UFC200D-8, Installation Operating & Maintenance Manual

Page 1: ...INSTALLATION OPERATING MAINTENANCE MANUAL Ultima FreeCool Free Cooling Chiller 200 750 kW ...

Page 2: ...ternational Air Conditioning Ltd SPARES 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 TRAINING As well as our comprehensive range of products Airedale offers a modular range of Refrigeration and Air Conditioning Training courses for further information please contact Airedale AIAC Ltd endeavours to ensure that the inf...

Page 3: ...ting 13 Positioning 14 Water System Data 15 Standard Recommended Installation 15 Glycol Data 17 Electrical Data 18 Interconnecting Wiring 19 CONTROLS 23 Control Scheme Features 23 Operation 24 Setting Up 25 Viewing Unit Operating Status 26 Alarms 27 COMMISSIONING DATA 28 General Data 28 Mechanical Data 28 Waterside Pressure Drops 29 Electrical Data 31 COMMISSIONING PROCEDURE 33 Pre Commissioning C...

Page 4: ...petent personnel CAUTION 2 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 3 Also ensure that there are no other power feeds to the unit such as fire alarm circuits BMS circuits etc 4 Electrical installation commissioning and maintenance work on this equipment ...

Page 5: ...ale 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 acknowledgement beco...

Page 6: ...e PED 97 23 EC To comply with these directives appropriate national harmonised standards have been applied These are listed on the Declaration of Conformity supplied with each product REFRIGERANTS The range has been designed and optimised for operation with the ozone benign R407C refrigerant STANDARD FEATURES The Standard Ultima FreeCool chiller comes complete with Microprocessor Controlled Conden...

Page 7: ... maintenance Pressure transducers across evaporator to monitor water pressure drop Water Glycol Inlet water filter 1 16 mesh Controls microprocessor controlled providing 6 8 stages of mechanical cooling Depending on model size modulating condenser fans and valve to offer 0 100 free cooling when ambients permit The controller incorporates full Building Management System capabilities full details ca...

Page 8: ...hangeover current peaks when the compressor motor is switched over from Star to Delta Refer to the Commissioning Data section for a detailed description OPTIONAL EXTRAS GENERAL Anti Vibration Mounts Condenser Fan Discharge Air Plenum Instructions supplied with item Loose Item De aeration Epoxy Coated Condenser Coils Coil Guards Closed Transition Star Delta Compressor Start Refer to Compressor Star...

Page 9: ... 1450 1550 485 UFC450D 12 mm 6645 760 1800 1800 1800 485 UFC500D 12 mm 6645 760 1800 1800 1800 485 UFC575D 14 mm 7670 610 1100 1725 1920 1830 485 UFC650D 14 mm 7670 610 1100 1725 1920 1830 485 UFC700D 18 mm 9370 585 1100 2400 2400 2375 460 UFC750D 18 mm 9370 585 1100 2400 2400 2375 460 DQ Models A B C D E F G UFC200DQ 8 mm 4945 760 1850 1850 485 UFC225DQ 8 mm 4945 760 1850 1850 485 UFC250DQ 8 mm 4...

Page 10: ...920 1830 485 UFC400DSQ 14 mm 7670 610 1100 1725 1920 1830 485 UFC450DSQ 16 mm 8520 610 1100 2375 2120 1830 485 UFC500DSQ 16 mm 8520 610 1100 2375 2120 1830 485 UFC575DSQ 18 mm 9370 585 1100 2400 2400 2375 460 UFC650DSQ 18 mm 9370 585 1100 2400 2400 2375 460 UFC700DSQ 20 mm 10220 585 1100 2400 2800 2825 460 UFC750DSQ 20 mm 10220 585 1100 2400 2800 2825 460 CAUTION 8 Lifting points on 20 fan models ...

Page 11: ... UFC400D 10 UFC450D 12 UFC500D 12 UFC575D 14 Weight Machine kg 4130 4170 4870 5000 5490 Weight Operating kg 4890 4920 5860 5980 6570 QUIET DQ UFC350DQ 12 UFC400DQ 12 UFC450DQ 14 UFC500DQ 14 UFC575DQ 16 Weight Machine kg 4410 4440 5170 5290 5760 Weight Operating kg 5300 5320 6290 6390 6970 SUPER QUIET DSQ UFC350DSQ 14 UFC400DSQ 14 UFC450DSQ 16 UFC500DSQ 16 UFC575DSQ 18 Weight Machine kg 4820 4850 5...

Page 12: ...IFTING If the unit is dropped it should immediately be checked for damage and reported to Airedale Service CAUTION Only use lifting points provided The unit should be lifted from the base and where possible with all packing and protection in position If any other type of slinging is used due care should be taken to ensure that the slings do not crush the casework or coil 8 18 Fans J 2300 H K L 20 ...

Page 13: ...50 4 SPRING 180 130 225 186 20 16 B A C D E F E 1 Unloaded dimension 2 Refer to relevant Loose Parts Instructions sheet for positioning of each mount INSTALLATION 1 Locate and secure mount using bolting down holes 10 in base plate 2 Ensure mounts are located in line with the unit base 3 If applicable remove compressor enclosure covers to allow access to mount fixing holes in the unit base 4 Lock t...

Page 14: ...LS Type Optional 6 Adjust and lock nuts on transit bolts such that a small 3 5mm gap is left between washer and grommet Refer diagram below Mountings must be adjusted incrementally in turn Do not adjust 1 mount at a time as this may overload and damage springs CAUTION Do not connect any services until all anti vibration mounts have been fully adjusted 20 20 20 20 100 14 Ø BASE PLATE TOP PLATE 100 ...

Page 15: ...aintenance clearances Pipework and electrical connections are 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 Figures in brackets indicate airflow and maintenance clearances for side enclosed...

Page 16: ...g to be carried out correctly are A water flow commissioning valve set fitted to the system In multiple chiller installations 1 commissioning valve set is required per chiller Air vents are to be installed at all high points and where air is likely to be trapped at intermediate points Drain points are to be installed at all low points in the system and in particular adjacent to the unit for mainte...

Page 17: ... at all high points Once the system has been completely vented all vents should be closed 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 Model UFC200D 8 UFC225D 8 UFC250D 8 UFC275D 8 UFC300D 8 Connections Water Inlet O...

Page 18: ...efer to Technical Manual x 0 98 475 2 kW Input kW 194 0 refer to Technical Manual x 0 98 190 1 kW Flow l s 24 2 calculated 4 x T kW Cooling DX x 1 02 24 7 l s Pressure Drop kPa 122 0 refer to Waterside Pressure Drops x 1 15 30 Ethylene Glycol 140 3 kPa Waste glycol needs to be handled responsibly recycled or turned over to professional personnel for correct disposal Most anti freeze manufacturers ...

Page 19: ...able runs particularly low voltage wiring Once the connecting pipework is complete the electrical supply can be connected by routing the cable through the appropriate casing hole and connecting the cables refer to the Wiring Diagram supplied with each unit CAUTION A separately fused locally isolated permanent single phase and neutral supply MUST BE FITTED for the compressor sump heater evaporator ...

Page 20: ...e Alarm N O 575 Volt Free Alarm N C 576 Circuit 2 Volt Free Common Alarm 577 Volt Free Alarm N O UFC200 UFC750 578 Volt Free Alarm N C CAUTION 1 MUST be directly wired to the chiller to validate warranty With Pumps L1 Mains incoming supply 400V 3PH 50Hz L2 L3 E L4 Separate Permanent Supply 230V 1PH 50Hz N1 E 11 External Trace Heating Connections N 240V 500W max 502 Pump s Remote On Off 24VAC 506 5...

Page 21: ... 208 208 254 208 254 254 234 254 234 234 Type Of Start Star Delta QUIET DQ UFC200DQ 8 UFC225DQ 8 UFC250DQ 8 UFC275DQ 8 UFC300DQ 10 All data as above except Condenser Fan Per Fan Full Load Amps A 1 75 1 75 1 75 1 75 1 75 Locked Rotor Amps A 6 20 6 20 6 20 6 20 6 20 Motor Rating kW 0 98 0 98 0 98 0 98 0 98 SUPER QUIET DSQ UFC200DSQ 8 UFC225DSQ 8 UFC250DSQ 8 UFC275DSQ 10 UFC300DSQ 10 All data as abov...

Page 22: ...5 234 325 325 394 325 394 394 469 394 Type Of Start Star Delta QUIET DQ UFC350DQ 12 UFC400DQ 12 UFC450DQ 14 UFC500DQ 14 UFC575DQ 16 All data as above except Condenser Fan Per Fan Full Load Amps A 1 75 1 75 1 75 1 75 1 75 Locked Rotor Amps A 6 20 6 20 6 20 6 20 6 20 Motor Rating kW 0 98 0 98 0 98 0 98 0 98 SUPER QUIET DSQ UFC350DSQ 14 UFC400DSQ 14 UFC450DSQ 16 UFC500DSQ 16 UFC575DSQ 18 All data as ...

Page 23: ...er Rating W 150 150 150 Start Amps 3 469 538 469 538 Type Of Start Star Delta QUIET DQ UFC650DQ 16 UFC700DQ 18 UFC750DQ 18 All data as above except Condenser Fan Per Fan Full Load Amps A 1 75 1 75 1 75 Locked Rotor Amps A 6 20 6 20 6 20 Motor Rating kW 0 98 0 98 0 98 SUPER QUIET DSQ UFC650DSQ 18 UFC700DSQ 20 UFC750DSQ 20 All data as above except Condenser Fan Per Fan Full Load Amps A 1 15 1 15 1 1...

Page 24: ...ng Stage Sequence 1 2 3 4 5 6 Return Water Temperature Supply Water Temperature Compressor Off Mean Value Constant Supply Temperature Control 6 7 8 9 10 11 12 13 14 0 2 4 6 8 10 12 14 Supply Water Temperature Return Water Temperature Chiller Capacity Cooling Stage Sequence 20 40 55 70 85 100 1 2 3 4 5 6 WATER TEMPERATURE C Factory set to Variable Supply Temperature Control unless otherwise stated ...

Page 25: ...sed for Viewing Unit Operating Status and Adjusting Customer Control Settings by allowing the operator access to a series of Menus sub menus Viewing information is unrestricted however set up and adjustment requires password entry refer to Password Protection 1 Initially use the Prg key to access Menus the symbol will appear top right and the first menu will appear in CAPITALS these indicators sho...

Page 26: ...Default 4648 Setpoint Allows setpoint adjustment includes supply temperature setpoint and unit temperature differential Default 4648 Status Displays current status on digital and analogue inputs and outputs Open Access Maintenance Displays hours run for compressors and pumps if fitted Also includes Electronic Expansion Valves if fitted Default 4648 Clock Allows adjustment of real time clock time z...

Page 27: ...t 2 Low Pressure Switch ID12 Compressor 2 Overload Analogue Outputs ID13 Circuit 2 Isolator Status Y1 Free Cooling Valve ID14 Circuit 2 Discharge Gas Thermostat Y2 Circuit 1 Condenser Fan Speed Controller ID15 Remote Pump Interlock or Pump 1 Contactor Status Optional Y3 Not Used ID16 Pump 2 Contactor Status Optional Y4 Pump 1 Contactor Optional ID17 Remote Pump Enable Y5 Pump 2 Contactor Optional ...

Page 28: ...ter temperature falls below the low limit value set All controller outputs are de activated INDIVIDUAL CIRCUIT ALARMS Outlined below is a selection of Individual Circuit Alarms a full list is available please contact Airedale Electronic Expansion Valve Failure This indicates that the electronic expansion valve controller has detected an operating problem Low Suction Pressure When the suction press...

Page 29: ...275DSQ 10 UFC300DSQ 10 Refrigerant Charge Circuit kg 40 40 45 40 45 45 60 55 60 60 STANDARD D UFC350D 10 UFC400D 10 UFC450D 12 UFC500D 12 UFC575D 14 Compressor Screw Semi Hermetic Quantity 2 2 2 2 2 Oil Charge Volume Total l 7 5 7 5 7 5 7 5 10 7 5 10 10 10 10 Oil Type Polyol Ester Refrigeration Dual Circuit Refrigerant Control Electronic Expansion Valve Refrigerant Precharged R407C Charge Total kg...

Page 30: ...OPS 20 Ethylene Glycol Concentration Standard D Models WATERSIDE PRESSURE DROP kPa 0 50 100 150 200 250 300 0 10 20 30 40 50 60 200 275 300 400 350 450 500 575 650 700 750 WATERFLOW l s Quiet DQ Models WATERSIDE PRESSURE DROP kPa 0 50 100 150 200 250 300 0 10 20 30 40 50 60 200 275 300 400 350 450 500 575 650 700 750 WATERFLOW l s ...

Page 31: ...04 A Commissioning Data WATERSIDE PRESSURE DROPS 20 Ethylene Glycol Concentration Super Quiet DSQ Models WATERSIDE PRESSURE DROP kPa 0 50 100 150 200 250 0 10 20 30 40 50 60 200 250 275 300 400 350 450 500 575 700 650 750 WATERFLOW l s 1 For glycol solutions please refer to Glycol Data ...

Page 32: ...is present at compressor start up Crankcase Heater The mains supply to the crankcase oil heater should be switched on at least 8 hours prior to compressor starting to avoid refrigerant migration CAUTION A separately fused locally isolated permanent single phase and neutral supply MUST BE FITTED for the compressor sump heater evaporator trace heating and control circuits FAILURE to do so could INVA...

Page 33: ...conds before further loading Adding Refrigerant Additional refrigerant should be added to the system via 1 4 schrader connection on the expansion line Pump Down Never shut the liquid injection solenoid valve during or before pump down Never pump down without the low pressure trip and high discharge temperature switches being operative UNLOADING PROTECTION Head Pressure The microprocessor has inbui...

Page 34: ...V and secondary 24V voltages at each of the transformers and record on the commissioning document Check all timer settings are correct Check Sump Heater Check oil level Check design water flow is available Check pump interlocks are fitted to the water system and wired directly to the chiller Switch on the controls and individual circuits primary and secondary MCBs to the ON position At this stage ...

Page 35: ...d closed checking pressure drop across the unit to ensure equal pressure drops are achieved Reduce the flow rate to 75 of design and ensure that the evaporator flow switch trips at this flow rate adjust as necessary Ensure this alarm is recognised as Water Flow Fail at the display and disengages the circuits operation immediately Restore flow rate to the design and check the alarm has self cleared...

Page 36: ...owing settings RECORD LP micro adjustable refer to Controls section LP safety 0 6 0 1 BarG fixed HP safety 24 5 0 7 BarG fixed Clear the alarm as detailed in the Controls section CAUTION The microprocessor LP setting is adjustable via the micro display The standard setting is 3 2BarG This can be altered to suit the medium however this MUST NOT be lower than the medium s freezing point Ensure that ...

Page 37: ...Chilled water flow is within design limits of zero to plus 10 Concurrently ensure chilled water pump and flow switch operate efficiently and that interlocks function correctly Operation of waterflow switch and pump interlock Finally Record operating conditions FABRIC Visually inspect the unit for general wear and tear treat metalwork Rust should be inhibited primed and touched up with matching pai...

Page 38: ...rator pressure drop If lower than commissioning data check water filter and clean if necessary Check 3 port valve by driving fully open and closed ELECTRICAL Tighten all electrical terminals Periodic maintenance and inspection of this equipment is necessary to prevent premature failure the following periodic inspections should be carried out by period or hourly use which ever is sooner 1 Year Meas...

Page 39: ...URE RELIEF VALVE 3bar EXPANSION VESSEL EXPANSION VESSEL INJECTION PUMP f INJECTION PUMP OPTIONA ISOLATION VALVE ISOLATION VALVE INJECTION PUMP SOLENOID VALVE AV MOUNT PUMP OPTIONAL PRESSURE GAUGE SINGLE PUMP OPTION a AV MOUNT BUTTERFLY ISOLATION VALVE OPTIONAL PRESSURE GAUGE TWIN HEAD PUMP OPTION b RUN STANDBY PUMP OPTION c NOTE Auto Air Vents to be fitted at all High Point Traps NOTE Drain Points...

Page 40: ...Chillers ULTIMA FREECOOL Chillers Installation Maintenance Manual 903 125 IM E 05 04 A 39 Notes ...

Page 41: ...cting 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 SPARES The serial plate can be located inside the Controls Panel labelled 13 2 1 3 5 6 7 8 4 ...

Page 42: ...ins Panel Circuit 1 10 Mains Panel Circuit 2 11 Incoming Customer Terminals 12 Incoming Customer Mains Access Points 13 Bus bar Chamber 3 phase Mains Incoming 14 Door Interlocking isolator 15 Star Delta Contactors 16 Closed Transition Connection 17 Power Factor Correction 18 Modulating Head Pressure Controller 19 Phase Rotation Relay 20 Condenser Fan Contactors 21 Microprocessor Controller 22 Elec...

Page 43: ...ULTIMA FREECOOL Chillers Chillers 42 Installation Maintenance Manual 903 125 IM E 05 04 A Notes ...

Page 44: ...Chillers ULTIMA FREECOOL Chillers Installation Maintenance Manual 903 125 IM E 05 04 A 43 Notes ...

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