AIREDALE Ultima Remote Air Cooled, Installation, Operating And Maintenance Manual

Page 1: ...INSTALLATION OPERATING MAINTENANCE MANUAL Ultima Remote Air Cooled Air Cooled Chiller 75kW 450kW ...

Page 2: ...nternational 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 CUSTOMER SERVICES For further assistance ...

Page 3: ...12 Positioning 13 Refrigeration System 14 Pipework Installation Good Practices 15 Water System 16 Glycol Data 18 Electrical data 19 Interconnecting Wiring 19 Electrical Data 20 CONTROLS 23 Control Scheme Features 23 Operation 24 Setting up 25 Viewing Unit Operating Status 26 Alarms 27 COMMISSIONING DATA 28 Operating Limits 28 Mechanical Data 28 Waterside Pressure Drops 29 Operational Sequence 30 C...

Page 4: ...mpetent 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: ... place an official 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...

Page 6: ...ective EMC 89 336 EEC Low Voltage Directive LVD 73 23 EEC Machinery Directive MD 89 392 EEC in the version 98 37 EC Pressure Equipment Directive 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...

Page 7: ...ncing Master Slave and Run Standby to meet all your system requirements please confirm at time of order Unit initial set up details can be found in the Controls section Electrical Dedicated weatherproof electrical power and controls panels are situated at the end of the unit and contain Separate fully accessible controls compartment allowing adjustment of control set points whilst the unit is oper...

Page 8: ...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 Leak Detection Kit DQ DSQ Only Electronic Soft Start Alternative Refrigerant Outside EU OPTIONAL UNIT COVER Commissioning For details and a competitive quota...

Page 9: ...380 397 200 220 280 380 710 462 1076 462 URAC175 mm 2000 760 1850 380 397 200 220 280 380 710 462 1076 462 URAC200 mm 2000 760 1850 380 397 200 220 280 380 710 462 1076 462 URAC225 mm 2000 760 1850 268 628 200 220 280 380 710 462 1076 462 URAC240 mm 3200 900 1900 256 628 500 250 250 450 850 970 1730 500 URAC250 mm 2000 760 1850 268 628 200 220 280 380 710 462 1076 462 URAC300 mm 3200 900 1900 256 ...

Page 10: ...55 355 1230 380 420 URAC175DQ kg 285 285 378 378 1325 380 420 URAC200DQ kg 305 305 405 405 1420 380 820 URAC225DQ kg 325 325 420 420 1490 380 420 URAC240DQ kg 580 580 230 230 1620 450 1461 URAC250DQ kg 340 340 438 438 1555 380 820 URAC270DQ kg 630 630 250 250 1760 450 1461 URAC300DQ kg 680 680 270 270 1900 450 1462 URAC330DQ kg 700 700 280 280 1960 450 1464 URAC360DQ kg 730 730 300 300 2060 450 14...

Page 11: ...propriate spreader bars lifting slings with the holes lugs provided Lift the unit slowly and evenly 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...

Page 12: ...ach 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 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 o...

Page 13: ...ible fit spring anti vibration mounts and flexible water connections Observe airflow and maintenance 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 CAUTION Prior to connecting services ensure that the equipment is installed and...

Page 14: ...mp The pump should be connected to the high and low pressure sides of the system via a gauge manifold fitted with compound gauges A high vacuum gauge should be fitted to the system at the furthest point from the vacuum pump 2 Triple evacuation should be used to ensure that all contaminants are removed or at least reduced to significantly low proportions 3 The vacuum pump should be operated until a...

Page 15: ... to ensure a slight gradient toward the compressor in the direction of the refrigerant flow for suction lines running horizontal This assists oil return to the compressor A gradient of approximately 1 200 0 5 shall be used Condenser above Chiller Condenser below Chiller 6m Chiller t Condenser s t Condenser s Chiller Discharge Line Liquid 1 U oil traps to be installed at 6m intervals on suction lin...

Page 16: ...ent fitted adjacent to the water outlet side of the Chiller CAUTION The correct operation of the flow switch is critical if the chiller warranty is to be valid A 20 mesh strainer fitted prior to the evaporator inlet 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 ...

Page 17: ...AC150 URAC175 Connections Evaporator Suits Victaulic type Coupling Pipe Assembly Water Inlet Outlet mm in 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 65 2 1 2 Connections Condenser Discharge Line brazed in 1 1 8 1 1 8 1 3 8 1 5 8 1 5 8 Liquid Line brazed in 7 8 7 8 1 1 8 1 3 8 1 3 8 Water System Evaporator Min System Water Volume 1 l 358 489 625 755 696 Max System Press Bar 10 10 10 10 10 URAC200 URAC225 ...

Page 18: ... 12 C water temperature 45 C dew point 20 Ethylene Glycol Cooling kW 287 3 refer to Technical Data x 0 97 20 Ethylene Glycol 278 7 kW Input kW 77 2 refer to Technical Data x 0 98 75 7 kW Flow l s 13 7 calculated 4 19 x T kW Cooling DX x 1 02 14 0 l s Pressure Drop kPa 47 0 refer to Waterside Pressure Drops x 1 20 56 4 kPa CAUTION Waste glycol needs to be handled responsibly recycled or turned over...

Page 19: ...or sump heater evaporator trace heating and control circuits FAILURE to do so could INVALIDATE WARRANTY Interlocks Protection Always electrically interlock the operation of the chiller with the pump controls and water flow switch These safety devices prevent the chiller operating with low water flow which can cause serious damage CAUTION Failure to install both safety devices will invalidate the c...

Page 20: ...Heating Available fitted by others W 500 500 500 500 500 Compressor Per Compressor Quantity 4 4 4 4 2 2 Motor Rating kW 5 3 7 3 9 1 10 9 10 9 14 4 Nominal Run Amps 1 A 11 5 14 2 16 3 20 0 20 0 25 2 Crankcase Heater Rating W 70 0 70 0 70 0 70 0 70 0 120 0 Start Amps 2 99 127 167 198 198 225 Type Of Start Direct on line OPTIONAL EXTRAS Power Factor Correction Nominal Run Amps 1 A 41 51 58 72 81 Maxi...

Page 21: ...rs W 500 500 500 500 500 Compressor Per Compressor Quantity 4 2 2 3 3 4 3 3 Motor Rating kW 14 4 14 4 17 9 10 9 10 9 17 9 10 9 14 4 Nominal Run Amps 1 A 25 2 25 2 32 2 20 0 20 0 32 2 20 0 25 2 Crankcase Heater Rating W 120 0 120 0 150 0 70 0 70 0 150 0 70 0 120 0 Start Amps 2 225 225 272 198 198 272 198 225 Type Of Start Direct on line OPTIONAL EXTRAS Power Factor Correction Nominal Run Amps 1 A 9...

Page 22: ...pressor Per Compressor Quantity 3 3 3 3 3 3 3 3 3 3 Motor Rating kW 14 4 14 4 17 9 14 4 17 9 17 9 22 5 17 9 22 5 22 5 Nominal Run Amps 1 A 25 2 25 2 32 2 25 2 32 2 32 2 40 3 32 2 40 3 40 3 Crankcase Heater Rating W 120 0 120 0 150 0 120 0 150 0 150 0 150 0 150 0 150 0 150 0 Start Amps 2 225 225 272 225 272 272 320 272 320 320 Type Of Start Direct on line OPTIONAL EXTRAS Power Factor Correction Nom...

Page 23: ...e the supply water temperature is not critical to its operation Selection of the best application control scheme can be made via a soft switch in the microprocessor during initial commissioning Examples based on Models URAC200D having 6 Stages of Cooling Variable Supply Temperature Control 6 7 8 9 10 11 12 13 14 WATER TEMPERATURE C 20 40 50 60 80 100 Chiller Capacity Cooling Stage Sequence 1 2 3 4...

Page 24: ...y refer to Password Protection Initially use the Prg key to access Menus the symbol will appear top right and the first menu will appear in CAPITALS these indicators shows which menu is selected Use the keys to move the indicator to the desired menu and press to open the menu Use the key to move the flashing cursor to adjustable fields and the keys to change the values Press the key to move the cu...

Page 25: ...fault 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 zon...

Page 26: ...on Pressure Not connected with EEV option or Leak Detector B4 Return Water Temperature B5 Supply Water Temperature B6 Circuit 2 Suction Pressure Not connected with EEV option or Leak Detector B7 Chilled Water Differential Pressure Optional B8 Remote Setpoint Adjustment or Condenser Water Inlet B9 Evaporator Inlet Water or Coil 1 Temperature B10 Ambient or Coil 2 Temperature Analogue Inputs Fitted ...

Page 27: ...oller outputs are de activated Low Supply Temperature Supply Water Temperature Low Limit alarm is generated when the supply water 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 indicate...

Page 28: ... 1 Oil Type Polyol Ester Refrigeration Dual Circuit Refrigerant Control Electronic Expansion Valve Refrigerant Type R407C Holding Charge Dry Nitrogen URAC200 URAC225 URAC240 URAC250 URAC270 Compressor Tandem Scroll Hermetic Trio Scroll Hermetic Tandem Scroll Hermetic Trio Scroll Hermetic Quantity 4 4 6 4 6 Oil Charge Volume Total l 4 x 4 7 2 x 6 3 4 7 6 x 4 1 4 x 6 3 3 x 4 7 3 x 4 1 Oil Type Polyo...

Page 29: ... volume is NOT recommended UWC75 UWC250 Except UWC240 CHILLER PRESSURE DROP kPa 0 20 40 60 80 2 4 6 8 10 12 14 16 URAC75 100 URAC125 URAC150 URA175 URAC200 URAC225 URAC250 WATERFLOW l s URAC240 URAC450 Except URAC250 CHILLER PRESSURE DROP kPa 0 25 50 75 100 5 10 15 20 25 30 35 URAC240 URAC400 URAC360 URAC330 URAC300 URAC270 URAC450 WATERFLOW l s 1 For glycol solutions please refer to Glycol Data ...

Page 30: ...compressor sight glass and that all refrigerant ball valves are opened CAUTION Check phase rotation by connecting pressure gauges to the suction and discharge ports if no differential pressure occurs isolate immediately Adding Refrigerant Additional refrigerant should be added to the system via 1 4 schrader connection on the expansion line if required Pump Down Never pump down without the low pres...

Page 31: ...tage at permanent supply Measure and record the primary 230V and secondary 24V voltages at each of the transformers adjust tapping if necessary and record on the commissioning document Check all timer settings are correct Check Sump Heater Check oil level Check water filter is fitted Check design water flow is available Check flow switch and pump interlocks are fitted to the water system and wired...

Page 32: ... RECORD Reduce the flow rate to 75 of design and ensure that the evaporator pressure or flow protection switch trips at this flow rate adjust as necessary With compressors off 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 To switch the unit OFF use the micropro...

Page 33: ... LP setting is adjustable via the micro display It is recommended that this setting be 0 6Bar below the equipment freezing point of the cooling medium ie for water no glycol LP micro settings is 3 2BarG Ensure that the low water temperature safety cuts out at the correct setting 0 5 C to clear the alarms refer to Alarm Handling section For water no glycol application the recommended setting is 3 C...

Page 34: ...following against the commissioning records Investigate and adjust as necessary Control settings Alarm log for unusual occurrences Chilled water control maintains design temperature 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 int...

Page 35: ...load the height of summer is recommended Recheck the charge following major adjustment of the superheats Adjust as necessary A period of 30 minutes should be allowed between each resetting of the valve to allow pressures to stabilise Thermostatic expansion valve only ELECTRICAL Tighten all electrical terminals COMPRESSOR MAINTENANCE Periodic maintenance and inspection of this equipment is necessar...

Page 36: ...t and is also available from our Spares department on request The serial plate can be located inside Item 9 2 3 4 5 6 7 8 10 12 13 14 15 6 10 17 9 19 19 20 20 1 16 1 AireTronix Microprocessor Controller 11 N A 2 Controls Transformer 12 Filter Drier 3 Electronic Expansion Valve drives 13 Sight Glass 4 Earth 14 Evaporator 5 Compressor MCBs 15 Electronic Expansion Valve 6 Door Interlocking Isolator 1...

Page 37: ...Chillers ULTIMA REMOTE AIR COOLED Chillers 37 Installation Maintenance 6259535 IM E 02 2013 Notes ...

Page 38: ...ULTIMA REMOTE AIR COOLED Chillers 38 Chillers Installation Maintenance 6259535 IM E 02 2013 Notes ...

Page 39: ...Chillers ULTIMA REMOTE AIR COOLED Chillers 39 Installation Maintenance 6259535 IM E 02 2013 Notes ...

Page 40: ...tional 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 903 127 IM E A 01 10 04 B 29 03 2010 V1 2 0 18 02 2013 ...