AIREDALE ULTIMA 2000 User manual

AIACE

INSTALLATION, OPERATING

& MAINTENANCE MANUAL

Ultima 2000

Air Cooled Screw Liquid Chiller

250 - 650 kW

Chillers

ULTIMA 2000

Chillers

2Installation & Maintenance Manual : 903-099 IM E 05/00

About Airedale Products & Customer Services asTM

Airedale participates in Eurovent Certification as a founder member. The Eurovent

Certification programme verifies product performance by managing random independent

testing of certified products.

STD

We participate in certification programmes for Air Conditioners, Chillers and Fan Coil

units, which enable consultants, specifiers and End Users to compare and select

products with assurance that the catalogue data is accurate.

STD

EUROVENT

All new products are tested by Eurovent before being Certified. For certified products only

the Eurovent symbol appears alongside the certified product performance data.

STD

THE ENVIRONMENT -

R407C – THE NATURAL

REPLACEMENT FOR

R22

Protecting the environment is a priority and we take care to ensure our products are

developed and manufactured with this in mind. Airedale introduced R407C refrigerant in

1992 and now has the most extensive in-field experience in the air conditioning industry.

R407C is offered on all Airedale products and all new products are developed to provide

optimum efficiency with this refrigerant ensuring maximum customer choice.

STD

WARRANTY,

COMMISSIONING &

MAINTENANCE

The equipment carries the Airedaleunit parts and labour warranty in respect of non-

consumable parts, for a period of 12 months from the date of despatch. Commissioning

will be carried out by Airedale International Air Conditioning Ltd or an approved Airedale

commissioning company.

CHILLERS

ONLY

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 Airedale Service or your local Sales Engineer.

ukonly

CAUTION Warranty cover is not a substitute for Maintenance. Warranty cover is conditional

to maintenance being carried out in accordance with the recommendations

provided during the warranty period. Failure to have the maintenance procedures

carried out will invalidate the warranty and any liabilities by Airedale International

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

our Training Co-ordinator.

STD

For further assistance, please e-mail: [email protected] or telephone:

CUSTOMER SERVICES UK Sales Enquiries...........................Tel: + 44 (0) 113 238 7789 & 7799

International Enquiries.....................Tel: + 44 (0) 113 239 1000

Spares Enquiries...............................Tel: + 44 (0) 113 238 7723 & 7727

Airedale Service.................................Tel: + 44 (0) 113 238 7704, 7746 & 7748

Training Enquiries.............................Tel: + 44 (0) 113 238 7738

For information, visit us at our Web Site: www.airedale.co.uk

AIAC Ltd endeavours to ensure that the information in this document is correct and fairly

stated, but none of the statements are to be relied upon as a statement or representation

of fact. AIAC Ltd does not accept liability for any error or omission, or for any reliance

placed on the information contained in this document.

STD

The development of Airedale products and services is continuous and the information in

this document may not be up to date. It is important to check the current position with

AIAC Ltd at the address stated. This document is not part of a contract or licence unless

expressly agreed.

STD

No part of this document may be reproduced or transmitted in any form or by any means,

electronic or mechanical, including photocopying, recording, or information storage and

retrieval systems, for any purpose other than the purchaser's personal use, without the

express written permission of AIAC Ltd.

STD

ULTIMA 2000

Chillers

Installation & Maintenance Manual : 903-099 IM E 05/00 3

Contents

GENERAL STATEMENT

Safety Page 4

EMC Page 4

Warranty Page 5

GENERAL DESCRIPTION

Unit Identification Page 6

Introduction Page 6

Standard Features Page 6

Optional Extras - Energy Saving Page 7

Optional Extras - General Page 8

INSTALLATION DATA

Dimensions & Weights Page 9

Point Loadings Page 9

Unit Lifting Page 10

Centre of Gravity Page 10

Positioning Page 11

Water System Data Page 12

Glycol Data Page 13

Electrical Data Page 14

CONTROLS

Control Scheme Features Page 18

Operation Page 19

Setting Up Page 20

Viewing Unit Operating Status Page 21

Adjusting Customer Control Settings Page 23

COMMISSIONING DATA

General Data Page 25

Mechanical Data Page 25

Water System Data Page 26

Electrical Data Page 27

COMMISSIONING PROCEDURE

Pre Commissioning Checklist Page 29

Commissioning Checklist Page 31

MAINTENANCE

General Maintenance Page 32

Compressor Maintenance Page 33

Refrigeration Page 33

Electrical Page 33

PARTS IDENTIFICATION

Spares Page 34

Chillers

ULTIMA 2000

Chillers

4Installation & Maintenance Manual : 903-099 IM E 05/00

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.

std

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.

std

CAUTION 1Service and maintenance of Airedale equipment should only be carried out

by Technically trained competent personnel. new

CAUTION 2When 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.

new

3Also ensure that there are no other power feeds to the unit such as fire alarm

circuits, BMS circuits etc std

4Electrical installation commissioning and maintenance work on this equipment

should be undertaken by competent and trained personnel in accordance with

local relevant standards and codes of practice.

std

5Refrigerant 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.

std

6A full hazard data sheet in accordance with COSHH regulations is available

should this be required. std

EMC STATEMENT In accordance with CE marking requirements, all Airedale products are tested for EMC

emissions and susceptibility to European Standards EN 50081-1 and

EN 50082-1 respectively.

new

To ensure trouble-free operation of all electronic equipment, the operating environment

must comply with the same EN standards.Failure to ensure the environment meets this

standard could affect the operation of the equipment.

new

ULTIMA 2000

Chillers

Installation & Maintenance Manual : 903-099 IM E 05/00 5

Warranty new

Please refer to theOrder Acknowledgement for details of the warranty package.

Inclusions Warranty will cover parts and labour for a period of 12 months.

Warranty cover will commence from the date of invoice unless an alternative date is

requested in writing.

Airedale will accept warranty commencing dates from completion of commissioning or on

date of contract completion up to a maximum of 6 months from date of delivery, subject to

the equipment being properly protected and serviced in the period between delivery and

hand over.

Airedale will provide labour costs for replacement of part failed under warranty conditions

subject to the following:

•The on site contractor or service company 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.

•When warranty is accepted, following inspection of the faulty component, a credit

note will be issued against an invoice raised in line with the acknowledgement.

•Should warranty be refused the invoice raised against the acknowledgement

becomes payable on normal terms.

•Airedale reserve the right to carry out site warranty labour work using their own

direct labour or by sub contracting to an approved company of their choice.

Exclusions Warranty may be refused for the following reasons:

•Misapplication of product or component.

•Incorrect site installation.

•Incomplete commissioning documentation.

•Inadequatesite installation.

•Inadequatesitemaintenance.

•Damage caused by mishandling.

General Dead on arrival or manufacturing defects are the responsibility of Airedale and should be

reported immediately.

In the event of a warranty failure, dead on arrival or manufacturing defect, the Airedale

Service department should be contacted and on receipt of an order, an Airedale engineer

(or representative) will be directed to site as soon as possible.

Chillers

ULTIMA 2000

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6Installation & Maintenance Manual : 903-099 IM E 05/00

General Description asTM

UNIT IDENTIFICATION AIR COOLED SCREW LIQUID CHILLER

USC Ultima Screw Chiller

250 - 650 Model Size (Expressed as Nominal Cooling in kW)

D- Dual Circuit - Standard Chiller

DQ- Dual Circuit - Quiet Chiller

DSQ- Dual Circuit - Super Quiet Chiller

8, 12 or 16

Number of Fans

Example USC300D-8

INTRODUCTION The Airedale range of Ultima air cooled liquid chillers covers the nominal capacity range

250kW to 650kW in 27 model sizes including Standard D, Quiet DQ and

Super QuietDSQ variations.

asTM

Attention has been placed on maximising the unit’s performance while keeping the sound

levels and footprint to an absolute minimum. asTM

REFRIGERANTS The range has been designed and optimised for operation with the ozone benign

R407C refrigerant. asTM

The Standard Ultima chiller comes complete with: asTM

•Head Pressure Control - fans are individually switched by a Microprocessor

STANDARD CHILLER

- D •Evaporator Trace Heating

•Quiet Fans

•Single Screw Compressors

•Shell & Tube Evaporator

•Dual Independent Refrigeration Circuits

With the benefits of the Standard range, the Quiet chiller is supplied with an acoustic

package, which incorporates: asTM

QUIET CHILLER

- DQ •Acoustically lined compressor enclosures

•3phase Head Pressure Controllers, which modulate the fan speeds collectively to

maintain a constant condensing pressure with minimum fan speeds.

SUPER QUIET CHILLER

- DSQ With the benefits of the Standard range, the Super Quiet chiller is supplied with a Quiet

acoustic package, which incorporates the following to become one of the quietest

chillers available:

asTM

•Acoustically lined compressor enclosures

•Reduced speed 680 rpm condenser fans

•3phase Head Pressure Controllers, which modulate the fan speeds collectively to

maintain a constant condensing pressure with minimum fan speeds.

•The use of enhanced performance condenser coils on the DSQ Quiet Package

enables a chiller capacity similar to the D and DQmodels to be maintained.

ULTIMA 2000

Chillers

Installation & Maintenance Manual : 903-099 IM E 05/00 7

General Description

REFRIGERATION Each refrigeration circuit is supplied with the following: asTM

•Full operating charge of R407C

•Liquid injection oil cooling circuit fitted to each compressor as standard with sight

glass, strainer and non-return valve

•Thermostatic expansion valve with external equaliser

•Liquid line ball valve

•Discharge line ball valve

•Liquid line solenoid valve

•Large capacity filter drier with replaceable cores

•Liquid line sight glass

•Low pressure switch with manual reset

•High pressure switch with manual reset

•Suction and liquid pressure transducers

•Pressure relief valve with integral rupture disc and indicator gauge

CONTROLS Microprocessor controller to provide between 6 to 8 stages of capacity control (dependant

uponmodel size) as standard.The controller incorporates full Building Management

System capabilities, full details can be found in theControls section.

asTM

ELECTRICAL A weatherproof electrical power and controls panel is situated at the end of the unit

and contains: asTM

•Individual mains power compartments for each refrigeration circuit

•Separate door locking electrical isolation for each mains compartment

•Emergency Stop fitted to controls compartment door

•Separate, fully accessible, controls compartment, allowing adjustment of control

set points whilst the unit is operational

•Dedicated bus-bar chamber for connection of incoming 3 phase and earth mains

powersupply

•Circuit breakers for protection of all major unit components

•Phase Rotation Relay also incorporating loss of phase protection

•The electrical power and control panel is wired to the latest European standards

and codes of practice

OPTIONAL EXTRAS - ENERGY SAVING asTM

Power Factor Correction When applied to the motors of each compressor, the compressor power factor is

controlled to a minimum operating value of 0.95 at the full operating capacity. This

satisfies many supply authorities that may impose surcharges on equipment with power

factor less than 0.95.

Electronic Expansion

Valves Electronic expansion valves differ to the normal thermostatic expansion valves in their

ability to maintain control of the suction superheat at reduced head pressures. This can

lead to significant energy savings particularly at minimum loading and low

ambienttemperatures.

Modulating Head

Pressure Control (-20°C)

Model D Only

A 3

phase head pressure controller which modulates t

he fan speed to maintain a constant

condensing pressure can be fitted on request.

Chillers

ULTIMA 2000

Chillers

8Installation & Maintenance Manual : 903-099 IM E 05/00

General Description

OPTIONAL EXTRAS - GENERAL new

•

Anti Vibration Mounts

Loose Item •Flow Switch

•Condenser Fan Discharge

Air Plenum

Instructions supplied with item

•Sequence Controller Refer toSequence Controller Manualprovided

with this option

•Epoxy Coated Condenser

Coils

Factory Fitted

•Coil Guards

•Dual Pressure Relief Valve

•Electronic Expansion Valve

•Modem Link Refer toAiredale for further details

•Closed Transition Star/Delta

Compressor Start Refer toCommissioning Section for details

Optional Unit Cover •Commissioning

•Chillerguard® Health Check

•Chillerguard® Maintenance

For details and a competitive quotation, contact

Airedale Service.

ULTIMA 2000

Chillers

Installation & Maintenance Manual : 903-099 IM E 05/00 9

Installation Data asTM

DIMENSIONS &

WEIGHTS Note: Water connections shown are standard, other handing options are available

upon request.

A85

2595

852200

GEDC F

2100

Electrical Panels

with Mains

Isolator

AcousticEnclosure

(DQ & DSQ Only)

P1 P2 P3 P4

P5 P6 P7 P8

20mm Ø Mounting Holes

(located on the underside of

the base frame)

90 90

Water Connections:

USC250-8 to USC350-12 = DN150 PN16

USC400-12 to USC650-16 = DN200 PN16

Dimensions

A B C D EFGHJ

USC250DSQ-8 to

USC300DSQ-8 mm 4040 460 435 1120 (1) (1) 655 1837 1753

USC350DSQ-12 mm 5740 460 400 1410 1465 1880 585 2198 1753

USC400DSQ-12 to

USC500DSQ-12 mm 5740 475 400 1410 1465 1880 585 2213 1723

USC575DSQ-16 to

USC650DSQ-16 mm 7440 525 400 2000 1645 2810 585 2522 1723

Point Loadings & Total Weights

P1 P2 P3 P4 P5 P6 P7 P8 Machine Operational

USC250DSQ-8

680

540

(1)

340

680

540

(1)

340

3120

3208

USC275DSQ-8

690

550

(1)

340

680

540

(1)

340

3140

3228

USC300DSQ-8

690

550

(1)

340

690

550

(1)

340

3160

3248

USC350DSQ-12

655

680

540

255

615

640

510

245

4140

4217

USC400DSQ-12

655

680

540

255

655

680

540

255

4260

4383

USC450DSQ-12

675

700

540

255

655

680

540

255

4300

4416

USC500DSQ-12

675

700

540

255

675

700

540

255

4340

4449

USC575DSQ-16

885

915

650

365

780

800

650

365

5410

5550

USC650DSQ-16

885

915

650

365

885

915

650

365

5630

5770

(1) Only 6 fixing and loading points to this model.

(2) For AV mount selection on D and DQmodels, use the DSQ data provided.

Chillers

ULTIMA 2000

Chillers

10 Installation & Maintenance Manual : 903-099 IM E 05/00

Installation Data asTM

UNIT LIFTING •Employ lifting specialists. IM133

•Local codes and regulations relating to the lifting of this type of equipment should

be observed. asTM

•Use the appropriate spreader bars/lifting slings with the holes/lugs provided. IM135

•Attach lifting chains to the 4 lifting lugs provided, each chain must be capable of

lifting the whole chiller. asTM

•Lifting hole/lug dimension: 40mm IM136

•Lift the unit slowly and evenly. IM134

•If the unit is dropped, it should immediately be checked for damage and reported

to Airedale Service. IM120

CAUTION Only use lifting points provided. asTM

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.

IM118

LIFTING DIMENSIONS &

CENTRE OF GRAVITY

400 LK

2330

C of G 1

P1 P2 P3

P5 P6 P7 P8

C of G 2

KLM (min) C of G1 C of G2

USC250D-8 to

USC300D-8 mm 2465 1175 3200 1460 1100

USC350D-12 mm 3420 1920 3500 2150 1100

USC400D-12 to

USC500D-12 mm 3420 1920 3500 2130 1100

USC575D-16 to

USC650D-16 mm 5100 1940 5100 2780 1100

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