Chillers ULTIMA 2000

AIAC E
INSTALLATION, OPERATING
& MAINTENANCE MANUAL
Ultima 2000
Air Cooled Screw Liquid Chiller
250 - 650 kW
ULTIMA 2000
All new products are tested by Eurovent before being Certified. For certified products only
the Eurovent symbol appears alongside the certified product performance data.
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.
WARRANTY,
COMMISSIONING &
MAINTENANCE
The equipment carries the Airedale unit parts and labour warranty in respect of nonconsumable 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.
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.
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.
CUSTOMER SERVICES
For further assistance, please e-mail: marketing@airedale.co.uk or telephone:
STD
STD
STD
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.
ST
D
CAUTION
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
Airedale participates in Eurovent Certification as a founder member. The Eurovent
Certification programme verifies product performance by managing random independent
testing of certified products.
EUROVENT
as TM
CHILLERS
ONLY
About Airedale Products & Customer Services
uk only
Chillers
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.
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.
 2000 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
2
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
STD
STD
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.
ST STD
D
For information, visit us at our Web Site: www.airedale.co.uk
ST
D
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
ULTIMA 2000
Chillers
Contents
GENERAL STATEMENT
Safety
EMC
Warranty
Page
Page
Page
4
4
5
GENERAL DESCRIPTION
Unit Identification
Introduction
Standard Features
Optional Extras - Energy Saving
Optional Extras - General
Page
Page
Page
Page
Page
6
6
6
7
8
INSTALLATION DATA
Dimensions & Weights
Point Loadings
Unit Lifting
Centre of Gravity
Positioning
Water System Data
Glycol Data
Electrical Data
Page
Page
Page
Page
Page
Page
Page
Page
9
9
10
10
11
12
13
14
CONTROLS
Control Scheme Features
Operation
Setting Up
Viewing Unit Operating Status
Adjusting Customer Control Settings
Page
Page
Page
Page
Page
18
19
20
21
23
COMMISSIONING DATA
General Data
Mechanical Data
Water System Data
Electrical Data
Page
Page
Page
Page
25
25
26
27
COMMISSIONING PROCEDURE
Pre Commissioning Checklist
Commissioning Checklist
Page
Page
29
31
MAINTENANCE
General Maintenance
Compressor Maintenance
Refrigeration
Electrical
Page
Page
Page
Page
32
33
33
33
PARTS IDENTIFICATION
Spares
Page
34
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3
Chillers
ULTIMA 2000
General Statement
IMPORTANT
std
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.
std
CAUTION
1
Service and maintenance of Airedale equipment should only be carried out
by Technically trained competent personnel.
new
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.
new
3
Also ensure that there are no other power feeds to the unit such as fire alarm
circuits, BMS circuits etc
std
4
Electrical 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
5
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.
std
6
A full hazard data sheet in accordance with COSHH regulations is available
should this be required.
std
EMC STATEMENT
4
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
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ULTIMA 2000
Chillers
new
Warranty
Please refer to the Order 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.
•
Inadequate site installation.
•
Inadequate site maintenance.
•
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.
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5
Chillers
ULTIMA 2000
as TM
General Description
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
INTRODUCTION
USC300D-8
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 Quiet DSQ variations.
as TM
Attention has been placed on maximising the unit’s performance while keeping the sound as TM
levels and footprint to an absolute minimum.
REFRIGERANTS
The range has been designed and optimised for operation with the ozone benign
R407C refrigerant.
as TM
STANDARD CHILLER
-D
The Standard Ultima chiller comes complete with:
•
Head Pressure Control - fans are individually switched by a Microprocessor
•
Evaporator Trace Heating
•
Quiet Fans
•
Single Screw Compressors
•
Shell & Tube Evaporator
•
Dual Independent Refrigeration Circuits
as TM
QUIET CHILLER
- DQ
With the benefits of the Standard range, the Quiet chiller is supplied with an acoustic
package, which incorporates:
•
Acoustically lined compressor enclosures
•
3 phase Head Pressure Controllers, which modulate the fan speeds collectively to
maintain a constant condensing pressure with minimum fan speeds.
as TM
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:
•
Acoustically lined compressor enclosures
•
Reduced speed 680 rpm condenser fans
•
3 phase 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 DQ models to be maintained.
as TM
6
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ULTIMA 2000
Chillers
General Description
as TM
REFRIGERATION
Each refrigeration circuit is supplied with the following:
•
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 as TM
upon model size) as standard. The controller incorporates full Building Management
System capabilities, full details can be found in the Controls section.
ELECTRICAL
A weatherproof electrical power and controls panel is situated at the end of the unit
and contains:
•
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
power supply
•
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
as TM
OPTIONAL EXTRAS - ENERGY SAVING
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
ambient temperatures.
Modulating Head
Pressure Control (-20°C)
Model D Only
as TM
A 3 phase head pressure controller which modulates the fan speed to maintain a constant
condensing pressure can be fitted on request.
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Chillers
ULTIMA 2000
General Description
new
OPTIONAL EXTRAS - GENERAL
Loose Item
•
•
•
•
Factory Fitted
Optional Unit Cover
8
•
Anti Vibration Mounts
Flow Switch
Condenser Fan Discharge
Air Plenum
Sequence Controller
Instructions supplied with item
Refer to Sequence Controller Manual provided
with this option
•
•
•
•
•
Epoxy Coated Condenser
Coils
Coil Guards
Dual Pressure Relief Valve
Electronic Expansion Valve
Refer to Airedale for further details
Modem Link
Closed Transition Star/Delta Refer to Commissioning Section for details
Compressor Start
•
•
•
Commissioning
Chillerguard® Health Check
Chillerguard® Maintenance
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
For details and a competitive quotation, contact
Airedale Service.
ULTIMA 2000
Chillers
as TM
Installation Data
Note: Water connections shown are standard, other handing options are available
upon request.
DIMENSIONS &
WEIGHTS
2595
Electrical Panels
with Mains
Isolator
Acoustic Enclosure
(DQ & DSQ Only)
B
90
A
50
H
2200
85
J
P2
P3
20mm Ø Mounting Holes
(located on the underside of
the base frame)
P4
2100
P1
Water Connections:
USC250-8 to USC350-12 = DN150 PN16
USC400-12 to USC650-16 = DN200 PN16
P5
50
90
85
C
P6
P7
D
P8
E
F
G
Dimensions
USC250DSQ-8 to
USC300DSQ-8
USC350DSQ-12
USC400DSQ-12 to
USC500DSQ-12
USC575DSQ-16 to
USC650DSQ-16
A
B
C
D
E
F
G
H
J
mm
mm
4040
5740
460
460
435
400
1120
1410
(1)
1465
(1)
1880
655
585
1837
2198
1753
1753
mm
5740
475
400
1410
1465
1880
585
2213
1723
mm
7440
525
400
2000
1645
2810
585
2522
1723
Point Loadings & Total Weights
USC250DSQ-8
USC275DSQ-8
USC300DSQ-8
USC350DSQ-12
USC400DSQ-12
USC450DSQ-12
USC500DSQ-12
USC575DSQ-16
USC650DSQ-16
(1)
(2)
kg
kg
kg
kg
kg
kg
kg
kg
kg
P1
P2
P3
P4
P5
P6
P7
680
690
690
655
655
675
675
885
885
540
550
550
680
680
700
700
915
915
(1)
(1)
(1)
540
540
540
540
650
650
340
340
340
255
255
255
255
365
365
680
680
690
615
655
655
675
780
885
540
540
550
640
680
680
700
800
915
(1)
(1)
(1)
510
540
540
540
650
650
P8 Machine
340
340
340
245
255
255
255
365
365
Operational
3120
3140
3160
4140
4260
4300
4340
5410
5630
3208
3228
3248
4217
4383
4416
4449
5550
5770
Only 6 fixing and loading points to this model.
For AV mount selection on D and DQ models, use the DSQ data provided.
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9
Chillers
ULTIMA 2000
as TM
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 with the holes/lugs provided.
Attach lifting chains to the 4 lifting lugs provided, each chain must be capable of
lifting the whole chiller.
Lifting hole/lug dimension: 40mm
Lift the unit slowly and evenly.
If the unit is dropped, it should immediately be checked for damage and reported
to Airedale Service.
•
•
•
•
•
CAUTION
IM135
as TM
IM136
IM134
IM120
Only use lifting points provided.
as TM
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
2330
M
K
400
L
C of G 1
P1
P2
P3
P4
C of G 2
P5
P6
USC250D-8 to
USC300D-8
USC350D-12
USC400D-12 to
USC500D-12
USC575D-16 to
USC650D-16
10
IM133
as TM
P7
P8
K
L
M (min)
C of G1
C of G2
mm
mm
2465
3420
1175
1920
3200
3500
1460
2150
1100
1100
mm
3420
1920
3500
2130
1100
mm
5100
1940
5100
2780
1100
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ULTIMA 2000
Chillers
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 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
or multiple chiller applications.
•
Ensure there are no obstructions directly above the fans.
•
Allow free space above the fans to prevent air recirculation.
IM019
IM121
Ensure the unit is completely level and secured prior to connecting services.
new
Louvred Wall with 50%
Free Area
1.2m (2.4)
1.2m (2.4)
1.2m (2.4)
1.2m (2.4)
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11
as TM
IM137
IM139
IM057
IM122
IM142
as TM
IM140
as TM
Chillers
ULTIMA 2000
Installation Data
WATER SYSTEM DATA
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.
•
In ambients of 0°C and below and when water supply temperatures of +5°C are
required, the necessary concentration of Glycol or use of an electrical trace heater
is added where static water can be expected.
•
The schematic is referred to as a guide to ancillary recommendations.
IM144
IM145
IM146
IM147
as TM +
mods
No liability for externally connected pipework will be regarded by Airedale
International Air Conditioning Ltd.
new
The water flow commissioning valve set is not shown in the diagram, as the valve can be
fitted elsewhere within the Chilled Water circuit.
as TM
as TM
as TM
P
T
BINDER
POINTS
CHILLER
STRAINER
BYPASS CIRCUIT
(For Flushing)
IN
PRESSURE
GAUGES
FLEXIBLE
CONNECTIONS
P
TEMPERATURE
GAUGES
T
FLOW
AUTO AIR
SWITCH
VENT (At
Highest Point)
SHUT OFF
VALVES
PUMP
PUMP
STRAINER
OUT
Component
Recommended
Requirements
Pump Statement
The recommended requirements to allow commissioning to be carried out correctly are:
•
The inclusion of Binder Point To Allow Temperature and pressure readings
•
A flow switch or pressure differential switch fitted adjacent to the water outlet side
of the Chiller
•
An 80-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 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 maintenance to be carried out.
•
Isolating valves should be installed adjacent to all major items of equipment for
ease of maintenance.
•
Balancing valves can be installed if required to aid correct system balancing.
•
All chilled water pipework must be insulated and vapour sealed to
avoid condensation.
•
If several units are installed in parallel adjacent to each other, reverse return
should be applied to avoid unnecessary balancing valves.
CAUTION
12
new
new
new
new
new
new
new
new
IM149
When installing circulating water pumps or equipment containing them, the following rules new
should be applied:
•
Ensure the system is filled with water then vented and the pump primed with water new
before running the pump. This is required as the pump bearings and mechanical
seal faces are cooled by the pumped liquid.
•
Pressure Testing
new
new
new
To avoid cavitation the NPSH (Net Positive Suction Head) and a safety margin of
0.5m head must be available at the pump inlet during operation.
new
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.
new
new
When the pressure remains at the operating pressure for 1 hour, the system can be
considered leak free.
new
Although a pressure of 1.5 x working pressure is adequate for testing purposes,
most local water authorities require 2 x working pressure.
new
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
ULTIMA 2000
Chillers
Installation Data
IM144
WATER SYSTEM DATA
Filling
CAUTION
It is recommended that the system be flushed prior to filling to remove debris left
in the water pipework between the strainer and cooler to avoid serious damage to
the tubes in the cooler.
new
During filling the system should be vented at all high points.
new
Once the system has been completely vented all vents should be closed.
new
To prevent air locking in the system it is advisable to fill the systems from the lowest
point, ie drain point on pipework.
new
If auto air vents are used then we strongly recommend an auto pressurisation unit be
fitted to the system.
new
as TM
Model
Connections
Water Inlet / Outlet - Evap
Water Drain/Bleed - Evap
(2)
in
in
Water System
Min. System Water Volume
Max. System Test Pressure
(3)
L
Bar
USC250…-8
USC275…-8
USC300…-8 USC350…-12 USC400…-12
DN 150
1/2
DN 150
1/2
DN 150
1/2
DN 150
1/2
DN200
1/2
1782
10
1960
10
2138
10
2608
10
3014
10
as TM
Model
USC450…-12 USC500…-12 USC575…-16 USC650…-16
Connections
Water Inlet / Outlet - Evap
Water Drain/Bleed - Evap
(2)
in
in
Water System
Min. System Water Volume
Max. System Test Pressure
(3)
L
Bar
(2)
(3)
DN200
1/2
DN200
1/2
DN200
1/2
DN200
1/2
3294
10
3624
10
4253
10
4564
10
as TM
new
Flanged to PN16.
For minimum system volume calculations, refer to the Technical Manual.
GLYCOL DATA
Glycol is recommended when a supply water temperature of +5°C or below is required or as TM
when static water can be exposed to freezing temperatures.
Ethylene Glycol Nominal Correction Factors
Glycol in System /
Freezing Point ºC
Cooling Duty
Input Power
Water Flow
Pressure Drop
Multiply by
10% / -4°C
0.98
0.99
0.99
0.99
20% / -9°C
0.97
0.98
0.99
0.99
30% / -15°C
0.95
0.96
0.99
0.99
40% / -23°C
0.93
0.95
1.00
1.00
20% / -6°C
0.95
0.98
0.97
0.99
30% / -12°C
0.91
0.96
0.95
0.98
40% / -20°C
0.88
0.95
0.95
0.98
Propylene Glycol Nominal Correction Factors
Glycol in System /
Freezing Point ºC
Cooling Duty
Input Power
Water Flow
Pressure Drop
Multiply by
10% / -2°C
0.97
0.99
0.98
0.99
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Chillers
ULTIMA 2000
Installation Data
IM024
ELECTRICAL DATA
•
General
CAUTION
•
•
•
CAUTION
•
•
•
CAUTION
Interlocks & Protection
CAUTION
Interconnecting Wiring
As standard the equipment is designed for 400V, 3 phase, 3 wire 50Hz and a
permanent 230V, 1 phase, 50Hz supply, to all relevant IEE regulations, British
standards and IEC requirements.
Ensure correct phase rotation.
A fused and isolated electrical supply of the appropriate phase, frequency and
voltage should be installed.
The control voltage to the interlocks is 24V. Always size the low voltage interlock
and protection cabling for a maximum voltage drop of 2V.
Wires should be capable of carrying the maximum load current under nonfault conditions at the stipulated voltage.
Avoid large voltage drops on cable 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.
A separately fused, locally isolated, permanent single phase and neutral supply is
required for the compressor sump heater, evaporator trace heating and
control circuits.
IM023
new
new
new
new
new
new
new
Always electrically interlock the operation of the chiller with the pump interlocks and water new
flow switch for safety reasons. Failure to do this will invalidate the chiller warranty.
Do not rely solely on the BMS to protect the chiller against low flow conditions. An new
evaporator interlock and flow switch MUST be fitted.
For full control panel component layout, refer to Parts Identification.
new
see TM
E
L1
L2 L3
(Red) (Yellow) (Blue)
Cable Entry
Side/Base
USC250…-12 to
USC650…-16
14
Cable Entry
Side/Base
L1
L2
L3
E
ç
ç
ç
ç
Mains Incoming Supply
400V/3PH/50HZ
L4
N
E
ç
ç
ç
Permanent Supply
230V/1PH/50HZ
502
503
è
ç
Evaporator Pump Interlock 24VAC
503
504
è
ç
Evaporator Pump Water Flow Switch 24VAC
502
505
è
ç
Remote ON/OFF 24VAC
800
801
803
è
è
ç
0V DC
24V DC
Remote Setpoint Adjustment 1 to 10v dc.
573
574
575
ç
è
è
576
577
578
ç
è
è
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
Circuit 1
Volt Free Alarm Common
Volt Free Alarm N/O
Volt Free Alarm N/C
Circuit 2
Volt Free Alarm Common
Volt Free Alarm N/O
Volt Free Alarm N/C
ULTIMA 2000
Chillers
Installation Data
as TM
ELECTRICAL DATA
Model
Unit Data
(1)
Nominal Run Amps
(2)
Maximum Start Amps
Permanent Supply
Mains Supply
Recommended Permanent
Fuse Size
Recommended Mains Fuse
Size
Maximum Permanent
Incoming Cable Size
Maximum Mains Incoming
Cable Size
Control Circuit
USC250...-8
USC275...-8
USC300...-8
A
A
VAC
VAC
A
164
275
188
344
16
176
287
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
A
200
250
250
mm²
4mm² Terminal
mm²
Direct to Bus Bar
VAC
24V / 230VAC
16
Evaporator
Trace Heater Rating
W
175
200
200
Condenser Fan - Per Fan
Full Load Amps
Locked Rotor Amps
Motor Rating
A
A
kW
1.75
6.20
0.98
1.75
6.20
0.98
1.75
6.20
0.98
kW
A
kW
43
75
150
193
50 + 43
87 + 75
150
250 + 193
Star / Delta
50
87
150
250
A
A
A
A
150
275
200
68
160
287
200
78 + 68
170
344
250
78
A
A
A
A
164
275
200
75
176
287
250
87 + 75
188
344
250
87
1.15
2.10
0.70
1.15
2.10
0.70
Compressor - Per Compressor
Motor Rating
Nominal Run Amps
(2)
Crankcase Heater Rating
Start Amps
(3)
Type Of Start
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(2)
Maximum Start Amps
(3)
Recommended Mains Fuse
Compressor Nominal Run
Amps - Per Compressor
Closed Transition Start
Nominal Run Amps
(2)
Maximum Start Amps
Recommended Mains Fuse
Compressor Nominal Run
Amps - Per Compressor
SUPER QUIET DSQ
Condenser Fan - Per Fan
Full Load Amps
Locked Rotor Amps
Motor Rating
(1)
(2)
(3)
All data as above except:
A
A
kW
1.15
2.10
0.70
EN001
EN008
EN004
Refers to standard speed fans.
Based at 12/7°C water and 30°C ambient
Starting amps refers to the Star connection only.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
15
Chillers
ULTIMA 2000
Installation Data
as TM
ELECTRICAL DATA
Model
Unit Data
(1)
Nominal Run Amps
(2)
Maximum Start Amps
Permanent Supply
Mains Supply
Recommended Permanent
Fuse Size
Recommended Mains Fuse
Size
Maximum Permanent
Incoming Cable Size
Maximum Mains Incoming
Cable Size
Control Circuit
USC350...-12
USC400...-12
USC450...-12
A
A
VAC
VAC
A
222
375
279
403
16
249
373
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
A
315
315
355
mm²
4mm² Terminal
mm²
Direct to Bus Bar
VAC
24V / 230VAC
16
Evaporator
Trace Heater Rating
W
200
200
200
Condenser Fan - Per Fan
Full Load Amps
Locked Rotor Amps
Motor Rating
A
A
kW
1.75
6.20
0.98
1.75
6.20
0.98
1.75
6.20
0.98
kW
A
kW
68 + 50
114 + 87
150
248 + 250
68
114
150
248
87 + 68
144 + 114
150
316 + 248
Compressor - Per Compressor
Motor Rating
Nominal Run Amps
(2)
Crankcase Heater Rating
Start Amps
(3)
Type Of Start
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(2)
Maximum Start Amps
(3)
Recommended Mains Fuse
Compressor Nominal Run
Amps - Per Compressor
Closed Transition Start
Nominal Run Amps
(2)
Maximum Start Amps
Recommended Mains Fuse
Compressor Nominal Run
Amps - Per Compressor
SUPER QUIET DSQ
Condenser Fan - Per Fan
Full Load Amps
Locked Rotor Amps
Motor Rating
(1)
(2)
(3)
16
Star / Delta
A
A
A
A
201
375
250
102 + 78
225
373
315
102
252
403
315
129 + 102
A
A
A
A
222
375
315
114 + 87
249
373
315
114
279
403
355
144 + 114
1.15
2.10
0.70
1.15
2.10
0.70
All data as above except:
A
A
kW
1.15
2.10
0.70
Refers to standard speed fans.
Based at 12/7°C water and 30°C ambient
Starting amps refers to the Star connection only.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
EN001
EN008
EN004
ULTIMA 2000
Chillers
Installation Data
as TM
ELECTRICAL DATA
Model
Unit Data
(1)
Nominal Run Amps
(2)
Maximum Start Amps
Permanent Supply
Mains Supply
Recommended Permanent
Fuse Size
Recommended Mains Fuse
Size
Maximum Permanent
Incoming Cable Size
Maximum Mains Incoming
Cable Size
Control Circuit
USC500...-12
USC575...-16
USC650...-16
A
A
VAC
VAC
A
309
471
390
484
16
353
511
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
A
400
450
500
mm²
4mm² Terminal
mm²
Direct to Bus Bar
VAC
24V / 230VAC
16
Evaporator
Trace Heater Rating
W
250
250
250
Condenser Fan - Per Fan
Full Load Amps
Locked Rotor Amps
Motor Rating
A
A
kW
1.75
6.20
0.98
1.75
6.20
0.98
1.75
6.20
0.98
kW
A
kW
87
144
150
316
107 + 87
181 + 144
150
289 + 316
Star / Delta
107
181
150
289
A
A
A
A
279
471
355
129
319
511
400
162 + 129
352
484
450
162
A
A
A
A
309
471
400
144
353
511
450
181 + 144
390
484
500
181
1.15
2.10
0.70
1.15
2.10
0.70
Compressor - Per Compressor
Motor Rating
Nominal Run Amps
(2)
Crankcase Heater Rating
Start Amps
(3)
Type Of Start
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(2)
Maximum Start Amps
(3)
Recommended Mains Fuse
Compressor Nominal Run
Amps - Per Compressor
Closed Transition Start
Nominal Run Amps
(2)
Maximum Start Amps
Recommended Mains Fuse
Compressor Nominal Run
Amps - Per Compressor
SUPER QUIET DSQ
Condenser Fan - Per Fan
Full Load Amps
Locked Rotor Amps
Motor Rating
(1)
(2)
(3)
All data as above except:
A
A
kW
1.15
2.10
0.70
EN001
EN008
EN004
Refers to standard speed fans.
Based at 12/7°C water and 30°C ambient
Starting amps refers to the Star connection only.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
17
Chillers
ULTIMA 2000
Controls
as TM
CONTROL SCHEME FEATURES
Airedale recognises that all chiller applications are different but fall mainly into 2
application categories; Variable Supply Temperature and Constant Supply Temperature.
General
The onboard microprocessor has the capability of satisfying either control requirement as
illustrated below. Using the Airedale Variable Supply Temperature control scheme,
energy savings are available when compared with previous schemes and that of the
Constant Supply Temperature application.
Variable Supply Temperature control schemes offer energy savings where the supply
water temperature is not critical to its operation.
Selection of the best application control scheme can be made via a software switch in the
microprocessor during initial commissioning.
Examples based on Models USC250...-8 to USC500…-12 having 6 Stages
of Cooling
14
WATER TEMPERATURE °C
Variable Supply
Temperature Control
13
Return Water Temperature
12
11
10
Mean Value
Supply Water Temperature
9
8
7
Compressor Off
6
20%
1
Constant Supply
Temperature Control
40%
55%
70%
85%
100%
2
3
4
5
6
Chiller
Capacity %
Cooling Stage
Sequence
14
13
WATER TEMPERATURE °C
12
Return Water Temperature
11
10
9
Supply Water Temperature
8
7
0
6
CAUTION
18
20%
2
1
440%
2
655%
3
70%
8
4
10 85%
5
100%
12
6
Chiller
14
Capacity
%
Cooling Stage
Sequence
Prior to enabling the unit, the mode of operation should be selected, refer to
Adjusting Customer Control Settings - Constant Supply Control.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
new
ULTIMA 2000
Chillers
Controls
new
OPERATION
Display Keypad
Flashing
Cursor
I/P 1 RETURN TEMPERATURE
11.8 DegC
new
2 Row LCD
External
Alarm Mute
On/Off
X!
I/O
1
2
3
4
(Not used)
4 Customer
Pre-Programmable
Displays only
Audible
Alarm
Visual
Alarm
Access, Navigation &
Adjustment
Password Protection
new
The display is used for Viewing Unit Operating Status and Adjusting Customer
Control Settings by allowing the operator access to a series of Display Pages. Viewing
information is unrestricted, however set up and adjustment requires password entry, refer
to Password Protection.
Use the cursor to direct you through the Display Pages, use the / keys to place the
cursor to the top left of the display and use / keys to scroll through available pages.
new
When the desired page is selected, to Adjust Customer Control Settings, place the
cursor under the item to change using the / keys and then increase/decrease the
value by using the / keys.
new
To guard against unauthorised adjustments, a password is required to gain access.
new
FACTORY SET PASSWORD PIN NUMBER: 4648 (or Customer chosen number).
new
Once protected, using a Software Knob for example, use the following instructions to
make a change:
new
1
2
new
new
3
4
CAUTION
Display Pages
(Listed in Sequence)
Cursor Movement, use to:
View Operating Status &
Adjust Customer Settings
Select the desired Software Knob display.
Attempt to change the Software Knob value which will result in the display
“5*** Enter your PIN”
To enter the PIN number, place the cursor under each of the 4 digits represented
as “5***” and select the desired numbers using the / keys.
Following entry of the last digit there will be a short delay, then access will be
made available.
new
new
The display will automatically Time Out after 2 minutes following the last keystroke
/cursor movement to prevent unauthorised access.
new
The display “EDIT INHIBITED” will appear if the PIN entered is invalid or excessive
time is taken to enter the PIN. Check and re-enter the PIN number to clear.
new
PAGE TITLE
SCREEN DISPLAYS
new
Status Page
Real Time Clock
Sensor Inputs
Digital Sensors
Software Knobs
Software Switches
Drivers
Time Zones
Optimum Start/Stop
Calendar
Alarms
Auto Dial Option
“Status”
“Time”
“Sens”
“Digin”
“Knob”
“Switch”
“Driver”
“Zone”
“Oss” - NOT USED
“Calendr”
“Alarm”
“DIALLER” - NOT USED
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
19
Chillers
ULTIMA 2000
Controls
new
Always start from the Status page.
SETTING UP
new
Real Time Clock
Time
On by
CAUTION
9:16 Tue 23 May 0
0 hour on 0 ? back on 0 ?
To set , move the cursor under the number or month you wish to change and increase or
decrease by using the / keys as required.
new
Line 2, refers to seasonal time changes which must only be programmed on one
unit within a network.
new
new
Time Zones
Zone 1 STD OPERATING TIMES
Next
Fri
0:00 to 24:00
24:00 to 24:00
24:00 to 24:00
on 0 ?
The programme provides 3 factory set periods, which provide 24 hour per day continuous new
operation and can be altered to suit. The unit will be factory set for continuous operation
and will not normally require further adjustment.
Set up 1
2
Position the cursor under the time value(s) to change and increase or decrease by
using the / keys as required.
new
Move the cursor to the period type eg “Next” and select as follows:
“Every” - will operate during the programme times every week.
“Next” - will operate on the next occurrence of the times set and then revert to
“Every”.
new
new
Calendar
Calendr 1
CAUTION
Free 0 ? - 0 ?
Zone 1 Unocc
The Calendar offers 20 holiday dates, programmable as individual days or periods of up
to 99 days. The unit will be factory set for no holiday shut down and will not normally
require further adjustment.
new
Holidays must be programmed at least 7 days before the actual holiday date.
new
Set up 1
2
3
4
5
6
7
Position cursor under the calendar number eg Calendr 1, to select the first set-up
period.
Move the cursor to period type eg “Free” and select as follows:
“Free” - holiday will not occur
“Next” - holiday displayed will activate at next occurrence only and then “Free”after
“Every” - holiday will occur every year.
Move to the start day eg “0”, scroll through 1-31 days as required.
Move to the start month eg “?”, select month.
Repeat 3 & 4 for the end date.
”Zone” and ”Unocc” are not used.
Repeat the above for each period.
Pre-Programmable Keys The keys numbered 1, 2, 3 and 4 can provide quick access to 4 customer
new
new
new
new
new
new
new
new
new
pre-programmed items such as frequently monitored or changed displays.
Set up 1
2
3
Technical Support
20
Select the required display and position the cursor under the value or setting
number.
Press Key 1 and hold down. Initially the display will revert to the previously
programmed page. After 5 seconds the display will revert to the new selection.
Repeat steps 1 and 2 for Keys 2, 3 and 4.
A full Controls Manual is available on request, please contact Airedale Services.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
new
new
new
new
ULTIMA 2000
Chillers
Controls
VIEWING UNIT OPERATING STATUS
Status Page
The Status page will appear following start up of the controller; it is recommended that
the display is always returned to the Status page following review or adjustment.
Strategy
Code
Outstation
Number
Status USC2E6A
Alarm 0 on LAN
Alarm
Address
new
new
Toggles “OK” or
“Data”, confirms
validity of data
Address
20 Data
0
Text ON IQ204 2.1
Alarm Message
Type, Always
ON
Controller &
Firmware
Issue
new
Sensor Inputs
Sens 1 RETURN TEMPERATURE
12.0 DegC
External
To view, position the cursor under the sensor number eg “Sens 1”, scroll through the
sensors as listed:
Sens 1
Sens 2
Sens 3
Sens 4
Sens 6
Sens 7
Sens 8
Sens 9
Sens 10
Sens 11
RETURN TEMPERATURE
SUPPLY TEMPERATURE
CP1 SUCTION PRESSURE
CP1 LIQUID PRESSURE
CP2 SUCTION PRESSURE
CP2 LIQUID PRESSURE
REM. SETPOINT INPUT
REMOTE SETPOINT
COMP. 1 HOURS RUN
COMP. 2 HOURS RUN
new
Hard Wired Input Sensors
Internally Calculated Sensor
Values
new
Digital Inputs
Digin 1 PHASE ROTATION
Off
External
To view, position the cursor under the digital input number eg “Digin 1”, scroll through
the sensors as listed:
Digin 1
Digin 2
Digin 3
Digin 4
Digin 5
Digin 6
Digin 7
Digin 8
Digin 9
Digin 10
Digin 11
Digin 12
Digin 13
Digin 14
Digin 15
Digin 16
Digin 17
Digin 18
PHASE ROTATION
EMERGENCY STOP
EVAP. FLOW SWITCH
REMOTE ON/OFF
COMPRESSOR 1 STATUS
NOT USED
COMPRESSOR 2 STATUS
EEV ALARM INPUT
EVAP. FLOW FAILURE
LOW SUPPLY TEMP.
CCT 1 FAULT
CCT 2 FAULT
CCT 1 LOW SUCTION
CCT 2 LOW SUCTION
CCT 1 HIGH LIQUID
CCT 2 HIGH LIQUID
REMOTE SP FAILURE
EEV CONTROL FAILURE
Hard Wired Input Sensors
Internally Calculated Sensor
Values
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
21
new
Chillers
ULTIMA 2000
Controls
VIEWING UNIT OPERATING STATUS
new
Driver Outputs
Driver
1
CCT 1 COMPRESSOR 0.0
0/p 1 = 0
Displays the status of the outputs from the controller and will show “ON/OFF” or a
percentage output as listed:
Driver 1
Driver 2
Driver 3
Driver 4
Driver 5
Driver 6
Driver 7
Driver 8
CCT 1 COMPRESSOR
CCT 2 COMPRESSOR
CCT 1 COMMON ALARM
CCT 2 COMMON ALARM
CCT 1 FAN HPC O/P 1
CCT 1 FAN HPC O/P 2
CCT 2 FAN HPC O/P 1
CCT 2 FAN HPC O/P 2
0 – 100 %
0 – 100 %
ON / OFF
ON / OFF
0 – 100 %
0 – 100 %
0 – 100 %
0 – 100 %
new
USC 575 & 650 Only
USC 575 & 650 Only
An Audio-Visual alarm will be triggered at the display by the conditions listed below and
the controller will effect the following actions.
new
Phase Rotation
A normally closed contact. When Phase Rotation is incorrect all controller outputs are
de-activated.
new
Emergency Stop
A normally open contact. On closing, all controller outputs are de-activated.
new
Evaporator Flow Failure
A normally closed contact. On opening, all controller outputs are de-activated.
new
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.
new
Remote Setpoint Failure
If the Remote Setpoint input becomes open or short-circuited while the remote setpoint is
enabled, the unit will revert to the internal Supply Water Temperature setpoint.
new
Electronic Expansion
Valve Control Failure
This indicates that the Electronic Expansion Valve (EEV) controller has detected an
operating problem with either one or both circuits.
new
Restart
When power is restored. A restart alarm message will be recorded in the alarm log
new
Alarms
COMMON ALARMS
new
INDIVIDUAL CIRCUIT ALARMS
Circuit 1 / 2 Fault
A normally closed contact when the compressor is operating. If this contact remains open new
for a period of 15 seconds during operation of the compressor, the relevant compressor
will be de-activated.
Circuit 1 / 2 Low Suction When the Suction Pressure Sensor Value falls below the value set by the low suction
level for a period exceeding 1 minute (or 3 minutes on compressor start-up), the relevant
Pressure
new
compressor will be de-activated.
Circuit 1 / 2 High Liquid
Pressure
When the Liquid Pressure Sensor Value reaches 23BarG, the relevant compressor will
unload its final stage and will only reset when its drops below 21BarG.
new
Alarm Handling
The Alarm page holds the last 20 alarm messages in descending chronological order.
The messages indicate active alarms and cleared alarms following rectification.
new
•
•
•
•
new
new
new
new
CAUTION
22
Press the Mute button to silence the audible alarm.
Display the Alarm page to identify the nature of the alarm.
Determine if the alarm is auto-resetting or requires some form of manual reset.
If the alarm requires manual reset isolate the unit before further investigation (refer
to Software Switches - Alarm Reset).
ALWAYS press the Mute button following an alarm to de-active automatically.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
new
ULTIMA 2000
Chillers
Controls
ADJUSTING CUSTOMER CONTROL SETTINGS
Software Knobs
The following factory set unit operating and alarms settings may be viewed and adjusted: new
Knob Title & Sequence
•
Restart Delay
•
Supply Water Temperature Setpoint
•
Unit Temperature Difference
•
Supply Water Temperature Low Limit
•
Low Suction Level
•
Compressor Loading Delay
•
Head Pressure Control Setpoint
•
Head Pressure Control Stage Differential
•
Head Pressure Control Proportional Gain
•
Head Pressure Control Integral Term
•
Unit Loading Stage 1 to 8
Factory Set
10 seconds
7°C
5°C
3°C
3.2 BarG
90 seconds
17 BarG
18%
-20
5
Refer to Airedale
Range
10
-7
4
-10
2.5
10
10
0
-100
0
0
-
120
20
8
20
10
120
25
18
0
100
100
Restart Delay
The Restart Delay is the delay before the controller energises any of its controlled outputs new
after a power failure. In order not to induce large currents on multiple unit systems startup, the restart delay may be adjusted to different values within each chiller controller.
Supply Water
Temperature Setpoint
The controller uses the Supply Water Temperature Setpoint and the unit temperature
difference setting to calculate the individual cooling stage setpoints, i.e. the temperatures
at which each of the compressor stages are activated or de-activated.
new
The setpoint is utilised for both Constant and Variable Supply Water Temperature
controls schemes.
new
Unit Temperature
Difference
new
The Unit Temperature Difference entered should be equal to the temperature difference
between supply and return water when the unit is operating at maximum cooling capacity.
Supply Water
Temperature Low Limit
If the Supply Water Temperature falls below the low limit value set by this knob the
controller will generate a manual reset alarm and de-activate all controller outputs.
new
Due to the application of low temperature glycol systems, it is possible to adjust this
temperature below 0°C.
new
Under no circumstances should the low temperature value be adjusted to within
less than 3°C of the freezing temperature of the fluid being used.
new
Low Suction Level
When the suction pressure sensor value falls below the value set by the Low Suction
Level for a period exceeding 1 minute or 3 minutes on compressor start-up, an audiovisual alarm will be generated at the display and the relevant compressor will be deactivated.
new
Compressor Loading
Delay
new
If, after a cooling stage has been initialised there is still a cooling demand; the controller
will inhibit the next cooling stage output until the duration in this knob setting has elapsed.
If the cooling demand is still required after this delay period has elapsed the controller will
initialise another cooling stage.
Head Pressure Control
Setpoint
The head pressure of each circuit will be controlled to the value entered in this knob.
new
Head Pressure Control
Stage Differential
When the stepped head pressure control option is selected the value in this knob is used
to calculate the actual on and off switching points for each condenser fan stage.
new
Head Pressure Control Gain & Integral Term
The Gain and Integral Term are used together to calculate the head pressure control
output. The proportional gain value must be entered as a negative number.
new
Unit Loading Stage 1 - 8
Factory set to suit the percentage loading of each cooling stage with respect to the unit
temperature difference.
new
CAUTION
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
23
Chillers
ULTIMA 2000
Controls
ADJUSTING CUSTOMER CONTROL SETTINGS
Software Switches
The following factory set application settings may be viewed and adjusted to user requirements:
Switch Title & Sequence
•
Local On/Off
•
Alarm Reset
•
Constant Supply Water Temperature Control Mode
•
Stepped or Modulated Head Pressure Control Output
•
8 or 12 Condenser Fans Fitted (Only available on 6 stage unit)
•
Enable Electronic Expansion Valve Control
•
Enable Remote Supply Water Temperature Setpoint
•
CP1 Hours Run Reset
•
CP2 Hours Run Reset
•
CP1 Force Lead / Auto Rotation
•
CP2 Force Lead / Auto Rotation
new
Factory Set
Off
Off
Off
Dependant on
unit options
fitted
Off
Off
Off
Off
Off
Local On / Off
If ON is selected the unit can be operated locally. If OFF is selected then the unit will be
operated using the remote on / off customer input.
new
Alarm Reset
If ON, the controller will reset any of the alarm conditions. After a short delay the switch
will automatically return to OFF.
new
Constant Supply Control If ON is selected then the cooling stages will be controlled to maintain a Constant
new
Supply Water Temperature. If OFF is selected then the cooling stages will be controlled
to provide a Variable Supply Water Temperature.
Head Pressure Control
Stepped / Modulated
Output
If ON is selected, the Head Pressure Control Output will produce fixed outputs to operate
the condenser fans individually. If OFF is selected, the head pressure control output will
modulate between 0 – 100%. When in this mode the output is used to operate the
condenser fan speed controllers to vary the fans between minimum and maximum speed.
new
Condenser Selection 8
or 12 Fan
This switch is only used when stepped head pressure control mode is selected. If OFF is
selected then 8 fan stepped head pressure control mode is enabled. If ON is selected
then 12 fan stepped head pressure control mode is enabled.
new
Only available on 6 stage units with a total of 8 or 12 condenser fans.
new
If ON is selected then unit will control temperature using the Remote Setpoint customer
input. If OFF is selected then the unit will use the supply water temperature setpoint to
control the temperature.
new
If ON is selected then the controller will monitor the Electronic Expansion Valve Input for
Enable Electronic
Expansion Valve Control an alarm. If OFF is selected then the alarm function is disabled.
new
CAUTION
Enable Remote Setpoint
Compressor 1 Hours
Run Reset
Compressor 1 Hours Run can be set to zero by setting this switch to ON. After a short
delay the switch will automatically return to OFF.
new
Compressor 2 Hours
Run Reset
Compressor 2 Hours Run can be set to zero by setting this switch to ON. After a short
delay the switch will automatically return to OFF.
new
Compressor 1 Force
Lead / Auto
If ON is selected Compressor 1 will be forced to be the lead compressor regardless of its
hours run. If OFF is selected the controller will automatically select the lead compressor
based on the lowest hours run.
new
Compressor 2 Force
Lead / Auto
If ON is selected Compressor 2 will be forced to be the lead compressor regardless of its
hours run. If OFF is selected the controller will automatically select the lead compressor
based on the lowest hours run.
new
Either Compressor Force Lead / Auto switch can be ON, but only one can be ON at
any one time.
new
CAUTION
24
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
ULTIMA 2000
Chillers
Commissioning Data
as TM
GENERAL DATA
Operating Limits
Standard Unit
Minimum Ambient Air DB °C
Maximum Ambient Air DB °C
Minimum Leaving Water Temperature °C
Maximum Return Water Temperature °C
-5°C
Refer to Technical Manual
+5°C
+20°C
Unit with Electronic Fan Speed HP Control (-20°C)
Minimum Ambient Air DB °C
-20°C
Maximum Ambient Air DB °C
Refer to Technical Manual
Minimum Leaving Water Temperature °C
+5°C
Maximum Return Water Temperature °C
+20°C
For conditions outside those quoted, please refer to Airedale.
CT018
MECHANICAL DATA
se TM
Oil & Refrigerant Charges
Model
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Charge (Total)
SUPER QUIET DSQ
Refrigerant Charge (Total)
USC250…-8
USC300…-8 USC350…-12 USC400…-12
L
2
10 + 10
Screw - Semi Hermetic
2
2
10 + 10
10 + 10
Polyolester
kg
45 + 45
55 + 45
All data as above except:
55 + 55
65 + 55
kg
Model
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
USC275…-8
2
13 + 10
2
13 + 13
Dual Circuit
55 + 55
95 + 80
95 + 95
65 + 65
105 + 90
105 + 105
USC450…-12 USC500...-12 USC575...-16 USC650...-16
L
2
13 + 13
Refrigeration
Charge (Total)
kg
95 + 95
SUPER QUIET DSQ
Refrigerant Charge (Total)
kg
Screw - Semi Hermetic
2
2
13 + 13
18 + 13
Polyolester
Dual Circuit
95 + 95
125 + 115
All data as above except:
105 + 105
110 + 110
145 + 145
2
18 + 18
125 + 125
145 + 145
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
25
Chillers
ULTIMA 2000
Commissioning Data
as TM
WATER SYSTEM DATA
Waterside Pressure
Drops
100
USC250 to USC300…-8
80
USC350…-12
60
40
20
0
5
10
15
20
25
30
WATERFLOW (l/s)
100
USC400…-12
80
USC450…-12
60
40
20
0
10
15
20
25
30
35
WATERFLOW (l/s)
100
USC500…-12
USC575 to USC650…-16
80
60
40
20
0
10
15
20
25
30
WATERFLOW (l/s)
26
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
35
40
45
ULTIMA 2000
Chillers
Commissioning Data
ELECTRICAL DATA
compressor Start-Up
Information
CLIENTS
INCOMING
SUPPLY
400/3/50
L1
L2
L3
PE
new
CB1
1 3 5
14
11
12
RED
YEL
BLU
2 4 6
2
4 6
1
3 5
2
4 6
RED
YEL
RED
YEL
BLU
RED
YEL
BLU
1
3 5
2
4 6
CP5
CP3
2 4 6
1 3 5
CP7
2 4 6
RED
YEL
BLU
1 3 5
CP1
BLU
5
2 4 6
BLU
RED
YEL
BLU
1 3
3 5
CLOSED TRANSITION START
OPTIONAL EXTRA
RED
YEL
POWER FACTOR CORRECTION
OPTIONAL EXTRA
PF1
1
CB2
1 3 5
OL1
POWER
FACTOR
CORRECTION
CAPACITOR
POWER
FACTOR
CORRECTION
CAPACITOR
YEL
BLU
RED
2 4 6
E
W
V
U
M1
3~
Y
Z
X
PRR1
Starting Sequence (StarDelta Starting)
U V W
PHASE
ROTATION
RELAY
14
11
12
COMPRESSOR
new
CP5
On
CP1
On
CP5
Off
5 Sec ± 1
Star
CP3
On
< 40 ms
Delta
new
Operational Sequence
Refrigerant Charge
Liquid refrigerant should be charged into the condenser before compressor starting to
ensure that refrigerant is present at compressor start-up.
new
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.
new
Pre-Start-Up Check
Before compressor start-up, make sure that an oil level is showing in the compressor
sight glass, and that all refrigerant ball valves are opened, including the liquid
injection line.
new
Checks at Compressor
Start-up
As soon as the compressor starts, make sure that the solenoid valve for liquid injection
opens, and that the suction and liquid/discharge pressure gauges are showing low and
high pressures respectively.
new
If there is no liquid present or no differential pressure occurs, isolate immediately.
new
Check phase rotation by connecting pressure gauges to the suction and
discharge ports.
new
Never shut down the liquid injection circuit whilst the compressor is still running, at any
loading condition as this may permanently damage the compressor.
new
CAUTION
Liquid Injection
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
27
Chillers
ULTIMA 2000
Commissioning Data
ELECTRICAL DATA
Capacity Control
The following staggered timings are recommended on compressor start-up:
new
100%
70%
40%
12%
Start
0%
•
•
•
15 Sec ± 5
180 Sec ± 10
12% load (starting position) should be used only at start-up, never as a stage of
capacity control.
12% load at start-up should be maintained for 10 - 20 seconds to avoid
liquid compression.
The first stage of capacity control (either 25 or 40% depending on compressor
size) should be maintained for at least 170 - 190 seconds before further loading.
new
Adding Refrigerant
Additional refrigerant should be added to the system via 1/4” schrader connection on the
expansion line.
new
Pump Down
Never shut the liquid injection solenoid valve during or before pump down, and never
pump down without the low pressure trip and high discharge temperature switches
being operative.
new
new
Unloading Protection
Head Pressure
The microprocessor has inbuilt protection against nuisance trips. If the head pressure
rises above 23BarG the compressor will unload to 70% and remain unloaded until the
head pressure drops below 21BarG.
new
Low Pressure
If low pressure drops below the microprocessor setting, the compressor will unload to
70%, if low pressure persists for 1 minute, the circuit will be switched off and sound
an alarm.
new
28
Chillers
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ULTIMA 2000
Chillers
Commissioning Procedure
GENERAL
CAUTION
To be read in conjunction with the commissioning sheets provided, items highlighted
should be recorded.
new
Please ensure all documents have been completed correctly and return to Airedale
Service immediately to validate warranty.
new
new
PRE COMMISSIONING CHECKLIST
CAUTION
RECORD
ALL work MUST be carried out by Technically Trained competent personnel.
new
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
new
Prior to carrying out the following, in order to prevent liquid entering the
compressor whilst the mains MCCB are in the OFF position, isolate the liquid
injection and liquid line solenoid valves at the terminal blocks (located above the
bus bar).
new
The door interlocking MCCB should be in the OFF position and the auxiliary alarm
contact from the MCCB should be linked out.
new
Ensure all items listed in the Pre commissioning section are complete.
new
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
CAUTION
The chiller will not start until microprocessor control SWITCH 1 is in the ON
position. DO NOT SWITCH TO ON AT THIS STAGE
new
•
Adjust the water temperature supply and return set points (if necessary) to call for
100% cooling (refer to the Control Section).
Ensure all KNOBS and SWITCHES are adjusted to suit the design requirements
(refer to the Control Section).
Turn the unit on by setting SWITCH 1 to enable unit to ON.
new
There will always be a delay between the enabling of the unit and the energising of
the compressor contactors, anything between 1 to 2 minutes. Be patient, refer to
Control Section.
new
•
new
•
•
CAUTION
CAUTION
new
The unit should be visually inspected and any damage noted.
Secure commissioning gauges to the high side of the system, check for a
positive charge.
Check tightness of electrical components.
Check that the remote on/off switch (if fitted) is in the off position.
With the MCBs in the off position measure the incoming voltage.
Check Phase Rotation.
Check voltage at permanent supply.
Measure and record the primary (230V) 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 water filter is fitted.
Check design water flow is available.
Check flow switch and pump interlocks are fitted to the water system.
Switch on the controls and individual circuits, primary and secondary, MCBs to the
ON position. At this stage the control display panel should be illuminated.
Record Optional Extras.
Record IQ Controller Data.
Check that there is a 5 seconds delay between the Star and Delta contactor
energising on each circuit.
Chillers
new
new
This delay period would be 0.7 seconds in Closed Transition Starting.
Installation & Maintenance Manual : 903-099 IM E 05/00
new
29
Chillers
ULTIMA 2000
Commissioning Procedure
PRE COMMISSIONING CHECKLIST (CONT..)
•
•
•
RECORD
•
•
•
•
CAUTION
30
Check capacity control timing as detailed previously.
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, clear the alarms as detailed
in the microprocessor manual.
Reduce the flow rate to 75% of design and ensure that the evaporator pressure
differential switch or flow switch trips off this flow rate, adjust if necessary.
Ensure this alarm is recognised at the display and disengages the circuits operation
immediately. Restore flow rate to the design and check the alarm has self-cleared.
Turn the unit OFF by setting SWITCH 1, enable unit to the OFF position.
Fully open all liquid line and discharge service ball valves on each circuit.
new
new
new
new
new
new
new
Re-instate both the liquid injection and liquid line solenoid valves.
new
Remove the link from the MCCB for the auxiliary alarm contact.
new
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
ULTIMA 2000
Chillers
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.
new
•
Switch the door interlocking MCCB to the ON position but again only on the circuit new
which is to be tested.
•
Adjust the water temperature supply and return set points to match the system
requirements. Turn the unit ON by setting SWITCH 1, enable unit to the ON
position. The unit will start after a short delay.
new
•
Check liquid injection solenoid valve is energised and sight glass is clear.
new
•
Check pressures at suction and discharge ports for correct phase rotation.
new
CAUTION
If there is no liquid present or no differential pressure occurs, isolate immediately.
new
RECORD
•
new
•
Check the unloading solenoids operate in the correct sequence - refer to
Commissioning Data - Electrical Data - Capacity Control.
Measure and record the compressor amps once the compressor is fully loaded
and at each stage of unloading.
•
Measure and record full speed amps of each condenser.
new
•
Ensure that the refrigeration safety cut outs trip at the following settings:
LP micro - adjustable – refer to Controls section - Software Knobs
LP safety 0.6 +/- 0.1 BarG - fixed
HP safety 24.5 +/- 0.7 BarG - fixed
Clear the alarm as detailed in the microprocessor manual
new
new
CAUTION
RECORD
new
The microprocessor LP setting is adjustable via the micro display. It is
recommended that this setting be 0.6 Bar below the equipment freezing point of the
cooling medium ie for water (no glycol) LP micro settings is 3.2BarG.
new
•
Ensure that the low water temperature safety cuts out at the correct setting
+/- 0.5°C clear the alarm as detailed in the microprocessor operating manual. For
water (no glycol) application the recommended setting is 3°C or 3°C below the
design supply water temperature.
new
•
Check the liquid line sight glass is clear and dry.
new
•
Check the superheat setting adjust the expansion valve to maintain a superheat
setting of 5 – 8°C at all operating loads.
new
•
Check and record the following:
Suction and discharge pressures
Liquid, discharge and suction line temperature
Water inlet and outlet temperature
new
new
new
new
•
Ensure the above are all within the design parameters.
new
•
Turn the unit off by setting SWITCH 1, to enable unit.
new
•
Repeat the above for each circuit.
new
•
Turn the unit ON by setting SWITCH 1, enable unit to ON.
new
new
The unit is now commissioned and will provide many years of trouble free operation
providing the following maintenance schedule is followed.
Chillers
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31
Chillers
ULTIMA 2000
Maintenance
CAUTION
GENERAL
MAINTENANCE
ALL work MUST be carried out by Technically Trained competent personnel.
new
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
new
The maintenance schedule indicates the time period between maintenance operation.
new
3 MONTHS
ACTION
NOTES
REFRIGERATION
Check the following and compare results with
commissioning records.
• Suction and discharge readings.
• Head pressure control is maintained.
• Pressure relief indicator gauge.
• Liquid injection solenoid valve and sight glass.
• Check each circuit sight glass for dryness and
bubbles for indication of leaks.
• Check compressor oil level and shell/sump
temperature.
Investigate and rectify variations.
Remember to re-cap the Schraeder
connections!
SYSTEM
Check the following against the commissioning
Investigate and adjust as necessary.
records.
• 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 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 paint (available
from Airedale or your Distributor).
Visually inspect pipe and pipework insulation.
Repair/rectify as necessary.
Clean evaporator water strainer.
At first maintenance visit and then as
frequently as necessary (12 months).
Clean condenser coils. Do not steam clean use
detergent and stiff bristled brush. For heavy dirt, use
either a high pressure water or chemical hose.
Do not damage fins and comb out if
necessary.
Visually check the following:
• Pipework clamps are secure.
• Tightness and condition of fan and compressor
mounts.
• Anti-Vibration mounts fixings (if fitted).
Secure/tighten as necessary.
Finally!
32
Ensure control panel lids and access panels have
been correctly replaced and securely fastened in
position.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
ULTIMA 2000
Chillers
Maintenance
GENERAL
MAINTENANCE (CONT..)
6 MONTHS
ACTION
NOTES
Repeat 3 month checks plus the following:
SYSTEM
Check evaporator trace heating and low ambient
thermostat are set to activate at 4.0ºC.
Remember to re-cap the Schraeder
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.
Leak test all R407C joints and inspect all water
connections.
Rectify as necessary.
Check superheats with chiller running on full 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.
ELECTRICAL
Tighten all electrical terminals.
COMPRESSOR
MAINTENANCE
SHUT DOWN PERIODS
Periodic maintenance and inspection of this equipment is necessary to prevent premature new
failure, the following periodic inspections should be carried out by period or hourly use
which ever is sooner.
1 Year
Measure compressor motor insulation.
7,500 Hours or 4 Years
Inspect compressor oil.
20,000 Hours or 4 Years
Inspect oil filter, gate rotor & suction filter.
For periods of winter shut down the following precautions are recommended:
•
Close the liquid and discharge ball valve
•
Cap service ports
•
Turn off electrical circuits
•
Drain the water from the chiller evaporator via the evaporator drain plug.
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
33
Chillers
ULTIMA 2000
Parts Identification
For ease of identification when ordering spares or contacting 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.
SPARES
std
A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from std
our Spares department on request.
new
The serial plate can be located inside Item 24.
1
2
2
8
9
5
3
10
4
11
6
12
14
14
19
5
7
13
7
7
20
15
16
15
17
18
17
7
21
22
28
23
24
25
27
29
26
26
30
16
17
31
32
33
34
35 36
39
40
34
38
37
42
33
41
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
47
44
43
45
48
46
50
49
52
51
16
ULTIMA 2000
Chillers
Parts Identification
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
new
Electronic Expansion Valve Controller (Optional Extra)
Power Factor Correction/Closed Transition Connection (Optional Extra)
Microprocessor Controller (IQ204)
Phase Rotation Relay
Circuit 1 Timers
Incoming Customer Terminals
Incoming Customer Mains Access Points
Modem
Condenser Fan Contactors
Modulating Head Pressure Controller
Star Delta Contactors
Isolator
Bus bar Chamber 3 phase Mains Incoming
Discharge Line Ball Valve
Liquid Injection (Flexible Pipe)
Liquid Line Ball Valve
Liquid Line Filter Drier
Liquid Line
Water Inlet Sensor
Water Inlet Flange Connection
Discharge Line
Water Outlet Flange Connection
Mains Panel Circuit 2
Control Panel (Serial Plate to inside)
Mains Panel Circuit 1
Door Interlocking isolator
Emergency Stop
Fan and Motor Assemblies
Condenser Coils
Evaporator
Compressor Housing (DQ and DSQ Models Only)
Suction Port
Low Pressure Switch
Liquid Injection Inlet
Oil Level Sight Glass
HP Switch
Discharge NRV
Discharge Shrader Connection
Oil Sump Draw Point
Compressor Feet/Resilient Pads
Sump Heater
Liquid Injection Sight Glass
Liquid Injection NRV and Strainer
Liquid Injection Solenoid Valve
Suction Pressure Transducer
Compressor Electrical Terminal Box
Discharge Thermostat Switch
Liquid Line Solenoid Valve
Liquid Line Sight Glass
70% Unloading Solenoid Valve
40% Unloading Solenoid Valve
12% Unloading Solenoid Valve
Chillers
Installation & Maintenance Manual : 903-099 IM E 05/00
35
std
Head Office:
Airedale International Air Conditioning Ltd
Leeds Road
Rawdon
Leeds LS19 6JY
United Kingdom
Tel:
Fax:
+44 (0) 113 239 1000
+44 (0) 113 250 7219
e-mail:
marketing@airedale.co.uk
website: www.airedale.co.uk
Regional Sales Offices:
South
Tel:
e-mail:
01483 751010
southern.sales@airedale.co.uk
Midlands
Tel:
e-mail:
0121 7071010
midland.sales@airedale.co.uk
Scotland
Tel:
e-mail:
0141 2044750
airesales@email.msn.com
International Sales Offices:
France
Tel:
e-mail:
+ 331 3448 3425
mahidineait@aol.com
Germany
Tel:
e-mail:
+ 49 610 890 040
info@airedale.de
†
Tel:
e-mail:
+ 27 11 794 6291
International.sales@airedale.co.uk
†
Tel:
e-mail
+1 215 639 6030
Sales@airedaleusa.com
South Africa
North America
†
Part No: 903-099 TM E 05/00
Manufacturing Facility Also