AIREDALE | ULTIMA 2000 | ULTIMA COMPACT Chillers

INSTALLATION, OPERATING &
MAINTENANCE MANUAL
Ultima Compact
Air Cooled Liquid Chiller
30kW - 450kW
ULTIMA COMPACT
Chillers
About Airedale Products & Customer Services
WARRANTY,
COMMISSIONING &
MAINTENANCE
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty for a period
of 12 months from the date of commissioning or 18 months from the date of despatch, which ever
is the sooner. (Excludes the cost of any specialist access or lifting equipment.) 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 our Airedale Service or
your local Sales Engineer.
All Airedale products are designed in accordance with EU Directives regarding prevention of build up
of water, associated with the risk of contaminants such as Legionella.
Where applicable, effective removal of condensate is achieved by gradient drainage to outlets and
where used, humidification systems produce sterile, non-toxic steam during normal operation.
For effective prevention of such risk it is necessary that the equipment is maintained in accordance
with Airedale recommendations.
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 Airedale.
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.
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.
 2004 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
CUSTOMER SERVICES
For further assistance, please e-mail: enquiries@airedale.com or telephone:
Customer Services
UK Sales Enquiries
International Enquiries
Spares Hot Line
Airedale Service
Technical Support
Training Enquiries
+ 44 (0) 113 238 7789
+ 44 (0) 113 239 1000
+ 44 (0) 113 238 7878
+ 44 (0) 113 239 1000
+ 44 (0) 113 239 1000
+ 44 (0) 113 239 1000
For information, visit us at our Web Site: www.airedale.com
2
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
uk.sales@airedale.com
enquiries@airedale.com
spares@airedale.com
service@airedale.com
tech.support@airedale.com
marketing@airedale.com
Chillers
ULTIMA COMPACT
Contents
GENERAL STATEMENT
4
WARRANTY
5
GENERAL DESCRIPTION
6
Unit Identification
Introduction
Features
Optional Extras – Energy Saving
Optional Extras – General
6
6
7
8
8
INSTALLATION DATA
9
Dimensions
Point Loadings, Weights & Centre of Gravity (C of G)
Unit Lifting
Anti Vibration Mounting (Optional)
Positioning
Water System
Flow Schemes
Pump Options - Flow Schemes
Glycol Data
Electrical Data
Interconnecting Wiring
Electrical Data
CONTROLS
Control Scheme Features
Controls
Operation
Setting up
Viewing Unit Operating Status
Alarms
COMMISSIONING DATA
Operating Limits
Mechanical Data
Waterside Pressure Drops
Operational Sequence
COMMISSIONING PROCEDURE
Pre Commissioning Checklist
Commissioning Checklist
MAINTENANCE
General Maintenance
Compressor Maintenance
Shut Down Periods
PARTS IDENTIFICATION
Spares
UCC30-UCC80 (Except 75) Single & Dual circuit
UCC .. /1 – Dual Circuit
UCC .. /2 – Dual Circuit
9
10
13
14
15
16
16
17
21
22
23
25
29
29
30
30
31
31
33
34
34
34
35
40
41
41
43
44
44
45
45
46
46
46
48
50
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
3
ULTIMA COMPACT
Chillers
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.
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.
4
CAUTION
1
Service and maintenance of Airedale equipment should only be carried out by
Technically trained competent 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
should be undertaken by competent and trained personnel in accordance with local
relevant standards and codes of practice.
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.
6
A full hazard data sheet in accordance with COSHH regulations is available should
this be required.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Warranty
GENERAL
To be read in conjunction with Airedale International Air Conditioning Ltd standard
Conditions of Sale and any related quotation.
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty
for a period of 12 months from the date of commissioning or 18 months from the date of
despatch, which ever is the sooner. Commissioning must be carried out by Airedale or an
approved Airedale company.
WARRANTY IS ONLY
VALID IN THE EVENT
THAT:
1
In the period between delivery and commissioning the equipment:
o
is properly protected & serviced
o
water flow safety devices are in place and fully operational
2
The equipment is serviced & maintained by Airedale or an approved Airedale
company in accordance with the Installation & Maintenance manual provided, during
the Warranty Period.
In the event of a problem being reported, Airedale will cover the full cost of rectification
(excluding costs for any specialist access or lifting equipment) if warranty is valid under
these conditions.
Any spare part supplied by Airedale under the warranty shall be warranted for the
unexpired period of the warranty or 3 months from delivery whichever period is the
longer, with the exception of compressors on which a further 12 months warranty
is granted.
PROCEDURE
•
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.
•
Should warranty be accepted, following inspection of the faulty component, a credit
note will be issued against the invoice raised in line with the acknowledgement.
•
Should warranty be refused the invoice raised against the acknowledgement
becomes payable on normal terms.
•
Airedale reserves 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.
•
Replaced part being returned damaged without explanation.
•
Unnecessary delays incurred in return of defective component.
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.
RETURNS ANALYSIS
All faulty components returned under warranty are analysed on a monthly basis as a
means of verifying component and product reliability as well as supplier performance. It is
important that all component failures are reported correctly.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
5
ULTIMA COMPACT
Chillers
General Description
UNIT IDENTIFICATION
INTRODUCTION
AIR COOLED LIQUID CHILLER
UCC
Ultima Compact Chiller - Cooling Only
30 - 450
Model Size (Expressed as Nominal Cooling in kW)
SQ-
Single Circuit - Quiet Chiller (Models 30-80 (Except 75) Only)
SSQ-
Single Circuit - Super Quiet Chiller (Models 30-80 (Except 75) Only)
D-
Double Circuit - Standard Chiller
DQ-
Double Circuit - Quiet Chiller
DSQ-
Double Circuit - Super Quiet Chiller
2-16
Number of Fans
/1 or /2
Single or Double Row of Fans
Example
UCC250DQ-8/2
The Airedale range of Ultima Compact air cooled liquid chillers covers the nominal
capacity range 30kW to 450kW in 23 model sizes. The range is available with many
optional variations including Quiet and Super Quiet sound level variants.
Attention has been placed on maximising the unit’s performance while keeping the sound
and vibration levels and footprint to an absolute minimum.
CE DIRECTIVE
Airedale certify that the equipment detailed in this manual conforms with the following
EC Directives:
Electromagnetic Compatibility Directive (EMC)
Low Voltage Directive (LVD)
Machinery Directive (MD)
Pressure Equipment Directive (PED)
89/336/EEC
73/23/EEC
89/392/EEC in the version 98/37/EC
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
6
The range has been designed and optimised for operation with the ozone benign
R407C refrigerant.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
UCC275, UCC300,
UCC30, UCC40,
UCC75, UCC100,
UCC110,
UCC200, UCC225
UCC330, UCC360,
UCC50, UCC60, UCC70
UCC125 &
UCC130, UCC160
& UCC250
UCC400 & UCC450
& UCC80
UCC150
& UCC180
Construction
4 x eye bolts to BS4278 or Integrated lugs/Mounting feet
Acoustically lined compressor enclosure
Integrated lugs
SSQ/DSQ Models
Lifting Eye Bolts
DSQ Models
Lifting Eye Bolts
DSQ Models
Lifting Eye Bolts
DSQ Models
Lifting Eye Bolts
DSQ Models
Std
1 or 2
Std
2
Std
2
Std
2
1 x Tandem Set
or 2 x Single
2 x Tandem Sets
2 x Tandem Sets
2 x Tandem Sets
Std
SSQ/DSQ Models
SQ/DQ Models
SSQ/DSQ Models
Std
Opt (SQ/DQ Models)
Opt (SSQ/DSQ Models)
Threaded BSP female
Std
Opt
Fixed Cores
Std
Std
Std
Std
Std
DSQ Models
Long Bellmouth
DQ Models
DSQ Models
Std
DQ/DSQ Models
Opt (D Models)
Flanged PN16
Std
Std
Replaceable Cores
Std
Std
Std
Std
Std
DSQ Models
Long Bellmouth
DQ Models
DSQ Models
Std
DQ/DSQ Models
Opt (D Models)
Flanged PN16
Std
Std
Replaceable Cores
Std
Std
Std
Std
Std
DSQ Models
Long Bellmouth
DQ Models
DSQ Models
Std
DQ/DSQ Models
Opt (D Models)
Flanged PN16
Std
Std
Replaceable Cores
Std
Std
Std
Std
Std
2
2 x Tandem Sets
(UCC275-300)
2 x Trio Sets
(UCC330-450)
Std
DSQ Models
Long Bellmouth
DQ Models
DSQ Models
-
Flanged PN16
Std
Std
Replaceable Cores
Std
Std
Std
Std
Std
Std
-
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
-
-
Std
Std
Std
-
-
Std
Std
Std
Std
Std
Std
Opt
-
Std
Std
Std
Opt
Opt
Std
Std
Std
Opt
Opt
Std
Std
Std
Std
Opt
Std
Std
Std
Opt
Opt
Chillers
FEATURES
Refrigeration
Full Operating Charge of R407C
Number of Independent Refrigeration Circuits
Scroll Compressor Arrangement
Plate Evaporator
Enhanced Refrigeration Condenser Coils
Sickle Bladed Fans
Low speed condenser fan
Extra Low speed condenser fan
Thermostatic Expansion valve & Liquid line solenoid valve
Std
Electrical
7
AireTronix Microprocessor Controller
Modulating Head Pressure Control
Emergency stop
Individual door isolated mains power compartments for
each refrigeration CCT, fans & pump option
Dedicated bus-bar chamber for incoming 3-phase & earth
mains power supply (no neutral required)
Evaporator Pad Heater
Trace Heating to Internal Pipework
Connections for External Trace Heating
Phase Rotation Protection
Power Factor Correction
ULTIMA COMPACT
Water Inlet/Outlet
Liquid line sight glass
Liquid and Discharge line ball valve
Large capacity filter drier
Manual reset HP/LP Switch (LP via microprocessor)
Suction and liquid pressure transducers
Compressor minimum differential pressure protection
Pressure relief valve, integral rupture disc & gauge
Chillers
Technical Manual : Part No 903-129 TM E 10/04/C
Electronic Expansion Valve
ULTIMA COMPACT
Chillers
General Description
STANDARD FEATURES
As standard, the
microprocessor controller can provide 2, 4 or 6 stages of
capacity control, dependent upon model type.
Controls
Optionally, the controller is designed to provide capabilities for;
•
•
•
Building Management Systems
Networking
Sequencing (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.
CAUTION
When adding to an existing network, please consult Airedale to ensure strategy
compatibility.
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 operational
•
Circuit breakers for protection of all major unit components
•
Separate, permanent supply for controls/trace heating, 230V/50Hz/1ph
Electrical
The electrical power and control panel is wired to the latest European standards and
codes of practice.
UCC75, 100-450
Mains supply is 3 phase and a neutral is not required. Refer to Interconnecting Wiring.
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. Factory fitted, for full details refer to the Technical Manual.
OPTIONAL EXTRAS – GENERAL
Loose Item
•
•
Anti Vibration Mounts
Condenser Fan Discharge Air Plenum Extension
•
•
•
Electronic Expansion Valves (UCC30 – UCC80 & UCC75D – UCC250D Models only
(Standard to all other models)
Epoxy Coated Condenser Coils
Coil Guards
Sequence Control
Factory Fitted
CAUTION
It is only possible to set up sequencing following completion of interconnecting
communication wiring. Airedale Service can arrange Sequence setup on request.
•
Power Factor Correction
•
Integral Pump Packages including
Flushing Bypass Kit
•
BMS Interface Card
•
Dual Pressure Relief Valve
•
Differential Pressure Switch
•
Leak Detection Kit
•
Remote Setpoint Adjust
•
Electronic Soft Start
•
Mini Pressurisation Package
•
Flow Switch
•
Buffer Tank & Expansion Vessel
•
Flushing Bypass
•
Alternative Refrigerant (Outside EU)
•
Water Filter
OPTIONAL UNIT COVER •
•
8
Instructions supplied with
item
Commissioning
Chillerguard® Maintenance
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
For details and a competitive quotation,
contact Airedale Service.
Chillers
ULTIMA COMPACT
Installation Data
DIMENSIONS
SINGLE ROW FANS - /1
80
55
UCC30 - UCC80
(Except UCC75)
1200
6
B
C
Electric Control Panels
Mains Electric Isolators
Mains Cable Entry
20mm Ø Mounting Holes
Optional Plenum Extension
Water Connections:
UCC30-40
- 1 1/2”
UCC50-80 (Ex 75) - 2”
Emergency Stop
55
4
1
2
3
4
5
6
D
7
500
5
1410
2
20
A
600
290
310
40
60
300
20
460
3
1
1310
(1)
mm
mm
mm
A
1650 (2500)
2500
2500
B
300
300
300
C
1050
1450
1450
D
300
750
750
Model SSQ/DSQ
UCC30 - UCC40 SSQ/DSQ mm
UCC50 - UCC70 SSQ/DSQ mm
UCC80 SSQ/DSQ
mm
A
1650 (2500)
2500
2500
(1)
B
300
300
300
C
1050
1450
1450
D
300
750
750
Model SQ/DQ
UCC30 – UCC40 SQ/DQ
UCC50 – UCC70 SQ/DQ
UCC80 SQ/DQ
25
(1) Figures in brackets apply when optional Buffer Tank option fitted.
1250
UCC75 - UCC150
(Except UCC80)
B
C
D
E
25
4
1
2
6 3
4
5
6
Electric Control Panels
Mains Electric Isolators
Mains Cable Entry
20mm Ø Mounting Holes
Optional Plenum Extension
Water Flange Connections:
DN65 PN16
Emergency Stop
7
5
500
6
1
2000
2
7
300
50
500
3
20
50
225
A
25
425
1300
Model D
UCC75D
UCC100D
UCC125 - UCC150D
mm
mm
mm
A
2775
2775
3625
B
390
390
390
C
1900
1900
1825
D
(2)
(2)
1135
E
485
485
275
Model DQ
UCC75DQ
UCC100 - UCC125DQ
UCC150DQ
mm
mm
mm
A
2775
3625
4475
B
390
390
390
C
1900
1825
1900
D
(2)
1135
1900
E
485
275
285
Model DSQ
UCC75DSQ
UCC100DSQ
UCC125- UCC150DSQ
mm
mm
mm
A
2775
3625
4475
B
390
390
390
C
1900
1825
1900
D
(2)
1135
1900
E
485
275
285
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
9
ULTIMA COMPACT
Chillers
Installation Data
POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)
SINGLE ROW FANS - /1
UCC30 - UCC80 (Except UCC75)
1
2
Model SQ/DQ
UCC30 SQ/DQ-1/1
UCC40 SQ/DQ-1/1
UCC50 SQ/DQ-2/1
UCC60 SQ/DQ-2/1
UCC70 SQ/DQ-2/1
UCC80 SQ/DQ-2/1
Model SSQ/DSQ
UCC30 SSQ/DSQ-1/1
UCC40 SSQ/DSQ-1/1
UCC50 SSQ/DSQ-2/1
UCC60 SSQ/DSQ-2/1
UCC70 SSQ/DSQ-2/1
UCC80 SSQ/DSQ-2/1
= C of G
P1
P3
P2
P4
P2
125
150
180
190
195
215
P3
125
140
185
200
205
230
P4
125
140
185
200
205
230
(1)
(1)
kg
kg
kg
kg
kg
kg
P1
125
150
180
190
195
215
P2
125
155
185
195
195
225
P3
125
145
185
200
210
240
P4
125
145
185
200
210
240
(1)
(1)
kg
kg
kg
kg
kg
kg
P1
125
155
185
195
195
225
Operating
Weight
500
580
730
780
800
890
C of G1
(mm)
600
600
600
600
600
600
C of G2
(mm)
825
800
1040
1040
1040
1040
Operating
Weight
500
600
740
790
810
930
C of G1
(mm)
600
600
600
600
600
600
C of G2
(mm)
825
800
1040
1040
1040
1040
UCC75 - UCC150 (Except UCC80)
1
2
Model D
UCC75D-2/1
UCC100D-2/1
UCC125D-3/1
UCC150D-3/1
Model DQ
UCC75DQ-2/1
UCC100DQ-3/1
UCC125DQ-3/1
UCC150DQ-4/1
Model DSQ
UCC75DSQ-2/1
UCC100DSQ-3/1
UCC125DSQ-4/1
UCC150DSQ-4/1
(1)
(2)
10
= C of G
P1
P3
P5
P2
P4
P6
kg
kg
kg
kg
P1
320
345
315
330
P2
320
345
295
330
P3
(1)
(1)
140
155
P4
(1)
(1)
130
155
P5
160
175
190
205
P6
160
175
190
205
Operating
Weight
960
1040
1260
1380
C of G1
(mm)
665
665
665
665
C of G2
(mm)
845
860
1380
1370
kg
kg
kg
kg
P1
330
285
320
340
P2
330
285
300
340
P3
(1)
135
155
195
P4
(1)
135
145
195
P5
170
175
200
250
P6
170
175
200
250
Operating
Weight
1000
1190
1320
1570
C of G1
(mm)
665
665
665
665
C of G2
(mm)
845
1365
1385
1590
kg
kg
kg
kg
P1
345
300
340
355
P2
345
300
320
355
P3
(1)
130
200
215
P4
(1)
130
190
215
P5
165
175
250
270
P6
165
175
240
270
Operating
Weight
1020
1210
1540
1680
C of G1
(mm)
665
665
665
665
C of G2
(mm)
845
1365
1575
1590
Have only 4 fixing and 4 point loadings.
Based on standard unit, for units fitted with pump, tank and expansion vessel options, please contact Airedale.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Installation Data
DIMENSIONS
DOUBLE ROW FANS - /2
1
2
3
4
5
6
L
25
UCC110 - UCC450
(Except UCC125 &
UCC150)
F
G
H
J
K
25
4
7
Electric Control Panels
Mains Electric Isolators
Mains Cable Entry
20mm Ø Mounting Holes
Optional Plenum Extension
Water Flange Connections:
UCC160-250 DN80 PN16
UCC275-450 DN100 PN16
Emergency Stop
5
500
E
6
D
7
C
1
630
2
3
20
50
50
25
A
25
B
Model D
UCC110D - UCC160D
UCC180D - UCC250D
UCC275D - UCC300D
UCC330D - UCC360D
UCC400D - UCC450D
mm
mm
mm
mm
mm
A
2365
3170
4650
5500
6350
B
1850
1850
2200
2200
2200
C
2100
2100
2180
2180
2180
D
955
955
975
975
975
E
925
925
1100
1100
1100
F
275
480
350
350
350
G
1600
1100
1750
1350
1700
H
(1)
1100
1925
1350
1925
J
(2)
(2)
1925
1925
K
490
490
625
525
450
L
1800
1800
2150
2150
2150
Model DQ
UCC110DQ - UCC130DQ
UCC160DQ - UCC200DQ
UCC225DQ - UCC250DQ
UCC275DQ
UCC300DQ - UCC330DQ
UCC360DQ - UCC400DQ
UCC450DQ
mm
mm
mm
mm
mm
mm
mm
A
2365
3170
3975
4650
5500
6350
7200
B
1850
1850
1850
2200
2200
2200
2200
C
2100
2100
2100
2180
2180
2180
2180
D
955
955
955
975
975
975
975
E
925
925
925
1100
1100
1100
1100
F
275
480
480
350
350
350
350
G
1600
1100
1500
1750
1350
1700
1700
H
(1)
1100
1500
1925
1350
1925
2700
J
(2)
(2)
1925
1925
2000
K
490
490
495
625
525
450
450
L
1800
1800
1800
2150
2150
2150
2150
Model DSQ
UCC110DSQ
UCC130DSQ - UCC200DSQ
UCC225DSQ - UCC250DSQ
UCC275DSQ
UCC300DSQ
UCC330DSQ - UCC360DSQ
UCC400DSQ - UCC450DSQ
mm
mm
mm
mm
mm
mm
mm
A
2365
3170
3975
5500
6350
7200
8050
B
1850
1850
1850
2200
2200
2200
2200
C
2100
2100
2100
2180
2180
2180
2180
D
955
955
955
975
975
975
975
E
925
925
925
1100
1100
1100
1100
F
275
480
480
350
350
350
350
G
1600
1100
1500
1350
1700
1700
1700
H
(1)
1100
1500
1350
1925
2700
2800
J
(2)
(2)
1925
1925
2000
2725
K
490
490
495
525
450
450
525
L
1800
1800
1800
2150
2150
2150
2150
Chillers
11
(1)
(2)
Have only 4 fixing and 4 point loadings.
Have only 6 fixing and 6 point loadings.
Installation & Maintenance : 903-129 IM E 10/04/C
ULTIMA COMPACT
Chillers
Installation Data
POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)
DOUBLE ROW FANS - /2
UCC110 - UCC450 (Except UCC125 & UCC150)
1
2
Model D
UCC110D-4/2
UCC130D-4/2
UCC160D-4/2
UCC180D-6/2
UCC200D-6/2
UCC225D-6/2
UCC250D-6/2
UCC275D-8/2
UCC300D-8/2
UCC330D-10/2
UCC360D-10/2
UCC400D-12/2
UCC450D-12/2
Model DQ
UCC110DQ-4/2
UCC130DQ-4/2
UCC160DQ-6/2
UCC180DQ-6/2
UCC200DQ-6/2
UCC225DQ-8/2
UCC250DQ-8/2
UCC275DQ-8/2
UCC300DQ-10/2
UCC330DQ-10/2
UCC360DQ-12/2
UCC400DQ-12/2
UCC450DQ-14/2
Model DSQ
UCC110DSQ-4/2
UCC130DSQ-6/2
UCC160DSQ-6/2
UCC180DSQ-6/2
UCC200DSQ-6/2
UCC225DSQ-8/2
UCC250DSQ-8/2
UCC275DSQ-10/2
UCC300DSQ-12/2
UCC330DSQ-14/2
UCC360DSQ-14/2
UCC400DSQ-16/2
UCC450DSQ-16/2
(1)
(2)
(3)
12
= C of G
P1
P3
P5
P7
P2
P4
P6
P8
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
P1
380
405
475
630
640
660
665
705
735
715
730
770
805
P2
380
405
475
560
570
660
665
705
735
715
730
770
805
P3
(1)
(1)
(1)
140
145
155
155
400
420
405
420
480
500
P4
(1)
(1)
(1)
125
130
155
155
400
420
405
420
480
500
P5
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
200
240
290
300
P6
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
200
240
290
300
P7
270
275
240
140
140
155
155
235
255
190
230
280
280
P8
270
275
240
150
150
160
160
235
255
190
230
280
280
Operating
Weight
1300
1360
1430
1745
1775
1945
1955
2680
2820
3020
3240
3640
3770
C of G1
(mm)
915
915
925
890
890
925
925
1100
1100
1100
1100
1100
1100
C of G2
(mm)
825
810
810
1020
1030
1015
1010
1515
1535
1650
1755
2230
2200
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
P1
380
405
570
645
655
700
710
735
700
715
735
770
810
P2
380
405
570
570
580
700
710
735
700
715
735
770
810
P3
(1)
(1)
115
130
135
165
165
395
375
405
440
485
535
P4
(1)
(1)
115
120
125
165
165
395
375
405
440
485
535
P5
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
215
250
270
300
360
P6
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
215
250
270
300
360
P7
270
275
115
130
135
165
220
235
205
240
260
290
340
P8
270
275
175
180
185
220
220
235
205
240
260
290
340
Operating
Weight
1300
1360
1660
1775
1815
2115
2190
2730
2990
3220
3410
3690
4090
C of G1
(mm)
915
915
955
910
910
950
925
1100
1100
1100
1100
1100
1100
C of G2
(mm)
825
810
1015
1010
1025
1260
1310
1490
1710
1800
2210
2260
2635
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
P1
380
430
570
645
655
700
710
680
715
740
780
810
840
P2
380
430
570
570
580
700
710
680
715
740
780
810
840
P3
(1)
280
115
130
135
165
165
350
390
445
490
525
545
P4
(1)
280
115
120
125
165
165
350
390
445
490
525
545
P5
(1)
(2)
(2)
(2)
(2)
(2)
(2)
255
280
320
340
460
470
P6
(1)
(2)
(2)
(2)
(2)
(2)
(2)
255
280
320
340
460
470
P7
270
205
115
130
135
165
220
245
270
310
330
350
350
P8
270
205
175
180
185
220
220
245
270
310
330
350
350
Operating
Weight
1300
1830
1660
1775
1815
2115
2190
3060
3310
3630
3880
4290
4410
C of G1
(mm)
915
915
955
910
910
950
925
1100
1100
1100
1100
1100
1100
C of G2
(mm)
825
1055
1015
1010
1025
1260
1310
1850
2270
2635
2640
2895
2860
Have only 4 fixing and 4 point loadings.
Have only 6 fixing and 6 point loadings.
Calculation based on standard unit, for units fitted with pump, tank and expansion vessel options, please contact Airedale.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
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 lifting eye bolts/lifting lugs provided.
Attach lifting chains to the 4 lifting eye bolts/lifting lugs provided, each chain and eye
bolt must be capable of lifting the whole chiller.
Use the appropriate 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.
Only use lifting points provided.
CAUTION
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.
LIFTING DIMENSIONS
E
D
A
B
UCC30 - 80 (Except UCC75)
1 FAN /1
mm
2 FANS /1
mm
(1)
A
300
300
C
(1)
B
1050 (1450)
1450
(1)
D
1900 (2200)
2200
(1)
E
1270
1270
C
585
1320
1315
605
925
1330
1625
1900
2275
2350
2550
D
2500
2500
3000
2500
2500
2500
3000
3500
3500
4000
5000
E
1450
1450
1450
2000
2000
2350
2350
2350
2350
2350
2350
C
300 (300)
750
Dimensions in brackets refer to the optional buffer tank when fitted.
E
D
A
UCC75 - UCC450 (Except
UCC80)
75, 100, 125 &
150
110, 130,160
,180, 200, 225 &
250
275, 300, 330,
360, 400 & 450
..-2/1
..-3/1
..-4/1
..-4/2
..-6/2
..-8/2
..-8/2
..-10/2
..-12/2
..-14/2
..-16/2
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
B
C
A
290
290
290
180
595
595
465
465
465
465
465
B
1900
2015
2870
1580
1650
2050
2560
3135
3610
4385
5035
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
13
ULTIMA COMPACT
Chillers
Installation Data
ANTI VIBRATION MOUNTING (OPTIONAL)
Spring Type
Each mount is coloured to indicate the different loads, refer to Loose Parts Instructions
supplied for correct allocation.
(1)
A
D
E
FØ
(2) mm 136 110 180 148
16
11
(3) mm 180 130 225 186
20
16
Dimensions
UCC30-70
UCC75
UCC80
UCC100
UCC125
UCC150
UCC110
UCC130
UCC160-450
A
F
B
D
E
(1)
(2)
(3)
Unloaded dimension
2 spring type
4 spring type
1
2
3
4
5
6a
6b
7
8
9
10
Locating Screw
Retaining Nut & Washer
Levelling Screw
Levelling Lock Nut
Retaining Studs
Upper Retaining Nuts
Lower Retaining Nuts
Spring assembly
Pressure Plate
Top Plate
Bolting-down holes
B
C
E
C
Components
2
1
9
6a
5
3
4
8
7
6b
10
Installation
1
2
3
CAUTION
CAUTION
Locate and secure mount using bolting down holes (10) in base plate.
Ensure mounts are located in line with the unit base.
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 onto the mounts and replace
retaining nut and washer.
6 Beginning with the mount with the largest deflection, adjust the height of each mount
using the levelling screw (3).
Mountings must be adjusted incrementally in turn. Do not fully adjust 1 mount at a
time as this may overload and damage springs.
7 When all mounts are level, lock each into place using the levelling lock nut (4).
8 Lock all retaining nuts (6a and 6b) to the extreme ends of the retaining studs (5).
Do not connect any services until all anti vibration mounts have been fully adjusted.
Pad Type
Components/Installation
2
2
14
1
5
3
64
3
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
7
1
2
3
4
5
6
7
M16 Bolt (Not Supplied)
Washer (Not Supplied)
Fixing Pad 506-063
A V Pad 506-062
2 x M16 Nut (Not Supplied)
Unit Base
Unit Mounting Plinth
Chillers
ULTIMA COMPACT
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.
Prior to connecting services, ensure that the equipment is installed and
completely level.
1.0m (1.8)
1.0m (2.0)
1.0m (2.0)
1.0m (1.8)
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
15
ULTIMA COMPACT
Chillers
Installation Data
WATER SYSTEM
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, where static water can be expected, or when water
supply temperatures of +5°C or below is required, the necessary concentration of
Glycol or use of an electrical trace heater must be included.
•
The schematic is referred to as a guide to ancillary recommendations.
The unit water connections are NOT designed to support external pipework,
pipework should be supported during installation.
The water flow commissioning valve set is not shown in the diagram, as the valve can be
fitted elsewhere within the chilled water circuit.
STANDARD RECOMMENDED INSTALLATION (PARTS SUPPLIED BY OTHERS)
4
2
1
5
T
3
P
M
6
7
P
FS
1
2
3
4
5
6
7
Filter 20 Mesh
Pump
Filter 1/16”
Pressure Sensor
Flow Switch
Flushing By Pass Leg
Pressure Sensor
CAUTION
Constant water flow MUST be maintained. Variable water volume is
NOT recommended and may invalidate warranty.
CAUTION
Following components are fitted within the chiller unit as standard:
•
Temperature Sensors
•
Drain Point
•
Auto Air Vent
FLOW SCHEMES
Key:
1 Water In
2 Water Out
Basic Supplied Water
Schematic
TT
F
1
(Includes Flow Switch
Optional Extra)
2
TT
16
FS
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
F
Chillers
ULTIMA COMPACT
Installation Data
FLOW SCHEMES
Key:
1 Water In
2 Water Out
Optional Flow Schemes
Filter Only Scheme Comprises:
Standard Circuit plus:
F
TT
1
Optional Extras:
•
Flow Switch
•
20 Mesh Water Filter
2
TT
Filter - Flushing Bypass
Scheme - Comprises:
Standard Circuit plus:
Optional Extras:
•
Flow Switch
•
20 Mesh Water Filter
•
Flushing Bypass Circuit
PUMP OPTIONS - FLOW Key:
SCHEMES
Single Head Pump
Scheme - Comprises:
Standard Circuit plus:
Optional Extras:
•
Flow Switch
•
20 Mesh Water Filter
•
Flushing Bypass Circuit
•
Single Head Pump
FS
F
TT
F
1
2
TT
F
FS
1 Water In
2 Water Out
F
TT
1
2
TT
F
FS
M
Twin Head Pump
Scheme - Comprises:
Standard Circuit plus:
Optional Extras:
• Flow Switch
• 20 Mesh Water Filter
• Flushing Bypass Circuit
• Twin Head Pump
F
TT
1
2
TT
FS
M
F
M
Single Head
Run/Standby Pump
Scheme - Comprises:
Standard Circuit plus:
Optional Extras:
•
Flow Switch
•
20 Mesh Water Filter
•
Flushing Bypass Circuit
•
Single Head
Run/Standby Pump
F
TT
1
2
TT
F
FS
M
M
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
17
ULTIMA COMPACT
Chillers
Installation Data
WATER SYSTEM
Component
Recommended
Requirements
CAUTION
The recommended requirements to allow commissioning to be carried out correctly are:
•
The inclusion of Binder Points adjacent to the flow and return connections, to allow
temperature and pressure readings.
•
A flow switch or equivalent, fitted adjacent to the water outlet side of the Chiller.
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 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.
Pump Statement
When installing circulating water pumps or equipment containing them, the following rules
should be applied:
•
Ensure the system is filled with water then vented and the pump primed with water
before running the pump. This is required because the pumped liquid cools the pump
bearings and mechanical seal faces.
•
To avoid cavitation the NPSH (Net Positive Suction Head) incorporating a safety
margin of 0.5m head must be available at the pump inlet during operation.
Pressure Testing
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.
When the pressure remains at the operating pressure for 1 hour, the system can be
considered leak free.
CAUTION
Although a pressure of 1.5 x working pressure is adequate for testing purposes,
most local water authorities require 2 x working pressure.
CAUTION
The whole system MUST be flushed prior to filling to remove debris left in the
water pipework by using a flushing bypass as shown to avoid serious damage to
the plate evaporator.
Filling
During filling the system should be vented at all high points.
Once the system has been completely vented all vents should be closed.
To prevent air locking in the system it is advisable to fill the systems from the lowest
point, ie drain point on pipework.
If auto air vents are used then we strongly recommend an auto pressurisation unit be
fitted to the system.
18
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Installation Data
UCC30SQ-1/1
UCC30DQ-1/1
UCC40SQ-1/1
UCC40DQ-1/1
UCC50SQ-2/1
UCC50DQ-2/1
UCC60SQ-2/1
UCC60DQ-2/1
UCC70SQ-2/1
UCC70DQ-2/1
UCC80SQ-2/1
UCC80DQ-2/1
1 1/2
1/2
1 1/2
1/2
2
1/2
2
1/2
2
1/2
2
1/2
l
Bar
308
10
411
10
514
10
493
10
719
10
822
10
kPa
kPa
kPa
kPa
145
189
145
195
121
147
135
185
113
215
121
170
131
188
116
164
115
169
107
155
l
35
35
35
35
35
35
l
250
250
250
250
250
250
in
1/2
1/2
1/2
1/2
1/2
1/2
UCC75D-2/1
UCC100D-2/1
UCC110D-4/2
UCC125D-3/1
UCC130D-4/2
UCC150D-3/1
DN65
1/2
DN65
1/2
DN80
1/2
DN65
1/2
DN80
1/2
DN65
1/2
l
Bar
399
10
519
10
533
10
453
10
460
10
800
10
kPa
kPa
kPa
kPa
125
200
105
135
115
190
155
130
100
170
150
205
100
150
100
150
155
200
140
200
WATER SYSTEM
Connections
Water Inlet / Outlet Female BSP
Water Drain/Bleed
Water System
Min. System Water Volume
(2)
Max. System Press
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(3)
Nom External Head Std Single / R&S
Nom External Head Larger Single/R&S
Nom External Head Standard Twin
Nom External Head Larger Twin
Expansion Tank
(4)
Water Capacity
Buffer Tank
Max. Water Capacity
(5)
Pressurisation Unit
Water Inlet Connection
Connections
Water Inlet / Outlet
(1)
Water Drain/Bleed
Water System
Min. System Water Volume
(2)
Max. System Press
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(3)
Nom External Head Std Single / R&S
Nom External Head Larger Single/R&S
Nom External Head Standard Twin
Nom External Head Larger Twin
Expansion Tank
(4)
Water Capacity
Buffer Tank
Max. Water Capacity - D
Max. Water Capacity - SQ/DQ
Max. Water Capacity - SSQ/DSQ
Pressurisation Unit
Water Inlet Connection
(1)
(2)
(3)
(4)
(5)
in
in
In
In Line Pump
133
235
131
180
In Line Pump
110
160
115
165
l
50
50
50
50
50
50
l
l
l
250
250
250
250
420
420
250
250
250
420
420
420
250
250
250
420
420
420
in
1/2
1/2
1/2
1/2
1/2
1/2
Flanged to PN16.
For minimum system volume refer to the Technical Manual.
Nominal Cooling Duties based on 12/7°C water temperature and 30°C ambient, where output is the chilled water duty and input is the compressor input power.
Expansion vessel may require reselecting for glycol and system volume, please refer to Airedale
UCC30 and UCC40 dimensions change to 1450 x 2500 x 1310 when Buffer Tank fitted.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
19
ULTIMA COMPACT
Chillers
Installation Data
WATER SYSTEM
Connections
Water Inlet / Outlet
(1)
Water Drain/Bleed
Water System
Min. System Water Volume
(2)
Max. System Press
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(3)
Nom External Head Std Single / R&S
Nom External Head Larger Single/R&S
Nom External Head Standard Twin
Nom External Head Larger Twin
Expansion Tank
(4)
Water Capacity
Buffer Tank
(6)
Max. Water Capacity - D
Max. Water Capacity - SQ/DQ
Max. Water Capacity - SSQ/DSQ
Pressurisation Unit
Water Inlet Connection
Connections
Water Inlet / Outlet
(1)
Water Drain/Bleed
Water System
Min. System Water Volume
(2)
Max. System Press
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(3)
Nom External Head Std Single / R&S
Nom External Head Larger Single/R&S
Nom External Head Standard Twin
Nom External Head Larger Twin
Expansion Tank
(4)
Water Capacity
Buffer Tank
(5)
Max. Water Capacity - D
Max. Water Capacity - SQ/DQ
Max. Water Capacity - SSQ/DSQ
Pressurisation Unit
Water Inlet Connection
(1)
(2)
(3)
(4)
(5)
20
UCC160D-4/2
UCC180D-6/2
UCC200D-6/2
UCC225D-6/2
UCC250D-6/2
UCC275D-8/2
DN 80
1/2
DN 80
1/2
DN 80
1/2
DN 80
1/2
DN 80
1/2
DN 100
1/2
l
Bar
802
10
669
10
736
10
820
10
1304
10
877
10
kPa
kPa
kPa
kPa
115
170
115
167
100
156
100
150
100
150
93
142
95
149
87
137
97
160
95
158
in
In Line Pump
100
155
99
148
l
50
50
50
50
50
50
l
l
l
250
250
250
250
250
420
250
250
420
250
420
420
250
420
420
420
420
420
in
1/2
1/2
1/2
1/2
1/2
1/2
UCC300D-8/2
UCC330D-10/2
UCC360D-10/2
UCC400D-12/2
UCC450D-12/2
DN 100
1/2
DN 100
1/2
DN 100
1/2
DN 100
1/2
DN 100
1/2
l
Bar
897
10
1130
10
1122
10
1322
10
1348
10
kPa
kPa
kPa
kPa
98
162
127
160
137
158
119
156
In Line Pump
135
156
115
154
128
151
105
148
125
181
127
175
in
l
50
50
50
50
50
l
l
l
420
420
420
420
420
420
420
420
420
420
420
420
420
420
420
in
1/2
1/2
1/2
1/2
1/2
Flanged to PN16.
For minimum system volume refer to the Technical Manual.
Nominal Cooling Duties based on 12/7°C water temperature and 30°C ambient, where output is the chilled water duty and input is the compressor input power.
Expansion vessel may require reselecting for glycol and system volume, please refer to Airedale
8 Fan units only: Maximum Water Capacity becomes 250 litres when the pump option is also selected.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Installation Data
Glycol is recommended when a supply water temperature of +5°C or below is required or
when static water can be exposed to freezing temperatures.
GLYCOL DATA
Ethylene Glycol Nominal Correction Factors
Glycol in System / Freezing Point ºC
Cooling Duty
Input Power
Catalogue Data x by:
Water Flow
Pressure Drop
10% / -4°C
0.98
0.99
0.99
1.05
20% / -9°C
0.97
0.98
1.02
1.20
30% / -15°C
0.95
0.96
1.04
1.38
40% / -23°C
0.93
0.95
1.07
1.57
10% / -2°C
0.97
0.99
0.98
1.08
20% / -6°C
0.95
0.98
0.97
1.17
30% / -12°C
0.91
0.96
0.95
1.31
40% / -20°C
0.88
0.95
0.95
1.45
Propylene Glycol Nominal Correction Factors
Glycol in System / Freezing Point ºC
Cooling Duty
Input Power
Catalogue Data x by:
Water Flow
Pressure Drop
Example
UCC250D-6/2 operating at 7/12, 30°C Ambient, 20% Ethylene Glycol
Cooling kW
Input kW
Flow l/s
Pressure Drop kPa
(refer to Technical Manual)
(refer to Technical Manual)
(DX (Mechanical Cooling kW)
calculated
∆T x 4.19
(refer to Waterside Pressure Drops)
CAUTION
Catalogue
Figure Multiplier
269.2
x 0.97
79.2
x 0.98
12.8
x 1.02
50.0
x 1.20
20%
Ethylene
Glycol =
Corrected
Figure
261.1 kW
77.6 kW
13.1 l/s
60.0 kPa
Waste glycol needs to be handled responsibly, recycled or turned over to professional
personnel for correct disposal. Most anti-freeze manufacturers recommend that used antifreeze be collected and disposed according to Local Legislation. Waste glycol should NOT be
drained onto the ground, rainwater drainage system or natural waters.
If the glycol contains heavy metals or other contaminants from gas or oil, the level of hazard
posed by the glycol is increased and could be characterised as hazardous waste.
STEPS IF GLYCOL IS RELEASED/SPILLED
Small spill - soak up with absorbent material.
Large spill - contain spill and pump to suitable container for disposal.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
21
ULTIMA COMPACT
Chillers
Installation Data
ELECTRICAL DATA
•
General
CAUTION
•
•
•
CAUTION
•
•
•
CAUTION
Interlocks & Protection
As standard the equipment is designed for 400V, 3 phase, 3 wire 50Hz and a
separate 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 non-fault
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
MUST BE FITTED for the compressor sump heater, evaporator trace heating and
control circuits, FAILURE to do so could INVALIDATE WARRANTY.
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 chiller warranty.
CAUTION
Do not rely solely on the BMS to protect the chiller against low flow conditions.
An evaporator pump interlock and flow switch MUST be directly wired to the
chiller, refer to Interconnecting Wiring diagram.
22
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Installation Data
INTERCONNECTING WIRING
No Pumps
Single Circuit
(not including: leak detector,
remote setpoint adjust and
differential pressure switch)
UCC30 - UCC80
(Excluding UCC75)
Double Circuit
UCC30 - UCC450
CAUTION
L1
L2
L3
N2
E
!
!
!
!
!
"
"
"
"
"
Mains incoming supply 400V/3PH/50Hz
(N2 only required for Models 30-80Q & 50-70SQ)
L4
N1
E
!
!
!
"
"
"
Separate Permanent Supply 230V/1PH/50Hz
2
N
!
!
#
"
External Trace Heating Connections
240V/500W max
506
522
!
!
#
"
(1) Evaporator Remote Pump Interlock 24Vac
506
504
!
!
#
"
(1) Evaporator Pump Water Flow Switch
506
505
!
!
#
"
573
574
575
!
!
!
"
#
#
RX-/TxRX+/Tx+
GND
!
!
!
"#
"#
"#
L1
L2
L3
N2
E
!
!
!
!
!
"
"
"
"
"
Mains incoming supply 400V/3PH/50Hz
(N2 only required for Models 30-80DQ & 50-70DSQ)
L4
N1
E
!
!
!
"
"
"
Separate Permanent Supply 230V/1PH/50Hz
2
N
!
!
#
"
External Trace Heating Connections
240V/500W max
502
522
!
!
#
"
(1) Evaporator Remote Pump Interlock 24VAC
502
504
!
!
#
"
(1) Evaporator Pump Water Flow Switch 24VAC
502
505
!
!
#
"
Unit Remote On/Off 24VAC
502
507
!
!
#
"
Setback Setpoint Temperature switch
573
574
575
!
!
!
"
#
#
Volt Free Common Alarm
Circuit 1 Volt Free Alarm N/O
Volt Free Alarm N/C
576
577
578
!
!
!
"
#
#
Volt Free Common Alarm
Circuit 2 Volt Free Alarm N/O
Volt Free Alarm N/C
RX-/TxRX+/Tx+
GND
!
!
!
"#
"#
"#
Unit Remote On/Off
Volt Free Common Alarm
Circuit 1 Volt Free Alarm N/O
Volt Free Alarm N/C
Network Connections
Dual Circuit Only
Network Connections
(1) MUST be directly wired to the chiller to validate warranty.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
23
ULTIMA COMPACT
Chillers
Installation Data
INTERCONNECTING WIRING
With Pumps
Single Circuit
(not including: leak detector,
remote setpoint adjust and
differential pressure switch)
UCC30 - UCC80
(Excluding UCC75)
Double Circuit
UCC30 - UCC450
24
L1
L2
L3
N2
E
!
!
!
!
!
"
"
"
"
"
Mains incoming supply 400V/3PH/50Hz
(N2 only required for Models 30-80Q & 50-70SQ)
L4
N1
E
!
!
!
"
"
"
Separate Permanent Supply 230V/1PH/50Hz
2
N
!
!
#
"
External Trace Heating Connections
240V/500W max
506
505
!
!
#
"
Unit Remote On/Off
573
574
575
!
!
!
"
#
#
RX-/TxRX+/Tx+
GND
!
!
!
"#
"#
"#
L1
L2
L3
N2
E
!
!
!
!
!
"
"
"
"
"
Mains incoming supply 400V/3PH/50Hz
(N2 only required for Models 30-80DQ & 50-70DSQ)
L4
N1
E
!
!
!
"
"
"
Separate Permanent Supply 230V/1PH/50Hz
2
N
!
!
#
"
External Trace Heating Connections
240V/500W max
502
506
!
!
#
"
Pump’s Remote On/Off 24VAC
502
505
!
!
#
"
Unit Remote On/Off 24VAC
502
507
!
!
#
"
Setback Setpoint Temperature switch
573
574
575
!
!
!
"
#
#
Circuit 1
Volt Free Common Alarm
Volt Free Alarm N/O
Volt Free Alarm N/C
576
577
578
!
!
!
"
#
#
Circuit 2
Volt Free Common Alarm
Volt Free Alarm N/O
Volt Free Alarm N/C
RX-/TxRX+/Tx+
GND
!
!
!
"#
"#
"#
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Circuit 1
Volt Free Common Alarm
Volt Free Alarm N/O
Volt Free Alarm N/C
Network Connections
Network Connections
Dual Circuit Only
Chillers
ULTIMA COMPACT
Installation Data
UCC30SQ-1/1
UCC30DQ-1/1
UCC40SQ-1/1
UCC40DQ-1/1
22
109
27
113
16
32
16
40
W
40
40
W
500
A
A
kW
ELECTRICAL DATA
Unit Data
Nominal Run Amps
(1)
Maximum Start Amps
(2)
Permanent Supply
Mains Supply
Rec Permanent Fuse Size
Rec Mains Fuse Size
Max Permanent Incoming Cable Size
Max Mains Incoming Cable Size
Control Circuit
Evaporator
Pad Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
Compressor - Per Compressor
Quantity
Motor Rating
Nominal Run Amps
(1)
Sump Heater Rating
Start Amps
(2)
Type Of Start
SUPER QUIET SQ
A
A
VAC
VAC
A
A
mm²
mm²
VAC
kW
A
W
Condenser Fan - Per Fan
Full Load Amps
A
Locked Rotor Amps
A
Motor Rating
kW
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Compressor Nominal Run Amps
A
- Per Compressor
Electronic Soft-start
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
(1)
(2)
UCC70SQ-2/1
UCC70DQ-2/1
UCC80SQ-2/1
UCC80DQ-2/1
38
156
41
159
51
204
16
50
16
63
16
80
40
40
40
40
500
500
500
500
500
1
3.0
7.0
0.63
1
3.5
7.5
0.78
2
3.0
7.0
0.63
2
3.0
7.0
0.63
2
3.0
7.0
0.63
2
3.5
7.5
0.78
2
4.7
9.3
70.0
101.0
2
6.2
11.7
65.0
98.0
2
2
8.1
9.5 / 8.1
14.6
17.6 / 14.6
65.0
65.0 / 75.0
120.0
135.0/120.0
Direct on line
UCC50SSQ-2/1
UCC60SSQ-2/1
UCC50DSQ-2/1
UCC60DSQ-2/1
2
9.5
17.6
65.0
135.0
2
11.7
22.0
70.0
175.0
UCC70SSQ-2/1
UCC70DSQ-2/1
UCC80SSQ-2/1
UCC80DSQ-2/1
UCC30SSQ-1/1
UCC40SSQ-1/1
UCC30DSQ-1/1
UCC40DSQ-1/1
All data as above except:
UCC50SQ-2/1
UCC50DQ-2/1
UCC60SQ-2/1
UCC60DQ-2/1
35
141
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
50
4 mm² terminals
35 (Direct to Isolator)
24V/230VAC
1.15
2.10
0.70
1.15
2.10
0.70
3.50
7.50
0.78
3.50
7.50
0.78
3.50
7.50
0.78
1.15
2.10
0.70
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
22
73
32
27
74
40
35
93
50
38
102
50
41
105
63
51
112
80
24
40
0.55
1.9
29
50
0.55
1.9
38
63
0.90
2.7
41
63
0.90
2.7
44
63
1.10
2.9
54
80
1.10
2.9
24
40
0.75
2.3
30
50
0.90
3.0
39
63
1.50
4.0
42
63
1.50
4.0
45
63
1.50
3.4
54
80
1.50
3.4
25
40
1.5
3.2
30
50
1.5
3.2
38
63
1.5
3.2
41
63
1.5
3.2
44
63
1.5
3.2
54
80
1.5
3.2
26
40
2.2
4.6
32
50
2.2
4.6
40
63
2.2
4.6
43
63
2.2
4.6
46
63
2.2
4.6
56
80
2.2
4.6
Based at 12/7°C water and 30°C ambient
Starting amps refers to the direct on line connections.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
25
ULTIMA COMPACT
Chillers
Installation Data
ELECTRICAL DATA
Unit Data
Nominal Run Amps
(1)
Maximum Start Amps
(2)
Permanent Supply
Mains Supply
Rec Permanent Fuse Size
Rec Mains Fuse Size
Max Permanent Incoming Cable Size
Max Mains Incoming Cable Size
Control Circuit
Evaporator
Pad Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
Compressor - Per Compressor
Quantity
Motor Rating
Nominal Run Amps
Sump Heater Rating
Start Amps
Type Of Start
QUIET DQ
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
SUPER QUIET DSQ
UCC75D-2/1
UCC100D-2/1
50
140
62
167
16
63
16
80
70 (Direct to
MCCB)
70 (Direct to
MCCB)
W
40
40
80
W
500
500
A
A
kW
2
1.75
6.20
0.98
2
1.75
6.20
0.98
4
6.2
11.7
65.0
98.0
4
8.1
14.6
65.0
120.0
A
A
VAC
VAC
A
A
mm²
mm²
VAC
(1)
kW
A
W
(2)
UCC75DQ-2/1
UCC100DQ-3/1
All data as above except:
A
A
kW
2
3
1.15
1.15
2.10
2.10
0.68
0.68
UCC75DSQ-2/1
UCC100DSQ-3/1
All data as above except:
Condenser Fan - Per Fan
Quantity
Full Load Amps
A
Locked Rotor Amps
A
Motor Rating
kW
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Compressor Nominal Run Amps
A
- Per Compressor
Electronic Soft-start
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
(1)
(2)
UCC125D-3/1
UCC130D-4/2
UCC150D-3/1
69
79
175
217
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
16
100
125
4 mm² terminals
70 (Direct to
Direct to Bus Bar
MCCB)
24V/230V AC
84
222
93
246
16
125
16
125
Direct to Bus Bar
70 (Direct to
MCCB)
80
80
80
500
500
500
500
4
2.70
7.00
1.60
3
1.75
6.20
0.98
4
2.70
7.00
1.60
3
1.75
6.20
0.98
4
2+2
8.1
8.1 / 11.7
14.6
14.6 / 22.0
65.0
65.0 / 75.0
120.0
120.0/ 175.0
Direct on line
UCC110DQ-4/2
UCC125DQ-3/1
2+2
8.1 / 11.7
14.6 / 22.0
65.0 / 75.0
120.0/ 175.0
4
11.7
22.0
75.0
175.0
UCC130DQ-4/2
UCC150DQ-4/1
4
1.25
4.50
0.69
UCC110DSQ-4/2
3
1.15
2.10
0.68
UCC125DSQ-4/1
4
1.25
4.50
0.69
UCC130DSQ-6/2
4
1.15
2.10
0.68
UCC150DSQ-4/1
2
0.83
1.50
0.32
3
0.83
1.50
0.32
4
0.78
1.50
0.48
4
0.83
1.50
0.32
6
0.78
1.50
0.48
4
0.83
1.50
0.32
48
140
63
56
167
80
63
175
100
71
217
125
77
222
125
85
246
125
4 x 11
4 x 13
4 x 13
2 x 20 / 2 x 13
2 x 20 / 2 x 13
4 x 20
50
97
63
62
119
80
69
132
100
79
147
125
84
152
125
93
176
125
55
80
2.2
4.8
67
100
2.2
4.8
75
100
3.0
6.1
83
125
2.2
4.8
90
125
3.0
6.1
98
160
2.2
4.8
57
80
3.0
6.8
69
100
3.0
6.8
77
100
4.0
7.7
85
125
3.0
6.8
92
125
4.0
7.7
100
160
3.0
6.8
56
80
3.0
6.1
65
100
3.0
6.1
75
100
3.0
6.1
85
125
3.0
6.1
90
125
3.0
6.1
99
160
3.0
6.1
58
80
4.0
7.7
70
100
4.0
7.7
77
100
4.0
7.7
86
125
4.0
7.7
92
125
4.0
7.7
101
160
4.0
7.7
Based at 12/7°C water and 30°C ambient
Starting amps refers to the direct on line connections.
26
UCC110D-4/2
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Installation Data
ELECTRICAL DATA
Unit Data
Nominal Run Amps
(1)
Maximum Start Amps
(2)
Permanent Supply
Mains Supply
Rec Permanent Fuse Size
Rec Mains Fuse Size
Max Permanent Incoming Cable Size
Max Mains Incoming Cable Size
Control Circuit
Evaporator
Pad Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
Compressor - Per Compressor
Quantity
Motor Rating
Nominal Run Amps
(1)
Sump Heater Rating
Start Amps
(2)
Type Of Start
QUIET DQ
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
SUPER QUIET DSQ
UCC160D-4/2
UCC180D-6/2
99
252
115
281
16
125
16
160
A
A
VAC
VAC
A
A
mm²
mm²
VAC
UCC225D-6/2
127
342
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
160
4 mm² terminals
Direct to Bus Bar
24V/230V AC
UCC250D-6/2
UCC275D-8/2
137
373
149
386
160
440
16
200
16
200
16
200
W
100
100
100
100
100
100
W
500
500
500
500
500
500
A
A
kW
4
2.70
7.00
1.60
6
2.70
7.00
1.60
6
2.70
7.00
1.60
6
2.70
7.00
1.60
6
2.70
7.00
1.60
8
1.75
6.20
0.98
4
11.7
22.0
75.0
175.0
2+2
15.0 / 11.7
27.0 / 22.0
130.0 / 75.0
215.0 / 175.0
2+2
2+2
18.2 / 11.7
18.2 / 15.0
33.0 / 22.0
33.0 / 27.0
130.0 / 75.0
130.0 / 130.0
270.0 / 175.0
270.0 / 215.0
Direct on line
UCC200DQ-6/2
UCC225DQ-8/2
4
18.2
33.0
130.0
270.0
2+2
22.8 / 18.2
40.0 / 33.0
130.0 / 130.0
320.0 / 270.0
UCC250DQ-8/2
UCC275DQ-8/2
6
1.25
4.50
0.69
UCC200DSQ-6/2
8
1.25
4.50
0.69
UCC225DSQ-8/2
8
1.25
4.50
0.69
UCC250DSQ-8/2
8
1.15
2.10
0.70
UCC275DSQ-10/2
kW
A
W
UCC160DQ-6/2
UCC180DQ-6/2
All data as above except:
A
A
kW
6
6
1.25
1.25
4.50
4.50
0.69
0.69
UCC160DSQ-6/2
UCC180DSQ-6/2
All data as above except:
Condenser Fan - Per Fan
Quantity
Full Load Amps
A
Locked Rotor Amps
A
Motor Rating
kW
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Compressor Nominal Run Amps
A
- Per Compressor
Electronic Soft-start
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
(1)
(2)
UCC200D-6/2
6
0.78
1.50
0.48
6
0.78
1.50
0.48
6
0.78
1.50
0.48
8
0.78
1.50
0.48
8
0.78
1.50
0.48
10
0.83
1.50
0.32
91
252
125
105
281
125
117
342
160
125
373
160
137
386
200
146
430
200
4 x 20
2 x 24/2 x 20
2 x 30/2 x 20
2 x 30/2 x 24
4 x 30
2 x 36 / 2 x 30
99
182
125
115
198
160
127
234
160
137
239
200
149
278
200
160
302
200
105
125
3.0
6.1
120
160
3.0
6.1
132
160
3.0
6.1
141
200
3.0
6.1
154
200
3.0
6.1
173
200
5.5
11.7
107
125
4.0
7.7
122
160
4.0
7.7
134
160
4.0
7.7
144
200
4.0
7.7
156
200
4.0
7.7
183
250
11.0
21.5
107
125
4.0
7.7
122
160
4.0
7.7
134
160
4.0
7.7
144
200
4.0
7.7
156
200
4.0
7.7
171
200
5.5
11.7
110
125
5.5
11.1
125
160
5.5
11.1
137
160
5.5
11.1
147
200
5.5
11.1
159
200
5.5
11.1
183
250
11.0
21.5
Based at 12/7°C water and 30°C ambient
Starting amps refers to the direct on line connections.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
27
ULTIMA COMPACT
Chillers
Installation Data
ELECTRICAL DATA
Unit Data
Nominal Run Amps
(1)
Maximum Start Amps
(2)
Permanent Supply
Mains Supply
Rec Permanent Fuse Size
Rec Mains Fuse Size
Max Permanent Incoming Cable Size
Max Mains Incoming Cable Size
Control Circuit
Evaporator
Pad Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
Compressor - Per Compressor
Quantity
Motor Rating
Nominal Run Amps
(1)
Sump Heater Rating
Start Amps
(2)
Type Of Start
QUIET DQ
Condenser Fan - Per Fan
Quantity
Full Load Amps
Locked Rotor Amps
Motor Rating
SUPER QUIET DSQ
UCC300D-8/2
UCC330D-10/2
UCC360D-10/2
UCC400D-12/2
UCC450D-12/2
173
454
198
435
240
520
260
540
16
200
16
250
216
453
230 V 1 PH 50 Hz
400 V 3 PH 50 Hz
16
315
4 mm² terminals
Direct to Bus Bar
24V/230V AC
16
315
16
355
A
A
VAC
VAC
A
A
mm²
mm²
VAC
W
100
100
100
100
100
W
500
500
500
500
500
A
A
kW
8
1.75
6.20
0.98
10
1.75
6.20
0.98
10
1.75
6.20
0.98
12
1.75
6.20
0.98
12
1.75
6.20
0.98
4
22.8
40.0
130.0
320.0
3+3
18.2 / 15.0
33.0 / 27.0
130.0 / 130.0
270.0 / 215.0
6
18.2
33.0
130.0
270.0
Direct on line
UCC360DQ-12/2
3+3
22.8 / 18.2
40.0 / 33.0
130.0 / 130.0
320.0 / 270.0
6
22.8
40.0
130.0
320.0
UCC400DQ-12/2
UCC450DQ-14/2
12
1.15
2.10
0.70
UCC360DSQ-14/2
12
1.15
2.10
0.70
UCC400DSQ-16/2
14
1.15
2.10
0.70
UCC450DSQ-16/2
kW
A
W
UCC300DQ-10/2
UCC330DQ-10/2
All data as above except:
A
A
kW
10
10
1.15
1.15
2.10
2.10
0.70
0.70
UCC300DSQ-12/2
UCC330DSQ-14/2
All data as above except:
Condenser Fan - Per Fan
Quantity
Full Load Amps
A
Locked Rotor Amps
A
Motor Rating
kW
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Compressor Nominal Run Amps
A
- Per Compressor
Electronic Soft-start
Nominal Run Amps
(1) A
Maximum Start Amps
(2) A
Recommended Mains Fuse
A
Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Single Head Pump (or Run/Standby)
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
Larger Twin Head Pump
Unit Nominal Run Amps
(1) A
Recommended Mains Fuse
A
Motor Rating
kW
Full Load Amps
A
(1)
(2)
12
0.83
1.50
0.32
14
0.83
1.50
0.32
14
0.83
1.50
0.32
16
0.83
1.50
0.32
16
0.83
1.50
0.32
158
442
200
180
435
250
198
453
250
219
520
250
237
540
315
4 x 36
3 x 30 / 3 x 24
6 x 30
3 x 36 / 3 x 30
6 x 36
173
314
200
198
327
250
216
345
315
240
392
315
260
412
355
189
250
5.5
11.7
210
250
7.5
15.2
228
315
7.5
15.2
252
315
7.5
15.2
272
355
7.5
15.2
197
250
11.0
21.5
220
315
11.0
21.5
238
315
11.0
21.5
261
315
11.0
21.5
282
355
11.0
21.5
185
250
5.5
11.7
209
250
5.5
11.7
227
315
5.5
11.7
251
315
5.5
11.7
275
355
7.5
15.2
198
250
11.0
21.5
220
315
11.0
21.5
238
315
11.0
21.5
262
315
11.0
21.5
282
355
11.0
21.5
Based at 12/7°C water and 30°C ambient
Starting amps refers to the direct on line connections.
28
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Controls
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.
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 soft switch in the
microprocessor during initial commissioning.
Examples based on Models UCC200D-6/2 having 6 Stages of Cooling
Key: 1
2
3
4
Return Water Temperature
Mean Value
Supply Water Temperature
Compressor Off
14
Variable Supply
Temperature Control
WATER TEMPERATURE °C
13
1
12
11
10
2
9
3
8
7
4
6
20% / 1
40% / 2
50% / 3
60% / 4
80% / 5
100% / 6
CHILLER CAPACITY % / COOLING STAGE SEQUENCE
14
WATER TEMPERATURE °C
Constant Supply
Temperature Control
13
1
12
11
10
9
3
8
7
6
20% / 1
40% / 2
50% / 3
60% / 4
80% / 5
100% / 6
CHILLER CAPACITY % / COOLING STAGE SEQUENCE
CAUTION
Factory set to Variable Supply Temperature Control unless otherwise stated
at order.
Only when the mode selection has been set can the unit be enabled.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
29
ULTIMA COMPACT
Chillers
Controls
CONTROLS
General Description
The
microprocessor controller offers powerful analogue and digital control to
meet a wide range of monitoring and control features including a real time clock and
Industry standard communication port and network connections.
The controller’s inbuilt display is used for viewing the unit operating status and making
adjustments to control parameters by allowing the operator access to a series of
display pages.
Also featured are a visual alarm and the facility to adjust and display control settings by
local operator for information and control.
OPERATION
Standard Keypad
/Display
5
6
4
3
Prg
Esc
1
2
08:44 13/05/02 Mst
Remote 0-10V Input
Signal Voltage
05.6V
Unit ON
3
7
1
2
4
5
6
7
Navigation
UP/DOWN KEYS
To change Adjustable Fields & Scrolls
up & down available Menus
ENTER
Selects Menus & Moves Cursor to
Adjustable Fields Green LED
ESC
Green LED lit when Operating Page
displayed, Returns to Operating Page
Screen when pressed
PROGRAM
Opens the Available Menus
ALARM
Red LED Indicates Alarm Present
4 ROW LCD DISPLAY
CURSOR (FLASHING): Top Left
Position = “HOME” Indicates
adjustable Fields
The display is used for Viewing Unit Operating Status and Adjusting Customer
Control Settings by allowing the operator access to a series of Menus & sub-menus.
Viewing information is unrestricted, however set up and adjustment requires password
entry, refer to Password Protection.
Prg
Initially, use the
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
open the menu.
keys to move the indicator
Use the
key to move the flashing cursor
keys to change the values.
Press the
the
Standard Operating
Page
30
to
to adjustable fields and the
key to move the cursor to the next field or Home.
When the cursor is Home either use the
Esc
to the desired menu and press
keys to scroll to next sub-menu or
to exit and return to the Standard Operating page.
The Operating Page will appear and remain present following start up of the controller
as illustrated:
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Controls
OPERATION (CONT..)
Standard Operating
Page cont.
The following Menus can be accessed from the Operating Page, it is recommended that
Password Protection
To guard against unauthorised adjustments, a password is required to gain access to
certain menus as defined below.
the display is always returned to the Operating Page by using the
Esc
key
FACTORY SET PASSWORD PIN NUMBER: 4648 (or Customer chosen number).
When a password is requested use the
access the page.
Menus
(Listed in Sequence)
Menu
Switch On/Off
Service
Setpoint
Status
Maintenance
Clock
Alarm Log
Manufacturer
keys to enter the number and
Description
Enable or Disable the unit
Allows selection of setpoint limits, enables unit on/off from
display, remote on/off and remote pump on/off.
Allows setpoint adjustment, includes supply temperature
setpoint and unit temperature differential.
Displays current status on digital and analogue inputs and
outputs.
Displays hours run for compressors and pumps (if fitted).
Also includes Electronic Expansion Valves (if fitted).
Allows adjustment of real time clock, time zones
Display last 100 alarms in chronological order.
Factory use only.
to
Password
Open Access
Default 4648
Default 4648
Open Access
Default 4648
Default 4648
Open Access
Airedale Only
SETTING UP
Esc
Unit ON/OFF
(Optional Extra)
By pressing the
and
simultaneously for approximately 5 seconds, the unit
operation will stop or start. The unit can also be enabled through the Switch On/Off menu.
Real Time Clock
The units leave the factory set, however follow the Navigation instructions if necessary.
(Optional to UCC30-80 Single
Circuit Only)
Time Zones
The programme provides 3 On/Off periods per day, 7 days per week. The unit is factory
set for continuous operation.
Technical Support
For further details, please contact Airedale.
VIEWING UNIT OPERATING STATUS
Status Menu
Allows access to view operating status of Digital and Analogue Inputs and Outputs.
Using the Navigation instructions, the following Sub-Menus shown in sequence can
be accessed:
Single Circuit Units UCC30 - UCC80 (Ex 75)
Digital Inputs
ID1
Compressor 1 Contactor Status
ID2
Compressor 2 Contactor Status
ID3
Evaporator Flow Switch
ID4
Remote On/Off
ID5
Pump 1 Contactor Status or Remote Pump Interlock
ID6
Pump 2 Contactor Status
Digital Outputs
NO1 Compressor 1 Contactor
NO2 Compressor 2 Contactor
NO3 Pump 1 Contactor
NO4 Pump 2 Contactor
NO5 Alarm
Analogue Inputs
B1
Circuit 1 Liquid Pressure
B2
Circuit 1 Suction Pressure without EEV
B3
Return Water Temperature
B4
Supply Water Temperature
Analogue Outputs
Y1
Condenser Controller (Modulated Head Pressure Control)
Y2
Not Used
Y3
Not Used
Y4
Not Used
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
31
ULTIMA COMPACT
Chillers
Controls
VIEWING UNIT OPERATING STATUS
Dual Circuit Units UCC30 - UCC450
Tandem Compressor Units
Digital Inputs
ID1
Phase Rotation (Optional) or MCCB Status
ID2
Emergency Stop
ID3
Evaporator Flow Switch (Optional)
ID4
Remote On/Off (Optional)
ID5
Compressor 1 Contactor Status
ID6
Compressor 2 Contactor Status
ID7
Compressor 3 Contactor Status
ID8
Compressor 4 Contactor Status
ID9
Circuit 1 Low Pressure Switch
ID10
Circuit 2 Low Pressure Switch
ID11
Pump 1 Contactor Status or Remote Pump Interlock
(Optional)
ID12
Pump 2 Contactor Status (Optional)
ID13
Remote Pump On/Off (Optional)
ID14
Remote Summer/Winter Or Night Setback
ID15
Not Used
ID16
Not Used
ID17
Not Used
ID18
Not Used
Phase Rotation (Optional) or MCCB Status
Emergency Stop
Evaporator Flow Switch (Optional)
Remote On/Off (Optional)
Compressor 1 Contactor Status
Compressor 2 Contactor Status
Compressor 3 Contactor Status
Compressor 4 Contactor Status
Circuit 1 Low Pressure Switch
Circuit 2 Low Pressure Switch
Pump 1 Contactor Status or Remote Pump Interlock
(Optional)
Pump 2 Contactor Status (Optional)
Remote Pump On/Off (Optional)
Remote Summer/Winter Or Night Setback
Not Used
Not Used
Compressor 5 Contactor Status
Compressor 6 Contactor Status
Digital Outputs
NO1
Compressor 1 Contactor
NO2
Compressor 2 Contactor
NO3
Pump 1 Contactor (Optional)
NO4
Compressor 3 Contactor
NO5
Compressor 4 Contactor
NO6
Pump 2 Contactor (Optional)
NO7-NO10
Not Used
NO11
Evaporator Heater Pad
NO12
Alarm Circuit 1
NO13
Alarm Circuit 2
NO14-NO16 Not Used
NO17
Not Used
NO18
Not Used
Compressor 1 Contactor
Compressor 2 Contactor
Compressor 3 Contactor
Compressor 4 Contactor
Compressor 5 Contactor
Compressor 6 Contactor
Not Used
Evaporator Heater Pad
Alarm Circuit 1
Alarm Circuit 2
Not Used
Pump 1 Contactor
Pump 2 Contactor
Analogue Inputs
B1
Circuit 1 Liquid Pressure
B2
Circuit 2 Liquid Pressure
B3
Circuit 1 Suction Pressure without EEV or Leak Detector
(Optional)
B4
Return Water Temperature
B5
Supply Water Temperature
B6
Circuit 1 Suction Pressure without EEV
B7
Chilled Water Differential Pressure (Optional)
B8
Remote Setpoint Adjustment (Optional)
B9
Not Used
B10
Not Used
Circuit 1 Liquid Pressure
Circuit 2 Liquid Pressure
Circuit 1 Suction Pressure without EEV or Leak Detector
(Optional)
Return Water Temperature
Supply Water Temperature
Circuit 1 Suction Pressure without EEV
Chilled Water Differential Pressure (Optional)
Remote Setpoint Adjustment (Optional)
Evaporator Inlet Water
Ambient
Analogue Outputs
Y1
Not Used
Y2
Circuit 1 & 2 Condenser Fan Speed Controller
(Modulated Head Pressure Control)
Y3 - Y6
Not Used
Not Used
Circuit 1 & 2 Condenser Controller (Modulated Head
Pressure Control)
Not Used
EVD Driver # Inputs
B1
Circuit # Suction Temperature
B2
Circuit # Suction Pressure
32
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Trio Compressor Units
Chillers
ULTIMA COMPACT
Controls
ALARMS
The controller logs and allows viewing of the last 100 conditions recorded in descending
chronological order.
1
2
3
4
1
2
5
3
4
5
Alarm Handling
1
A Red LED behind the Alarm
alarms, simply press the
2
Alarm Label
Alarm Status: Alarm Active
or Alarm Cleared
Time of Alarm
The most current alarm (Code)
Nos. 001 - 100
Date of Alarm
key will light in the event of an alarm. To view the
key and the
keys to scroll through.
Auto reset alarms will clear following this first depression of the Alarm
however the Red LED behind the Alarm
requires some form of manual reset.
key. If
key remains illuminated, the unit
3
For manual reset alarms, isolate the affected circuits before further investigation.
4
To reset or delete the alarms displayed in the alarm screen, simply press
again.
COMMON ALARMS
Outlined below is a selection of Common Alarms, a full list is available, please
contact Airedale.
Phase Rotation
A normally closed contact. When Phase Rotation is incorrect all controller outputs are
de-activated.
Emergency Stop
A normally open contact. On closing, all controller outputs are de-activated.
Evaporator Flow Failure
A normally closed contact. On opening, all controller 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 indicates that the electronic expansion valve controller has detected an
operating problem.
Low Suction Pressure
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), a visual alarm will
be generated at the in-built display and the relevant compressor will be de-activated. On
units with tandem compressors, both compressors from the same circuit will be
switched off.
High Liquid Pressure
When the liquid pressure reaches 25 barg, the relevant circuit will be switched off and an
alarm activated, this can only be rectified by manual reset via the microprocessor.
Compressor Status
A normally closed contact when the compressor is operating. If this contact remains open
for a period of 3 seconds during operation of the compressor, a visual alarm is generated
and the relevant compressor will be de-activated. This alarm comprises of compressor
motor protection module, discharge gas thermostat and safety high pressure switch.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
33
ULTIMA COMPACT
Chillers
Commissioning Data
OPERATING LIMITS
(For 100% Water)
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 - Performance Data - Capacity Data
+6°C
+20°C
Unit with Electronic Fan Speed HP Control (-20°C)
Minimum Ambient Air DB °C
Maximum Ambient Air DB °C
Minimum Leaving Water Temperature °C
Maximum Return Water Temperature °C
-20°C
Refer to Technical Manual - Performance Data - Capacity Data
+6°C
+20°C
1
2
Temperatures lower than those stated can be obtained with the addition of glycol.
For conditions outside those quoted, please refer to Airedale.
MECHANICAL DATA
Oil & Refrigerant Charges
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Precharged
Charge (Total)
l
kg
SUPER QUIET SSQ
Refrigerant Charge (Total)
Refrigeration Control
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Precharged
Charge (Total)
QUIET DQ
Refrigerant Charge (Total)
Refrigeration Control
SUPER QUIET DSQ
Refrigerant Charge (Total)
Refrigeration Control
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
kg
UCC30SQ-1/1
UCC30DQ-1/1
2
1.5 + 1.5
5+5
UCC30SSQ-1/1
UCC30DSQ-1/1
5+5
UCC75D-2/1
UCC100D-2/1
4
4 x 3.25
4
4 x 3.80
kg
20 + 20
UCC75DQ-2/1
20 + 20
22 + 22
UCC100DQ-3/1
25 + 25
kg
UCC75DSQ-2/1
20 + 20
UCC100DSQ-3/1
23 + 23
UCC160D-4/2
UCC180D-6/2
4
4 x 6.2
4
2 x 8.0 + 2 x 6.2
l
kg
l
Refrigerant Control
Refrigerant Precharged
Charge (Total)
QUIET DQ
Refrigerant Charge (Total)
Refrigeration Control
SUPER QUIET DSQ
Refrigerant Charge (Total)
Refrigeration Control
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Precharged
Charge (Total)
QUIET DQ
Refrigerant Charge (Total)
Refrigeration Control
SUPER QUIET DSQ
Refrigerant Charge (Total)
Refrigeration Control
34
UCC40SQ-1/1
UCC50SQ-2/1
UCC60SQ-2/1
UCC70SQ-2/1
UCC40DQ-1/1
UCC50DQ-2/1
UCC60DQ-2/1
UCC70DQ-2/1
Single Circuit - Tandem Scroll / Double Circuit - 2 Single Scroll
2
2
2
2
1.6 + 1.6
1.9 + 1.9
3.0 + 1.9
3.0 + 3.0
Polyol Ester
Single Circuit / Double Circuit
Thermostatic Expansion Valve
R407C
6+6
6+6
8+8
8+8
UCC40SSQ-1/1
UCC50SSQ-2/1
UCC60SSQ-2/1
UCC70SSQ-2/1
UCC40DSQ-1/1
UCC50DSQ-2/1
UCC60DSQ-2/1
UCC70DSQ-2/1
6+6
6+6
8+8
8+8
Thermostatic Expansion Valve
UCC110D-4/2
UCC125D-3/1
Tandem Scroll
4
4
4 x 3.80
2 x 6.20+2 x 3.80
Polyol Ester
Dual Circuit
Thermostatic Expansion Valve
R407C
22 + 22
25 + 25
UCC110DQ-4/2
UCC125DQ-3/1
22 + 22
30 + 30
Electronic Expansion Valve
UCC110DSQ-4/2
UCC125DSQ-4/1
22 + 22
40 + 40
Electronic Expansion Valve
UCC200D-6/2
UCC225D-6/2
Tandem Scroll
4
4
2 x 8.0 + 2 x 6.2
4 x 8.0
Polyol Ester
Dual Circuit
kg
kg
l
R407C
20 + 20
UCC160DQ-6/2
30 + 30
kg
R407C
42 + 42
UCC300DQ-10/2
40 + 40
kg
UCC300DSQ-12/2
46 + 46
kg
10 + 10
UCC80SSQ-2/1
UCC80DSQ-2/1
10 + 10
UCC130D-4/2
UCC150D-3/1
4
2 x 6.20+2 x 3.80
4
4 x 6.20
22 + 22
UCC130DQ-4/2
22 + 22
30 + 30
UCC150DQ-4/1
40 + 40
UCC130DSQ-6/2
30 + 30
UCC150DSQ-4/1
40 + 40
UCC250D-6/2
UCC275D-8/2
4
4 x 8.0
4
4 x 8.0
R407C
R407C
30 + 30
30 + 30
UCC200DQ-6/2
UCC225DQ-8/2
30 + 30
40 + 40
Electronic Expansion Valve
UCC200DSQ-6/2
UCC225DSQ-8/2
R407C
30 + 30
UCC250DQ-8/2
40 + 40
UCC250DSQ-8/2
UCC275DSQ-10/2
30 + 30
40 + 40
Electronic Expansion Valve
40 + 40
50 + 50
UCC330D-10/2
UCC360D-10/2
UCC400D-12/2
Trio Scroll
6
6
6 x 8.0
6 x 8.0
Polyol Ester
Dual Circuit
Electronic Expansion Valve (EEV)
R407C
R407C
R407C
43 + 39
53 + 53
65 + 60
UCC330DQ-10/2
UCC360DQ-12/2
UCC400DQ-12/2
54 + 49
49 + 49
65 + 60
Electronic Expansion Valve
UCC330DSQ-14/2 UCC360DSQ-14/2 UCC400DSQ-16/2
56 + 51
70 + 70
82 + 76
Electronic Expansion Valve
UCC450D-12/2
6
6 x 8.0
6
6 x 8.0
R407C
30 + 30
UCC180DQ-6/2
30 + 30
UCC160DSQ-6/2
UCC180DSQ-6/2
All data as D Model except:
30 + 30
30 + 30
UCC300D-8/2
Tandem Scroll
4
4 x 8.0
2
3.6 + 3.6
Electronic
Expansion Valve
(EEV)
R407C
41 + 41
UCC275DQ-8/2
41 + 41
Thermostatic Expansion Valve (TEV)
kg
UCC80SQ-2/1
UCC80DQ-2/1
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Thermostatic (TEV)
R407C
63 + 63
UCC450DQ-14/2
72 + 72
UCC450DSQ-16/2
80 + 80
Chillers
ULTIMA COMPACT
Commissioning Data
WATERSIDE PRESSURE DROPS
CAUTION
(1)
Constant water flow MUST be maintained. Variable water volume is
NOT recommended and may invalidate warranty.
Use the formula below to calculate the External Head Available:
Total Pump Head Available
-
Chiller Pressure Drop
=
External Head Available
=
103 kPa
Example: UCC200D-6/2 9.54 l/s, standard single pump:
145 kPa
UCC30 – UCC80
42 kPa
70
UCC70
CHILLER PRESSURE DROP (kPa)(2)
(Except UCC75)
-
UCC80
UCC60
60
UCC50
50
UCC40
UCC30
40
30
20
10
0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
WATERFLOW (l/s)
UCC75 - UCC150
125
CHILLER PRESSURE DROP (kPa)(2)
(Except UCC80)
100
UCC75
UCC100
UCC150
UCC125/130
UCC110
75
50
25
0
0
2
4
6
8
10
12
14
WATERFLOW (l/s)
(1)
(2)
For glycol solutions, please refer to Glycol Data.
Chiller pressure drop refers to standard unit without optional pumps and/or pipework.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
35
ULTIMA COMPACT
Chillers
Commissioning Data
WATERSIDE PRESSURE DROPS
CAUTION
(1)
Constant water flow MUST be maintained. Variable water volume is
NOT recommended and may invalidate warranty.
UCC160 - UCC250
CHILLER PRESSURE DROP (kPa)(2)
125
UCC180
UCC200 UCC225
UCC250
100
UCC160
75
50
25
0
2
4
6
8
10
12
14
16
18
20
WATERFLOW (l/s)
UCC240 - UCC450
120
CHILLER PRESSURE DROP (kPa)(2)
UCC400
UCC275
100
UCC330 UCC360
UCC450
UCC300
80
60
40
20
0
0
5
10
15
20
WATERFLOW (l/s)
(1)
(2)
36
For glycol solutions, please refer to Glycol Data.
Chiller pressure drop refers to standard unit without optional pumps and/or pipework.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
25
30
35
Chillers
ULTIMA COMPACT
Commissioning Data
PUMP PACKAGES
TOTAL PUMP HEAD AVAILABLE
(kPa)
UCC30 - UCC80 (Except UCC75)
250
9
200
8
150
100
50
0
0
1
2
3
4
5
6
7
5
6
7
5
6
7
WATERFLOW (l/s)
TOTAL PUMP HEAD AVAILABLE
(kPa)
300
7
6
250
200
150
100
50
0
0
1
2
3
4
WATERFLOW (l/s)
TOTAL PUMP HEAD AVAILABLE
(kPa)
350
5
4
300
250
3
2
1
200
150
100
50
0
0
1
2
3
4
WATERFLOW (l/s)
UCC30
UCC40
UCC50 - UCC60
UCC70 - UCC80
Curve
UCC30 - UCC80
Curve
Single Head Pump or Run / Standby Pump
Standard
1
1
2
3
Twin Head Pump
Standard
8
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Larger
6
7
5
4
Larger
9
37
ULTIMA COMPACT
Chillers
Commissioning Data
PUMP PACKAGES
Single Head Pump or
Run/Standby
TOTAL PUMP HEAD AVAILABLE
(kPa)
UCC75 - UCC450 (Except UCC80)
250
8
225
7
200
6
175
150
5
125
100
5
10
15
20
25
30
35
40
TOTAL PUMP HEAD AVAILABLE
(kPa)
WATERFLOW (l/s)
280
4
260
240
220
3
200
180
160
140
120
2
4
6
8
10
12
14
16
18
TOTAL PUMP HEAD AVAILABLE
(kPa)
WATERFLOW (l/s)
350
2
300
1
250
200
150
100
1
2
3
4
5
6
7
8
9
10
11
WATERFLOW (l/s)
UCC75 - 150 (Ex 80)
UCC110 - 250
UCC275 - 300
UCC330 - 400
UCC450
38
Curve
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Single Head Pump or Run / Standby Pump
Standard
1
3
5
6
6
Larger
2
4
7
7
8
Chillers
ULTIMA COMPACT
Commissioning Data
PUMP PACKAGES
260
240
7
220
6
200
5
180
160
140
5
10
15
20
25
30
35
TOTAL PUMP HEAD AVAILABLE
(kPa)
WATERFLOW (l/s)
200
4
180
160
140
120
100
5
10
15
20
25
30
WATERFLOW (l/s)
TOTAL PUMP HEAD AVAILABLE
(kPa)
Twin Head Pump
TOTAL PUMP HEAD AVAILABLE
(kPa)
UCC75 - UCC450 (Except UCC80)
350
3
300
2
250
1
200
150
100
50
2
4
6
8
10
12
14
16
18
WATERFLOW (l/s)
UCC75 - 130 (Ex 80)
UCC160 - 250
UCC275
UCC300 - 400
UCC450
Curve
Twin Head Pump
Standard
1
2
4
4
5
Larger
2
3
5
6
7
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
39
ULTIMA COMPACT
Chillers
Commissioning Data
OPERATIONAL SEQUENCE
Refrigerant Charge
Check for the presence of a refrigerant charge in the condenser side.
Sump Heater
The mains supply to the sump (oil) heater should be switched on at least 8 hours prior to
compressor starting to avoid refrigerant migration.
CAUTION
Pre-Start-Up Check
CAUTION
A separately fused, locally isolated, permanent single phase and neutral supply
MUST BE FITTED for the compressor sump heater, evaporator trace heating and
control circuits, FAILURE to do so could INVALIDATE WARRANTY.
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.
Check phase rotation by connecting pressure gauges to the suction and
discharge ports, if no differential pressure occurs, isolate immediately.
Adding Refrigerant
The unit is supplied with a full refrigerant charge, additional refrigerant should be added to
the system via 1/4” schraeder connection on the expansion line if required.
Pump Down
Never pump down without the low pressure trip and high discharge temperature switches
being operative.
UNLOADING PROTECTION
Head Pressure
The microprocessor has inbuilt protection against nuisance trips. If the head pressure
rises above 24barg the system will unload 1 compressor and remain unloaded until the
head pressure drops below 21barg.
Low Pressure
If low pressure drops below the microprocessor setting, the compressor will unload to 1
compressor, if low pressure persists for 1 minute, the circuit will be switched off and
sound an alarm.
40
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Commissioning Procedure
To be read in conjunction with the commissioning sheets provided, items highlighted
should be recorded.
GENERAL
CAUTION
Please ensure all documents have been completed correctly and return to Airedale
Technical Support immediately to validate warranty.
PRE COMMISSIONING CHECKLIST
CAUTION
ALL work MUST be carried out by Technically Trained competent personnel.
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
The door interlocking MCCB should be in the OFF position and the auxiliary alarm
contact from the MCCB should be linked out.
Ensure all items listed in the Pre commissioning section are complete.
RECORD
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, adjust tapping if necessary and record on the
commissioning document.
•
Check all timer settings are correct.
•
Check Sump Heater (ensure this is switched on for a minimum of 8 hours prior to the
unit operation).
•
Check oil level of each compressor.
•
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
directly to the chiller.
•
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 Controller Data.
CAUTION
Disable remote ON/OFF to ensure the unit does not start unintentionally.
The chiller will not start until microprocessor control SWITCH 1 is in the ON
position. DO NOT SWITCH TO ON AT THIS STAGE
•
•
Adjust the water temperature supply and return set points (if necessary) to call for
100% cooling (refer to the Controls section).
Ensure all KNOBS and SWITCHES are adjusted to suit the design requirements
(refer to the Controls section).
To switch the unit ON, use the microprocessor keypad as follows:
Press
CAUTION
Prg
, press
, press
, press
& finally
.
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.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
41
ULTIMA COMPACT
Chillers
Commissioning Procedure
PRE COMMISSIONING CHECKLIST
•
•
CAUTION
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, to clear the alarms refer
to Alarm Handling.
Prior to the chiller compressors being allowed to start, the Water Flow Fail and
Pump Interlock features MUST both be proven to work correctly.
•
To check the water flow fail safety protection is working satisfactorily:
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.
RECORD
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.
•
RECORD
To check the pump interlock safety feature works satisfactorily:
Switch off the chiller water pump and check the interlock wiring connections at the
chiller are open circuit.
To switch the unit OFF, use the microprocessor keypad as follows:
Press
Prg
, press
, press
, press
& finally
.
Fully open all liquid line and discharge service ball valves on each circuit.
42
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
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.
•
Switch the door interlocking MCCB to the ON position but again only on the circuit
which is to be tested.
•
Adjust the water temperature supply and return set points to match the
system requirements.
To switch the unit ON, use the microprocessor keypad as follows:
Press
•
Prg
, press
, press
, press
& finally
.
Check pressures at suction and discharge ports for correct phase rotation.
CAUTION
If no differential pressure occurs, isolate immediately.
RECORD
•
Measure and record the compressor amps once the compressors are fully loaded
and then at each of the unloading stage.
•
Measure and record full speed amps of each condenser.
CAUTION
RECORD
The microprocessor LP setting is adjustable via the micro display. It is
recommended that this setting be 0.4Bar 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 below the design
supply water temperature (to a minimum of 3°C).
•
Check the liquid line sight glass is clear and dry.
•
Check the superheat setting adjusts the expansion valve to maintain a superheat
setting of 5 – 8°C at all operating loads.
•
Check and record the following:
Suction and discharge pressures
Liquid, discharge and suction line temperature
Water inlet and outlet temperature
•
Ensure the above are all within the design parameters.
•
Repeat as follows for each circuit:
•
To switch the unit OFF, use the microprocessor keypad as follows:
•
, press
, press
, press
Press
To switch the unit ON, repeat above.
Prg
& finally
.
The unit is now commissioned and will provide many years of trouble free operation
providing the following maintenance schedule is followed.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
43
ULTIMA COMPACT
Chillers
Maintenance
CAUTION
ALL work MUST be carried out by Technically Trained competent personnel.
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
IMPORTANT
UK MAINLAND - The Chiller Maintenance Record and supporting maintenance
documents MUST be complete and available on request to validate warranty.
The Chiller Maintenance Record is located within the unit control panel.
The maintenance schedule indicates the time period between maintenance operations.
GENERAL
MAINTENANCE
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.
• Check each circuit sight glass for dryness and bubbles
for indication of leaks.
• Check compressor oil level and
shell/sump temperature.
• Visually inspect the unit for oil patches.
Investigate and rectify variations.
Remember to re-cap the Schraeder
connections!
Investigate and repair possible leaks.
SYSTEM
Investigate and adjust as necessary.
Check the following against the commissioning 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:
Secure/tighten as necessary.
• Pipework clamps are secure.
• Tightness and condition of fan and compressor mounts.
• Anti-Vibration mounts fixings (if fitted).
Finally!
44
Ensure control panel lids and access panels have been
correctly replaced and securely fastened in position.
Chillers
Installation & Maintenance : 903-129 IM E 10/04/C
Chillers
ULTIMA COMPACT
Maintenance
GENERAL MAINTENANCE
6 MONTHS
ACTION
NOTES
Repeat 3 month checks plus the following:
SYSTEM
Check evaporator trace heating and low ambient thermostat Remember to re-cap the Schraeder
are set to activate at 4.0ºC.
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.
ELECTRICAL
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.
Tighten all electrical terminals.
COMPRESSOR
MAINTENANCE
SHUT DOWN PERIODS
Periodic maintenance and inspection of this equipment is necessary to prevent premature
failure, the following periodic inspections should be carried out by period or hourly use
which ever is sooner.
1 Year
Measure compressor motor insulation.
7,500 Hours or 4 Years
Inspect compressor oil.
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 : 903-129 IM E 10/04/C
45
Chillers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Electrical Panel (Mains & Controls)
Compressors MCBs
Modulating Head Pressure Controller
Door Interlocking isolator
Fan Contactor MPCB
Incoming Customer Mains 3 Phase
Compressor Contactors
Microprocessor Controller
EMC Filter
Customer Permanent Supply/Controls Connections
Compressor Compartment
Incoming Customer Mains Access Points
HP Switch
Liquid Line Sight Glass
Discharge Thermostat Switch
Compressor Electrical Terminal Box
Suction Pressure Transducer & Low Pressure Switch
Suction Port
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Oil Sump Draw Point
Oil Level Sight Glass
Sump Heater
Compressor Feet/Resilient Mounts
Condenser Coils
Water Inlet Female BSP Connection
Water Outlet Female BSP Connection
Evaporator & Optional Pump Compartment
Evaporator
Flow Switch (Optional Extra)
Discharge Schraeder Connection
Water Inlet Sensor (Inside plate heat exchanger)
Water Outlet Sensor (Inside plate heat exchanger)
Electronic Expansion Valve or Thermostatic Expansion Valve
Liquid Line
Discharge Line Ball Valve (Optional)
Liquid Line Filter Drier
Chillers
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.
UCC30-UCC80 (EXCEPT 75) SINGLE & DUAL CIRCUIT
Dual Circuit Shown
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.
Installation Maintenance : 903-129 IM E 10/04/C
UK MAINLAND - Chiller Maintenance Record can be located inside
Item 1.
ULTIMA COMPACT
The serial plate can be located inside Item 1.
Parts Identification
SPARES
46
Parts Identification
8
9
10
1
11
29
4
Chillers
2
3
4
5
6
7
Parts Identification
UCC30-UCC80 (EXCEPT 75) SINGLE & DUAL CIRCUIT
Dual Circuit Shown
30
11
12
14
13
15
31
32
16
33
34
24
25
27
28
26
12
35
47
ULTIMA COMPACT
23
Chillers
Installation & Maintenance: 903-129 IM E 10/04/C
17
18
20 19
21
22
UCC .. /1 – DUAL CIRCUIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Discharge Line Ball Valve
Discharge Schraeder Connection
HP Switch
Compressor Electrical Terminal Box
Oil Level Sight Glass
Sump Heater
Liquid Line Filter Drier
Electronic Expansion Valve (Optional Extras on D Models)
Liquid Line Sight Glass
Liquid Line
Discharge Thermostat Switch
Low Pressure Switch
Suction Pressure Transducer
Suction Port
Oil Sump Draw Point
Compressor Feet/Resilient Mounts
Water Inlet Sensor
Evaporator
Flow Switch (Optional Extra)
Compressor Compartment
Evaporator & Optional Pump Compartment
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Water Inlet Flange Connection
Water Outlet Flange Connection
Mains Panel
Door Interlocking isolator
Emergency Stop
Incoming Customer Mains Access Points
Condenser Coils
Unit Controller Panel
Fan Contactor MPCB
Modulating Head Pressure Controller
Compressors MCBs
Condenser Fan MPCB
Compressor Contactors
Isolator
Incoming Customer Mains 3 Phase
Microprocessor Controller
Electronic Expansion Valve Controller (Optional Extra on D
Models)
39 Customer Permanent Supply/Controls Connections
40 EMC Filter
ULTIMA COMPACT
Chillers
Installation Maintenance : 903-129 IM E 10/04/C
UK MAINLAND - Chiller Maintenance Record can be located inside
Item 24.
Parts Identification
48
The serial plate can be located inside Item 24.
Chillers
25
26
27
29
15
16
34
28
6 5
7
8
9,10
11
33
38
39
40
49
ULTIMA COMPACT
22
23
Chillers
24
Parts Identification
18
Installation & Maintenance: 903-129 IM E 10/04/C
Chillers
19
32
4
37
21
17
20
36
4
12,13,14
30
31
1,2,3
35
UCC .. /2 – DUAL CIRCUIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Water Inlet Sensor
Evaporator
Flow Switch (Optional Extra)
Condenser Fan Contactors
Fan Contactor MCB
Modulating Head Pressure Controller
Compressors MCBs
Compressor Contactors
Isolator
Power Factor Correction (Optional Extra)
Evaporator & Optional Pump Compartment
Water Inlet Flange Connection
Door Interlocking isolator (x 3)
Water Outlet Flange Connection
Condenser Coils
Condenser Fan Mains Panel
Mains Panel Circuit 1
Mains Panel Circuit 2
Bus bar Chamber
Incoming Customer Mains Access Points
Incoming Customer Mains 3 Phase
Unit Controller Panel (Including Serial Plate)
Compressor Compartment
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Discharge Line Ball Valve
Low Pressure Switch
Suction Pressure Transducer
Oil Level Sight Glass
Oil Sump Draw Point
Discharge Thermostat Switch
Discharge Line
Suction Port
Liquid Line
Microprocessor Controller
Electronic Expansion Valve Controller (Optional Extra on D
Models)
Customer Permanent Supply/Controls Connections
EMC Filter
Discharge Schraeder Connection
HP Switch
Compressor Electrical Terminal Box
Sump Heater
Compressor Feet/Resilient Mounts
Electronic Expansion Valve (Optional Extras on D Models)
Liquid Line Sight Glass
Liquid Line Solenoid Valve (D Models Only)
Liquid Line Filter Drier
Liquid Line Ball Valve
ULTIMA COMPACT
Chillers
Installation Maintenance : 903-129 IM E 10/04/C
UK MAINLAND - Chiller Maintenance Record can be located inside
Item 22.
Parts Identification
50
The serial plate can be located inside Item 22.
Chillers
2
13
3
14
24
39
42
45
46
6
23
Chillers
Installation & Maintenance: 903-129 IM E 10/04/C
51
ULTIMA COMPACT
43
30
29
44
9
41
40
28
27
7
31
32
10
34
15
38
26
19
20
37
25
18
17
Chillers
12
33
1
21
8
16
5
22
4
Parts Identification
11
35
36
Head Office:
Airedale International Air Conditioning Ltd
Leeds Road
Rawdon
Leeds LS19 6JY
United Kingdom
Tel:
Fax:
e-mail:
website:
+44 (0) 113 239 1000
+44 (0) 113 250 7219
enquiries@airedale.com
www.airedale.com
Regional Sales Offices:
Midlands
Tel:
Fax:
e-mail:
0121 7071010
0121 7071069
ukmidlandsales@airedale.com
Scotland
Tel:
Fax:
e-mail:
0141 2044750
0141 2044755
mail@airesales.co.uk
International Sales Offices:
Germany
Tel:
Fax:
e-mail:
+ 49 6108 90040
+ 49 6108 77972
info@airedale.de
*South Africa
Tel:
Fax:
e-mail:
+ 27 11 794 6291
+ 27 11 794 6294
aiac@global.co.za
*North America
Tel:
Fax:
e-mail:
+ 1 215 639 6030
+ 1 215 639 0777
Sales@airedaleusa.com
*
PART NO:
903-129 IM E
ISSUE
A
B
C
DATE
01/10/04
01/02/05
01/11/05
Manufacturing Facility Also
Airedale Departmental Contact Details:
CUSTOMER SERVICES
For further assistance, please e-mail: enquiries@airedale.com or telephone:
Customer Services
UK Sales Enquiries
International Enquiries
Spares Hot Line
Airedale Service
Technical Support
Training Enquiries
+ 44 (0) 113 238 7789
+ 44 (0) 113 239 1000
+ 44 (0) 113 238 7878
+ 44 (0) 113 239 1000
+ 44 (0) 113 239 1000
+ 44 (0) 113 239 1000
For information, visit us at our Web Site: www.airedale.com
uk.sales@airedale.com
enquiries@airedale.com
spares@airedale.com
service@airedale.com
tech.support@airedale.com
marketing@airedale.com
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