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TurboChill™

Chillers

17

TurboChill Water Cooled Technical Manual 9216326 V1.10.0 06_2017

Flow Proving Device*

Evaporator and condenser differential pressure sensors facilitate low flow limiting and pressure drop monitoring via the

microprocessor which shall be fitted to ensure correct unit water flow.

Pump Interlock*

Provision for a pump interlock is available within the control panel.

Water Flow Switch*

If selected, a water flow switch shall be fitted ensuring integrity of the cooling solution flow. The flow switch shall protect

the chiller against low water flow conditions.

*Each feature is a flow proving device and 2 out of the 3 should be fitted to any unit to validate

warranty.

CAUTION

Water Connections

Water inlet and outlet connections are of a grooved and clamped type construction, enabling easy pipework termination.

The unit is supplied with a counter pipe and coupling assembly for quick installation. Water inlet and outlet are located at

the end of the unit.

Introduction

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Summary of Contents for TurboChill TCW

Page 1: ...TurboChill TCW Technical Manual Water Cooled Compact Chiller 150 375kW R134a R1234ze E ...

Page 2: ...edale Customer Services For further assistance please e mail enquiries airedale com or telephone UK Sales Enquiries 44 0 113 239 1000 enquiries airedale com International Enquiries 44 0 113 239 1000 enquiries airedale com Spares Hot Line 44 0 113 238 7878 spares airedale com Airedale Service 44 0 113 239 1000 service airedale com Technical Support 44 0 113 239 1000 tech support airedale com Traini...

Page 3: ...otection to at least 3K lower than ambient Water glycol solution should be constantly circulated through all waterside pipework and coils to avoid static water from freezing Ensure that pumps are started and running even during shut down periods when the ambient is within 3K of the solution freeze point 1 i e if the solution freezes at 0 C the pump must be operating at 3 C ambient Additional trace...

Page 4: ...ay from sunlight The refrigerant must never be stored above 50 C Global Warming Potential The R134a refrigerant has a GWP of 1430 Based on EN378 1 2016 100 year life Maximum and Minimum Operation Temperature TS and Pressure PS Allowable Temperature Range TS Min 20 C to Max 120 C Maximum Allowable Pressure PS High Side 14 0 Barg Based on the refrigerant temperature in the unit off state in the lowe...

Page 5: ...E REFRIGERANT IN AIR LFL LOWER FLAMMABILITY LEVEL AND UFL UPPER FLAMMABILITY LEVEL 5 8 Vol TO 11 3Vol 60 C EXISTENCE OF AN IGNITION SOURCE WITH AN IGNITION ENERGY MINIMUM IGNITION ENERGY 61 000mJ AT 54 C AMBIENT AIR TEMPERATURE 30 C AND A WIND SPEED BURNING VELOCITY Care must be taken when working around the discharge pipe work of the unit High surface temperatures may exist during unit operation ...

Page 6: ...Drop 30 Minimum System Water Volume Calculations 31 Installation Data 32 Lifting 32 Centre of Gravity 33 Dimensions 34 Module Installation 35 Standard Recommended Pipework Installation 37 Pressure Relief Valve Discharge Piping 38 Differential Pressure Connections 39 Water System 40 Electrical 42 Interconnecting Wiring 43 pLAN Termination 44 Sensor Connections 44 Power Quality Harmonics 45 Commissi...

Page 7: ...12 7 C Evaporator and 30 35 C Condenser water temperatures Refrigerant The range has been designed and optimised for operation with ozone benign R134a refrigerant or R1234ze E refrigerant Construction The base shall be fabricated from galvanised steel to ensure a rigid durable weatherproof construction Unit panels shall be manufactured from galvanised sheet steel coated with epoxy baked powder pai...

Page 8: ...ers 8 TurboChill Water Cooled Technical Manual 9216326 V1 13 0 07_2018 Oil Free Centrifugal Compressor Fan Assisted Ventilation Grille Isolator Economiser Unit Overview Image for illustration purposes only Introduction ...

Page 9: ...TurboChill Chillers 9 TurboChill Water Cooled Technical Manual 9216326 V1 10 0 06_2017 Evaporator Condenser Introduction ...

Page 10: ...pplied with the following Full operating charge of R134a or R1234ze E refrigerant Liquid injection cooling circuit fitted to each compressor as standard with Sight Glass Filter Drier and Ball Valve Discharge Line Shut Off Valves Liquid Line Shut Off Valves Filter Driers with Replaceable Core Evaporator and Liquid Line Sight Glass Low Pressure Switch with Auto Reset 2 High Pressure Switches with Au...

Page 11: ...cant reduction in refrigerant charge when compared to a flooded evaporator equivalent The evaporator incorporates an intergrated subcooler as standard further boosting its performance over other heat exchanger technologies Condenser The similarly designed condenser also adopts the compact design reducing footprint and refrigerant required for subcooling Economiser Via the economiser a portion of t...

Page 12: ...l of refrigerant flow and suction superheat at reduced head pressures The turn down rate of a typical EEV is superior to that of it s thermostatic equivalent such that a reduced optimum condensing pressure can be maintained at low compressor load An EEV can operate effectively between 10 100 of its rated capacity Sight Glass A liquid line sight glass is fitted to give an indication of the state of...

Page 13: ...individually shut off via a 3 way valve This allows the maintenance of individual pressure relief valves without any requirement for refrigerant evacuation Pressure relief valves have been sized to ensure that in the event of fire they can prevent excessive build up of pressure within the evaporator and condenser EN13136 2013 section 6 2 1 has been used to size valves accordingly External Fire Fir...

Page 14: ...ing additional impedance harmonics and voltage spikes in the ac waveform EMI EMC filter and comprising of o AC DC rectifier o DC capacitors o DC AC IGBT converter o Motor bearing management system and incorporated surge protection o Soft start module o Magnetic bearing system o Compressors are mounted on Turbocor specially designed vibration reducing isolating rubber mounts o Linear capacity modul...

Page 15: ...peration Very low start current only 2A The intelligent self optimising compressor offers near silent oil free operation and ultra efficient variable speed control Turbocor compressor shaft and impellers levitate on a magnetic cushion eliminating friction and vibration resulting in the compressor running at a smooth and reduced sound spectrum The TurboChill compressor s variable speed control offe...

Page 16: ...ion S G L Waterside Differential Water Pressure Transducers Grooved and Clamped Unit Terminations Manual and Actuated Isolation Valves Pump Interlock Water Flow Switch Standard Feature Optional Feature Feature Not Available Image for illustration purposes only Each feature is a flow proving device and 2 out of the 3 should be fitted to any unit to validate warranty CAUTION Introduction ...

Page 17: ... Flow Switch If selected a water flow switch shall be fitted ensuring integrity of the cooling solution flow The flow switch shall protect the chiller against low water flow conditions Each feature is a flow proving device and 2 out of the 3 should be fitted to any unit to validate warranty CAUTION Water Connections Water inlet and outlet connections are of a grooved and clamped type construction ...

Page 18: ...Comp Control Board Permanent Single Phase Supply Incoming Mains Supply Incoming Controls Wiring Access Point System Configuration S G L Electrical Electronic Soft Start Mains electric Isolator Ultracap Power Backup Control Panel Ventilation Ventilated Compressor Enclosure Phase Rotation Relay Energy Manager Power Meter Standard Feature Optional Feature Feature Not Available Image for illustration ...

Page 19: ...te unit isolation of the electrical panel during adjustment and maintenance a door interlocking isolator is provided as standard Ultracap UPS Unit controls are maintained by an Ultracap The Ultracap module is an external backup device for the controller The module guarantees temporary power to the controller in the event of power failures and allows for enough time to keep the controller running w...

Page 20: ... With an 8 x 22 character 132 x 64 pixel screen size back lit in white for improved contrast the larger screen shall provide for user friendly viewing and easy status recognition by displaying a combination of text and icons The default screen shall show the unit status without the need for interrogation and an easy to navigate menu structure for further interrogation and adjustment shall be provi...

Page 21: ...he first module shall ramp down to 30 to share the load This same process can be continued up to 8 modules Once all modules are active they will load up equally as the system load increases This loading strategy simply allows each module to operate at part load demand as much as possible maximising efficiency Offloading occurs via the process described above in reverse All modules shall ramp down ...

Page 22: ...hall be supplied with dedicated compressor enclosure as standard Ventilated Compressor Enclosure R1234ze units shall have ventilation with ATEX fans as standard in compliance with safety standards Lifting Eye Bolts M36 lifting eye bolts shall be fitted to the unit Sterling board L A T Wooden Case Packing Units shall be supplied complete with additional L A T corner protection and cross braces to a...

Page 23: ...nd Pressure Levels are calculated from sound power using the expanded parallelepiped method according to BS EN ISO 11203 2009 Resultant performance figures obtained from test will be proven to not differ from the claimed figures by more than the allowable deviations specified in table 7 of section VII of Eurovent RS 6 C 003 2016 A weighted sound power 3dBA Sound Directivity The global sound measur...

Page 24: ... 52 40 4 18 3 86 3 78 3 70 3 62 3 54 45 4 18 3 87 3 79 3 72 3 63 3 55 Glycol Percentage Freezing Point Temperature C 0 0 C 20 7 8 C 25 10 7 C 30 14 1 C 35 17 9 C 40 22 3 C 0 999 8 1035 7 1043 7 1051 8 1059 3 1066 8 5 999 9 1034 4 1042 4 1050 3 1057 8 1065 2 10 999 7 1032 9 1040 9 1048 8 1056 1 1063 5 15 999 0 1031 4 1039 2 1047 1 1054 4 1061 7 20 998 2 1029 7 1037 5 1045 3 1052 5 1059 7 25 997 0 1...

Page 25: ... 4 02 3 96 3 90 3 84 3 77 45 4 18 4 03 3 97 3 92 3 85 3 78 Glycol Percentage Freezing Point Temperature C 0 0 C 20 7 1 C 25 9 6 C 30 12 7 C 35 16 4 C 40 21 1 C 0 999 8 1025 8 1031 0 1036 2 1040 7 1045 1 5 999 9 1024 3 1029 4 1034 5 1038 8 1043 1 10 999 7 1022 7 1027 6 1032 6 1036 8 1040 9 15 999 0 1020 9 1025 7 1030 5 1034 6 1038 7 20 998 2 1019 0 1023 7 1028 4 1032 3 1036 2 25 997 0 1017 0 1021 5...

Page 26: ...poxy Baked Powder Paint Light Grey RAL 7035 Evaporator Type Compact Shell and Tube Insulation Class O Total Max Water Flow l s 23 6 23 6 23 6 Total Min Water Flow l s 1 6 1 6 1 6 Condenser Type Compact Shell and Tube Insulation N A Total Max Water Flow l s 27 7 27 7 27 7 Total Min Water Flow l s 1 6 1 6 1 6 Compressor Type TurboCor Oil Free Compressor Quantity 1 1 1 Capacity Control Variable Frequ...

Page 27: ... Start Amps 2 A 2 2 2 Type Of Start Electronic Soft Start TCW11RC1E1 S TCW11RC1E1 G TCW11RC1E1 L Technical 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz Overall dBA TCW11RC1E1 S Power 77 5 73 0 73 3 76 1 85 4 83 2 78 2 76 6 88 7 Pressure 10m 45 8 41 3 41 6 44 3 53 6 51 4 46 5 44 8 57 0 TCW11RC1E1 G Power 61 3 61 3 66 2 78 0 86 9 81 6 80 0 79 3 89 5 Pressure 10m 29 5 29 5 34 4 46 2 55 ...

Page 28: ...t Refrigeration Pre charged R134a R1234ze R134a GWP 1430 7 1430 Charge Total 5 kg 83 83 85 CO2 Tonnes equivalent 118 7 0 581 121 6 Refrigeration Control Electronic Expansion Valve EEV Water System Evaporator Grooved Type Coupling and Pipe Assembly Water Inlet Outlet DN100 DN100 DN100 Water Volume l 108 5 108 5 108 5 Min System Water Volume l 1530 1404 1782 Max System Pressure Barg 10 10 10 Flow Ra...

Page 29: ... 2 Type Of Start Electronic Soft Start Technical Data Electrical 63 Hz 125 Hz 250 Hz 500 Hz 1000 Hz 2000 Hz 4000 Hz 8000 Hz Overall dBA TCW11XC1E1 S Power 69 1 70 4 68 0 68 0 75 7 73 8 63 1 58 2 78 8 Pressure 10m 37 3 38 7 36 2 36 3 44 0 42 1 31 4 26 4 47 0 TCW11XC1E1 G Power 54 1 58 7 61 0 70 2 78 0 71 0 65 2 60 9 79 5 Pressure 10m 22 4 27 0 29 3 38 5 46 2 39 3 33 5 29 1 47 8 TCW11XC1E1 L Power 5...

Page 30: ... 9216326 V1 13 0 07_2018 Technical Waterside Pressure Drop Evaporator Condenser Graphs represent performance at 100 water 0 20 40 60 80 100 120 0 5 10 15 20 25 30 Pressure Drop kPa Flowrate l s 0 20 40 60 80 100 120 0 5 10 15 20 25 30 Pressure Drop kPa Flowrate l s ...

Page 31: ...rts per Hour Example 750kW output at 30 35 C Condenser and 7 12 C Evaporator Minimum Turndown 0 075 7 5 4 modules 750 x 3600 x 0 075 x 1 2 1038 Litre 3 9 x 5 12 Vmin kW x 3600 x Min turndown x 1 2 1038 Litre CP x Δt Maximum number of Compressor starts per hour Minimum Turndown 1 Module 30 2 Modules 15 3 Modules 10 4 Modules 7 5 Example 750kW output at 30 35 C Condenser and 7 12 C Evaporator Perman...

Page 32: ... 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 ALL work MUST be carried out by Technically Trained competent personnel Prior to connecting services ensure that the equipment is installed and completely level CAUTION Installation Installation Data Lifting The unit should be lifted f...

Page 33: ...oG 1 CoG 2 Lifting CoG kg kg P1 P2 P3 P4 mm mm x y TCW11RC1E1 S 2253 2465 405 815 410 830 505 1225 500 1220 TCW11RC1E1 G 2265 2477 410 820 420 830 505 1220 500 1220 TCW11RC1E1 L 2265 2477 410 820 420 830 505 1220 500 1220 TCW11XC1E1 S 2358 2570 435 840 440 855 505 1215 500 1220 TCW11XC1E1 G 2370 2582 440 845 445 855 505 1215 500 1220 TCW11XC1E1 L 2370 2582 440 845 445 855 505 1215 500 1220 ...

Page 34: ... 1956 MAINS ISOLATOR MAINS CABLE ENTRY EXTERNAL DISPLAY 1000 NOTE OUTER PANEL KIT IS OPTIONAL SEE TOP RIGHT VIEW FOR STANDARD R TYPE UNIT 2000 350 1130 955 282 464 254 AUTOMATIC ISOLATION VALVES MANUAL ISOLATION VALVES 2550 4 20 DIA MOUNTING HOLES IN BASE OF UNIT 1195 131 4 LIFTING EYES 126 1245 COMPRESSOR ACCESS PANEL PRV ACCESS PANEL REFRIGERATION PIPEWORK ACCESS PANEL LIQUID LEVEL PIPEWORK ACCE...

Page 35: ... can be disconnected from the common waterside and withdrawn for maintenance and or replacement with extra long 2m pallet truck wheels suitable for 2 5 tonnes Packing Due to the compact footprint of the modules and movability via pallet trucks they can fit into a standard series 1 shipping container for example an ISO 1AAA 40 foot high cube container shall accommodate 10 off modules circa 3 7MW to...

Page 36: ...talled standalone unable to move the unit provison must be made for maintenance around the chiller The following minimum clearance is required A B B C Pipework A Clearance between units 800mm B Clearance between unit and external walls 800mm C Clearance for chiller 2000mm D Clearance for chiller maneuverability 3000mm E 50mm Provision of 500mm is recommended above the unit for maintenance purposes...

Page 37: ...NT At Highest Point T PUMP PUMP STRAINER OUT IN DE AERATER Optional Extra DE AERATER Optional Extra T SHUT OFF VALVES TEMPERATURE SENSOR FLEXIBLE CONNECTIONS AUTO AIR VENT At Highest Point P T P T P T P T OUT BYPASS CIRCUIT For Flushing PUMP PUMP STRAINER T IN Condenser Water Circuit to TCW 3 WAY VALVE CONDENSER EVAPORATOR AUTO SHUT OFF VALVES AUTO SHUT OFF VALVES Supplied by Airedale PRESSURE AND...

Page 38: ...usible plugs may diffuse the charge into the air by adequate means but away from any air intake to the building or discharge into an adequate quantity of a suitable absorbing material Relief devices for refrigerant in group A1 R134a refrigerant may discharge into the machinery room provided the system charge is less that the limit set in Annex C of prEN378 1 2013 Such discharges of refrigerant sho...

Page 39: ...Manual 9216326 V1 10 0 06_2017 Installation Differential Pressure Connections The 1 4 BSP Male connection to the water pipework shall be connected through the bulkhead of the unit Trace heating must be applied to protect against freezing IMPORTANT A DETAIL A ...

Page 40: ...lled in parallel adjacent to each other reverse return should be applied to avoid unnecessary balancing valves 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 liquid is treated to prevent corrosion and algae forming In ambi...

Page 41: ...rols and flow proving device for safety reasons Maximum System Operating Pressure The system can safely operate at a maximum of 10bar 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 a...

Page 42: ...pable of carrying the maximum load current under non fault conditions at the stipulated voltage Ensure correct phase rotation A separately fused locally isolated permanent single phase and neutral supply is required for the evaporator trace heating and control circuit CAUTION Please refer to the electrical wiring diagrams provided for installation ALL work MUST be carried out by technically traine...

Page 43: ...ock 508 ç 502 è Setback Setpoint Temperature Switch 510 ç 808 ç Remote Setpoint Adjust 500 è 560 è Volt Free Alarm N O 561 ç Volt Free Common Alarm 562 è Volt Free Alarm N C 580 è Volt Free Alarm N O 581 ç Volt Free Common Alarm 582 è Volt Free Alarm N C Rx Tx ç pLAN Network Connection In Rx Tx ç GND ç Rx Tx è pLAN Network Connection Out Rx Tx è GND è 891 çè Wired BMS connection ModBUS BACNet LON ...

Page 44: ...ALVE WATER INLET TEMP SENSOR CONDENSER WATER OUTLET TEMP SENSOR EVAPORATOR EVAPORATOR FLOW SWITCH EVAPORATOR ISOLATION VALVE WATER INLET TEMP SENSOR EVAPORATOR Installation Sensor Connections RxTx RxTx GND RxTx RxTx GND Panel Side Customer Side The plugged termination ensures that the connections are made simultaniously Failure to attached the cables this this way may cause damage to the controlle...

Page 45: ...ssive currents in neutral conductor The 3rd 5th 7th and 9th harmonics are considered to be the predominant frequencies produced by non linear loads To minimize the harmonic effect each Turbocor compressor is fitted with a 5 line reactor to help reduce the harmonics and improve the displacement power factor above 0 95 1 However to further reduce the effects and to help meet limits for engineering r...

Page 46: ...heck and record the glycol type and strength Low levels of glycol can cause freeze up problems when operating at low temperatures or during the unit off state during cold ambient conditions Glycol concentration is measured by use of a Refractometer Differential Pressure Sensor Ensure that the differential pressure sensor operates satisfactorily the best way to do this is to Reduce the flow to the ...

Page 47: ...llow the unit to operate correctly Pump Interlock The pump interlock is fitted and functioning correctly Controls Controller Record on the commissioning sheet the controller serial numbers details Controller type Address Serial number Bios Boot Also record any expansion valve driver serial numbers Controller Settings The following controller settings are to be recorded on the commissioning sheet H...

Page 48: ... C Evaporator water supply temperature C Condenser water return temperature C Condenser water supply temperature C The supply and return water temperatures should be taken and recorded in both full and part load conditions approximately 1m away from the unit Liquid Line Sight Glass Record the status of the liquid line sight glass Clear flashing Wet dry yellow or green HP LP Trips Check operating o...

Page 49: ...e to seal the required port that is being changed Do not forget to set the valve into the centre to check that the valve does not leak refrigerant Then select one of the pressure relief valves and open that port Take extreme care that the correct port is selected Shut Down Periods For periods of winter shut down the following precautions are recommended Close the liquid and discharge ball valve Ca...

Page 50: ...f evaporator condenser Clean where appropriate Check glycol concentration if appropriate Adjust as necessary Clean evaporator water strainer Leak test all refrigerant joints and visually inspect pipe and pipework insulation Inspect all water connections for any leaks Pipe work clamps are secure Refrigeration System pressure readings suction liquid and discharge System temperature readings suction ...

Page 51: ...er information refer to compressor manual which is available from Airedale on request or the TurboCor website Controls Change the compressor capacitor Change the controller battery may be more frequent dependant on usage Electrical Check mains power supply voltage Check that electrical terminals are tight tighten as needed Check for signs of discolouration on power cables Check amperage are as per...

Page 52: ...ing correct refrigerant handling techniques Air or other non condensable gas in system Evacuate system and re charge with new refrigerant Head pressure controller faulty Check EC fan control module if faulty replace Head pressure too low Water temperature too low Check condenser temperature setpoint Suction Pressure too low Flash gas bubbles in sight glass at liquid line Investigate for refrigeran...

Page 53: ...ocedures must be carried out over and above any commissioning checks Any low temperature protection devices must be turned on for a minimum of 8 hour These include Panel heaters Electric trace heating Checks must be carried out for the operation of unit components Waterside Check 3 way valve operates correctly Check that flow switches operate correctly Check that differential pressure sensor opera...

Page 54: ...onditions of Sale Warranty and Warranty Procedure available upon request Procedure When a component part fails a replacement part should be obtained through our Spares department If the part is considered to be under warranty the following details are required to process this requirement Full description of part required including Airedale s part number if known The original equipment serial numbe...

Page 55: ...ir temperature C Evaportator inlet outlet water temperatures C Fixed outlet A 100 35 12 7 B 93 25 7 C 87 15 7 D 80 5 7 EU 2016 2281 Table 22 Rating Point T1 C Part load ratio Outdoor air dry bulb temperature C Fan coil application inlet outlet water temperature C Cooling floor application inlet outlet water temperatures C Fixed outlet Variable outlet A 35 100 35 12 7 12 7 23 18 B 30 74 30 7 8 5 18...

Page 56: ...ared EERDC B 6 67 7 03 6 56 Declared Refrigerant Capacity PC 1 3 5 kW 259 1 237 6 302 1 Declared Power Input DC kW 25 3 24 9 34 4 Declared EERDC C 10 23 9 55 8 78 Declared Refrigerant Capacity PD 1 3 5 kW 239 1 219 3 278 8 Declared Power Input DD kW 24 7 21 4 28 4 Declared EERDC D 9 67 10 27 9 82 SSCEE 2 3 5 265 289 224 SSCEE Tier Tier 2 2021 Tier 2 2021 Tier 2 2021 Rated Cooling Capacity Prated c...

Page 57: ...d Power Input DB kW 41 8 36 4 49 6 Declared EERDC B 6 67 7 03 6 56 Declared Refrigerant Capacity PC 1 3 5 kW 259 1 237 6 302 1 Declared Power Input DC kW 25 3 24 9 34 4 Declared EERDC C 10 23 9 55 8 78 Declared Refrigerant Capacity PD 1 3 5 kW 239 1 219 3 278 8 Declared Power Input DD kW 24 7 21 4 28 4 Declared EERDC D 9 67 10 27 9 82 SSCEE 2 3 5 265 289 224 SSCEE Tier Tier 2 2021 Tier 2 2021 Tier...

Page 58: ...TurboChill Chillers 58 TurboChill Water Cooled Technical Manual 9216326 V1 13 0 07_2018 Troubleshootng ...

Page 59: ...Head Office Airedale International Air Conditioning Ltd Leeds Road Rawdon Leeds LS19 6JY Tel 44 0 113 2391000 Fax 44 0 113 2507219 E mail enquiries airedale com Web www airedale com ...

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