AIAC E
I N S T A L L A T I O N , O P E R A T I N G
& M A I N T E N A N C E M A N U A L
Ultima 2000
Air Cooled Screw Liquid Chiller
250 - 650 kW
Page 1: ...AIACE INSTALLATION OPERATING MAINTENANCE MANUAL Ultima 2000 Air Cooled Screw Liquid Chiller 250 650 kW ...
Page 2: ...ranty 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 ...
Page 3: ...ty Page 10 Positioning Page 11 Water System Data Page 12 Glycol Data Page 13 Electrical Data Page 14 CONTROLS Control Scheme Features Page 18 Operation Page 19 Setting Up Page 20 Viewing Unit Operating Status Page 21 Adjusting Customer Control Settings Page 23 COMMISSIONING DATA General Data Page 25 Mechanical Data Page 25 Water System Data Page 26 Electrical Data Page 27 COMMISSIONING PROCEDURE P...
Page 4: ... 3 Also ensure that there are no other power feeds to the unit such as fire alarm circuits BMS circuits etc std 4 Electrical installation commissioning and maintenance work on this equipment should be undertaken by competent and trained personnel in accordance with local relevant standards and codes of practice std 5 Refrigerant used in this range of products is classified under the COSHH regulati...
Page 5: ...e this order with detailed prices for components travel and labour rates When warranty is accepted following inspection of the faulty component a credit note will be issued against an invoice raised in line with the acknowledgement Should warranty be refused the invoice raised against the acknowledgement becomes payable on normal terms Airedale reserve the right to carry out site warranty labour w...
Page 6: ...trol fans are individually switched by a Microprocessor STANDARD CHILLER D Evaporator Trace Heating Quiet Fans Single Screw Compressors Shell Tube Evaporator Dual Independent Refrigeration Circuits With the benefits of the Standard range the Quiet chiller is supplied with an acoustic package which incorporates asTM QUIET CHILLER DQ Acoustically lined compressor enclosures 3 phase Head Pressure Con...
Page 7: ...ate door locking electrical isolation for each mains compartment Emergency Stop fitted to controls compartment door Separate fully accessible controls compartment allowing adjustment of control set points whilst the unit is operational Dedicated bus bar chamber for connection of incoming 3 phase and earth mains power supply Circuit breakers for protection of all major unit components Phase Rotatio...
Page 8: ...er Refer to Sequence Controller Manual provided with this option Epoxy Coated Condenser Coils Factory Fitted Coil Guards Dual Pressure Relief Valve Electronic Expansion Valve Modem Link Refer to Airedale for further details Closed Transition Star Delta Compressor Start Refer to Commissioning Section for details Optional Unit Cover Commissioning Chillerguard Health Check Chillerguard Maintenance Fo...
Page 9: ...198 1753 USC400DSQ 12 to USC500DSQ 12 mm 5740 475 400 1410 1465 1880 585 2213 1723 USC575DSQ 16 to USC650DSQ 16 mm 7440 525 400 2000 1645 2810 585 2522 1723 Point Loadings Total Weights P1 P2 P3 P4 P5 P6 P7 P8 Machine Operational USC250DSQ 8 kg 680 540 1 340 680 540 1 340 3120 3208 USC275DSQ 8 kg 690 550 1 340 680 540 1 340 3140 3228 USC300DSQ 8 kg 690 550 1 340 690 550 1 340 3160 3248 USC350DSQ 1...
Page 10: ...nd evenly IM134 If the unit is dropped it should immediately be checked for damage and reported to Airedale Service IM120 CAUTION Only use lifting points provided asTM The unit should be lifted from the base and where possible with all packing and protection in position If any other type of slinging is used due care should be taken to ensure that the slings do not crush the casework or coil IM118 ...
Page 11: ...ipework and electrical connections are readily accessible IM057 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 IM122 Within a side enclosed installation the fan MUST be higher than the enclosing structure IM142 Figures in brackets indicate airflow and maintenance clearances for side enclosed or m...
Page 12: ...er installations 1 commissioning valve set is required per chiller new Air vents are to be installed at all high points and where air is likely to be trapped at intermediate points new 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 new Isolating valves should be installed adjacent to all major items of equip...
Page 13: ...ystem Water Volume 3 L 1782 1960 2138 2608 3014 Max System Test Pressure Bar 10 10 10 10 10 asTM Model USC450 12 USC500 12 USC575 16 USC650 16 Connections Water Inlet Outlet Evap 2 in DN200 DN200 DN200 DN200 Water Drain Bleed Evap in 1 2 1 2 1 2 1 2 Water System Min System Water Volume 3 L 3294 3624 4253 4564 Max System Test Pressure Bar 10 10 10 10 2 Flanged to PN16 asTM 3 For minimum system volu...
Page 14: ...ach unit new CAUTION A separately fused locally isolated permanent single phase and neutral supply is required for the compressor sump heater evaporator trace heating and control circuits new Interlocks Protection Always electrically interlock the operation of the chiller with the pump interlocks and water flow switch for safety reasons Failure to do this will invalidate the chiller warranty new C...
Page 15: ...0 98 0 98 0 98 Compressor Per Compressor Motor Rating kW 43 50 43 50 Nominal Run Amps 2 A 75 87 75 87 Crankcase Heater Rating kW 150 150 150 Start Amps 3 193 250 193 250 Type Of Start Star Delta OPTIONAL EXTRAS Power Factor Correction Nominal Run Amps 2 A 150 160 170 Maximum Start Amps 3 A 275 287 344 Recommended Mains Fuse A 200 200 250 Compressor Nominal Run Amps Per Compressor A 68 78 68 78 Clo...
Page 16: ...8 Compressor Per Compressor Motor Rating kW 68 50 68 87 68 Nominal Run Amps 2 A 114 87 114 144 114 Crankcase Heater Rating kW 150 150 150 Start Amps 3 248 250 248 316 248 Type Of Start Star Delta OPTIONAL EXTRAS Power Factor Correction Nominal Run Amps 2 A 201 225 252 Maximum Start Amps 3 A 375 373 403 Recommended Mains Fuse A 250 315 315 Compressor Nominal Run Amps Per Compressor A 102 78 102 129...
Page 17: ... 98 0 98 Compressor Per Compressor Motor Rating kW 87 107 87 107 Nominal Run Amps 2 A 144 181 144 181 Crankcase Heater Rating kW 150 150 150 Start Amps 3 316 289 316 289 Type Of Start Star Delta OPTIONAL EXTRAS Power Factor Correction Nominal Run Amps 2 A 279 319 352 Maximum Start Amps 3 A 471 511 484 Recommended Mains Fuse A 355 400 450 Compressor Nominal Run Amps Per Compressor A 129 162 129 162...
Page 18: ...the supply water temperature is not critical to its operation Selection of the best application control scheme can be made via a software switch in the microprocessor during initial commissioning Examples based on Models USC250 8 to USC500 12 having 6 Stages of Cooling Variable Supply Temperature Control 6 7 8 9 10 11 12 13 14 WATER TEMPERATURE C 20 40 55 70 85 100 Chiller Capacity Cooling Stage S...
Page 19: ...n To guard against unauthorised adjustments a password is required to gain access new FACTORY SET PASSWORD PIN NUMBER 4648 or Customer chosen number new Once protected using a Software Knob for example use the following instructions to make a change new 1 Select the desired Software Knob display new 2 Attempt to change the Software Knob value which will result in the display 5 Enter your PIN new 3...
Page 20: ...holiday dates programmable as individual days or periods of up to 99 days The unit will be factory set for no holiday shut down and will not normally require further adjustment new Holidays must be programmed at least 7 days before the actual holiday date new CAUTION Set up 1 Position cursor under the calendar number eg Calendr 1 to select the first set up period new 2 Move the cursor to period ty...
Page 21: ...Sens 3 CP1 SUCTION PRESSURE Sens 4 CP1 LIQUID PRESSURE Sens 6 CP2 SUCTION PRESSURE Sens 7 CP2 LIQUID PRESSURE Sens 8 REM SETPOINT INPUT Hard Wired Input Sensors Sens 9 REMOTE SETPOINT Sens 10 COMP 1 HOURS RUN Sens 11 COMP 2 HOURS RUN Internally Calculated Sensor Values Digital Inputs Digin 1 PHASE ROTATION Off External new To view position the cursor under the digital input number eg Digin 1 scrol...
Page 22: ...ill revert to the internal Supply Water Temperature setpoint new Electronic Expansion Valve Control Failure This indicates that the Electronic Expansion Valve EEV controller has detected an operating problem with either one or both circuits new Restart When power is restored A restart alarm message will be recorded in the alarm log new INDIVIDUAL CIRCUIT ALARMS new Circuit 1 2 Fault A normally clo...
Page 23: ...ooling capacity new Supply Water Temperature Low Limit If the Supply Water Temperature falls below the low limit value set by this knob the controller will generate a manual reset alarm and de activate all controller outputs new Due to the application of low temperature glycol systems it is possible to adjust this temperature below 0 C new CAUTION Under no circumstances should the low temperature ...
Page 24: ...speed controllers to vary the fans between minimum and maximum speed new Condenser Selection 8 or 12 Fan This switch is only used when stepped head pressure control mode is selected If OFF is selected then 8 fan stepped head pressure control mode is enabled If ON is selected then 12 fan stepped head pressure control mode is enabled new Only available on 6 stage units with a total of 8 or 12 conden...
Page 25: ...e refer to Airedale CT018 MECHANICAL DATA seTM Oil Refrigerant Charges Model USC250 8 USC275 8 USC300 8 USC350 12 USC400 12 Compressor Screw Semi Hermetic Quantity 2 2 2 2 2 Oil Charge Volume Total L 10 10 10 10 10 10 13 10 13 13 Oil Type Polyolester Refrigeration Dual Circuit Charge Total kg 45 45 55 45 55 55 95 80 95 95 SUPER QUIET DSQ All data as above except Refrigerant Charge Total kg 55 55 6...
Page 26: ...ioning Data WATER SYSTEM DATA asTM Waterside Pressure Drops 0 20 40 60 80 100 5 10 15 20 25 30 WATERFLOW l s USC250 to USC300 8 USC350 12 0 20 40 60 80 100 10 15 20 25 30 35 WATERFLOW l s USC450 12 USC400 12 0 20 40 60 80 100 10 15 20 25 30 35 40 45 WATERFLOW l s USC500 12 USC575 to USC650 16 ...
Page 27: ...re compressor starting to ensure that refrigerant is present at compressor start up new Crankcase Heater The mains supply to the crankcase oil heater should be switched on at least 8 hours prior to compressor starting to avoid refrigerant migration new Pre Start Up Check Before compressor start up make sure that an oil level is showing in the compressor sight glass and that all refrigerant ball va...
Page 28: ...rther loading new Adding Refrigerant Additional refrigerant should be added to the system via 1 4 schrader connection on the expansion line new Pump Down Never shut the liquid injection solenoid valve during or before pump down and never pump down without the low pressure trip and high discharge temperature switches being operative new Unloading Protection new Head Pressure The microprocessor has ...
Page 29: ...position With the MCBs in the off position measure the incoming voltage Check Phase Rotation Check voltage at permanent supply Measure and record the primary 230V and secondary 24V voltages at each of the transformers and record on the commissioning document Check all timer settings are correct Check Sump Heater Check oil level Check water filter is fitted Check design water flow is available Chec...
Page 30: ...he flow rate to 75 of design and ensure that the evaporator pressure differential switch or flow switch trips off this flow rate adjust if necessary new Ensure this alarm is recognised at the display and disengages the circuits operation immediately Restore flow rate to the design and check the alarm has self cleared new Turn the unit OFF by setting SWITCH 1 enable unit to the OFF position new Ful...
Page 31: ...ts trip at the following settings new LP micro adjustable refer to Controls section Software Knobs LP safety 0 6 0 1 BarG fixed HP safety 24 5 0 7 BarG fixed Clear the alarm as detailed in the microprocessor manual new CAUTION The microprocessor LP setting is adjustable via the micro display It is recommended that this setting be 0 6 Bar below the equipment freezing point of the cooling medium ie ...
Page 32: ...r 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 m...
Page 33: ...r is recommended Recheck the charge following major adjustment of the superheats Adjust as necessary A period of 30 minutes should be allowed between each resetting of the valve to allow pressures to stabilise ELECTRICAL Tighten all electrical terminals COMPRESSOR MAINTENANCE Periodic maintenance and inspection of this equipment is necessary to prevent premature failure the following periodic insp...
Page 34: ...ber and the date of manufacture which can be found on the unit serial plate std 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 std The serial plate can be located inside Item 24 new 23 24 25 26 27 26 31 28 29 30 16 17 32 33 34 35 36 37 38 39 40 41 33 42 43 44 45 46 47 48 49 50 51 52 2 1 3 7 4 5 6 7 2 8 9 10 7 11 5 12 1...
Page 35: ...t Flange Connection 21 Discharge Line 22 Water Outlet Flange Connection 23 Mains Panel Circuit 2 24 Control Panel Serial Plate to inside 25 Mains Panel Circuit 1 26 Door Interlocking isolator 27 Emergency Stop 28 Fan and Motor Assemblies 29 Condenser Coils 30 Evaporator 31 Compressor Housing DQ and DSQ Models Only 32 Suction Port 33 Low Pressure Switch 34 Liquid Injection Inlet 35 Oil Level Sight ...
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