AIREDALE Ultima Compact UCCU100D-2/1 Installation Operating & Maintenance Manual Download Page 1

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INSTALLATION, OPERATING &

MAINTENANCE MANUAL

Ultima Compact Condensing Unit

Air Cooled Condensing Unit

30kW - 450kW

Summary of Contents for Ultima Compact UCCU100D-2/1

Page 1: ...INSTALLATION OPERATING MAINTENANCE MANUAL Ultima Compact Condensing Unit Air Cooled Condensing Unit 30kW 450kW ...

Page 2: ... 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 CUSTOMER SERVICES For further assistance please e mail enquiries airedale com or telephone CUSTOM ER SER VIC ES UK Sales...

Page 3: ...n Mounting Optional 15 Positioning 16 Refrigeration System 17 Refrigeration Connections 18 Pipe Sizing Guide 18 Pipework Installation 18 Pressure Testing 19 Evacuation 19 Electrical 19 Interconnecting Wiring 20 Electrical Data 22 CONTROLS 26 Viewing Unit Operating Status 27 Setting up 27 Alarms 28 COMMISSIONING DATA 29 Operating Limits 29 Mechanical Data 29 Unloading Protection 29 COMMISSIONING PR...

Page 4: ... 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 thi...

Page 5: ...DATE OF INVOICE 1 Original Equipment DATE OF INSTALLATION 2 Component if different DATE OF FAILURE Airedale International Air Conditioning Limited Leeds Road Rawdon Leeds LS19 6JY Tel 0113 239 1000 Fax 0113 250 7219 CUSTOMER COPY To be filled in and attached complete to faulty component 700 006 The original equipment serial U or BP number An appropriate purchase order number A spares order will be...

Page 6: ... with the following EC Directives Electromagnetic Compatibility Directive EMC 2014 30 EU Low Voltage Directive LVD 2014 35 EU Machinery Directive MD 89 392 EEC in the version 98 37 EC Pressure Equipment Directive PED 97 23 EC Article 13 of 2014 68 EU To comply with these directives appropriate national harmonised standards have been applied These are listed on the Declaration of Conformity supplie...

Page 7: ...to the rigid galvanised heavy duty sub frame with the use of vibration reducing isolation Refrigeration Each refrigeration circuit is supplied with the following Holding charge of Helium Liquid line ball valve Suction line ball valve Low pressure cut out with manual reset via microprocessor controller High pressure switch with manual reset Pressure relief valve with integral rupture disc and indic...

Page 8: ...Std Std Number of Independent Refrigeration Circuits 1 or 2 2 2 2 2 Scroll Compressor Arrangement 1 x Tandem Set or 2 x Single 2 x Tandem Sets 2 x Tandem Sets 2 x Tandem Sets 2 x Trio Sets Sickle Bladed Fans Std Std c w Long Bellmouth Std c w Long Bellmouth Std c w Long Bellmouth Std c w Long Bellmouth Low speed condenser fan SQ DQ Models DQ Models DQ Models DQ Models DQ Models Extra Low speed con...

Page 9: ...ities that may impose surcharges on equipment with power factor less than 0 95 OPTIONAL EXTRAS GENERAL Loose Item Anti Vibration Mounts Condenser Fan Discharge Air Plenum Extension Power Factor Correction Factory Fitted Epoxy Coated Condenser Coils Coil Guards Dual Pressure Relief Valve Discharge Line Ball Valve Discharge Line non Return Valve Suction Line Accumulator Liquid Receiver Pressure Reli...

Page 10: ... UCCU100D 2 1 mm 2775 390 1900 1 485 200 170 UCCU125D 3 1 mm 3625 390 1825 1135 275 200 170 UCCU150D 3 1 mm 3625 390 1825 1135 275 200 170 Model DQ A B C D E F G UCCU75DQ 2 1 mm 2775 390 1900 1 485 200 170 UCCU100DQ 2 1 mm 2775 390 1900 1 485 200 170 UCCU125DQ 3 1 mm 3625 390 1825 1135 275 200 170 UCCU150DQ 4 1 mm 4475 390 1900 1900 285 200 170 Model DSQ A B C D E F G UCCU75DSQ 3 1 mm 3625 390 182...

Page 11: ...5 190 190 750 600 1035 UCCU70 SSQ DSQ 2 1 kg 185 185 200 200 770 600 1055 UCCU80 SSQ DSQ 2 1 kg 210 210 225 225 870 600 1050 UCC75 UCC150 Except UCC80 P1 P3 P5 P2 P4 P6 2 1 C of G Model D P1 P2 P3 P4 P5 P6 Operating Weight C of G1 mm C of G2 mm UCCU75D 2 1 kg 305 305 1 1 165 165 940 650 1055 UCCU100D 2 1 kg 320 320 1 1 165 165 970 650 1035 UCCU125D 3 1 kg 300 280 185 175 135 135 1210 635 1595 UCCU...

Page 12: ...50 1750 1925 2 625 2150 UCCU250DQ mm 3975 1850 2100 115 140 205 480 1500 1500 2 495 1800 UCCU270DQ UCCU300DQ mm 5500 2200 2180 140 150 225 350 1350 1350 1925 525 2150 UCCU330DQ UCCU360DQ mm 6350 2200 2180 140 150 225 350 1700 1925 1925 450 2150 UCCU400DQ UCCU450DQ mm 7200 2200 2180 140 150 225 350 1700 2700 2000 450 2150 Model DSQ A B C D E F G H J K L M UCCU110DSQ mm 2365 1850 2100 115 140 205 27...

Page 13: ...Q 6 2 kg 505 545 210 230 2 2 125 125 1740 955 1075 UCCU225DQ 8 2 kg 545 545 290 290 2 2 225 225 2120 925 1525 UCCU240DQ 8 2 kg 655 655 330 330 2 2 190 190 2350 1100 1435 UCCU250DQ 8 2 kg 545 545 290 290 2 2 225 225 2120 925 1525 UCCU270DQ 10 2 kg 650 650 325 325 195 195 180 180 2700 1100 1680 UCCU300DQ 10 2 kg 690 690 335 335 200 200 185 185 2820 1100 1660 UCCU330DQ 12 2 kg 715 715 375 375 245 245...

Page 14: ...e lifting points provided 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 A C B E D UCCU30 80 Except UCCU75 A B 1 C 1 D 1 E 1 FAN 1 mm 300 1050 1450 300 300 1900 2200 1270 2 FANS 1 mm 300 1450 750 2200 1...

Page 15: ...ioning of each mount INSTALLATION 1 Locate and secure mount using bolting down holes 10 in base plate 2 Ensure mounts are located in line with the unit base 3 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...

Page 16: ...bserve 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 clearanc...

Page 17: ... 3 LIQUID RECEIVER PRESSURE RELIEF ASSEMBLY Optional Factory Fitted 4 SUCTION LIQUID LINE BALL VALVES OUTDOOR UNIT ULTIMA COMPACT CONDENSING UNIT INDOOR UNIT BY OTHERS 1 Suction accumulator optional factory fitted 2 Receiver pump down ball valve optional factory fitted 3 Liquid receiver pressure relief assembly optional factory fitted 4 Suction liquid line ball valves standard factory fitted 5 Fil...

Page 18: ...1 8 2 1 8 Suction Line in 2 5 8 2 5 8 2 5 8 2 5 8 2 5 8 3 1 8 3 1 8 1 Suitable For Brazed Connections PIPE SIZING GUIDE Pipework sizes and routes should be set in accordance with good refrigeration practice PIPEWORK INSTALLATION The suction line should be insulated Liquid lines should be insulated in areas of high temperature or when exposed to direct sunlight Special consideration should be given...

Page 19: ... system at the furthest point from the vacuum pump Triple evacuation should be used to ensure that all contaminants are removed Operate the vacuum pump until a pressure of 1 5 torr 200 Pa absolute pressure is reached then stop the vacuum pump to break the vacuum using oxygen free Nitrogen until the pressure rises above zero The above operation should be repeated a second time The system should the...

Page 20: ...z N2 Only Required For UCCU30 80Q DQ UCCU50 60SSQ DSQ L2 L3 N2 E L4 Separate Permanent Supply 230V 1PH 50Hz N1 E 502 Circuit 1 24VAC Suction Pressure Control Option Compressor 1 24VAC Digital I P Control Option 504 502 Unit Remote On Off 24VAC Circuit 2 24VAC Suction Pressure Control Option Compessor 2 24VAC Digital I P Control Option 505 502 Compressor 3 24VAC Digital I P Control Option 506 502 C...

Page 21: ...rs Condensing Units 21 Installation Maintenance 6259675 IM V1 9 0 04 2016 pLAN Terminations The plugged termination ensures that the connections are made simultaneously Failure to attach the cables this way may cause damage to the controller ...

Page 22: ...W 4 7 6 2 8 1 9 5 8 1 9 5 11 7 Nominal Run Amps 1 A 12 0 12 7 16 1 20 7 16 1 20 7 26 0 Crankcase Heater Rating W 70 0 65 0 65 0 65 0 75 0 65 0 70 0 Start Amps 2 101 0 98 0 120 0 135 0 120 0 135 0 175 0 Type Of Start Direct on line SUPER QUIET SQ UCCU30SSQ 1 1 UCCU30DSQ 1 1 UCCU40SSQ 1 1 UCCU40DSQ 1 1 UCCU50SSQ 2 1 UCCU50DSQ 2 1 UCCU60SSQ 2 1 UCCU60DSQ 2 1 UCCU70SSQ 2 1 UCCU70DSQ 2 1 UCCU80SSQ 2 1 ...

Page 23: ... W 65 0 65 0 65 0 65 0 75 0 65 0 75 0 75 0 Start Amps 2 98 0 120 0 120 0 120 0 175 0 120 0 175 0 175 0 Type Of Start Direct on line QUIET DQ UCCU75DQ 2 1 UCCU100DQ 2 1 UCCU110DQ 4 2 UCCU125DQ 3 1 UCCU130DQ 4 2 UCCU150DQ 4 1 All data as above except Condenser Fan Per Fan Full Load Amps A 1 15 1 15 1 25 1 15 1 25 1 15 Locked Rotor Amps A 2 10 2 10 4 50 2 10 4 50 2 10 Motor Rating kW 0 68 0 68 0 69 0...

Page 24: ...Start Amps 2 175 0 215 0 175 0 270 0 175 0 270 0 215 0 175 0 270 0 Type Of Start Direct on line QUIET DQ UCCU160DQ 6 2 UCCU180DQ 6 2 UCCU200DQ 6 2 UCCU225DQ 8 2 UCCU240DQ 8 2 UCCU250DQ 8 2 All data as above except Condenser Fan Per Fan Full Load Amps A 1 25 1 25 1 25 1 25 1 15 1 25 Locked Rotor Amps A 4 50 4 50 4 50 4 50 2 10 4 50 Motor Rating kW 0 69 0 69 0 69 0 69 0 70 0 69 SUPER QUIET DSQ UCCU1...

Page 25: ...art Amps 2 215 0 175 0 215 0 270 0 215 0 270 0 320 0 270 0 320 0 Type Of Start Direct on line QUIET DQ UCCU270DQ 10 2 UCCU300DQ 10 2 UCCU330DQ 12 2 UCCU360DQ 12 2 UCCU400DQ 14 2 UCCU450DQ 14 2 All data as above except Condenser Fan Per Fan Full Load Amps A 1 15 1 15 1 15 1 15 1 15 1 15 Locked Rotor Amps A 2 10 2 10 2 10 2 10 2 10 2 10 Motor Rating kW 0 70 0 70 0 70 0 70 0 70 0 70 SUPER QUIET DSQ U...

Page 26: ...Opens the Available Menus 5 ALARM Red LED Indicates Alarm Present 6 4 ROW LCD DISPLAY 7 CURSOR FLASHING Top Left Position HOME Indicates adjustable Fields Navigation 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 pa...

Page 27: ...adjustment includes supply temperature setpoint and unit temperature differential Default 4648 Status Displays current status on digital and analogue inputs and outputs Open Access Maintenance Displays hours run for compressors and pumps if fitted Also includes Electronic Expansion Valves if fitted Default 4648 Clock Allows adjustment of real time clock time zones Default 4648 Alarm Log Display la...

Page 28: ...orrect all controller outputs are de activated Emergency Stop A normally open contact On closing 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 Low Suction Pressure When the suction pressure sensor value falls below the value set by the low suction level for a period excee...

Page 29: ...tic Tandem Trio Tandem Quantity 4 4 4 4 6 4 Oil Charge Volume Total l 4 x 6 2 2 x 8 0 2 x 6 2 2 x 8 0 2 x 6 2 4 x 8 0 4 x 8 0 4 x 8 0 Oil Type Polyol Ester Refrigeration Dual Circuit Holding Charge Helium to 6 9 barg Refrigerant Type R407C Charge Total 1 kg 20 20 30 30 30 30 30 30 32 32 30 30 QUIET DQ UCCU160DQ 6 2 UCCU180DQ 6 2 UCCU200DQ 6 2 UCCU225DQ 8 2 UCCU240DQ 8 2 UCCU250DQ 8 2 Refrigerant C...

Page 30: ...d any damage noted Secure commissioning gauges to the high side of the system check for a positive charge Check tightness of electrical components and properly terminated Check external fuses MCB are of correct rating Check units properly earthed Check pipework is earth bonded Check that the remote on off switch if fitted is in the off position With the MCBs in the off position measure the incomin...

Page 31: ... 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 Prg press press press finally CAUTION 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 Check that each circuit trips on low pressure The a...

Page 32: ... isolate immediately RECORD Measure and record the compressor amps once the compressors are fully loaded and at the unloading stage Measure and record full speed amps of each condenser CAUTION The microprocessor LP setting is adjustable via the microprocessor keypad factory set to 3 2BarG RECORD Check the liquid line sight glass is clear and dry Check the superheat setting adjusts the expansion va...

Page 33: ...ng suction line burn out drier Compressor thermal protection device operated Check if compressor overheated possibly short of refrigerant Noisy Compressor Expansion valve malfunction abnormally cold suction Iine Ensure feeler bulb is tight on suction and superheat is correct normally 5 to 6 C Replace power assembly or valve as necessary Lack of oil Repair leaks if any add oil if required but not t...

Page 34: ...tor tripped Carry out continuity check at terminals TK in motor terminal box If tripped and motor hot check bearings If tripped and motor cold replace motor Faulty motor windings capacitor Motor humming would indicate fault in motor or capacitor Check windings for continuity and if OK replace capacitor Minimum speed set too low Adjust head pressure controller to suit Condenser fan runs too fast Hi...

Page 35: ...lowing against the commissioning records Investigate and adjust as necessary Control settings Alarm log for unusual occurrences Concurrently ensure chilled water pump and flow switch operate efficiently and that interlocks function correctly Finally Record operating conditions FABRIC Visually inspect the unit for general wear and tear treat metalwork Rust should be inhibited primed and touched up ...

Page 36: ...t 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 Thermostatic expansion valve only ELECTRICAL Tighten all electrical terminals COMPRESSOR MAINTENANCE Periodic maintenance and inspection of this equipment is necessary to prevent premature failure the following periodic inspections should be carried o...

Page 37: ... Pressure Transducer 6 Compressor Electrical Terminal Box 7 Oil Level Sight Glass 8 Oil Sump Draw Point 9 Suction Port 10 Sump Heater 11 Compressor Feet Resilient Mounts 12 Liquid Line 13 Suction Line 14 Compressor Compartment 15 Refrigeration Pipework Optional Refrigeration components Compartment 16 Customer pipe connections Liquid 17 Customer pipe connections Suction 18 Mains Panel 19 Door Inter...

Page 38: ...TIMA COMPACT Condensing Units 38 Installation Maintenance 6259675 IM V1 9 0 04 2016 Chillers 1 2 4 6 5 3 7 8 9 10 12 13 17 16 22 15 14 19 20 21 22 18 24 25 26 27 19 28 29 30 23 11 24 Parts Identification ...

Page 39: ...Condensing Units ULTIMA COMPACT Condensers Condensing Units 39 Installation Maintenance 6259675 IM V1 9 0 04 2016 Notes ...

Page 40: ...don Leeds LS19 6JY United Kingdom Tel 44 0 113 239 1000 Fax 44 0 113 250 7219 e mail enquiries airedale com website www airedale com PART NO ISSUE DATE 904 048 IM E A 01 03 05 B 06 06 05 C 29 03 2010 V1 3 0 18 02 13 V1 4 0 10 2013 V1 6 0 10 2014 V1 7 0 11 2015 V1 8 0 01 2016 V1 9 0 04 2016 ...

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