Airedale TurboChill FreeCool User Manual

TurboChill™
200kW to 900kW
Single Circuit
Air Cooled (TCC) and FreeCool (TCF) Chiller
Technical Manual
TurboChill™ Air Cooled and FreeCool

Warranty, Commissioning & Maintenance

As standard, Airedale guarantees all non consumable parts only for a period of 12 months, variations tailored to suit product and application are also available; please contact Airedale for full terms and details.
Introduction
To further protect your investment in Airedale products, Airedale can provide full commissioning services, comprehensive maintenance packages and service cover 24 hours a day, 365 days a year (UK mainland).
For a free quotation contact Airedale 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.
For effective prevention of such risk it is necessary that the equipment is maintained in accordance with Airedale recommendations.

ChillerGuard™

In addition to commissioning, a 24 hour, 7 days a week on-call service is available throughout the year to UK mainland sites. This service will enable customers to contact a duty engineer outside normal working hours and receive assistance over the telephone. The duty engineer can, if necessary, attend site, usually within 24 hours or less.
Full details will be forwarded on acceptance of the maintenance agreement.
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.

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 Training Enquiries + 44 (0) 113 239 1000 marketing@airedale.com
For information, visit us at our Web Site: www.airedale.com
Airedale 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. Airedale 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 Airedale 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 Airedale Ltd.
© 2013 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
2
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool

Warranty

All Airedale products or parts (non consumable) supplied for installation within the UK mainland and commissioned by an Airedale engineer, carry a full Parts & Labour warranty for a period of 12 months from the date of commissioning or 18 months from the date of despatch, whichever is the sooner.
Parts or Equipment supplied by Airedale for installation within the UK or for Export that are properly commissioned in
accordance with Airedale standards and specication, not commissioned by an Airedale engineer; carry a 12 month
warranty on non consumable Parts only from the date of commissioning or 18 months from the date of despatch, whichever is the sooner.
Parts or equipment installed or commissioned not to acceptable Airedale standards or specication invalidate all
warranty.
Warranty is only valid in the event that
In the period between delivery and commissioning the equipment, is properly protected & serviced as per the Airedale installation & maintenance manual provided where applicable the glycol content is maintained to the correct level.
In the event of a problem being reported and once warranty is conrmed as valid under the given installation and
operating conditions, the Company will provide the appropriate warranty coverage (as detailed above) attributable to the
rectication of any affected Airedale equipment supplied (excluding costs for any specialist access or lifting equipment
that must be ordered by the customer).
Any spare part supplied by Airedale under warranty shall be warranted for the unexpired period of the warranty or 3 months from delivery, whichever period is the longer.
To be read in conjunction with the Airedale Conditions of Sale - Warranty and Warranty Procedure, available upon request.
Introduction
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 number. An appropriate purchase order number.
A spares order will be raised under our warranty system and the replacement part will be despatched, usually within 24 hours should they be in stock. When replaced, the faulty part must be returned to Airedale with a suitably completed and securely attached “Faulty Component Return” (FCR) tag. FCR tags are available from Airedale and supplied with each Warranty order.
On receipt of the faulty part, suitably tagged, Airedale will pass to its Warranty department, where it will be fully
inspected and tested in order to identify the reason for failure, identifying at the same time whether warranty is justied
or not.
On completion of the investigation of the returned part, a full “Report on Goods Returned” will be issued. On occasion the release of this complete report may be delayed as component manufacturers become involved in the investigation.
When warranty is allowed, a credit against the Warranty invoice will be raised. Should warranty be refused the Warranty invoice becomes payable on normal terms.
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
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.
Chiller Technical Manual 7525355 V1.1.0_04_2013
3
TurboChill™ Air Cooled and FreeCool

Health and Safety

IMPORTANT
The information contained in this manual is critical to the correct operation and maintenance of the unit and should be
Introduction
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.
CAUTION
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.
Also ensure that there are no other power feeds to the unit such as re alarm circuits, BMS circuits, crankcase heater
permanent supplies etc.
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.
Refrigerant Warning
The Airedale chillers use R134a refrigerant which requires careful attention to proper storage and handling procedures in accordance with EN 378.
Use only manifold gauge sets designed for use with refrigerants. Use only refrigerant recovery units and cylinders designed for the pressure category of the refrigerants.
The refrigerant used in this range of products is classied under the COSHH regulations as an irritant, with set Workplace Exposure Levels (WEL) for consideration if this plant is installed in conned or poorly ventilated areas.
A full hazard data sheet in accordance with COSHH regulations is available should this be required. Refrigerants must only be charged in the liquid state to ensure correct blend makeup.
The refrigerant must be stored in a clean, dry area away from sunlight. The refrigerant must never be stored above 50°C.
Global Warming Potential
R134a = 1300
EN378-1 :2008 (100 year life)
Protective Personal Equipment
Airedale recommends that personal protective equipment is used whilst installing, maintaining and commissioning equipment.
Manual Handling
Some operations when servicing or maintaining the unit may require additional assistance with regard to manual handling. This requirement is down to the discretion of the engineer.
Remember do not perform a lift that exceeds your ability.
CAUTION PACEMAKER WEARERS
To avoid any risk of injury, any work to be carried out on or around the magnetic check valve should be done with personnel that don’t have pacemakers tted.
4
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool

Environmental Considerations

Freeze Protection
Airedale recommends the following actions to help protect the unit during low temperature operation. This also includes the units subject to low ambient temperatures.
Units with supply water temperatures below +5°C
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.
Units subject to ambient temperatures lower than 0°C, a minimum of 1 of the following is required:
1. Glycol of an appropriate concentration Please ensure that the concentration is capable of protection at least 3°C lower than the minimum operating ambient.
2. Ensure water / glycol solution is constantly circulated through all waterside pipework and coils to avoid static water from freezing.
3. Ensure that pumps are started and running even during shut down periods, when the ambient is within 3°C of the solution freeze point
4. Additional trace heating is provided for interconnecting pipework.
(1) Refer to your glycol supplier for details.
(2) If this option is selected with ooded evaporators, an actuated suction ball valve must be tted to protect the
compressor from liquid migration.
(1)
(i.e. if the solution freezes at 0°C, the pump must be operating at 3°C ambient).
(1)
is used within the system to ensure adequate protection.
(2)
Introduction
Free Cooling Chillers
A minimum of 20% glycol concentration must be applied to all free cooling chillers. Concentration should be increased so that its capable of protection at least 3°C lower than the minimum operating ambient.

Environmental Policy

It is our policy to:
Take a proactive approach to resolve environmental issues and ensure compliance with regulatory requirements
Train personnel in sound environmental practices
Pursue opportunities to conserve resources, prevent pollution and eliminate waste
Manufacture products in a responsible manner with minimum impact on the environment
Reduce our use of chemicals and minimise their release to the environment
Measure, control and verify environmental performance through internal and external audits
Continually improve our environmental performance
CE Directive
Airedale certify that the equipment detailed in this manual conforms with the following EC Directives:
Electromagnetic Compatibility Directive (EMC) 2004/108/EC Low Voltage Directive (LVD) 2006/95/EC Machinery Directive (MD) 89/392/EEC version 2006/42/EC Pressure Equipment Directive (PED) 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.

Occupancy Note

When placing a chiller the occupancy of the surrounding area needs to be classied in accordance with EN 378-
1:2008+A2:2012 section 4.2. In most cases the level of occupancy for a chiller would be ‘Authorised occupancy C’ as
described in EN 378-1:2008+A2:2012 section 4.2.5 Table 1. This level needs to be conrmed by the customer.
Given that an air-cooled chiller can be classied as an ‘indirect system’ in accordance with EN 378-1:2008+A2:2012
section 4.1.3 and the R134a refrigerant falls into refrigerant safety group A1, EN 378-1:2008+A2:2012 Table E.1, no charge limitations apply if the level of occupancy is ‘C’. Please refer to EN 378-1:2008+A2:2012 Table C.1 for further details.
Chiller Technical Manual 7525355 V1.1.0_04_2013
5
TurboChill™ Air Cooled and FreeCool
Contents
Warranty, Commissioning & Maintenance 2
ChillerGuard™ 2
Introduction
Customer Services 2
Warranty 3
Health and Safety 4
Safety 4
Environmental Considerations 5
Environmental Policy 5
Occupancy Note 5
Nomenclature 8
Range Layout 10
Unit Overview 14
Unit Components 16
Refrigeration 16
Turbocor Compressor 18
Condenser 19
Electrical 20
Condenser Fans 22
Waterside 24
Controls 29
Mechanical 33
Design Features & Information 35
Pipework Design 35
Refrigeration Schematic 35
Specic Heat Capacity (SHC) 36
Minimum System Water Volume Calculations 36
Typical Part Load Efciencies 38
Water System 41
Grooved & Clamped Type Connection 41
Standard Recommended Installation 41
Water Systems and Recommended Flow Schemes 42
Flow Schemes 42
Technical Data - TCC R 46
TCC11R04S-01, TCC11R06S-01, TCC11R08S-01 46
TCC11R06L-02, TCC11R08L-03, TCC11R10L-03 48
TCC12R08S-04, TCC12R10S-04, TCC12R12S-04 50
TCC12R14S-04, TCC12R10L-05, TCC12R12L-06 52
TCC12R14L-06, TCC12R16S-06, TCC12R18S-06, TCC12R20L-06 54
Technical Data - TCC X 56
TCC11X04S-01, TCC11X06S-01, TCC11X08S-01 56
TCC11X06L-02, TCC11R08L-03, TCC11X10L-03 58
TCC12X08S-04, TCC12X10S-04, TCC12X12S-04 60
TCC12X14S-04, TCC12X10L-05, TCC12X12L-05 62
TCC12X14L-06, TCC12X16L-06, TCC12X18L-06, TCC12X20L-06 64
Sound Data - TCC 66
TCC - AC Fans 66
TCC - EC Fans 68
TCC - High Airow EC Fans 70
6
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Technical Data - TCF R 72
TCF11R06S-07, TCF11R08S-07, TCF11R06L-11 72
TCF11R08L-08, TCF11R10L-10, TCF12R08S-09 74
TCF12R10S-05, TCF12R12S-05, TCF12R14S-05 76
TCF12R12L-12, TCF12R14L-12, TCF12R16L-12 78
TCF12R18L-13, TCF12R20L-13 80
Technical Data -TCF X 82
TCF11X06S-07, TCF11X08S-07, TCF11X06L-01 82
TCF11X08L-08, TCF11X10L-10, TCF12X08S-09 84
TCF12X10S-05, TCF12X12S-05, TCF12X14S-05 86
TCF12X12L-12, TCF12X14L-12, TCF12X16L-12 88
TCF12X18S-13, TCF12X20L-13 90
Sound Data - TCF 92
TCF - AC Fans 92
TCF - EC Fans 94
TCF - High Airow EC Fans 96
Hydronic Data 98
TCC Waterside Pressure Drop kPa (100% Water) 98
TCF Waterside Pressure Drop kPa (20% Ethylene Glycol) 99
Evaporator Pressure Drop - 100% Water 100
Evaporator Pressure Drop - 20% Ethylene Glycol 101
Strainer Pressure Drop - 100% Water 102
Strainer Pressure Drop - 20% Ethylene Glycol 102
Installation Data 103
Air Cooled Masses & Centre of Gravity (C of G) 103
Point Loadings 105
Unit Lifting 107
Lifting Dimensions 107
General Arrangement 109
Positioning 114
Airow & Maintenance Clearances 114
Anti Vibration Mounting (Optional) 115
Interconnecting Wiring 117
Power Quality & Harmonics 118
Liquid Level Sensor 119
Pre Start Checks 120
pCO5 Built In Display and Keypad 121
Monitoring 121
Unit Operation 122
Restarting the Unit 122
Changing the Setpoint 123
Enabling Pumps 124
Maintenance 125
General Inspections 125
Electrical Inspection 126
Refrigeration 127
Waterside 128
Controls 130
System 131
Troubleshooting 132
Alarms 134
Alarm Menu Display 134
Pump Alarms 141
Chiller Technical Manual 7525355 V1.1.0_04_2013
Introduction
7
TurboChill™ Air Cooled and FreeCool

Nomenclature

Introduction
TCC TCF
1 or 2
1 to 4
R X
TurboChill Air Cooled (TCC) and Freecool (TCF)
Number of Circuits (1 or 2)
Number of Compressors (1 to 4)
Sound Variants (Regular Quiet R, or Extra Quiet X)
TCC
1
1 R 8 S
12
4 to 20
1 to 13
Number of Fans (4 to 20)
S
Compressor Code (S = TT300, L = TT350)
L
Evaporator Code
Introduction
The Airedale range of TurboChill air cooled and Freecool liquid chillers uses the technologically superior centrifugal Turbocor compressors. Designed to cover the high capacity range between 200kW and 900kW.
Each single circuit model is individually selected to provide the optimum solution for each application by offering
maximum exibility and matching customer requirements in terms of:
Capacity
EER/ESEER (Energy Efciency Ratio and European Seasonal Energy Efciency ratio)
Sound Levels - Quiet TC (C/F)....R and Super Quiet TC (C/F)… X
Footprint
For guidance the unit’s information within this manual has been generated at nominal conditions, due to the unit’s ability to modulate capacity individually tailored unit solutions are available.
Please contact Airedale with your specic requirements and we will be pleased to provide you with an individually
tailored selection and technical detail.
8
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Refrigerants
The range has been designed and optimised for operation with ozone benign R134a 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 paint to provide a
durable and weatherproof nish.
Standard unit colour shall be Light Grey (RAL 7035).
Free Cooling Operation
The TurboChill Free Cool chiller has been designed to provide the cooling load required whilst optimising energy
efciency at all times and as such will take advantage of free cooling whenever available. If the free cooling available
cannot satisfy the required full cooling load, direct expansion cooling is used to supplement the output.
In high ambients where free cooling is not available the fan speed modulates in the conventional manner to maintain an optimised head pressure. Free cooling is initiated wherever the outdoor ambient is 2°C less than the return water temperature.
During concurent cooling mode condensing temperature is constantly monitored and intelligently kept within the compressor envelope to allow the fans to run as fast as possible and therefore achieve the most free-cooling without having a negative impact on compressor integrity.
Introduction
In ambients where the free cooling coil is capable of satisfying the full cooling demand, the condenser fans are modulated to provide the desired duty. The condenser fans are capable of being modulated between 15-100% (EC) or
40% - 100% (AC) of airow to maintain the supply water temperature.
During periods where the condenser fan speed has been reduced to a minimum, the supply water temperature will then be controlled by the 3 way valve.
Free - cooling vs Mechanical cooling
System operated on 100% Free Cooling (77% of Year)
Cooling Load
System operated on mechanical cooling only (33% of Year)
-7°C
Mechanical (Compressor) cooling
Free - Cooling
0.5°C
12.5°C Ambient Temp
Chiller Technical Manual 7525355 V1.1.0_04_2013
9
TurboChill™ Air Cooled and FreeCool

Range Layout

Introduction
Regular Quiet - Single Circuit - Air Cooled
Model
TCC11R04S-01 240 3.54 4.90 - - 54.7 2785 x 2200 x 2626
TCC11R06S-01 265 3.84 5.55 - - 52.9 2785 x 2200 x 3758
TCC11R08S-01 275 4.04 5.86 - - 52.1 2785 x 2200 x 4890
TCC11R06L-02 390 3.33 4.81 - - 56.7 2785 x 2200 x 3758
TCC11R08L-03 425 3.51 5.19 - - 55.3 2785 x 2200 x 4890
TCC11R10L-03 450 3.55 5.42 - - 54.5 2785 x 2200 x 6022
TCC12R08S-04 470 3.55 5.34 - - 57.1 2785 x 2200 x 4890
TCC12R10S-04 500 3.73 5.53 - - 55.9 2785 x 2200 x 6022
TCC12R12S-04 530 3.84 5.64 - - 55.2 2785 x 2200 x 7154
TCC12R14S-04 560 3.90 5.72 - - 55.0 2785 x 2200 x 8286
TCC12R10L-05 600 3.32 5.18 - - 58.6 2785 x 2200 x 6022
TCC12R12L-06 670 3.50 5.28 - - 57.9 2785 x 2200 x 7154
TCC12R14L-06 750 3.58 5.39 - - 57.5 2785 x 2200 x 8286
TCC12R16L-06 800 3.62 5.48 - - 57.1 2785 x 2200 x 9418
TCC12R18L-06 850 3.63 5.52 - - 56.6 2785 x 2200 x 10550
TCC12R20L-06 900 3.56 5.52 - - 56.4 2785 x 2200 x 11682
Nominal
Cooling (kW)
EER ESEER Free Cooling (kW) Free Cooling EER
Sound
Pressure @
10m (dBA)
Dimensions H x W x L
(mm)
Extra Quiet - Single Circuit - Air Cooled
Model
TCC11X04S-01 200 3.48 5.17 - - 52.4 2785 x 2200 x 2626
TCC11X06S-01 225 3.94 5.58 - - 52.5 2785 x 2200 x 3758
TCC11X08S-01 235 4.16 5.87 - - 51.8 2785 x 2200 x 4890
TCC11X06L-02 350 3.25 4.80 - - 53.4 2785 x 2200 x 3758
TCC11X08L-03 385 3.60 5.22 - - 53.4 2785 x 2200 x 4890
TCC11X10L-03 410 3.75 5.42 - - 53.4 2785 x 2200 x 6022
TCC12X08S-04 430 3.45 5.40 - - 54.9 2785 x 2200 x 4890
TCC12X10S-04 460 3.73 5.59 - - 54.9 2785 x 2200 x 6022
TCC12X12S-04 490 3.90 5.74 - - 54.8 2785 x 2200 x 7154
TCC12X14S-04 520 3.99 5.81 - - 54.7 2785 x 2200 x 8286
TCC12X10L-05 560 3.15 5.24 - - 55.8 2785 x 2200 x 6022
TCC12X12L-06 630 3.39 5.32 - - 55.7 2785 x 2200 x 7154
TCC12X14L-06 710 3.53 5.43 - - 55.6 2785 x 2200 x 8286
TCC12X16L-06 760 3.63 5.52 - - 55.5 2785 x 2200 x 9418
TCC12X18L-06 810 3.67 5.59 - - 55.5 2785 x 2200 x 10550
TCC12X20L-06 860 3.66 5.60 - - 55.4 2785 x 2200 x 11682
Nominal
Cooling (kW)
EER ESEER Free Cooling (kW) Free Cooling EER
Sound
Pressure @
10m (dBA)
Dimensions H x W x L
(mm)
10
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Range Layout
Regular Quiet - Single Circuit - FreeCool
Model
TCF11R06S-07 290 3.70 5.36 279.8 20.01 53.5 2785 x 2200 x 3758
TCF11R08S-07 300 3.91 5.69 335.8 18.01 52.6 2785 x 2200 x 4890
TCF11R06L-11 390 3.32 4.73 308.7 22.08 56.7 2785 x 2200 x 3758
TCF11R08L-08 425 3.47 5.00 386.2 20.72 55.5 2785 x 2200 x 4890
TCF11R10L-10 450 3.67 5.28 453.4 19.46 54.4 2785 x 2200 x 6022
TCF12R08S-09 470 3.39 5.11 399.4 21.42 57.4 2785 x 2200 x 4890
TCF12R10S-05 500 3.67 5.40 472.3 20.27 56.2 2785 x 2200 x 6022
TCF12R12S-05 530 3.80 5.51 540.0 19.31 55.4 2785 x 2200 x 7154
TCF12R14S-05 560 3.89 5.60 604.5 18.53 54.8 2785 x 2200 x 8286
TCF12R12L-12 670 3.43 5.13 589.2 21.07 58.2 2785 x 2200 x 7154
TCF12R14L-12 750 3.55 5.25 677.8 20.78 57.7 2785 x 2200 x 8286
TCF12R16L-12 800 3.63 5.34 755.7 20.27 57.2 2785 x 2200 x 9418
TCF12R18L-13 850 3.63 5.36 831.9 19.83 56.8 2785 x 2200 x 10550
TCF12R20L-13 900 3.62 5.37 906.9 19.46 56.5 2785 x 2200 x 11682
Nominal
Cooling (kW)
EER ESEER Free Cooling (kW) Free Cooling EER
Sound
Pressure @
10m (dBA)
Dimensions H x W x L
(mm)
Introduction
Extra Quiet - Single Circuit - FreeCool
Model
TCF11X06S-07 250 3.82 5.33 223.5 45.63 52.4 2785 x 2200 x 3758
TCF11X08S-07 260 4.07 5.73 274.8 42.07 52.1 2785 x 2200 x 4890
TCF11X06L-11 350 3.14 4.59 245.2 50.04 53.3 2785 x 2200 x 3758
TCF11X08L-08 385 3.48 5.01 311.0 47.62 53.2 2785 x 2200 x 4890
TCF11X10L-10 410 3.79 5.30 370.7 45.40 53.2 2785 x 2200 x 6022
TCF12X08S-09 430 3.24 5.22 320.4 49.06 54.8 2785 x 2200 x 4890
TCF12X10S-05 460 3.63 5.46 383.8 47.01 54.7 2785 x 2200 x 6022
TCF12X12S-05 490 3.83 5.61 444.2 45.34 54.7 2785 x 2200 x 7154
TCF12X14S-05 520 3.96 5.69 502.8 43.99 54.6 2785 x 2200 x 8286
TCF12X12L-12 630 3.24 5.18 477.7 48.76 55.6 2785 x 2200 x 7154
TCF12X14L-12 710 3.43 5.28 552.3 48.31 55.5 2785 x 2200 x 8286
TCF12X16L-12 760 3.58 5.38 619.8 47.44 55.4 2785 x 2200 x 9418
TCF12X18L-13 810 3.63 5.43 686.4 46.71 55.3 2785 x 2200 x 10550
TCF12X20L-13 860 3.66 5.45 752.3 46.07 55.2 2785 x 2200 x 11682
Nominal
Cooling (kW)
EER ESEER Free Cooling (kW) Free Cooling EER
Sound
Pressure @
10m (dBA)
Dimensions H x W x L
(mm)
Chiller Technical Manual 7525355 V1.1.0_04_2013
11
TurboChill™ Air Cooled and FreeCool
Range Layout
Introduction
4 Fan
6 Fan
8 Fan
TCC 200 - 240kW
TCC 235 - 470kW
TCF 260 - 430kW
TCC 410 - 600kW
TCF 410 - 500kW
12
TCC 225 - 265kW
10 Fan
TCF 250 - 430kW
12 Fan
Chiller Technical Manual 7525355 V1.1.0_04_2013
TCC 490 -630kW
TCF 490 - 530kW
TurboChill™ Air Cooled and FreeCool
Introduction
14 Fan
16 Fan
18 Fan
TCC 560 - 750kW
TCF 520 - 750kW
TCC 760 - 800kW
TCF 760 - 800kW
TCC 810 - 850kW
TCF 810 - 850kW
20 Fan
TCC 860 - 900kW
TCF 860 - 900kW
Chiller Technical Manual 7525355 V1.1.0_04_2013
13
TurboChill™ Air Cooled and FreeCool
Refrigeration
Centrifugal Compressors
Flooded Evaporator with Integral Subcooler
Actuated Suction Ball Valves
Liquid and Discharge Shut Off Valves
Liquid Line Sight Glasses
Dual Pressure Relief Valves
Micro-Plate Economiser

Unit Overview

Introduction
Airflow
AC Condenser Fans
EC Condenser Fans
High Airflow EC Condenser Fans
Fan Discharge Plenum
Extended Height Fan Discharge Plenum
Electrical Panel
Single Point Isolation
UltraCap Power Backup
Control Panel Heater
Panel Ventilation
Emergency Stop
Power Monitoring
● Rain Hood
14
Controls
● Microprocessor
● Leak Detection
● Inteligent Head Pressure Control
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Coils
Epoxy Coated Microchannel Condenser Coils
● RTPF FreeCooling Coils
Introduction
Refrigeration
Centrifugal Compressors
Flooded Evaporator with Integral Subcooler
Actuated Suction Ball Valves
Liquid and Discharge Shut Off Valves
Liquid Line Sight Glasses
● Dual Pressure Relief Valves
Micro-Plate Economiser
Waterside
● Differential Pressure Sensor
● Flow Switch
● Pump Interlock
● Water Filter
● Various Pump Options
● Immersion Heater
● Grooved and Clamped Type Connections
Chiller Technical Manual 7525355 V1.1.0_04_2013
15
TurboChill™ Air Cooled and FreeCool

Unit Components

Refrigeration

Refrigeration TCC TCF
Introduction
Compressors - Turbocor Centrifugal
Dual Maintainable Pressure Relief Valves
Microchannel Epoxy Coated Condensing Coils
RTPF Free Cooling Coils
Epoxy Coated RTPF Free Cooling Coils
Actuated Starting Line Assembly
Filter Driers with Replaceable Cores
Electronic Expansion Valves
Flooded Evaporator with integral subcooler
Stainless Steel Suction Pipe Assembly
Full Operating Charge of R134a
Acoustically Lined Compressor Enclosure(s)
Liquid and Discharge Shut Off Valves
Liquid Line Sight Glasses (integral to EEV)
Micro-Plate Economiser
Actuated Suction Ball Valve(s)*
Liquid level control valve (LLCV)
Full operating charge of R134a
Large capacity lter drier(s) with replaceable cores
Liquid line sight glasses
Low pressure switch with auto reset
2 High pressure switches with manual reset per compressor
High ambient starting valves
Suction and liquid pressure transducers
Discharge check (non return) valve(s)
-
-
● ○ ○ ○
16
Standard features Optional features Feature not available
CAUTION
* Feature required if unit is to be shut down for winter with water still circulating through unit. Freeze protection.
This is to stop potential liquid migration.
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Evaporator
Flooded evaporator incorporating an internal round tube heat exchanger. This heat exchanger is used to further sub-cool refrigerant leaving the condenser extending the potential cooling
capacity and as a result, efciency of the system. At the same time
suction gas vapour that passes over the heat exchanger within the shell is superheated to a higher temperature, eliminating the risk of wet vapour returning to the compressor.
The heat exchanger is insulated with closed cell polyurethane
foam which is to Class O re rating and the material is UV
resistant.
The ooded evaporator results in signicant energy savings in
compressor operation particularly at part load.
Two immersion heater(s) and thermostat protect the evaporator against freeze up in ambient temperatures down to -20°C. (in compliance with Airedale freeze protection policy).
Connections for External Trace Heating (240V / 500W available).
Compressors and evaporator shall be mounted on a rigid galvanised heavy duty sub frame. Fully weatherproofed electrical panels are situated at one end of the unit.
Introduction
Actuated Suction Ball Valve(s)
To protect the compressors against liquid migration, actuated
suction line ball valves shall be tted. This protects the
compressors when their is no cooling demand by keeping the
refrigerant in the evaporator, even if water is still owing through
the unit.
Economiser Circuit for Increased Part Load Efciency
The addition of an economiser circuit provides increased cooling and enhances EER, in full and part load operation.
Sub cooled liquid is expanded using a dedicated EEV (electronic expansion valve) to medium pressure and passed through one side of a plate heat exchanger.
Through the other side ows the ‘normal’ pressure liquid.
The result is that the sub cooling of the liquid entering the system EEV is increased, which improves evaporator performance and at the same time the suction pressure within the compressor body is lifted, improving compressor
efciency.
Chiller Technical Manual 7525355 V1.1.0_04_2013
17
TurboChill™ Air Cooled and FreeCool

Turbocor Compressor

Turbocor centrifugal compressor supplied with as standard:
Suction and discharge shut off valves
Discharge non-return valve
Introduction
Line reactor (for removing additional impedance harmonics and voltage spikes in the ac waveform)
EMI/EMC lter and comprising of:
o AC-DC rectier
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 The compressors are mounted on Turbocor specially designed vibration reducing isolating rubber mounts
o Linear capacity modulation is provided by a variable frequency drive
Key benets of Turbocor compressor technology:
Oil Free Operation
More efcient use of heat exchangers
No oil entrainment issues – pipe work can be optimised for
performance not oil return
Variable speed operation offering exact capacity match and optimum
part load performance
Magnetic bearing system constantly optimises shaft / impeller
position
Small and light, only 120kg or 132kg (compressor size dependant)
No mechanical contact, very quiet operation
Very low start current, only 2A
The intelligent, self optimising compressor offers near silent, oil free operation and ultra efcient 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 offers 2 major benets:
o Uses substantially less power at part load and gives accurate set-point control and exact capacity match
o The inbuilt electronic soft start produces a very low starting current of just 2A and eradicates the need to oversize electrical supply components on site
18
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool

Condenser

Large surface area microchannel coil(s) (ideally positioned to optimise airow and heat transfer) shall be manufactured
a “V-block” arrangement. This “V-block” arrangement has a lower airside pressure drop making the fans run more
efciently. The coils have freeowing liquid drains that enables us to reduce the amount of subcooling done in the coil,
leaving more area for heat eachange.
R134a Leak Detection System
A factory calibrated leak detection system shall be tted as standard to units containing circuits carrying > 300kg / circuit
of refrigerant to comply with F-gas legislation, however the leak detection system can be supplied as an optional extra with refrigerant charges <300kg.
A dedicated refrigerant sensor shall be tted within each compressor enclosure and will raise an alarm on detection of
refrigerant gas.
Maintainable Dual Pressure Relief Valve
An auto resetting pressure relief valve assembly shall be provided per evaporator circuit, opening on pressure rise above 10.3 barg. The dual shut-off valve assembly incorporates 2 pressure relief valves which can be individually shut off via a 3 way valve. This allows the maintenance of individual pressure relief valves without any requirement for refrigerant evacuation.
In accordance with EN13136:2001, pressure relief valves have been sized to ensure that in the event of re they can
prevent excessive build-up of pressure within the evaporator. EN13136:2001 section 6.2.1 has been used to size valves accordingly.
Fire is a hazard that these units have not been designed to operate under. However, the inclusion of various safety
devices ensures that any damage due to re is limited via the release of pressure in the form of gas discharge.
Introduction
If concerns of the ability of the pressure relief valve to discharge in the event of a re >107°C exist, then it is the
responsibility of the end user to protect the pressure relief valve assembly from excessive external temperatures.
This must however allow the pressure relief valve to discharge effectively and not act as a ‘choke’ (offer any resistance) when discharging.
Chiller Technical Manual 7525355 V1.1.0_04_2013
19
TurboChill™ Air Cooled and FreeCool

Electrical

Introduction
Controls and Electrical TCC TCF
Leak detection on circuits containing >300kg of refrigerant
Controls
Circuit 1
Compressors 1 & 2
Pumps
Fans
Speed Controllers (AC Fans)
Bus-bar Chamber
Circuit 2 Compressors 3 & 4
Intelligent head pressure control
Actuated suction shut off valve
Power monitoring
Individual mains power isolator for each compressor
Separate electrical isolation for fans
Single point isolation for 3 connection of incoming 3-phase and earth mains power supply
Emergency Stop tted to controls compartment door
Circuit breakers for protection of all major unit components
Phase rotation relay incorporating phase loss protection
Mains power loss emergency shutdown via ultracap
Standard features Optional features – Feature not available
20
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
3 Phase Single Point Isolaton
Single point isolation shall be tted as a standard feature.
Ultracap Power Backup
The Ultracap module is a standard feature utilising the latest Ultra Capacitor technology in external backup device for the EVD Evolution drivers and pCO controllers. The module guarantees temporary power to the controller and drivers in the event of mains power failures. The Ultra Capacitors are used to maintain the controller’s main functions, to close the electronic valves in the event of mains power failures. This avoids the need to install a solenoid valve in the refrigerant circuit or use the battery backup module and allows the system to resume control as soon as mains or backup power returns to the unit.
Energy Manager
Analysis of system energy consumption can be monitored via a dedicated LCD display. Unit parameters can be adjusted via the unit microprocessor control to affect energy usage in line with the system need.
Mains Cable Entry
The unit mains cable can enter from either side of the electrical control panel.
Introduction
Twin cable
gland
Single cable
gland
Twin cable
gland
Maximum Cable Gland Sizes
Single 1 x M75S Twin 2 x M63S
Control Panel Light
A control panel light shall be tted to enable control panel maintenance to be carried out during poor light conditions.
Maintenance Socket
A single phase maintenance socket (RCD protected) is available located within the control panel. This socket enables UK plugs to be connected.
Chiller Technical Manual 7525355 V1.1.0_04_2013
21
TurboChill™ Air Cooled and FreeCool

Condenser Fans

Introduction
Fans TCC TCF
800 mm diameter AC axial fans
800 mm diameter EC axial fans
800 mm diameter high airow EC fans
● ○ ○ ○
Standard features Optional features Feature not available
Condenser Fan and Motor - AC
Axial fan assemblies with nger proof grille and incorporating external rotor AC motor technology, capable of highly
accurate discreet speed control., Discharges air vertically. The fans offer maximum performance whilst keeping sound levels to a minimum.
22
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
0
20
40
60
80
100
120 0
20 40 60 80 100 120
Energy saving Electronically Commutated (EC) Fan Motor
Each 800 mm diameter fan incorporates on board electronics with AC / DC conversion and inverter driven
DC motor control to offer unparalleled high efciency levels
combined with smooth step-less speed control and quiet operation.
Sickle blades reduce air turbulence to minimise sound levels and power consumption whilst maximising performance.
The long bell mouth design provides improved aerodynamics, up to 10% more air movement, and an extended vertical throw of air to reduce the chance of air re-circulation. As standard the enclosure is complete with
an integral nger proof grille.
The fans offer maximum airow performance while keeping
sound levels to a minimum.
A mains EMC lter is tted when the EC fan option is selected with the unit. The lter is designed for convenient
mains connection within the bus bar chamber.
Introduction
The in built EC fan control module allows for fan speed modulation from 15-100%, a standard AC fans modulating range is typically 40-100% of full fan speed.
The EC fan presents superior energy efciency at full and reduced fan speed compared to the equivalent AC fan motor, offering efciency savings anywhere between 30 to 100% compared with an AC fan.
Fan speeds are factory set depending on sound level variant.
Standard voltage regulated (VR) fan speed controllers offer a linear response. By comparison the EC fan is adjusted on
demand via the unit microprocessor with precision, offering substantial energy savings. The following illustration shows a comparison of the typical power input required by each method.
Fan speed of 60% Voltage regulated input power required 60% EC input power required 18%
EC (Electronically Commutated) Fan Speed Control
Input Power %
Voltage Regulated Fan Speed Control
Fan Speed %
Chiller Technical Manual 7525355 V1.1.0_04_2013
23
TurboChill™ Air Cooled and FreeCool

Waterside

Introduction
Strainer
Grooved Connection
Pump(s) Inverter housing
Return Supply
Waterside TCC TCF
Free Cooling Coil
Evaporator Immersion Heaters
Water lter
Pump hydronic options**
Water ow meter
Grooved and clamped type connections
Flanged connections
Pump vibration eliminators
Pump interlock*
Flow switch*
Differential pressure transducer*
Standard features Optional features – Feature not available
● ○ ● ○ ○ ○
● ○
● ○ ○ ○
24
* CAUTION
Each feature is a ow proving device, and 2 out of the 3 should be tted to any unit to validate warranty.
**Pump options only available on units with sufcient space.
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Free Cooling Coil
A free cooling coil constructed in a “V” frame arrangement, allowing for efcient heat transfer from the ambient air
temperature to the cooling process.
The free cooling coil is manufactured from copper tube and aluminium n.
Free cooling is initiated whenever the outdoor ambient temperature is 2°C less than the return water temperature.
The “V” frame arrangement enables efcient concurrent cooling.
The TurboChill free cool chiller’s pipe work has been designed to optimise pressure drop, reducing pump input power.
It shall be tted with a water drain valve (schrader point located at lowest point of coils) for maintenance purposes.
Flow Proving Device
An evaporator differential pressure sensor facilitates low ow limiting and pressure drop monitoring via the microprocessor which shall be tted to ensure correct unit water ow.
Water Flow Meter
A water ow meter shall be tted to the unit to monitor water owrates.
Grooved and Clamp Type Connections
Grooved and clamp type connections shall be tted to the unit.
Flanged Connections
Flanged connections shall be tted to the unit upon request. Please contact Airedale.
Introduction
Pump Interlock*
Provision for a pump interlock is available within the control panel.
Water Flow Switch*
If selected. A water ow switch is tted ensuring integrity of the cooling solution ow. The ow switch shall protect the Chiller against low water ow conditions.
Despatched loose for on site tment. A 1” BSP socket is required for this tment.
* CAUTION
Each feature is a ow proving device and 2 out of the 3 should be tted to any unit to validate warranty.
Pump Vibration Eliminator
Flexible couplings shall be tted to the pumps to reduce any vibration through the system pipework.
Chiller Technical Manual 7525355 V1.1.0_04_2013
25
TurboChill™ Air Cooled and FreeCool
Pump Options
A variety of pump options to suit a wide range of applications are available:
Factory tted in line as a single pump or run / standby conguration and available in standard and larger nominal
Introduction
external head pressures.
Factory tted run/standby pumps have a shut off valve to the inlet and a non return valve to the outlet, enabling one pump to be maintained without interrupting Chiller ow. Supplied with electrical switchgear and isolating valve as
standard.
Run / standby pumps are rotated automatically to ensure even pump usage and prolong component life.
Pump - AC Motor - Fixed Speed
A factory tted in line single or run / standby pump is available with various pump external head options; please specify
at order.
Flow can be proven via the microprocessor display.
Factory tted and supplied as standard complete with:
Differential pressure sensor
Isolating valves
Inlet strainer
Vibration isolation
Electrical switch gear
Pump - Inverter Driven - Variable Speed
A factory tted in line single or run / standby pump is available with various pump external head options; please specify
at order.
Flow is varied via an electronic ow meter, depending on system requirements.
Adjustment and monitoring is via the microprocessor display.
Factory tted and supplied as standard complete with:
Differential pressure sensor
Isolating valves
Inlet strainer
Vibration isolation
Electrical switch gear
Inverter panel with ventilation fan and panel heater (high / low ambient operation)
26
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool
Waterside Options
Air Cooled
EVAPORATOR
TCC11R04S-01
TCC11R06S-01
TCC11R08S-01
TCC12R08S-04
TCC12R10S-04
TCC12R12S-04
TCC12R14S-04
TCC11R06L-02
TCC11R08L-03
TCC11R10L-03
TCC12R10L-05
TCC12R12L-06
TCC12R14L-06
TCC12R16L-06
TCC12R18L-06
TCC12R20L-06
ONLY
EXTENDED
PIPEWORK
NO BYPASS
(FILTER + SOV)
BYPASS
(FILTER + SOV)
SINGLE
PUMP
- - - - -
- - -
- - -
- - -
- - -
- -
Introduction
RUN AND
STANDBY
Free Cooled
TCF11R06S-07
TCF11R08S-07
TCF12R08S-09
TCF12R10S-05
TCF12R12S-05
TCF12R14S-05
TCF11R06L-11
TCF11R08L-08
TCF11R10L-10
TCF12R12L-12
TCF12R14L-12
TCF12R16L-12
TCF12R18L-13
TCF12R20L-13
NO BYPASS
(FILTER + SOV)
BYPASS
(FILTER + SOV)
SINGLE
PUMP
- -
- - -
- -
- - -
- - -
- -
RUN AND
STANDBY
Waterside + internal strainer ○ Waterside + external strainer (supplied loose) – Not avaliable
Chiller Technical Manual 7525355 V1.1.0_04_2013
27
TurboChill™ Air Cooled and FreeCool
Water Connections
Water inlet and outlet connections shall be of a grooved and clamped type construction.
Optional anged connections shall be available on request, please consult Airedale.
Introduction
Water connection to evaporator only (air cooled only)
Water inlet and outlet connections shall terminate directly on the evaporator.
Extended Water Connections (air cooled only)
Extended water connections shall be available on all air cooled units,it allows the water connections to terminate at the end of the unit.
Water Filter
A 1/16” mesh water lter can be supplied tted to protect the evaporator from clogging by sediment. On certain models the lter is tted externally.
Bypass Options
No bypass
Comprises
Shut off valves
Filter
Pump Congurations
Single pump + lter + bypass (ushing)
Comprises:
Single pump with vibration isolation
Shut off valves
Filter
Bypass leg
Flushing bypass kit (standard)
Comprises:
Shut off valves
Filter
Bypass leg with shut off valve
Flushing bypass kit (regulating)
Comprises:
Shut off valves
Filter
Bypass leg with Double
regulating valve
Single pump + lter + bypass (regulating)
Comprises:
Single pump with vibration isolation
Shut off valves
Filter
Double regulating valves
Run & standby pumps + lter + bypass (ushing)
Comprises:
Run and standby pumps with vibration isolation
Shut off valves
Filter
Non return valves
Run & standby pumps + lter + bypass (regulating)
Comprises:
Run and standby pumps with vibration isolation
Shut off valves
Filter
Double regulating valve
Non return valve
28
Chiller Technical Manual 7525355 V1.1.0_04_2013
TurboChill™ Air Cooled and FreeCool

Controls

The microprocessor controller shall offer 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 shall be 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 shall be a visual alarm and the facility to adjust and display control settings by local operator for information and control.
ALARM - Red LED indicates alarm present
LCD Display
PROGRAM opens the available menus
ESC - Green LED lit when operating page displayed, returns to operating page screen when pressed
Introduction
UP/DOWN KEYS - To change adjustable elds & scrolls up & down available menus
1 UP / DOWN KEYS - To change adjustable elds & scrolls up & down available menus
2 ENTER - Selects menus & moves cursor to adjustable elds green led
3 ESC - Green led lit when operating page displayed, returns to operating page screen when pressed
4 PROGRAM - Opens the available menus
5 ALARM - Red led indicates alarm present
6 LCD Display
ENTER -Selects menus & moves cursor to adjustable elds green LED
Chiller Technical Manual 7525355 V1.1.0_04_2013
29
TurboChill™ Air Cooled and FreeCool
Temperature Control
The microprocessor controller shall monitor the return and supply temperatures. The supply temperature is used to calculate the required cooling demand. Further calculations are then made to determine the optimum compressors to be
selected and their individual cooling demands. These calculations ensure the unit efciency is maximised under all load
Introduction
conditions. As standard, the microprocessor controller can provide an innite capacity control between 15% and 100%, depending on the component selection. Refer to mechanical data tables for unit specic control ranges.
Monitoring
The microprocessor shall also monitor and display the following measured parameters:
Supply water temperature
Return water temperature
Liquid pressure
Alarm Handling
The controller shall log and allow viewing of the last 150 conditions recorded in descending chronological order through the keypad display.
The following conditions shall be detected, triggering a visual display:
High compressor discharge temperature (per compressor)
Low supply temperature
Phase rotation
Emergency stop
Evaporator ow failure
Low pressure safety switch
Low suction pressure (per compressor)
High liquid pressure
Compressor 1 contactor status
Compressor 2 contactor status (dependant on model)
Volt free contact non-critical alarm indication
Volt free contact critical alarm indication
Suction pressure
Evaporator differential water pressure
Building Management Systems (BMS)
Sequencing (Master / Slave and Run / Standby) via the Airedale sequence manager.
Please specify at time of enquiry.
Chiller Sequence Manager
For the efcient temperature and capacity operation of multiple units on a single site, the sequence manager will permit
interlinked operation of the complete system thereby providing optimum temperature control and minimum power consumption.
Up to 6 units can be sequenced. Included within this package is a site visit by an Airedale Control Specialist to set up multiple unit sequence control. The chiller sequence manager is supplied as a separate control panel to be mounted remotely in an indoor location,
such as a plant room.
30
Chiller Technical Manual 7525355 V1.1.0_04_2013
Loading...
+ 114 hidden pages