Airedale Ultima Compact Condensing Unit User Manual

INSTALLATION, OPERATING &

MAINTENANCE MANUAL

Ultima Compact Condensing Unit

Air Cooled Condensing Unit

30kW - 450kW

ULTIMA COMPACT

Condensing Units

2

Condensers & Condensing Units

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

About Airedale Products & Customer Services

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.

To further protect your investment in Airedale products, we have introduced Airedale Service, who can provide full commissioning services, comprehensive maintenance packages and service cover 24 hours a day, 365 days a year (UK mainland). For a free quotation contact our Airedale Service or your local Sales Engineer.

All Airedale products are designed in accordance with EU Directives regarding prevention of build up of water, associated with the risk of contaminants such as Legionella.

Where applicable, effective removal of condensate is achieved by gradient drainage to outlets and where used, humidification systems produce sterile, non-toxic steam during normal operation.

For effective prevention of such risk it is necessary that the equipment is maintained in accordance with Airedale recommendations.

CAUTION

Warranty cover is not a substitute for Maintenance. Warranty cover is conditional to maintenance being carried out in accordance with the recommendations provided during the warranty period. Failure to have the maintenance procedures carried out will invalidate the warranty and any liabilities by Airedale International Air Conditioning Ltd.

SPARES

A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our Spares department on request.

TRAINING

As well as our comprehensive range of products, Airedale offers a modular range of Refrigeration and Air Conditioning Training courses, for further information please contact Airedale.

CUSTOMER SERVICES

For further assistance, please e-mail: [email protected] or telephone:

CUSTOMER SERVICES

UK Sales Enquiries

+ 44 (0) 113 238 7789

[email protected]

International Enquiries

+ 44 (0) 113 239 1000

[email protected]

Spares Hot Line

+ 44 (0) 113 238 7878

[email protected]

Airedale Service

+ 44 (0) 113 239 1000

[email protected]

Technical Support

+ 44 (0) 113 239 1000

[email protected]

Training Enquiries

+ 44 (0) 113 239 1000

[email protected]

For information, visit us at our Web Site: www.airedale.com

AIAC Ltd endeavours to ensure that the information in this document is correct and fairly stated, but none of the statements are to be relied upon as a statement or representation of fact. AIAC Ltd does not accept liability for any error or omission, or for any reliance placed on the information contained in this document.

The development of Airedale products and services is continuous and the information in this document may not be up to date. It is important to check the current position with AIAC Ltd at the address stated. This document is not part of a contract or licence unless expressly agreed.

No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or information storage and retrieval systems, for any purpose other than the purchaser's personal use, without the express written permission of AIAC Ltd.

Condensing Units

ULTIMA COMPACT

Condensers & Condensing Units

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Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Contents

GENERAL STATEMENT 4

WARRANTY 5

GENERAL DESCRIPTION 6

Unit Identification 6 Introduction 6 Standard Features 6 Features - Variations 8 Optional Extras - Energy Saving 9 Optional Extras – General 9

INSTALLATION DATA 10

Dimensions 10 Unit Lifting 14 Anti Vibration 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 21

CONTROLS 25

Viewing Unit Operating Status 26 Setting up 26 Alarms 27

COMMISSIONING DATA 28

Operating Limits 28 Mechanical Data 28 Unloading Protection 28

COMMISSIONING PROCEDURE 29

Pre Commissioning Checklist 29 Commissioning Checklist 31

MAINTENANCE 34

General Maintenance 34 Compressor Maintenance 35 Shut Down Periods 35

PARTS IDENTIFICATION 36

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General Statement

IMPORTANT

The information contained in this manual is critical to the correct operation and maintenance of the unit and should be read by all persons responsible for the installation, commissioning and maintenance of this Airedale unit.

SAFETY

The equipment has been designed and manufactured to meet international safety standards but, like any mechanical/electrical equipment, care must be taken if you are to obtain the best results.

CAUTION

1 Service and maintenance of Airedale equipment should only be carried out

by Technically trained competent personnel.

CAUTION

2 When working with any air conditioning units ensure that the electrical

isolator is switched off prior to servicing or repair work and that there is no power to any part of the equipment.

3 Also ensure that there are no other power feeds to the unit such as fire alarm

circuits, BMS circuits etc

4 Electrical installation commissioning and maintenance work on this equipment

should be undertaken by competent and trained personnel in accordance with local relevant standards and codes of practice.

5 Refrigerant used in this range of products is classified under the COSHH

regulations as an irritant, with set Occupational Exposure Levels (OEL) for consideration if this plant is installed in confined or poorly ventilated areas.

6 A full hazard data sheet in accordance with COSHH regulations is available

should this be required.

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Warranty

GENERAL

To be read in conjunction with Airedale International Air Conditioning Ltd standard Conditions of Sale.

The equipment carries Airedale’s standard warranty for a period of 24 months from the date of

despatch or of invoice which ever is the sooner in respect of non-consumable parts only and does not include for the cost of labour incurred during the investigation or replacement of a defective item.

WARRANTY IS ONLY VALID IN THE EVENT THAT:

1 The equipment is serviced & maintained by Airedale or an approved Airedale company

in accordance with the Installation & Maintenance manual provided, during the Warranty Period.

2 Commissioning is carried out by Airedale or an approved Airedale company.

3 Commissioning documents have been completed and returned to Airedale within

28 days of the date of commissioning.

4 Replaced faulty parts have been returned to Airedale within 21days of replacement

for evaluation.

Any spare part supplied by Airedale under the warranty shall be warranted for the unexpired period of the warranty or 3 months from delivery whichever period is the longer, with the exception of compressors on which a further 12 months warranty is granted.

PROCEDURE

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.

Faulty Component Return Tag

No 28401

CUSTOMER

DATE

ADDRESS

AIREDALE U/No

CUST. O/No

Ex G/S No

TYPE OF UNIT

COMPONENT DESCRIPTION

SERIAL No (where applicable)

FAULTY DESCRIPTION (‘Faulty’ or ‘Defective’ not sufficient)

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 raised under our "G" number 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 "G" 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 justified 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 manufacturer becomes involved in the investigation.

When warranty is allowed, a credit against the "G" number invoice will be raised. Should warranty be refused the "G" number 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.

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General Description

UNIT IDENTIFICATION

AIR COOLED CONDENSING UNIT

UCCU

Ultima Compact Condensing Unit - Cooling Only

30 - 450

Model Size (Expressed as Nominal Cooling in kW)

SQ-

Single Circuit - Quiet (Models 30-80 (Except 75) Only)

SSQ-

Single Circuit - Super Quiet (Models 30-80 (Except 75) Only)

D-

Double Circuit - Standard

DQ-

Double Circuit - Quiet

DSQ-

Double Circuit - Super Quiet

2-16

Number of Fans

/1 or /2

Single or Double Row of Fans

Example

UCCU250DQ-8/2

INTRODUCTION

The Airedale range of Ultima Compact air cooled condensing units covers the nominal capacity range 30kW to 450kW in 24 model sizes. The range is available with many optional variations including Quiet and Super Quiet sound level variants.

The range is suitable for a wide range of split-system applications such as Cold Storage, large Retail Comfort Cooling, Process Cooling, Healthcare, Hi-Tech environments and leisure.

Attention has been placed on maximising the unit’s performance while keeping the sound and vibration levels and footprint to an absolute minimum.

CE DIRECTIVE

Airedale certify that the equipment detailed in this manual conforms with the following EC Directives:

Electromagnetic Compatibility Directive (EMC)

89/336/EEC

Low Voltage Directive (LVD)

73/23/EEC

Machinery Directive (MD)

89/392/EEC in the version 98/37/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.

REFRIGERANTS

The range has been designed and optimised for operation with the ozone benign R407C refrigerant.

STANDARD FEATURES

All models sizes.

Construction

The base is fabricated from galvanised steel to ensure a tough, durable, weatherproof construction.

The superstructure is manufactured from galvanised sheet steel coated with epoxy baked powder paint to provide a durable and weatherproof finish. Standard unit colour is Light Grey (RAL 7035).

Compressors and heat exchangers are mounted on a rigid galvanised heavy-duty sub frame. Fully weatherproofed electrical panels are situated at one end of the unit. Access to the compressors is via end panels adjacent to the electrical control panel.

Other features include:

 Dedicated Compressor Enclosure

 Condenser Fan Discharge Plenum

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General Description

STANDARD FEATURES

All models sizes.

Condenser

Large surface area coil(s) ideally positioned to optimise airflow and heat transfer, manufactured from refrigeration quality copper tubes with mechanically bonded aluminium fins.

Condenser Fan

Axial fan assemblies with fingerproof grille and incorporating external rotor motor technology, to provide highly accurate discreet speed control, discharge air vertically. The fans offer maximum performance while keeping sound levels to a minimum.

Electrical supply dependent upon model size, refer to Electrical Data.

Head Pressure Control

Electronic head pressure controllers are fitted which modulate the fan speed to maintain a constant condensing pressure, allowing the system to operate satisfactorily in ambient temperatures as low as -20°C.

Head pressure can be set, monitored and values viewed at the microprocessor keypad.

Compressor

Scroll compressors comprising:

 Internal motor protection  Internal pressure relief  Non return valve  External discharge temperature protection  Oil sight glass  Sump heater

Each Tandem / Trio set has an oil equalisation line.

The compressors are mounted 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 indicator gauge

Refer to Features - Variations for further detail.

Controls

microprocessor controller can provide 2-6 stages of capacity control, dependent upon model type, as standard. The controller incorporates full Building Management System capabilities, full details can be found in the Controls section.

Control management is offered in 1 of 4 of the most common types, to select via the microprocessor, to be specified at time of order:

 External 0-10V Signal

 Suction Pressure Monitoring

 Remote Space Temperature Sensor

 Remote Digital Inputs

Electrical

Dedicated weatherproof electrical power and controls panels are situated at the end of the unit and contain:

 Separate, fully accessible, controls compartment, allowing adjustment of control

set points whilst the unit is operational

 Circuit breakers for protection of all major unit components

 Separate, permanent supply for controls/trace heating, 230V/50Hz/1ph

The electrical power and control panel is wired to the latest European standards and codes of practice.

Refer to Features - Variations for further detail.

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Condensing Units

FEATURES - VARIATIONS

UCCU30, UCCU40, UCCU50, UCCU60,

UCCU70 &

UCCU80

UCCU75,

UCCU100,

UCCU125 &

UCCU150

UCCU110, UCCU130,

UCCU160 &

UCCU180

UCCU200,

UCCU225 &

UCCU250

UCCU240, UCCU270, UCCU300, UCCU330,

UCCU360, UCCU400

& UCC450

Construction

4 x eye bolts to BS4278 or Integrated lugs/Mounting feet

Integrated lugs

Lifting Eye Bolts

Acoustically lined compressor enclosure

SSQ/DSQ Models

DSQ Models

Refrigeration

Holding charge of Helium

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 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

Extra Low speed condenser fan

SSQ/DSQ Models

DSQ Models

Electrical

Emergency stop

-

Std

Door isolated mains power compartments

- - Std

Std

Dedicated bus-bar chamber for incoming 3-phase & earth mains power supply (no neutral required)

- - Std

Std

Mains Supply 3 Phase

Std

Neutral Required

Yes

No

Phase Rotation Protection

Opt

Std

Power Factor Correction

-

Opt

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Chillers

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General Description

OPTIONAL EXTRAS - ENERGY SAVING

Power Factor Correction

When applied to the motors of each compressor, the compressor power factor is controlled to a minimum operating value of 0.95 at the full operating capacity. This satisfies many supply authorities that may impose surcharges on equipment with power factor less than 0.95.

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 Relief Valve

 Filter Drier & Sight Glass

 Leak Detection Kit

 Electronic Soft Start

 Phase Rotation Protection

 BMS Interface Card

 Remote Setpoint Adjust

 Alternative Refrigerant (Outside EU)

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Installation Data

DIMENSIONS

SINGLE ROW FANS - /1

A

20

2

3

6

B D C

1200

55

4

300

1

60

80

1410

1200

460

40 500

5

1410

1200

460

40

7

8

E

UCCU30 - UCCU80

(Except UCCU75)

Model SQ/DQ A B C D E

UCCU30 – UCCU40 SQ/DQ

mm

1650

300

1050

300

200

UCCU50 – UCCU70 SQ/DQ

mm

2500

300

1450

750

200

UCCU80 SQ/DQ

mm

2500

300

1450

750

200

Model SSQ/DSQ A B C D E

UCCU30 - UCCU40 SSQ/DSQ

mm

1650

300

1050

300

200

UCCU50 - UCCU70 SSQ/DSQ

mm

2500

300

1450

750

200

UCCU80 SSQ/DSQ

mm

2500

300

1450

750

200

UCCU75 - UCCU150

(Except UCCU80)

A

2000

1300

50

E

2

3

B D C

1250

25

4

25

300

1

7

500

5

565

F

G

F

6

Model D A B C D E F G

UCCU75D-2/1

mm

2775

390

1900

(1)

485

200

170

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

285

200

170

Model DSQ A B C D E F G

UCCU75DSQ-3/1

mm

3625

390

1825

1135

275

200

170

UCCU100DSQ-3/1

mm

3625

390

1825

1135

275

200

170

UCCU125DSQ-4/1

mm

4475

390

1900

285

200

170

UCCU150DSQ-4/1

4475

390

1900

285

200

170

(1)

Have only 4 fixing and 4 point loadings.

1 Electric Control Panels 2 Mains Electric Isolators 3 Mains Cable Entry 4 20mm Ø Mounting Holes 5 Optional Plenum Extension 6 Refrigeration Connections

7 Single Circuit 8 Dual Circuit

1 Electric Control Panels 2 Mains Electric Isolators 3 Mains Cable Entry 4 20mm Ø Mounting Holes 5 Optional Plenum Extension 6 Refrigeration Connections 7 Emergency Stop

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Chillers

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Installation Data

POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)

SINGLE ROW FANS - /1

UCCU30 - UCCU80 (Except UCCU75)

P1

P2

P3

P4

2

1

= C of G

Model SQ/DQ

P1

P2

P3

P4

(1)

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU30 SQ/DQ-1/1

kg

120

115

470

600

815

UCCU40 SQ/DQ-1/1

kg

140

135

550

600

815

UCCU50 SQ/DQ-2/1

kg

170

175

690

600

1035

UCCU60 SQ/DQ-2/1

kg

180

190

740

600

1045

UCCU70 SQ/DQ-2/1

kg

185

195

760

600

1045

UCCU80 SQ/DQ-2/1

kg

200

215

830

600

1050

Model SSQ/DSQ

P1

P2

P3

P4

(1)

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU30 SSQ/DSQ-1/1

kg

120

480

600

825

UCCU40 SSQ/DSQ-1/1

kg

145

140

570

600

815

UCCU50 SSQ/DSQ-2/1

kg

175

700

600

1025

UCCU60 SSQ/DSQ-2/1

kg

185

190

750

600

1035

UCCU70 SSQ/DSQ-2/1

kg

185

200

770

600

1055

UCCU80 SSQ/DSQ-2/1

kg

210

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

(1)

165

940

650

1055

UCCU100D-2/1

kg

320

(1)

165

970

650

1035

UCCU125D-3/1

kg

300

280

185

175

135

1210

635

1595

UCCU150D-3/1

kg

305

190

130

1250

650

1560

Model DQ P1

P2

P3

P4

P5

P6

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU75DQ-2/1

kg

305

(1)

165

940

650

1055

UCCU100DQ-2/1

kg

325

(1)

180

1010

650

1065

UCCU125DQ-3/1

kg

305

285

185

175

135

125

1210

630

1570

UCCU150DQ-4/1

kg

325

240

190

1510

650

1950

Model DSQ P1

P2

P3

P4

P5

P6

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU75DSQ-3/1

kg

285

165

125

1150

650

1555

UCCU100DSQ-3/1

kg

290

165

135

1180

650

1580

UCCU125DSQ-4/1

kg

315

295

250

240

195

185

1480

635

1995

UCCU150DSQ-4/1

kg

330

270

210

1620

650

2010

(1)

Have only 4 fixing and 4 point loadings.

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Installation Data

DIMENSIONS

DOUBLE ROW FANS - /2

UCCU110 - UCCU450

A C B

50

F 375

K

2 3 1

G J H

M

25

4

25

7

500

5

L

6

D

E

Model D A B C D E F G H J K L

M

UCCU110D - UCCU160D

mm

2365

1850

2100

115

140

205

275

1600

(1)

490

1800

UCCU180D - UCCU225D

mm

3170

1850

2100

115

140

205

480

1100

(2)

490

1800

UCCU240D

mm

4650

2200

2180

140

150

225

350

1750

1925

(2)

625

2150

UCCU250D

mm

3170

1850

2100

115

140

205

480

1100

(2)

490

1800

UCCU270D - UCCU300D

mm

4650

2200

2180

140

150

225

350

1750

1925

(2)

625

2150

UCCU330D - UCCU360D

mm

5500

2200

2180

140

150

225

350

1350

1925

525

2150

UCCU400D - UCCU450D

mm

6350

2200

2180

140

150

225

350

1700

1925

450

2150

Model DQ A B C D E F G H J K L

M

UCCU110DQ - UCCU130DQ

mm

2365

1850

2100

115

140

205

275

1600

(1)

490

1800

UCCU160DQ - UCCU200DQ

mm

3170

1850

2100

115

140

205

480

1100

(1)

490

1800

UCCU225DQ

mm

3975

1850

2100

115

140

205

480

1500

(2)

495

1800

UCCU240DQ

mm

4650

2200

2180

140

150

225

350

1750

1925

(2)

625

2150

UCCU250DQ

mm

3975

1850

2100

115

140

205

480

1500

(2)

495

1800

UCCU270DQ - UCCU300DQ

mm

5500

2200

2180

140

150

225

350

1350

1925

525

2150

UCCU330DQ - UCCU360DQ

mm

6350

2200

2180

140

150

225

350

1700

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

275

1600

(1)

490

1800

UCCU130DSQ - UCCU180DSQ

mm

3170

1850

2100

115

140

205

480

1100

(2)

490

1800

UCCU200DSQ

mm

3975

1850

2100

115

140

205

480

1500

(2)

495

1800

UCCU225DSQ

mm

3975

1850

2100

115

140

205

480

1500

(2)

495

1800

UCCU240DSQ

mm

5500

2200

2180

140

150

225

350

1350

1925

525

2150

UCCU250DSQ

mm

3975

1850

2100

115

140

205

480

1500

(2)

495

1800

UCCU270DSQ - UCCU300DSQ

mm

6350

2200

2180

140

150

225

350

1700

1925

450

2150

UCCU330DSQ - UCCU360DSQ

mm

7200

2200

2180

140

150

225

350

1700

2700

2000

450

2150

UCCU400DSQ - UCCU450DSQ

mm

8050

2200

2180

140

150

225

350

1700

2800

2725

525

2150

(1)

Have only 4 fixing and 4 point loadings.

(2)

Have only 6 fixing and 6 point loadings.

1 Electric Control Panels 2 Mains Electric Isolators 3 Mains Cable Entry 4 20mm Ø Mounting Holes 5 Optional Plenum Extension 6 Refrigeration Connections 7 Emergency Stop

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13

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Chillers

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Installation Data

POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)

DOUBLE ROW FANS - /2

UCCU110 - UCCU450

P1

P3

P5

P2

P4

P6

P7

P8

1

2

= C of G

Model D P1

P2

P3

P4

P5

P6

P7

P8

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU110D-4/2

kg

380

(1)

280

1320

925

955

UCCU130D-4/2

kg

395

415

(1)

280

1370

940

930

UCCU160D-4/2

kg

470

(1)

235

1410

925

810

UCCU180D-6/2

kg

550

590

205

225

(2)

120

1810

955

1035

UCCU200D-6/2

kg

550

590

205

225

(2)

120

1810

955

1035

UCCU225D-6/2

kg

620

220

(2)

125

1930

925

1015

UCCU240D-8/2

kg

635

325

(2)

190

2300

1100

1450

UCCU250D-6/2

kg

620

220

(2)

125

1930

925

1015

UCCU270D-8/2

kg

680

330

(2)

195

2410

1100

1425

UCCU300D-8/2

kg

715

350

(2)

200

2530

1100

1415

UCCU330D-10/2

kg

690

340

190

2820

1100

1665

UCCU360D-10/2

kg

715

345

190

2880

1100

1640

UCCU400D-12/2

kg

740

380

255

245

3240

1100

2160

UCCU450D-12/2

kg

775

395

255

245

3340

1100

2120

Model DQ P1

P2

P3

P4

P5

P6

P7

P8

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU110DQ-4/2

kg

370

(1)

270

1280

925

950

UCCU130DQ-4/2

kg

385

405

(1)

265

1320

940

915

UCCU160DQ-6/2

kg

480

210

(2)

125

1630

925

1100

UCCU180DQ-6/2

kg

505

545

210

230

(2)

125

1740

955

1075

UCCU200DQ-6/2

kg

505

545

210

230

(2)

125

1740

955

1075

UCCU225DQ-8/2

kg

545

290

(2)

225

2120

925

1525

UCCU240DQ-8/2

kg

655

330

(2)

190

2350

1100

1435

UCCU250DQ-8/2

kg

545

290

(2)

225

2120

925

1525

UCCU270DQ-10/2

kg

650

325

195

180

2700

1100

1680

UCCU300DQ-10/2

kg

690

335

200

185

2820

1100

1660

UCCU330DQ-12/2

kg

715

375

245

230

3130

1100

2140

UCCU360DQ-12/2

kg

730

385

250

230

3190

1100

2130

UCCU400DQ-14/2

kg

760

415

300

290

3530

1100

2550

UCCU450DQ-14/2

kg

805

425

300

290

3640

1100

2490

Model DSQ

P1

P2

P3

P4

P5

P6

P7

P8

Operating

Weight

C of G1

(mm)

C of G2

(mm)

UCCU110DSQ-4/2

kg

380

(1)

270

1300

925

940

UCCU130DSQ-6/2

kg

380

400

210

(2)

200

1600

935

1320

UCCU160DSQ-6/2

kg

405

220

(2)

200

1650

925

1305

UCCU180DSQ-6/2

kg

425

465

225

245

(2)

200

1760

955

1275

UCCU200DSQ-8/2

kg

480

520

265

285

(2)

240

2030

950

1300

UCCU225DSQ-8/2

kg

535

290

(2)

245

2140

925

1575

UCCU240DSQ-10/2

kg

635

315

190

180

2640

1100

1690

UCCU250DSQ-8/2

kg

535

290

(2)

245

2140

925

1575

UCCU270DSQ-10/2

kg

695

340

245

225

3010

1100

2155

UCCU300DSQ-12/2

kg

730

355

250

225

3120

1100

2120

UCCU330DSQ-14/2

kg

760

405

280

270

3430

1100

2475

UCCU360DSQ-14/2

kg

780

410

280

270

3480

1100

2450

UCCU400DSQ-16/2

kg

805

460

430

320

4030

1100

2830

UCCU450DSQ-16/2

kg

835

475

435

320

4130

1100

2790

(1)

Have only 4 fixing and 4 point loadings.

(2)

Have only 6 fixing and 6 point loadings.

ULTIMA COMPACT

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14

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Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Installation Data

UNIT LIFTING

 Employ lifting specialists.

 Local codes and regulations relating to the lifting of this type of equipment should

be observed.

 Use the lifting eye bolts/lifting lugs provided.

 Attach lifting chains to the 4 lifting eye bolts/lifting lugs provided, each chain and

eye bolt must be capable of lifting the whole chiller.

 Use the appropriate spreader bars/lifting slings with the holes/lugs provided.

 Lift the unit slowly and evenly.

 If the unit is dropped, it should immediately be checked for damage and reported

to Airedale Service.

CAUTION

Only use 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

1270

E

A

B

C

D

UCCU75 - UCCU250 (Except UCCU80)

A B C D E

2 FANS /1

mm

290

1900

585

2500

1450

3 FANS /1

mm

290

2015

1320

2500

1450

4 FANS /1

mm

290

2870

1315

3000

1450

4 FANS /2

mm

180

1580

605

2500

2000

6 FANS /2

mm

595

1650

925

2500

2000

8 FANS /2 (Tandem Compressor)

mm

595

2050

1330

2500

2350

8 FANS /2 (Trio Compressor)

mm

465

2560

1625

3000

2350

10 FANS/2

mm

465

3135

1900

3500

2350

12 FANS/2

mm

465

3610

2275

3500

2350

14 FANS/2

mm

465

4385

2350

4000

2350

16 FANS/2

mm

465

5035

2600

5000

2350

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15

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

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COMPONENTS:

1 Locating Screw 2 Retaining Nut & Washer 3 Levelling Screw 4 Levelling Lock Nut 5 Retaining Studs 6a Upper Retaining Nuts 6b Lower Retaining Nuts 7 Spring assembly 8 Pressure Plate 9 Top Plate 10 Bolting-down holes

2

1

6a

5

6b

10 9 8 7 3 4

DIMENSIONS:

B

A

C

D

E F E

A

(1)

B C D E

FØ

UCC30-70

2 SPRING

136

110

180

148

16

11

UCC75, 80, 100, 125 & 150

UCCU30-70

UCCU75, 80, 100, 125 & 150

UCFC75-150

UCC110, 130, 160-450

4 SPRING

180

130

225

186

20

16

UCCU110, 130, 160-450

UCFC160-450

UFC200-750

URAC75-450

USC200-750

UWC75-450

(1) Unloaded dimension (2) Refer to relevant Loose Parts Instructions sheet for positioning 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 the unit onto the mounts and replace retaining

nut and washer.

6 Beginning with the mount with the largest deflection, adjust the height of each mount using

the levelling screw (3).

CAUTION

Mountings must be adjusted incrementally in turn. Do not fully adjust 1 mount at a time as this may overload and damage springs.

7 When all mounts are level, lock each into place using the levelling lock nut (4).

8 Lock all retaining nuts (6a and 6b) to the extreme ends of the retaining studs (5).

CAUTION

Do not connect any services until all anti vibration mounts have been fully adjusted.

Installation Data

ANTI VIBRATION MOUNTING – OPTIONAL

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Condensers & Condensing Units

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Installation Data

POSITIONING

The installation position should be selected with the following points in mind:

 Position on a stable and even base, levelled to ensure that the compressor

operates correctly.

 Levelling should be to +/- 5mm.

 Where vibration transmission to the building structure is possible, fit spring anti-

vibration mounts and flexible water connections.

 Observe airflow and maintenance clearances.

 Pipework and electrical connections are readily accessible.

 Where multiple units are installed, due care should be taken to avoid the

discharge air from each unit adversely affecting other units in the vicinity.

 Within a side enclosed installation, the fan MUST be higher than the

enclosing structure.

 Figures in brackets indicate airflow and maintenance clearances for side-enclosed

or multiple condensing unit applications.

 Ensure there are no obstructions directly above the fans.

 Allow free space above the fans to prevent air recirculation.

CAUTION

Prior to connecting services, ensure that the equipment is installed and completely level.

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Chillers

17

Chillers

ULTIMA COMPACT

OUTDOOR UNIT - ULTIMA COMPACT CONDENSING UNIT

INDOOR UNIT - BY OTHERS

1 2 3 4 5 6 7

8

Installation Data

REFRIGERATION SYSTEM

Standard Recommended Installation

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 Filter drier (optional - supplied loose) 6 Sight glass (optional - supplied loose) 7 Solenoid valve (supplied by others) 8 Expansion valve (supplied by others)

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18

Condensers & Condensing Units

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Installation Data

REFRIGERATION CONNECTIONS

UCCU30SQ-1/1

UCCU40SQ-1/1

UCCU50SQ-2/1

UCCU60SQ-2/1

UCCU70SQ-2/1

UCCU80SQ-2/1

Connections - Single Circuit

(1)

Liquid Line

in

7/8

1 1/8

Suction Line

in

1 3/8

1 5/8

UCCU30DQ-1/1

UCCU40DQ-1/1

UCCU50DQ-2/1

UCCU60DQ-2/1

UCCU70DQ-2/1

UCCU80DQ-2/1

Connections - Dual Circuit

(1)

Liquid Line

in

3/4

7/8 / 3/4

7/8

Suction Line

in

1 1/8

1 3/8 / 1 1/8

1 3/8

UCCU75D-2/1

UCCU100D-2/1

UCCU110D-4/2

UCCU125D-3/1

UCCU130D-4/2

UCCU150D-3/1

Connections

(1)

Liquid Line

in

1 1/8

Suction Line

in

1 3/8

1 5/8

UCCU160D-4/2

UCCU180D-6/2

UCCU200D-6/2

UCCU225D-6/2

UCCU240D-8/2

UCCU250D-6/2

Connections

(1)

Liquid Line

in

1 1/8

1 3/8

1 5/8

1 3/8

Suction Line

in

2 1/8

2 5/8

2 1/8

UCCU270D-8/2

UCCU300D-8/2

UCCU330D -10/2

UCCU360D -10/2

UCCU400D -12/2

UCCU450D-12/2

Connections

(1)

Liquid Line

in

1 5/8

1 5/8 / 2 1/8

2 1/8

Suction Line

in

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 to vertical pipe runs and heat pump installation.

Unit performance will reduce if there are vertical rises of above 5m. Please consult Airedale Service for risers above 10m.

When insulating refrigerant lines, cut approximately 30 - 50cm longer than the distance between the units to ensure the insulation goes right upto the unit. Leave connections uncovered for leak testing.

Remove burrs to the ends of the copper tube, holding the tube downward to avoid allowing dirt to contaminate the tube.

Where applicable insert flare nuts removed from the pipework terminations and make a flare at the end of the copper tube to conform with the following:

 Inside surface is glossy and smooth

 Tapered sides are of uniform length

 Refrigeration lubrication is applied to mating surfaces

The installation of a sight glass close to the indoor unit is recommended.

Where applicable braze incoming pipe to rotalock service valve.

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Installation & Maintenance : 6259675 IM V1.4.0 10/2013

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Installation Data

PRESSURE TESTING

In accordance with PED 97/23/EC, a strength test should be carried out in order to ensure that all interconnecting joints, pipework and components are sufficiently strong to cater for maximum permissible operating pressures. Once installation is completed, the high side of the system should be strength tested with dry nitrogen to a recommended

minimum pressure of 27 barg and the low side to 17 barg.

CAUTION

Pressure testing can be dangerous if not properly conducted, personnel undertaking pressure testing MUST be technically competent and suitably qualified.

When installation is complete, the system should be pressure tested.

Fill the system with dry nitrogen to a pressure of between 17 bar/250psig and 34bar/ 500 psig.

Record the pressure over a minimum of 60 minutes to detect major leaks (a 24 hour period should preferably be allowed).

If a reduction in pressure is detected, trace the leak and repair before conducting a further pressure test and charging.

EVACUATION

Evacuation for systems operating with R407C refrigerant to be carried out as follows (for alternative refrigerants please refer to Airedale).

Use a high vacuum pump and connect to the high and low pressure sides of the system via a gauge manifold fitted with compound gauges. A high vacuum gauge should be fitted to the 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 then be evacuated a third time but this time to 0.5 torr absolute pressure.

Break with the correct refrigerant, until pressures equalise between the charging bottle and the system.

ELECTRICAL

General

 As standard the equipment is designed for 400V, 3 phase, 3 wire 50Hz and a

separate permanent 230V, 1 phase, 50Hz supply, to all relevant IEE regulations, British standards and IEC requirements.

 A fused and isolated electrical supply of the appropriate phase, frequency and

voltage should be installed.

 The control voltage to the interlocks is 24V. Always size the low voltage interlock

and protection cabling for a maximum voltage drop of 2V.

CAUTION

Wires should be capable of carrying the maximum load current under non-fault conditions at the stipulated voltage.

 Avoid large voltage drops on cable runs, particularly low voltage wiring.

 Once the connecting pipework is complete the electrical supply can be connected

by routing the cable through the appropriate casing hole and connecting the cables, refer to the Wiring Diagram supplied with each unit.

CAUTION

A separately fused, locally isolated, permanent single phase and neutral supply MUST BE FITTED for the compressor sump heater and control circuits, FAILURE to do so could INVALIDATE WARRANTY.

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20

Condensers & Condensing Units

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Installation Data

INTERCONNECTING WIRING

Single Circuit

(not including: leak detector, and remote setpoint adjust)

UCCU30–

UCCU80

(Excluding

UCCU75)

L1





Mains incoming supply 400V/3PH/50Hz 50Hz (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





Remote On/Off 24VAC, Compressor.2 24VAC (Digital I/P Control Option)

505





500





0 v

Remote Capacity Control (0-10VDC Control Option)

806





0-10v 52





Circuit 1 Solenoid Valve

53





Volt Free Contact N/O

573





Circuit 1

Volt Free Common Alarm

574





Volt Free Alarm N/O

575





Volt Free Alarm N/C

RX-/TX-





RX+/TX+





/ Optional EEV Connections

GND





Double Circuit

UCCU30 –

UCCU450

L1





Mains incoming supply 400V/3PH/50Hz (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





Compressor.4 24VAC (Digital I/P Control Option)

507





502





Compressor.5 24VAC (Digital I/P Control Option UCCU240-450 Only Excluding UCCU250)

508





502





Compressor.6 24VAC (Digital I/P Control Option UCCU240-450 Only Excluding UCCU250)

509





502





Remote On/Off 24VAC, Compressor.2 24VAC (Digital I/P Control Option)

505





500





0 v

Remote Capacity Control (0-10VDC Control Option)

806





0-10v

52





Circuit 1 Solenoid Valve

53





Volt Free Contact N/O

54





Circuit 2 Solenoid Valve

55





Volt Free Contact N/O

573





Circuit 1

Volt Free Common Alarm

574





Volt Free Alarm N/O

575





Volt Free Alarm N/C

576





Circuit 2

Volt Free Common Alarm

Dual Circuit Only

577





Volt Free Alarm N/O

578





Volt Free Alarm N/C

RX-/TX-





/ Optional EEV Connections

RX+/TX+





GND





Condensing Units

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Condensers & Condensing Units

21

Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Chillers

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Installation Data

ELECTRICAL DATA

UCCU30SQ-1/1

UCCU30DQ-1/1

UCCU40SQ-1/1 UCCU40DQ-1/1

UCCU50SQ-2/1

UCCU50DQ-2/1

UCCU60SQ-2/1

UCCU60DQ-2/1

UCCU70SQ-2/1 UCCU70DQ-2/1

UCCU80SQ-2/1 UCCU80DQ-2/1

Unit Data

Nominal Run Amps

(1)

A

27

28

38

43

47

58

Maximum Start Amps

(2)

A

116

114

142

157

162

207

Permanent Supply

VAC

230 V 1 PH 50 Hz

Mains Supply

VAC

400 V 3 PH 50 Hz

Rec Permanent Fuse Size

A

16

Rec Mains Fuse Size

A

32

40

50

63

80

Max Permanent Incoming Cable Size

mm²

4 mm² terminals

Max Mains Incoming Cable Size

mm²

35 (Direct to Isolator)

Control Circuit

VAC

24V/230VAC

Condenser Fan - Per Fan

Full Load Amps

A

3.00

Locked Rotor Amps

A

7.00

7.50

Motor Rating

Kw

1.75

Compressor - Per Compressor

Quantity

2 2 2 2 2

2

Motor Rating

kW

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 / 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 UCCU80DSQ-2/1

All data as above except:

Condenser Fan - Per Fan

Full Load Amps

A

1.15

3.50

1.15

Locked Rotor Amps

A

2.10

7.50

2.10

Motor Rating

kW

0.70

0.78

0.70

OPTIONAL EXTRAS

Power Factor Correction

Nominal Run Amps

(1)

A

N/A

Maximum Start Amps

(2)

A

N/A

Recommended Mains Fuse

A

N/A

Compressor Nominal Run Amps

- Per Compressor

A

N/A

Electronic Soft-start

Nominal Run Amps

(1)

A

27

28

38

43

47

58

Maximum Start Amps

(2)

A

76

77

94

103

108

137

Recommended Mains Fuse

A

32

40

50

63

80

(1)

Based at 7.2°C Evaporating and 54.4°C Condensing temperatures.

(2)

Starting amps refers to the direct on line connections.

ULTIMA COMPACT

Condensing Units

22

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Installation Data

ELECTRICAL DATA

UCCU75D-2/1

UCCU100D-2/1

UCCU110D-4/2

UCCU125D-3/1

UCCU130D-4/2

UCCU150D-3/1

Unit Data

Nominal Run Amps

(1)

A

54

68

75

89

95

109

Maximum Start Amps

(2)

A

140

172

179

238

244

258

Permanent Supply

VAC

230 V 1 PH 50 Hz

Mains Supply

VAC

400 V 3 PH 50 Hz

Rec Permanent Fuse Size

A

16

Rec Mains Fuse Size

A

63

80

100

125

Max Permanent Incoming Cable Size

mm²

4 mm² terminals

Max Mains Incoming Cable Size

mm²

70 (Direct to

MCCB)

70 (Direct to

MCCB)

Direct to Bus Bar

70 (Direct to

MCCB)

Direct to Bus Bar

70 (Direct to

MCCB)

Control Circuit

VAC

24V/230V AC

Condenser Fan - Per Fan

Full Load Amps

A

1.75

3.00

1.75

3.00

1.75

Locked Rotor Amps

A

6.20

7.00

6.20

7.00

6.20

Motor Rating

kW

0.98

1.75

0.98

1.75

0.98

Compressor - Per Compressor

Quantity

4 4 4

2 + 2

4

Motor Rating

kW

6.2

8.1

8.1 / 11.7

11.7

Nominal Run Amps

(1)

A

12.7

16.1

16.1/ 26.0

16.1 / 26.0

26.0

Crankcase Heater Rating

W

65.0

65.0 / 75.0

75.0

Start Amps

(2)

98.0

120.0

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

1.25

1.15

1.25

1.15

Locked Rotor Amps

A

2.10

4.50

2.10

4.50

2.10

Motor Rating

kW

0.68

0.69

0.68

0.69

0.68

SUPER QUIET DSQ

UCCU75DSQ-3/1

UCCU100DSQ-3/1

UCCU110DSQ-4/2

UCCU125DSQ-4/1

UCCU130DSQ-6/2

UCCU150DSQ-4/1

All data as above except:

Condenser Fan - Per Fan

Full Load Amps

A

0.83

0.78

0.83

0.78

0.83

Locked Rotor Amps

A

1.50

Motor Rating

kW

0.32

0.48

0.32

0.48

0.32

OPTIONAL EXTRAS

Power Factor Correction

Nominal Run Amps

(1)

A

49

61

68

80

86

97

Maximum Start Amps

(2)

A

140

172

179

238

244

258

Recommended Mains Fuse

A

63

80

100

125

Compressor Nominal Run Amps

- Per Compressor

A

4 x 11

4 x 13

2 x 20 / 2 x 13

4 x 20

Electronic Soft-start

Nominal Run Amps

(1)

A

54

68

75

89

95

109

Maximum Start Amps

(2)

A

100

124

131

168

174

188

Recommended Mains Fuse

A

63

80

100

125

(1)

Based at 7.2°C Evaporating and 54.4°C Condensing temperatures.

(2)

Starting amps refers to the direct on line connections.

Condensing Units

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Chillers

ULTIMA COMPACT

Installation Data

ELECTRICAL DATA

UCCU160D-4/2

UCCU180D-6/2

UCCU200D-6/2

UCCU225D-6/2

UCCU240D-8/2

UCCU250D-6/2

Unit Data

Nominal Run Amps

(1)

A

115

132

146

158

170

172

Maximum Start Amps

(2)

A

264

315

377

389

319

403

Permanent Supply

VAC

230 V 1 PH 50 Hz

Mains Supply

VAC

400 V 3 PH 50 Hz

Rec Permanent Fuse Size

A

16

Rec Mains Fuse Size

A

125

160

200

Max Permanent Incoming Cable Size

mm²

4 mm² terminals

Max Mains Incoming Cable Size

mm²

Direct to Bus Bar

Control Circuit

VAC

24V/230V AC

Condenser Fan - Per Fan

Full Load Amps

A

3.00

Locked Rotor Amps

A

7.00

6.20

7.00

Motor Rating

kW

1.75

Compressor - Per Compressor

Quantity

4

2 + 2

2 + 2 6 4

Motor Rating

kW

11.7

15.0 / 11.7

18.2 / 11.7

18.2 / 15.0

11.7

18.2

Nominal Run Amps

(1)

A

26.0

32.0 / 26.0

39.0 / 26.0

39.0 / 32.0

26.0

39.0

Crankcase Heater Rating

W

75.0

130.0 / 75.0

130.0 / 130.0

75.0

130.0

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

1.15

1.25

Locked Rotor Amps

A

4.50

2.10

4.50

Motor Rating

kW

0.69

0.70

0.69

SUPER QUIET DSQ

UCCU160DSQ- 6/2

UCCU180DSQ- 6/2

UCCU200DSQ- 8/2

UCCU225DSQ- 8/2

UCCU240DSQ-10/2

UCCU250DSQ- 8/2

All data as above except:

Condenser Fan - Per Fan

Full Load Amps

A

0.78

0.83

0.78

Locked Rotor Amps

A

1.50

Motor Rating

kW

0.48

0.32

0.48

OPTIONAL EXTRAS

Power Factor Correction

Nominal Run Amps

(1)

A

103

118

132

142

152

156

Maximum Start Amps

(2)

A

264

315

377

389

319

403

Recommended Mains Fuse

A

125

160

200

Compressor Nominal Run Amps

- Per Compressor

A

4 x 20

2 x 24 / 2 x 20

2 x 30 / 2 x 20

2 x 30 / 2 x 24

6 x 20

4 x 30

Electronic Soft-start

Nominal Run Amps

(1)

A

115

132

146

158

170

172

Maximum Start Amps

(2)

A

194

229

269

281

249

295

Recommended Mains Fuse

A

125

160

200

(1)

Based at 7.2°C Evaporating and 54.4°C Condensing temperatures.

(2)

Starting amps refers to the direct on line connections.

ULTIMA COMPACT

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Installation & Maintenance : 6259675 IM V1.4.0 10/2013

Installation Data

ELECTRICAL DATA

UCCU270D-8/2

UCCU300D-8/2

UCCU330D-10/2

UCCU360D-10/2

UCCU400D-12/2

UCCU450D-12/2

Unit Data

Nominal Run Amps

(1)

A

188

206

231

252

279

303

Maximum Start Amps

(2)

A

337

389

462

483

552

576

Permanent Supply

VAC

230 V 1 PH 50 Hz

Mains Supply

VAC

400 V 3 PH 50 Hz

Rec Permanent Fuse Size

A

16

Rec Mains Fuse Size

A

200

250

315

355

Max Permanent Incoming Cable Size

mm²

4 mm² terminals

Max Mains Incoming Cable Size

mm²

Direct to Bus Bar

Control Circuit

VAC

24V/230V AC

Condenser Fan - Per Fan

Full Load Amps

A

1.75

Locked Rotor Amps

A

6.20

Motor Rating

kW

0.98

Compressor - Per Compressor

Quantity

3 + 3 6 3 + 3 6 3 + 3

6

Motor Rating

kW

15.0 / 11.7

15.0

18.2 / 15.0

18.2

22.8 / 18.2

22.8

Nominal Run Amps

(1) A 32.0 / 26.0

32.0

39.0 / 32.0

39.0

47.0 / 39.0

47.0

Crankcase Heater Rating

W 130.0 / 75.0

130.0

130.0 / 130.0

130.0

130.0 / 130.0

130.0

Start 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

Locked Rotor Amps

A

2.10

Motor Rating

kW

0.70

SUPER QUIET DSQ

UCCU270DSQ-12/2

UCCU300DSQ- 12/2

UCCU330DSQ- 14/2

UCCU360DSQ- 14/2

UCCU400DSQ- 16/2

UCCU450DSQ- 16/2

All data as above except:

Condenser Fan - Per Fan

Full Load Amps

A

0.83

Locked Rotor Amps

A

1.50

Motor Rating

kW

0.32

OPTIONAL EXTRAS

Power Factor Correction

Nominal Run Amps

(1)

A

167

182

207

228

246

261

Maximum Start Amps

(2)

A

337

389

362

483

552

576

Recommended Mains Fuse

A

200

250

315

Compressor Nominal Run Amps

- Per Compressor

A

3 x 24 / 3 x 20

6 x 24

3 x 30 / 3 x 24

6 x 30

3 x 36 / 3 x 30

6 x 36

Electronic Soft-start

Nominal Run Amps

(1)

A

188

206

231

252

279

303

Maximum Start Amps

(2)

A

267

303

354

375

424

448

Recommended Mains Fuse

A

200

250

315

355

(1)

Based at 7.2°C Evaporating and 54.4°C Condensing temperatures.

(2)

Starting amps refers to the direct on line connections.

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Chillers

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-

Controls

GENERAL DESCRIPTION

The microprocessor controller offers powerful analogue and digital control to meet a wide range of monitoring and control features including a real time clock and Industry standard communication port and network connections.

The controller’s inbuilt display is used for viewing the unit operating status and making

adjustments to control parameters by allowing the operator access to a series of display pages.

Also featured are a visual alarm and the facility to adjust and display control settings by local operator for information and control.

DISPLAY/KEYPAD

5

3

6

2

1

4

08:44 13/05/02 Mst Remote 0-10V Input Signal Voltage 05.6V Unit ON

7

Esc

Prg

1 UP/DOWN KEYS

To change Adjustable Fields & Scrolls up & down available Menus

2 ENTER

Selects Menus & Moves Cursor to Adjustable Fields 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 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 password entry, refer to Password Protection.

Initially, use the

Prg

key to access Menus, the symbol will appear top right and the

first menu will appear in CAPITALS, these indicators shows which menu is selected.

Use the keys to move the indicator to the desired menu and press to open the menu.

Use the key to move the flashing cursor to adjustable fields and the keys to change the values.

Press the key to move the cursor to the next field or Home.

When the cursor is Home either use the keys to scroll to next sub-menu or

the

Esc

to exit and return to the Standard Operating page.

Standard Operating Page

The Operating Page will appear and remain present following start up of the controller as illustrated:

13:43 25/11/02 M1 Space Temp. 12.0°C Supply Temp. 07.0°C Unit ON:

Indicates current Time, Date, Space and Supply air Temperatures and Unit On/Off

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-

Controls

OPERATION (CONT..)

Standard Operating Page cont.

The following Menus can be accessed from the Operating Page, it is recommended that

the display is always returned to the Operating Page by using the

Esc

key

Password Protection

To guard against unauthorised adjustments, a password is required to gain access to certain menus as defined below.

FACTORY SET PASSWORD PIN NUMBER: 4648 (or Customer chosen number).

When a password is requested use the keys to enter the number and to access the page.

Menus (Listed in Sequence)

Menu

Description

Password

Switch On/Off

Enable or Disable the unit

Open Access

Service

Allows selection of setpoint limits, enables unit on/off from display, remote on/off and remote pump on/off.

Default 4648

Setpoint

Allows setpoint 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 last 100 alarms in chronological order.

Open Access

Manufacturer

Factory use only.

Airedale Only

VIEWING UNIT OPERATING STATUS

Status Menu

Allows access to view operating status of Digital and Analogue Inputs and Outputs.

Using the Navigation instructions and the wiring diagram provided, the relevant Sub-

Menus can be accessed.

SETTING UP

Real Time Clock

(Optional to UCC30-80 Single Circuit Only)

The units leave the factory set, however follow the Navigation instructions if necessary.

Time Zones

The programme provides 3 On/Off periods per day, 7 days per week. The unit is factory set for continuous operation.

Technical Support

For further details, please contact Airedale.

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Controls

ALARMS

The controller logs and allows viewing of the last 100 conditions recorded in descending chronological order.

13/05/02 11:32 Event number 001 Alarm Active 37-Diff Pressr Evap

Alarm Handling

1 A Red LED behind the Alarm key will light in the event of an alarm. To view

the alarms, simply press the key and the keys to scroll through.

2 Auto reset alarms will clear following this first depression of the Alarm key. If

however the Red LED behind the Alarm key remains illuminated, the unit requires some form of manual reset.

3 For manual reset alarms, isolate the affected circuits before further investigation.

4 To reset or delete the alarms displayed in the alarm screen, simply press

again.

COMMON ALARMS

Outlined below is a selection of Common Alarms, a full list is available, please contact Airedale.

Phase Rotation (Optional)

A normally closed contact. When Phase Rotation is incorrect all controller outputs are de-activated.

Emergency Stop

A normally open contact. On closing, all controller outputs are de-activated.

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 exceeding 1 minute (or 3 minutes on compressor start-up), a visual alarm will be generated at the in-built display and the relevant compressor will be de-activated. On units with tandem compressors, both compressors from the same circuit will be switched off.

High Liquid Pressure

When the liquid pressure reaches 25 BarG, the relevant circuit will be switched off and an alarm activated, this can only be rectified by manual reset via the microprocessor.

Compressor Status

A normally closed contact when the compressor is operating. If this contact remains open for a period of 3 seconds during operation of the compressor, a visual alarm is generated and the relevant compressor will be de-activated. This alarm comprises of compressor motor protection module, discharge gas thermostat and safety high pressure switch.

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Commissioning Data

OPERATING LIMITS

Cooling

Standard Unit with Electronic Fan Speed Control (-20°C)

Minimum Ambient Air DB °C

-20°C

Maximum Ambient Air DB °C

Refer to Technical Manual - Performance Data - Capacity Data

Minimum Evaporating Temperature °C

-5°C

Maximum Evaporating Temperature °C

+10°C

1

For conditions outside those quoted, please refer to Airedale.

MECHANICAL DATA

Oil & Refrigerant Charges

UCCU30SQ-1/1

UCCU30DQ-1/1

UCCU40SQ-1/1

UCCU40DQ-1/1

UCCU50SQ-2/1

UCCU50DQ-2/1

UCCU60SQ-2/1

UCCU60DQ-2/1

UCCU70SQ-2/1

UCCU70DQ-2/1

UCCU80SQ-2/1 UCCU80DQ-2/1

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 UCCU80DSQ-2/1

Compressor

Single Circuit - Tandem Scroll / Double Circuit – 2 x Single Scroll

Quantity

2 2 2 2 2

2

Oil Charge Volume (Total)

l

1.5 + 1.5

1.6 + 1.6

1.9 + 1.9

3.0 + 1.9

3.0 + 3.0

3.6 + 3.6

Oil Type

Polyol Ester

Refrigeration

Single Circuit / Double Circuit

Holding Charge

Helium to 6.9 barg

Refrigerant Type

R407C

Charge (Total)

(1)

kg

5 + 5

6 + 6

8 + 8

10 + 10

UCCU75D-2/1

UCCU100D-2/1

UCCU110D-4/2

UCCU125D-3/1

UCCU130D-4/2

UCCU150D-3/1

Compressor

Tandem Scroll - Hermetic

Quantity

4 4 4 4 4

4

Oil Charge Volume (Total)

l

4 x 3.25

4 x 3.80

2 x 6.20+2 x 3.80

4 x 6.20

Oil Type

Polyol Ester

Refrigeration

Dual Circuit

Holding Charge

Helium to 6.9 barg

Refrigerant Type

R407C

Charge (Total)

(1)

kg

20 + 20

22 + 22

25 + 25

22 + 22

30 + 30

QUIET DQ

UCCU75DQ-2/1

UCCU100DQ-2/1

UCCU110DQ-4/2

UCCU125DQ-3/1

UCCU130DQ-4/2

UCCU150DQ-4/1

Refrigerant Charge (Total)

(1)

kg

20 + 20

25 + 25

22 + 22

30 + 30

22 + 22

40 + 40

SUPER QUIET DSQ

UCCU75DSQ-3/1

UCCU100DSQ-3/1

UCCU110DSQ-4/2

UCCU125DSQ-4/1

UCCU130DSQ-6/2

UCCU150DSQ-4/1

Refrigerant Charge (Total)

(1)

kg

20 + 20

23 + 23

22 + 22

40 + 40

30 + 30

40 + 40

UCCU160D-4/2

UCCU180D-6/2

UCCU200D-6/2

UCCU225D-6/2

UCCU240D-8/2

UCCU250D-6/2

Compressor - Scroll Hermetic

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

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

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 Charge (Total)

(1)

kg

30 + 30

40 + 40

32 + 32

40 + 40

SUPER QUIET DSQ

UCCU160DSQ-6/2

UCCU180DSQ-6/2

UCCU200DSQ-8/2

UCCU225DSQ-8/2

UCCU240DSQ-10/2

UCCU250DSQ-8/2

Refrigerant Charge (Total)

(1)

kg

30 + 30

40 + 40

38 + 38

40 + 40

UCCU270D-8/2

UCCU300D-8/2

UCCU330D-10/2

UCCU360D-10/2

UCCU400D-12/2

UCCU450D-12/2

Compressor

Trio Scroll - Hermetic

Quantity

6 6 6 6 6

6

Oil Charge Volume (Total)

l 3 x 4.7 + 3 x 4.1

6 x 4.7

3 x 6.3 + 3 x 4.7

6 x 6.3

3 x 5.9 + 3 x 6.3

6 x 5.9

Oil Type

Polyol Ester

Refrigeration

Dual Circuit

Holding Charge

Helium to 6.9 barg

Refrigerant Type

R407C

Charge (Total)

(1)

kg

43 + 39

42 + 42

43 + 39

53 + 53

65 + 60

63 + 63

QUIET DQ

UCCU270DQ-10/2

UCCU300DQ-10/2

UCCU330DQ-12/2

UCCU360DQ-12/2

UCCU400DQ-14/2

UCCU450DQ-14/2

Refrigerant Charge (Total)

(1)

kg

43 + 39

40 + 40

54 + 49

49 + 49

65 + 60

72 + 72

SUPER QUIET DSQ

UCCU270DSQ-12/2

UCCU300DSQ-12/2

UCCU330DSQ-14/2

UCCU360DSQ-14/2

UCCU400DSQ-16/2

UCCU450DSQ-16/2

Refrigerant Charge (Total)

(1)

kg

52 + 48

46 + 46

56 + 51

70 + 70

82 + 76

80 + 80

(1)

Unit supplied with a holding charge of Helium, the refrigerant charge is suitable for upto10 metres of interconnecting pipework, additional refrigerant must be added for longer pipe runs.

Adding Refrigerant

Refrigerant should be added to the system via 1/4” schrader connection on the expansion line as required.

UNLOADING PROTECTION

Head Pressure

The microprocessor has inbuilt protection against nuisance trips. If the head pressure rises above 23 barg the system will unload 1 compressor and remain unloaded until the head pressure drops below 21 barg.

Low Pressure

If low pressure drops below the microprocessor setting, the compressor will unload to 1 compressor, if low pressure persists for 1 minute, the circuit will be switched off and sound an alarm.

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Commissioning Procedure

GENERAL

To be read in conjunction with the commissioning sheets provided, items highlighted should be recorded.

CAUTION

Please ensure all documents have been completed correctly and return to Airedale Technical Support immediately to validate warranty.

PRE COMMISSIONING CHECKLIST

CAUTION

ALL work MUST be carried out by Technically Trained competent personnel.

The equipment contains live electrical and moving parts, ISOLATE prior to maintenance or repair work.

The door interlocking MCCB should be in the OFF position and the auxiliary alarm contact from the MCCB should be linked out.

All pipework is complete and insulated where necessary.

Check for the presence of a refrigerant charge in the condenser side.

IMPORTANT

Check phase rotation of electrical supply prior to running compressor as compressor is direction sensitive.

RECORD

The unit should be visually inspected and any damage noted.  Secure commissioning gauges to the high side of the system, check for a

positive charge.

 Check tightness of electrical components 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 incoming voltage.  Check Phase Rotation.  Check voltage and frequency at permanent supply.  Measure and record the primary (230V) and secondary (24V) voltages at each of

the transformers, adjust tapping if necessary and record on the commissioning document.

 Check all timer settings are correct.  Check Sump Heater (ensure this is switched on for a minimum of 2 hours

prior to the unit operation).

 Check oil level.  Check fans rotate freely.  Check system correctly evacuated.  Check operating of HP/LP cut-out, settings LP cut-out - Auto/HP switch - manual:

High pressure switch - 26 bar ( 400 psi ) - cut out Low pressure cut-out - 0.5 bar ( 7 psi ) - cut out

 Switch on the controls and individual circuits, primary and secondary, MCBs to the

ON position. At this stage the control display panel should be illuminated.

 Record Optional Extras.  Record Controller Data.

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Commissioning Procedure

CAUTION

Disable remote ON/OFF to ensure the unit does not start unintentionally.

The unit will not start until microprocessor control SWITCH 1 is in the ON position. DO NOT SWITCH TO ON AT THIS STAGE

 Adjust the temperature supply and return set points (if necessary, via the chosen

control management scheme) to call for 100% cooling (refer to the

Controls section).

 Ensure all KNOBS and SWITCHES are adjusted to suit the design requirements

(refer to the Controls section).

To switch the unit ON, use the microprocessor keypad as follows:

Press

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 alarm should appear within

3 minutes.

 The alarm will be recognised at the display circuit trip, to clear the alarms refer

to Alarm Handling.

To switch the unit OFF, use the microprocessor keypad as follows:

Press

Prg

, press , press , press & finally .

Fully open all liquid line and discharge service ball valves on each circuit.

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Commissioning Procedure

COMMISSIONING CHECKLIST

The following should be carried out with a load on the system, otherwise the unit is likely to short cycle. The following tests are to be carried out on 1 circuit at a time.

 Switch the door interlocking MCCB to the ON position but again only on the circuit

which is to be tested.

 Adjust the temperature supply and return set points to match the

system requirements.

To switch the unit ON, use the microprocessor keypad as follows:

Press

Prg

, press , press , press & finally .

 Check pressures at suction and discharge ports for correct phase rotation.

CAUTION

If no differential pressure occurs, isolate immediately.

RECORD

 Measure and record the compressor amps once the compressors are fully loaded

and 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 valve to maintain a superheat

setting of 5 – 8°C at all operating loads.

 Check and record the following:

Suction and discharge pressures

Liquid, discharge and suction line temperature

 Ensure the above are all within the design parameters.

 Repeat as follows for each circuit:

 To switch the unit OFF, use the microprocessor keypad as follows:

Press

Prg

, press , press , press & finally .

 To switch the unit ON, repeat above.

The unit is now commissioned and will provide many years of trouble free operation providing the following maintenance schedule is followed.

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Troubleshooting

FAULT

POSSIBLE CAUSE

REMEDY/ACTION

Unit Will Not Start

No power.

Check power supply to the controller.

Wired incorrectly.

Check wire connections in accordance with wiring diagram on control box lid.

Loose wires.

Check all wires, connections, terminals etc.

Compressor not operating

No power to compressor.

Check isolator, fuses, MCBs, contactor and control circuit wiring.

Low pressure cut-out operated (large or complete loss of refrigerant charge).

Recover refrigerant, repair, evacuate and recharge system.

Condenser fan thermal trip open circuit.

Investigate and correct.

Seized compressor, possibly due to lack of oil.

Replace compressor - investigate oil trapping and general installation.

Defective compressor motor.

Check winding resistances - replace compressor. If burnt out follow burn out procedure using 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 too much - Remember too much is as bad as too little. Investigate pipe system and trapping. If no oil still, drain compressor and measure in correct quantity.

Head Pressure too high/HP cut-out operated

Condenser coil clogged or dirty.

Clean condenser.

Overcharge of refrigerant. Normally troublesome in warm weather.

Remove excess refrigerant from system.

Air or other non-condensable gas in system.

Evacuate system and re-charge with new refrigerant.

Head pressure controller faulty.

Check fan speed controller - if faulty - replace.

Fan not operating or operating inefficiently.

Check motor - if faulty - replace.

Head pressure too low

Fan operating too fast in low ambient conditions.

Check fan speed controller adjustment - if faulty - replace.

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Troubleshooting

FAULT

POSSIBLE CAUSE

REMEDY / ACTION

Suction Pressure too low

Low evaporator airflow (not Airedale Unit).

Check fan motors, belts and drives.

Flash gas (bubbles in sight glass) at expansion valve.

Investigate for refrigerant leaks, repair and re-charge system.

Clogged filter drier (pressure / temperature drop across it).

Replace. Obstruction in liquid line solenoid valve.

Inspect, clean or replace.

Obstruction in expansion valve.

Inspect, clean or replace.

Condenser fan not operating power on

Power supply failure.

Check power supply at circuit breaker. Wiring to motors.

Check voltage at motor terminals.

Motor / fan assembly jammed.

Isolate unit and check free rotation of motor/fan assembly. If faulty - replace.

Motor internal overheat protector 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

High ambient condition or excessive recirculation of air around condenser coil.

Check installation against design. Minimum set speed setting incorrect.

Adjust as necessary.

Incorrect pressure sensor setting.

Adjust via microprocessor.

Faulty Fan Speed Controller.

Replace controller and sensor (as they are matched sets).

Faulty pressure sensor.

Replace sensor.

Condenser fans runs only slowly

Incorrect pressure setting.

Adjust via microprocessor.

Faulty Controller.

Replace controller and sensor (as they are matched sets).

Faulty Pressure sensor.

Replace sensor.

Motor/capacitor faulty.

Replace.

Motor wired incorrectly.

Check against wiring diagram - correct as required.

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Maintenance

CAUTION

ALL work MUST be carried out by Technically Trained competent personnel.

The equipment contains live electrical and moving parts, ISOLATE prior to maintenance or repair work.

GENERAL MAINTENANCE

The maintenance schedule indicates the time period between maintenance operations.

3 MONTHS

ACTION

NOTES

REFRIGERATION

Check the following and compare results with commissioning records.

Investigate and rectify variations.  Suction and discharge readings.

Remember to re-cap the Schraeder connections!

 Head pressure control is maintained.

 Pressure relief indicator gauge.

 Check each circuit sight glass for dryness and

bubbles for indication of leaks.

 Check compressor oil level and

shell/sump temperature.

 Visually inspect the unit for oil patches.

Investigate and repair possible leaks.

SYSTEM

Check the following 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 with matching paint (available from Airedale or your Distributor).

Visually inspect pipe and pipework insulation.

Repair/rectify as necessary.

Clean evaporator water strainer.

At first maintenance visit and then as frequently as necessary (12 months).

Clean condenser coils. Do not steam clean use detergent and stiff bristled brush. For heavy dirt, use either a high pressure water or chemical hose.

Do not damage fins and comb out if necessary. Visually check the following:

Secure/tighten as necessary.

 Pipework clamps are secure.

 Tightness and condition of fan and

compressor mounts.

 Anti-Vibration mounts fixings (if fitted).

Finally!

Ensure control panel lids and access panels have been correctly replaced and securely fastened in position.

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Maintenance

GENERAL MAINTENANCE (CONT.)

12 MONTHS

ACTION

NOTES

Repeat 3 month checks plus the following:

SYSTEM

Check safety devices cut out the compressor at the correct settings.

REFRIGERATION

Leak test all R407C joints and inspect all water connections.

Rectify as necessary.

Check superheats with system running on full load (the height of summer 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. 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 out by period or hourly use which ever is sooner.

1 Year

Measure compressor motor insulation.

7,500 Hours or 4 Years

Inspect compressor oil.

SHUT DOWN PERIODS

For periods of winter shut down the following precautions are recommended:

 Close the liquid and discharge ball valve  Cap service ports  Turn off electrical circuits

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SPARES

Parts Identification

UCC .. /1 – DUAL CIRCUIT

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.

For ease of identification when ordering spares or contacting Airedale about your unit,

please quote the unit type, unit serial number and the date of manufacture, which can

be found on the unit serial plate.

1 Discharge Line Ball Valve (optional) 2 Discharge non return valve (optional) 3 Discharge Thermostat Switch 4 HP Switch 5 Suction 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 Interlocking isolator 20 Emergency Stop 21 Condenser Coils 22 Incoming Customer Mains Access Points

23 Unit Controller Panel

24 Compressors MCBs 25 Modulating Head Pressure Controller 26 Fan Contactor MPCB 27 Compressor Contactors 28 Incoming Customer Mains 3 Phase 29 AireTronix Microprocessor Controller 30 Customer Permanent Supply/Controls Connections

The serial plate can be located inside Item 18.

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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

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Notes:

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Notes:

Where to Find Us

Head Office:

Airedale International Air Conditioning Ltd

Leeds Road

Rawdon

Leeds LS19 6JY

United Kingdom

Tel:

+44 (0) 113 239 1000

Fax:

+44 (0) 113 250 7219

e-mail:

[email protected]

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