AIREDALE UCFC160D-6/2 User manual

INSTALLATION, OPERATING
& MAINTENANCE MANUAL
Ultima Compact FreeCool
Free-Cooling Chiller
75 – 450 kW

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About Airedale Products & Customer Services
WARRANTY,
COMMISSIONING &
MAINTENANCE
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty for a period
of 12 months from the date of commissioning or 18 months from the date of despatch, which ever
is the sooner. (Excludes the cost of any specialist access or lifting equipment.) Commissioning will
be carried out by Airedale International Air Conditioning Ltd or an approved Airedale commissioning
company.
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 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.
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.
2005 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
CUSTOMER SERVICES For further assistance, please e-mail: [email protected] or telephone:
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 [e-mail]
Customer Services
Training Enquiries + 44 (0) 113 239 1000 [email protected]
For information, visit us at our Web Site: www.airedale.com

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Contents
GENERAL STATEMENT 4
WARRANTY 5
GENERAL DESCRIPTION 6
Unit Identification 6
Standard Features 6
Optional Extras – Energy Saving 8
Optional Extras – General 8
INSTALLATION DATA 9
Dimensions 9
Point Loadings, Weights & Centre of Gravity (C of G) 9
Unit lifting 12
Anti Vibration Mounting 13
Positioning 14
Water System 15
Standard Recommended Installation 15
Water System 17
Glycol Data 18
Electrical Data 18
Interconnecting Wiring 19
CONTROLS 23
Control Scheme Features 23
Operation 24
Setting up 25
Viewing Unit Operating Status 26
Alarms 27
COMMISSIONING DATA 28
General Data 28
Mechanical Data 28
Waterside Pressure Drops 29
Pump Packages 32
Operational Sequence 34
COMMISSIONING PROCEDURE 35
Pre Commissioning Checklist 35
Commissioning Checklist 37
MAINTENANCE 38
General Maintenance 38
Compressor Maintenance 39
Shut Down Periods 39
PARTS IDENTIFICATION 40

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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.
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.
CAUTION
6 A full hazard data sheet in accordance with COSHH regulations is available should
this be required.

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Warranty
To be read in conjunction with Airedale International Air Conditioning Ltd standard
Conditions of Sale and any related quotation.
GENERAL
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty
for a period of 12 months from the date of commissioning or 18 months from the date of
despatch, which ever is the sooner. Commissioning must be carried out by Airedale or an
approved Airedale company.
1 In the period between delivery and commissioning the equipment:
is properly protected & serviced
water flow safety devices are in place and fully operational
WARRANTY IS ONLY
VALID IN THE EVENT
THAT:
2 The equipment is serviced & maintained by Airedale or an approved Airedale
company in accordance with the Installation & Maintenance manual provided, during
the Warranty Period.
In the event of a problem being reported, Airedale will cover the full cost of rectification
(excluding costs for any specialist access or lifting equipment) if warranty is valid under
these conditions.
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.
•The on site contractor or service company place an official order on Airedale for the
replacement part including site labour if required. Airedale will acknowledge this
order with detailed prices for components, travel and labour rates.
•Should warranty be accepted, following inspection of the faulty component, a credit
note will be issued against the invoice raised in line with the acknowledgement.
•Should warranty be refused the invoice raised against the acknowledgement
becomes payable on normal terms.
PROCEDURE
•Airedale reserves the right to carry out site warranty labour work using their own
direct labour or by sub contracting to an approved company of their choice.
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.
EXCLUSIONS
•Unnecessary delays incurred in return of defective component.
Dead on arrival or manufacturing defects are the responsibility of Airedale and should be
reported immediately.
GENERAL
In the event of a warranty failure, dead on arrival or manufacturing defect, the Airedale
Service department should be contacted and on receipt of an order, an Airedale engineer
(or representative) will be directed to site as soon as possible.
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
ULTIMA COMPACT FREE-COOLING CHILLER
UCFC Ultima Compact FreeCool
75 - 450 Model Size (Expressed as Nominal Cooling in kW)
D- Double Circuit - Standard Chiller
DQ- Double Circuit - Quiet Chiller
DSQ- Double Circuit - Super Quiet Chiller
2 - 16 Number of Fans
/1 or /2 Single or Double Row of Fans
Example UCFC75DQ-2/1
UNIT IDENTIFICATION
INTRODUCTION The Airedale range of Ultima Compact FreeCool air cooled liquid chillers covers the
cooling capacity range 75kW to 450kW in 45 model sizes incorporating Standard D, Quiet
DQ and Super Quiet DSQ variations.
Attention has been placed on maximising the unit’s cooling and energy performance
while keeping the sound, vibration levels and footprint to an absolute minimum.
Refer to the Technical Manual for further details.
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
CE DIRECTIVE
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
The Standard Ultima Compact FreeCool chiller comes complete with:
•Microprocessor Control
•Condenser Coil & integral Free-cooling Coil Assembly
•Plate Evaporator
•Evaporator Pad Heater
•Multiple Scroll Compressors
•Dual Independent Refrigeration Circuits
•Intelligent Head Pressure Control
•Compressor Enclosures
•Electronic Expansion Valve (EEV)
•3 way modulating valve to control free-cooling operation
•Butterfly shut off valve for Free-cooling coil isolation to allow for maintenance
•Water Flow Switch & Water Filter
•Pressure Relief Valve
•Sickle Bladed fans with Long Bellmouth 900 rpm
•Condenser Fan Discharge Plenum
•Connections for External Trace Heating (240V/500W available)
Standard Chiller
- D
•A set of 4 collared eye bolts to BS4278

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General Description
STANDARD FEATURES
With all the features of the Standard range, the Quiet and Super Quiet chillers are
available with additional features:
Quiet Chiller - DQ •Fan speed reduced to 750 rpm
•Fan speed reduced to 570 rpm
•Acoustically lined compressor compartment
Super Quiet Chiller -
DSQ
•Enhanced Refrigeration Condenser Coils
Each refrigeration circuit is supplied with the following:
•Full operating charge of R407C
•Electronic Expansion Valve (EEV)
•Liquid line ball valve
•Discharge line ball valve
•Large capacity filter drier with replaceable cores
•Liquid line sight glass
•Low pressure switch with manual reset via microprocessor controller
•High pressure switch with manual reset
•Suction and liquid pressure transducers
•Pressure relief valve with integral rupture disc and indicator gauge, complying with
Pressure Regulations
•Valves for refrigeration head pressure control
Refrigeration
•Compressor minimum differential pressure protection
Each water glycol circuit is supplied with the following:
•Water Flow switch
•3 way modulating valve to control free-cooling operation
•Strategically placed automatic air vents
•Strategically placed drain valves
•Butterfly shut off valve for Free-cooling coil isolation to allow for maintenance
•Pressure transducers across evaporator to monitor water pressure drop
Water / Glycol
•Inlet water filter 20 mesh
As standard, the microprocessor controller can provide 2, 4 or 6 stages of
capacity control, dependent upon model type.
Optionally, the controller is designed to provide capabilities for;
•Building Management Systems
•Networking
•Sequencing (Master/Slave and Run/Standby)
to meet all your system requirements, please confirm at time of order.
Controls
Unit initial set up details can be found in the Controls section.
Dedicated weatherproof electrical power and controls panels are situated at the end of
the unit and contain:
•Emergency Stop fitted to controls compartment door
•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
Electrical
•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.
Mains supply is 3 phase and a neutral is not required. Refer to Interconnecting Wiring.

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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
•Anti Vibration Mounts
Loose Item
•Condenser Fan Discharge Air Plenum Extension
Instructions supplied with
item
Factory Fitted •Epoxy Coated Condenser Coils
•Coil Guards
•Sequence Control
CAUTION It is only possible to set up sequencing following completion of
interconnecting communication wiring. Airedale Service can
arrange Sequence setup on request.
•BMS Interface Card
•Dual Pressure Relief Valve
•Leak Detection Kit
•Electronic Soft Start
•Power Factor Correction
•Differential Pressure Switch
•Remote Setpoint Adjust
•Flushing Bypass Kit (Incl. Shut off & Water Regulating Valve)
•Integral Pump Packages
•Mini Pressurisation Package
•Alternative Refrigerant (Outside EU)
•Commissioning
OPTIONAL UNIT COVER
•Chillerguard® Maintenance
For details and a competitive quotation,
contact Airedale Service.

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Installation Data
DIMENSIONS SINGLE ROW FANS - /1
UCFC75 - UCFC150
A
2000
1300
50 50
E
2
3
BD C
1250 2525
4
25
300
1 7
500
5
6
500
425225
20
6
Model D ABCDE
UCFC75D-2/1 mm 2775 390 1900 (1) 485
UCFC100D-2/1 mm 2775 390 1900 (1) 485
UCFC125D-3/1 mm 3625 390 1825 1135 275
UCFC150D-3/1 mm 3625 390 1825 1135 275
Model DQ ABCDE
UCFC75DQ-2/1 mm 2775 390 1900 (1) 485
UCFC100DQ-3/1 mm 3625 390 1825 1135 275
UCFC125DQ-3/1 mm 3625 390 1825 1135 275
UCFC150DQ-4/1 mm 4475 390 1900 1900 285
Model DSQ ABCDE
UCFC75DSQ-2/1 mm 2775 390 1900 (1) 485
UCFC100DSQ-3/1 mm 3625 390 1825 1135 275
UCFC125DSQ-4/1 mm 4475 390 1900 1900 285
UCFC150DSQ-4/1 mm 4475 390 1900 1900 285
POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)
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)
UCFC75D-2/1 kg 365 365 (1) (1) 295 295 1320 640 265
UCFC100D-2/1 kg 380 380 (1) (1) 305 305 1370 640 265
UCFC125D-3/1 kg 405 385 255 245 240 240 1770 640 1450
UCFC150D-3/1 kg 410 410 255 255 250 250 1830 640 1435
Model DQ P1 P2 P3 P4 P5 P6
Operating
Weight
C of G1
(mm)
C of G2
(mm)
UCFC75DQ-2/1 kg 365 365 (1) (1) 295 295 1320 640 265
UCFC100DQ-3/1 kg 385 385 240 240 230 230 1710 640 1440
UCFC125DQ-3/1 kg 410 390 255 245 235 235 1770 640 1450
UCFC150DQ-4/1 kg 415 415 360 360 340 340 2230 640 1670
Model DSQ P1 P2 P3 P4 P5 P6
Operating
Weight
C of G1
(mm)
C of G2
(mm)
UCFC75DSQ-2/1 kg 375 375 (1) (1) 295 295 1340 640 265
UCFC100DSQ-3/1 kg 390 390 240 240 235 235 1730 640 1440
UCFC125DSQ-4/1 kg 430 410 350 340 335 335 2200 640 1690
UCFC150DSQ-4/1 kg 430 430 355 355 340 340 2250 640 1670
(1) Have only 4 fixing and 4 point loadings.
(2) Based on standard unit, for units fitted with pump options, please contact Airedale.
1 Electric Control Panels
2 Mains Electric Isolators
3 Mains Cable Entry
4 20mm Ø Mounting Holes
5 Optional Plenum Extension
6 Water Flange Connections:
DN65 PN16
7 Emergency Stop

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Installation Data
DIMENSIONS DOUBLE ROW FANS - /2
UCFC160 - UCFC450
A
2200
50 50
D
2
3
1
350 CB
2150 2525
4
25 25
7
500
5
E
6
1100
20
2180
975 630
Model D A B C D E
UCFC160D - UCFC225D mm 3800 1750 1925 (1) 625
UCFC250D - UCFC300D mm 4650 1750 1925 (1) 625
UCFC330D - UCFC360D mm 5500 1350 1350 1925 525
UCFC400D - UCFC450D mm 6350 1700 1925 1925 450
Model DQ A B C D E
UCFC160DQ - UCFC200DQ mm 3800 1750 1925 (1) 625
UCFC225DQ - UCFC250DQ mm 4650 1750 1925 (1) 625
UCFC275DQ - UCFC300DQ mm 5500 1350 1350 1925 525
UCFC330DQ - UCFC360DQ mm 6350 1700 1925 1925 450
UCFC400DQ - UCFC450DQ mm 7200 1700 2700 2000 450
Model DSQ A B C D E
UCFC160DSQ - UCFC200DSQ mm 4650 1750 1925 (1) 625
UCFC225DSQ - UCFC250DSQ mm 5500 1350 1350 1925 525
UCFC275DSQ - UCFC300DSQ mm 6350 1700 1925 1925 450
UCFC330DSQ - UCFC450DSQ mm 8050 1700 2800 2725 525
(1) 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 Water Flange Connections:
UCFC160-250 DN80 PN16
UCFC275-450 DN100
PN16
7 Emergency Stop

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Installation Data
POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)
UCCU160 - 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)
UCFC160D-6/2 kg 590 590 340 340 (1) (1) 235 235 2330 1100 1460
UCFC180D-6/2 kg 630 630 350 350 (1) (1) 240 240 2440 1100 1450
UCFC200D-6/2 kg 630 630 350 350 (1) (1) 245 245 2450 1100 1460
UCFC225D-6/2 kg 680 680 360 360 (1) (1) 250 250 2580 1100 1440
UCFC250D-8/2 kg 700 700 440 440 (1) (1) 360 360 3000 1100 1900
UCFC275D-8/2 kg 715 715 455 455 (1) (1) 370 370 3080 1100 1900
UCFC300D-8/2 kg 730 730 460 460 (1) (1) 375 375 3130 1100 1900
UCFC330D-10/2 kg 680 680 450 450 420 420 350 350 3800 1100 2200
UCFC360D-10/2 kg 680 680 450 450 420 420 350 350 3800 1100 2200
UCFC400D-12/2 kg 700 700 520 520 490 490 425 425 4270 1100 2770
UCFC450D-12/2 kg 720 720 530 530 500 500 430 430 4360 1100 2760
Model DQ P1 P2 P3 P4 P5 P6 P7 P8
Operating
Weight
C of G1
(mm)
C of G2
(mm)
UCFC160DQ-6/2 kg 650 650 370 370 (1) (1) 245 245 2530 1100 1440
UCFC180DQ-6/2 kg 685 685 390 390 (1) (1) 250 250 2650 1100 1430
UCFC200DQ-6/2 kg 685 685 390 390 (1) (1) 250 250 2650 1100 1430
UCFC225DQ-8/2 kg 730 730 500 500 (1) (1) 360 360 3180 1100 1860
UCFC250DQ-8/2 kg 740 740 505 505 (1) (1) 360 360 3210 1100 1850
UCFC275DQ-10/2 kg 655 655 440 440 410 410 340 340 3690 1100 2200
UCFC300DQ-10/2 kg 675 675 445 445 410 410 340 340 3740 1100 2190
UCFC330DQ-12/2 kg 790 790 530 530 465 465 415 415 4400 1100 2670
UCFC360DQ-12/2 kg 790 790 530 530 465 465 415 415 4400 1100 2670
UCFC400DQ-14/2 kg 830 830 585 585 545 545 485 485 4890 1100 3090
UCFC450DQ-14/2 kg 865 865 590 590 545 545 485 485 4970 1100 3060
Model DSQ P1 P2 P3 P4 P5 P6 P7 P8
Operating
Weight
C of G1
(mm)
C of G2
(mm)
UCFC160DSQ-8/2 kg 675 675 415 415 (1) (1) 380 380 2940 1100 1950
UCFC180DSQ-8/2 kg 695 695 435 435 (1) (1) 395 395 3050 1100 1950
UCFC200DSQ-8/2 kg 700 700 440 440 (1) (1) 395 395 3070 1100 1950
UCFC225DSQ-10/2 kg 640 640 420 420 400 400 335 335 3590 1100 2210
UCFC250DSQ-10/2 kg 640 640 420 420 405 405 340 340 3610 1100 2220
UCFC275DSQ-12/2 kg 685 685 485 485 465 465 420 420 4110 1100 2790
UCFC300DSQ-12/2 kg 700 700 490 490 465 465 420 420 4150 1100 2770
UCFC330DSQ-16/2 kg 815 815 640 640 605 605 550 550 5220 1100 3390
UCFC360DSQ-16/2 kg 815 815 640 640 605 605 550 550 5220 1100 3390
UCFC400DSQ-16/2 kg 825 825 650 650 615 615 555 555 5290 1100 3390
UCFC450DSQ-16/2 kg 845 845 660 660 625 625 560 560 5380 1100 3380
(1) Have only 4 fixing and 4 point loadings.
(2) Based on standard unit, for units fitted with pump options, please contact Airedale.

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Installation Data
•Employ lifting specialists.
•Local codes and regulations relating to the lifting of this type of equipment should
be observed.
•Use the lifting eye bolts provided.
•Use the appropriate spreader bars/lifting slings with the holes/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.
•Lift the unit slowly and evenly.
UNIT LIFTING
•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
E
A
B C
D
UCFC75 - UCFC450 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
6 FANS /2 mm 465 2195 1140 2500 2350
8 FANS /2 mm 465 2560 1625 2500 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 2550 5000 2350

Date: 18/10/05
Airedale International Air Conditioning Ltd
Leeds Road, Rawdon, Leeds. LS19 6JY England
Tel: + 44 (0) 113 239 1000 Fax: + 44 (0) 113 250 7219
E-mail: [email protected] Website: www.airedale.com
TECHNICAL UPDATE
MANUAL AFFECTED: TECHNICAL & INSTALLATION
ULTIMA: UCC/UCCU 30-450
UCFC/URAC/UWC75-450
UFC/USC200-750
MANUAL PART NO: 901-108 TM E 02/05/A
CHANGE: ANTI-VIBRATION MOUNT (SPRING TYPE) SPECIFICATION &
INSTALLATION INSTRUCTIONS:
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
34
DIMENSIONS:
A(1) BCDEFØ
UCC30-70
UCC75, 80, 100, 125 & 150
UCCU30-70
UCCU75, 80, 100, 125 & 150
UCFC75-150
2 SPRING
136 110 180 148 16 11
UCC110, 130, 160-450
UCCU110, 130, 160-450
UCFC160-450
UFC200-750
URAC75-450
USC200-750
UWC75-450
4 SPRING
180 130 225 186 20 16
B
A
C
D E
F
E
(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.

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Installation Data
ANTI VIBRATION MOUNTING - OPTIONAL
Spring Type (CLS)
1 High deflection steel spring
2 Spring pressure plate
3 Height adjusting nut
4 Locking nut
5 Load bearing supports
6 Load bearing top plate
7 High frequency isolation pad
8 10 dia holding down bolt holes
9 High frequency isolation grommets
10 Steel spring location rings
11 Transportation/restraining bolts
12 Machine frame
13 Machine holding M16 stud/nuts
14 ELEVATION
15 BASE PLATE
16 TOP PLATE
Selection:
Model Size A B C D X
75 - 450 mm 100 200 20 14 180 - 210
Installation:
1 Locate and secure mount using bolting down holes
provided in base plate.
2 Ensure mounts are located in line with the
chiller base.
3 Position the machine using the centrally located
stud, which allows the machine to be bolted
down securely.
4 Loosen transit bolts and turn nut 3 clockwise until
top plate 6 lifts clear of support posts. Tighten lock
nut 4 when machine is at desired height and level.
5 Adjust and lock nuts on transit bolts such that a
small (3-5mm) gap is left between washer and
grommet. Refer to diagram.
CAUTION
Mountings must be adjusted in increments of no
more than 1mm in turn. Do not adjust 1 mount
completely at a time as this may overload and
damage springs.
Do not connect any services until all anti vibration
mounts have been fully adjusted.
CC
CC
A
DØ
15
1
6
A
B
14
1
2
3
4
5
6
7
8
9
10
11
12
13
13
5
X
= =
==
3 - 5mm
3 - 5mm
FINALLY, recheck/adjust mounts following unit
connection to services and system is filled.
Pad Type
1 2
3
2
5
4
3
6
7
1 M16 Bolt (Not Supplied)
2 Washer (Not Supplied)
3 Fixing Pad 506-063
4 A V Pad 506-062
5 2 x M16 Nut (Not Supplied)
6 Unit Base
7 Unit Mounting Plinth

ULTIMA COMPACT FREECOOL Chillers
Chillers
14 Installation & Maintenance : 903-132 IM E 06/05/A
Installation Data
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 chiller applications
•Ensure there are no obstructions directly above the fans
POSITIONING
•Allow free space above the fans to prevent air recirculation
CAUTION Ensure the unit is completely level and secured prior to connecting services.
1.0m (2.0)
1.0m (1.8)
1.0m (1.8)
1.0m (2.0)

Chillers ULTIMA COMPACT FREECOOL
Chillers
Installation & Maintenance : 903-132 TM E 06/05/A 15
Installation Data
Chilled water pipework and ancillary components must be installed in accordance with:
•National and Local Water supply company standards
•The manufacturer's instructions are followed when fitting ancillary components
•The system liquid is treated to prevent corrosion and algae forming
•Glycol required as standard, with the correction concentration to suit the lowest
ambient the equipment will experience
WATER SYSTEM
•The schematic is referred to as a guide to ancillary recommendations
CAUTION The unit water connections are NOT designed to support external pipework,
pipework should be supported during installation.
STANDARD RECOMMENDED INSTALLATION
CAUTION The following installation recommendations should be adhered to. Failure to do
this will invalidate the chiller warranty.
TT
M
F
P
FP
(1)
(2) (3) (4)
(4)
(1) Flushing By Pass Leg (Optional Extra)
(2) Pump (Optional Extra)
(3) Filter 1/16”(Supplied by Others)
(4) Pressure Sensor (Optional Extra)
Following components are fitted within the chiller unit as standard:
•Temperature Sensors
•Drain Point
•Auto Air Vent
•Flow Switch
CAUTION
•20 Mesh Inlet Filter
The recommended requirements to allow commissioning to be carried out correctly are:
•The inclusion of Binder Points adjacent to the flow and return connections, to allow
temperature and pressure readings.
Component
Recommended
Requirements
•A flow switch or equivalent, fitted adjacent to the water outlet side of the Chiller.
CAUTION Constant water flow MUST be maintained. Variable water volume is NOT
recommended and may invalidate warranty.
CAUTION The correct operation of the flow switch is critical if the chiller warranty is to
be valid.
•A water-flow commissioning valve set fitted to the system.
•In multiple chiller installations, 1 commissioning valve set is required per chiller.
•Air vents are to be installed at all high points and where air is likely to be trapped at
intermediate points.
•Drain points are to be installed at all low points in the system and in particular
adjacent to the unit for maintenance to be carried out.
•Isolating valves should be installed adjacent to all major items of equipment for ease
of maintenance.
•Balancing valves can be installed if required to aid correct system balancing.
•All chilled water pipework must be insulated and vapour sealed to
avoid condensation.
•If several units are installed in parallel adjacent to each other, reverse return should
be applied to avoid unnecessary balancing valves.

ULTIMA COMPACT FREECOOL Chillers
Chillers
16 Installation & Maintenance : 903-132 IM E 06/05/A
Installation Data
WATER SYSTEM
When installing circulating water pumps or equipment containing them, the following rules
should be applied:
•Ensure the system is filled with liquid then vented and the pump primed with water
before running the pump. This is required because the pumped liquid cools the pump
bearings and mechanical seal faces.
Pump Statement
•To avoid cavitation the NPSH (Net Positive Suction Head) incorporating a safety
margin of 0.5m head must be available at the pump inlet during operation.
When all the pipework has been connected in the system, proceed as follows:
•Ensure all shut off and control valves are fully open.
•Pressurise system to the operating pressure, hold for 1 hour (a gradual fall in
pressure shown on the gauge indicates a leak).
•Leaks should be found and repaired and the unit pressure tested for a further hour.
Pressure Testing
When the pressure remains at the operating pressure for 1 hour, the system can be
considered leak free.
CAUTION Although a pressure of 1.5 x working pressure is adequate for testing purposes,
most local water authorities require 2 x working pressure.
Filling
The whole system MUST be flushed prior to filling to remove debris left in the water
pipework by using a flushing bypass as shown to avoid serious damage to the
plate evaporator.
During filling the system should be vented at all high points.
Once the system has been completely vented all vents should be closed.
To prevent air locking in the system it is advisable to fill the systems from the lowest
point, ie drain point on pipework.
CAUTION
If auto air vents are used then we strongly recommend an auto pressurisation unit be
fitted to the system.

Chillers ULTIMA COMPACT FREECOOL
Chillers
Installation & Maintenance : 903-132 TM E 06/05/A 17
Installation Data
WATER SYSTEM
UCFC75D-2/1 UCFC100D-2/1 UCFC125D-3/1 UCFC150D-3/1 UCFC160D-6/2
Connections
Water Inlet / Outlet (1) DN65 DN65 DN65 DN65 DN80
Water Drain/Bleed in 1/2 1/2 1/2 1/2 1/2
Water System
Min. System Water Volume (2) l 377 469 419 727 717
Max. System Press Bar 10 10 10 10 10
OPTIONAL EXTRAS
Water Pump (3) (4) In Line Pump
Nom External Head Std Single /
R&S
kPa 143 109 145 122 187
Nom External Head Larger
Single/R&S
kPa 184 150 190 185 254
Nom External Head Standard
Twin
kPa 100 82 88 89 184
Nom External Head Larger Twin kPa 146 125 133 152 254
Pressurisation Unit
Water Inlet Connection in 1/2 1/2 1/2 1/2 1/2
UCFC180D-6/2 UCFC200D-6/2 UCFC225D-6/2 UCFC250D-8/2 UCFC275D-8/2
Connections
Water Inlet / Outlet (1) DN80 DN80 DN80 DN80 DN100
Water Drain/Bleed in 1/2 1/2 1/2 1/2 1/2
Water System
Min. System Water Volume (2) l 645 715 811 1156 1004
Max. System Press Bar 10 10 10 10 10
OPTIONAL EXTRAS
Water Pump (3) (4) In Line Pump
Nom External Head Std Single /
R&S
kPa 169 160 151 136 163
Nom External Head Larger
Single/R&S
kPa 236 226 217 201 228
Nom External Head Standard
Twin
kPa 166 156 147 130 157
Nom External Head Larger Twin kPa 235 225 215 199 225
Pressurisation Unit
Water Inlet Connection in 1/2 1/2 1/2 1/2 1/2
UCFC300D-8/2 UCFC330D-10/2 UCFC360D-10/2 UCFC400D-12/2 UCFC450D-12/2
Connections
Water Inlet / Outlet (1) DN100 DN100 DN100 DN100 DN100
Water Drain/Bleed in 1/2 1/2 1/2 1/2 1/2
Water System
Min. System Water Volume (2) l 1374 1168 1122 1337 1395
Max. System Press Bar 10 10 10 10 10
OPTIONAL EXTRAS
Water Pump (3) (4) In Line Pump
Nom External Head Std Single /
R&S
kPa 151 138 121 125 108
Nom External Head Larger
Single/R&S
kPa 218 206 190 196 182
Nom External Head Standard
Twin
kPa 144 129 110 109 87
Nom External Head Larger Twin kPa 213 198 180 181 161
Pressurisation Unit
Water Inlet Connection in 1/2 1/2 1/2 1/2 1/2
(1) Flanged to PN16.
(2) For minimum system volume refer to the Technical Manual.
(3) Based on 12/7°C water temperature and 30°C ambient with a 20% Ethylene Glycol Water Concentration.
(4) Figures based on D Model, for DQ & DSQ details, please contact Airedale.

ULTIMA COMPACT FREECOOL Chillers
Chillers
18 Installation & Maintenance : 903-132 IM E 06/05/A
Installation Data
GLYCOL DATA
CAUTION All free-cooling units should use minimum 20% glycol concentration.
Ethylene Glycol Nominal Correction Factors
Glycol in System /
Freezing Point ºC 20% / -9°C 30% / -15°C 40% / -23°C
Cooling Duty 1.00 0.98 0.96
Input Power 1.00 0.98 0.97
Water Flow 1.00 1.09 1.12
Pressure Drop
Catalogue Data x by:
1.00 1.29 1.48
Propylene Glycol Nominal Correction Factors
Glycol in System /
Freezing Point ºC 20% / -6°C 30% / -12°C 40% / -20°C
Cooling Duty 0.98 0.94 0.91
Input Power 1.00 0.98 0.97
Water Flow 1.00 0.99 0.99
Pressure Drop
Catalogue Data x by:
1.08 1.22 1.35
Example UCFC150DQ-4/1 operating at 7/12, 30°C Ambient, 30% Ethylene Glycol
Catalogue
Figure Multiplier
Corrected
Figure
Cooling kW (refer to the Technical Manual) 146.1 x 0.98 143.2 kW
Input kW (refer to the Technical Manual) 54.1 x 0.98 53.0 kW
(DX (Mechanical Cooling kW)
Flow l/s calculated ∆T x 3.9 7.49 x 1.09 8.16 l/s
Pressure Drop kPa (refer to Waterside Pressure Drops) 146 x 1.29
30%
Ethylene
Glycol =
188 kPa
ELECTRICAL DATA
•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.
General
•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.
CAUTION A separately fused, locally isolated, permanent single phase and neutral supply
must be fitted for the compressor sump heater, evaporator trace heating and
control circuits, failure to do so could invalidate warranty.
Always electrically interlock the operation of the chiller with the pump controls.
Interlocks & Protection
This safety device prevents the chiller operating with low water flow which can cause
serious damage.
CAUTION Failure to install this safety device will invalidate the chiller warranty.
Do not rely solely on the BMS to protect the chiller against low flow conditions.
CAUTION
An evaporator pump interlock MUST be directly wired to the chiller, refer to
Interconnecting Wiring diagram.

Chillers ULTIMA COMPACT FREECOOL
Chillers
Installation & Maintenance : 903-132 TM E 06/05/A 19
Installation Data
INTERCONNECTING WIRING
L1 ! "
L2 ! "
L3 ! "
E ! "
Mains incoming supply 400V/3PH/50Hz
L4 ! "
N1 ! "
E ! "
Separate Permanent Supply 230V/1PH/50Hz
2 ! # External Trace Heater Connections
N ! " 240V/500W max.
502 ! #
522 ! " (1) Evaporator Remote Pump Interlock 24VAC
502 ! #
505 ! " Unit Remote On/Off 24VAC
502 ! #
507 ! " Setback Setpoint Temperature switch
573 ! " Volt Free Common Alarm
574 ! # Volt Free Alarm N/O
575 ! #
Circuit 1
Volt Free Alarm N/C
576 ! " Volt Free Common Alarm
577 ! # Volt Free Alarm N/O
578 ! #
Circuit 2
Volt Free Alarm N/C
RX-/TX- !"#
RX+/TX+ !"#
No Pumps
UCFC75 - 450
GND !"#
Network Connections
CAUTION (1) Must be directly wired to the chiller to validate warranty.
L1 ! "
L2 ! "
L3 ! "
E ! "
Mains incoming supply 400V/3PH/50Hz
L4 ! "
N1 ! "
E ! "
Separate Permanent Supply 230V/1PH/50Hz
2 ! # External Trace Heating Connections
N ! " 240V/500W max
502 ! #
526 ! " Pump/s Remote On/Off 24VAC
502 ! #
505 ! " Unit Remote On/Off 24VAC
502 ! #
507 ! " Setback Setpoint Temperature switch
573 ! " Volt Free Common Alarm
574 ! # Volt Free Alarm N/O
575 ! #
Circuit 1
Volt Free Alarm N/C
576 ! " Volt Free Common Alarm
577 ! # Volt Free Alarm N/O
578 ! #
Circuit 2
Volt Free Alarm N/C
RX-/TX- !"#
RX+/TX+ !"#
With Pumps
UCFC75 - 450
GND !"#
Network Connections