AIREDALE TurboChill TCC11R04G-01 User manual

Technical Manual
TurboChill™
200kW to 1360kW
Air Cooled (TCC) and FreeCool (TCF) Chiller
R1234ze(E)

Introduction
Chillers
TurboChill™ R1234ze Air Cooled and FreeCool
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Chiller Technical Manual 7752785 V1.12.0_10_2018
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, Airedale can provide full commissioning services,
comprehensive maintenance packages and service cover 24 hours a day, 365 days a year (UK mainland).
For a free quotation contact Airedale or your local Sales Engineer.
All Airedale products are designed in accordance with EU Directives regarding prevention of build up of water,
associated with the risk of contaminants such as Legionella.
For effective prevention of such risk it is necessary that the equipment is maintained in accordance with Airedale
recommendations.
ChillerGuard™
In addition to commissioning, a 24 hour, 7 days a week on-call service is available throughout the year to UK mainland
sites. This service will enable customers to contact a duty engineer outside normal working hours and receive
assistance over the telephone. The duty engineer can, if necessary, attend site, usually within 24 hours or less.
Full details will be forwarded on acceptance of the maintenance agreement.
Airedale Ltd endeavours to ensure that the information in this document is correct and fairly stated, but none of the
statements are to be relied upon as a statement or representation of fact. Airedale Ltd does not accept liability for any
error or omission, or for any reliance placed on the information contained in this document. The development of Airedale
products and services is continuous and the information in this document may not be up to date. It is important to check
the current position with Airedale Ltd at the address stated. This document is not part of a contract or licence unless
expressly agreed. No part of this document may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying, recording, or information storage and retrieval systems, for any purpose other
than the purchaser’s personal use, without the express written permission of Airedale Ltd.
© 2018 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
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:
UK Sales Enquiries + 44 (0) 113 239 1000 [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
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.
CAUTION

Introduction
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TurboChill™ R1234ze Air Cooled and FreeCool
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Warranty
All Airedale products or parts (non consumable) supplied for installation within the UK mainland and commissioned by
an Airedale engineer, carry a full Parts & Labour warranty for a period of 12 months from the date of commissioning or
18 months from the date of despatch, whichever is the sooner.
Parts or Equipment supplied by Airedale for installation within the UK or for Export that are properly commissioned in
accordance with Airedale standards and specication, not commissioned by an Airedale engineer; carry a 12 month
warranty on non consumable Parts only from the date of commissioning or 18 months from the date of despatch,
whichever is the sooner.
Parts or equipment installed or commissioned not to acceptable Airedale standards or specication invalidate all
warranty.
Warranty is only valid in the event that
In the period between delivery and commissioning the equipment,
●is properly protected & serviced as per the Airedale installation & maintenance manual provided
●where applicable the glycol content is maintained to the correct level.
In the event of a problem being reported and once warranty is conrmed* as valid under the given installation and
operating conditions, the Company will provide the appropriate warranty coverage (as detailed above) attributable to the
rectication of any affected Airedale equipment supplied (excluding costs for any specialist access or lifting equipment
that must be ordered by the customer).
*Once warranty is conrmed, maintenance must be continued to validate the warranty period.
Any spare part supplied by Airedale under warranty shall be warranted for the unexpired period of the warranty or 3
months from delivery, whichever period is the longer.
To be read in conjunction with the Airedale Conditions of Sale - Warranty and Warranty Procedure, available upon
request.
Procedure
When a component part fails, a replacement part should be obtained through our Spares department. If the part is
considered to be under warranty, the following details are required to process this requirement. Full description of part
required, including Airedale’s part number, if known. The original equipment serial number. An appropriate purchase
order number.
A spares order will be raised under our warranty system and the replacement part will be despatched, usually within 24
hours should they be in stock. When replaced, the faulty part must be returned to Airedale with a suitably completed and
securely attached “Faulty Component Return” (FCR) tag. FCR tags are available from Airedale and supplied with each
Warranty order.
On receipt of the faulty part, suitably tagged, Airedale will pass to its Warranty department, where it will be fully
inspected and tested in order to identify the reason for failure, identifying at the same time whether warranty is justied
or not.
On completion of the investigation of the returned part, a full “Report on Goods Returned” will be issued. On occasion
the release of this complete report may be delayed as component manufacturers become involved in the investigation.
When warranty is allowed, a credit against the Warranty invoice will be raised. Should warranty be refused the Warranty
invoice becomes payable on normal terms.
Exclusions
Warranty may be refused for the following reasons:
●Misapplication of product or component
●Incorrect site installation
●Incomplete commissioning documentation
●Inadequate site installation
●Inadequate site maintenance
●Damage caused by mishandling
●Replaced part being returned damaged without explanation
●Unnecessary delays incurred in return of defective component
Returns Analysis
All faulty components returned under warranty are analysed on a monthly basis as a means of verifying component and
product reliability as well as supplier performance. It is important that all component failures are reported correctly.

Introduction
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Health and Safety
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.
Personal Refrigerant Leak Detector
Personal refrigerant leak detectors must be worn when servicing this machine.
Service Equipment
Use only manifold gauge sets designed for use with hydrocarbon refrigerants. Use only refrigerant recovery units and
cylinders designed for the pressure category of the refrigerants. Hydrocarbon refrigerant recovery machines must be used.
The refrigerant used in this range of products is classied under the COSHH regulations as an irritant, with set Workplace
Exposure Levels (WEL) for consideration if this plant is installed in conned or poorly ventilated areas.
The refrigerant must be stored in a clean, dry area away from sunlight. The refrigerant must never be stored above 50°C.
A full hazard data sheet in accordance with COSHH regulations is available should this be required.
Refrigerants must only be charged in the liquid state.
Protective Personal Equipment
Airedale recommends that personal protective equipment is used whilst installing, maintaining and commissioning
equipment.
Care must be taken when working around the discharge pipe work of the unit. High surface temperatures may exist during
unit operation.
The refrigerant has a boiling point of -19°C.
Manual Handling
Some operations when servicing or maintaining the unit may require additional assistance with regard to manual handling.
This requirement is down to the discretion of the engineer.
Remember do not perform a lift that exceeds your ability.
Pressure Equipment Directive
Minimum and Maximum Operation Temperature (TS) and Pressure (PS)
Refrigeration
AllowableTemperature Range (TS), Min -20°C* to Max 120°C**
Maximum Allowable Pressure (PS) High Side 13.0 Barg Low side 10.3 Barg
*Based on the refrigerant temperature in the unit off state in the lowest permitted ambient temperature.
**Based on the maximum allowable super heated refrigerant temperature.
Waterside
AllowableTemperature Range (TS, Min -20°C* to Max 40°C*
Maximum Allowable Pressure (PS) 10.0 Barg
*Based on the water temperature in the unit off state in the lowest permitted ambient temperature.
*Based on the waterside temperature in the unit off state in the highest permitted ambient temperature.
Ecodesign Directive 2009/125/EC
The product range within this document is designed in accordance to the European Ecodesign Directive 2009/125/EC.
The appendix at the rear section of the manual gives the product compliancy metrics. Products sold outside of the EU
are exempt from this directive.
When working with any air conditioning units, ensure that the electrical isolator is switched off
prior to servicing or repair work and that there is no power to any part of the equipment.
Also ensure that there are no other power feeds to the unit such as re alarm circuits, BMS
circuits, crankcase heater permanent supplies etc.
Electrical installation commissioning and maintenance work on this equipment should be
undertaken by competent and trained personnel in accordance with local relevant standards and
codes of practice.
These Airedale chillers use R1234ze(E) refrigerant which requires careful attention to proper
storage and handling procedures in accordance with EN 378. Maximum water temperature
owing through the chiller should be 40°C.
All service personnel must have hydrocarbon refrigerant handling training.
CAUTION

Introduction
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Global Warming Potential
R1234ze(E) = 7 EN378-1 :2016 (100 year life)
Safe Operating Limits
The TurboChill R1234ze(E) chiller has operating limits set to ensure that the refrigerant does not become unstable.
Certain aspects of the installation and design must be considered.
The installation of the unit is subject to various design aspects, see below.
Flammability
In the event of a leak the combination of the following 3 operating conditions detailed in the re triangle MUST be
avoided at all times. Failure to do this could cause a re.
O
X
Y
GEN
H
E
A
T
FUEL
A CONCENTRATION OF THE REFRIGERANT IN AIR
>LFL (LOWER FLAMMABILITY LEVEL) AND
< UFL (UPPER FLAMMABILITY LEVEL)
5.8 Vol.% TO 11.3Vol.% @ 60°C
EXISTANCE OF AN IGNITION
SOURCE WITH AN IGNITION ENERGY
>MINIMUM IGNITION ENERGY
(61,000mJ AT 54°C)
AMBIENT AIR TEMPERATURE
>+30°C AND A WIND SPEED
< BURNING VELOCITY
No smoking or NAKED FLAME.
CAUTION PACEMAKER WEARERS
To avoid any risk of injury, any work to be carried out on or around the
compressor and magnetic check valve should be completed by personnel that do
not have pacemakers tted.
This refrigerant is not ammable as per the Material Safety Data Sheet (MSDS) “Hazards
Identication” supplied by the refrigerant manufacturer.
CAUTION

Introduction
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TurboChill™ R1234ze Air Cooled and FreeCool
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Environmental Considerations
Freeze Protection
Airedale recommends the following actions to help protect the unit during low temperature operation. This also includes
the units subject to low ambient temperatures.
Units with supply water temperatures below +5°C
Glycol is recommended when a supply water temperature of +5°C or below is required or when static water can be
exposed to freezing temperatures.
Units subject to ambient temperatures lower than 0°C, a minimum of 1 of the following is required:
1. Glycol of an appropriate concentration (1) is used within the system to ensure adequate protection.
Please ensure that the concentration is capable of protection at least 3K lower than the minimum operating
ambient.
2. Ensure water/glycol solution is constantly circulated through all waterside pipework and coils to prevent static
water from freezing.
3. Ensure that pumps are started and running even during shut down periods, when the ambient is within 3K of
the solution freeze point (1) (i.e. if the solution freezes at 0°C, the pump must be operating at 3°C ambient).(2)
4. Additional trace heating is provided for interconnecting pipework.
(1) Refer to your glycol supplier for details.
(2) An actuated suction ball valve shall be tted to protect the compressor from liquid migration.
Free Cooling Chillers
A minimum of 20% glycol concentration must be applied to all free cooling chillers. Concentration should be increased
so that its capable of protection at least 3K lower than the minimum operating ambient.
Environmental Policy
It is our policy to:
●Take a proactive approach to resolve environmental issues and ensure compliance with regulatory requirements.
●Train personnel in sound environmental practices.
●Pursue opportunities to conserve resources, prevent pollution and eliminate waste.
●Manufacture products in a responsible manner with minimum impact on the environment.
●Reduce our use of chemicals and minimise their release to the environment.
●Measure, control and verify environmental performance through internal and external audits.
●Continually improve our environmental performance.
CE Directive
Airedale certify that the equipment detailed in this manual conforms with the following EC Directives:
Electromagnetic Compatibility Directive (EMC) 2014/30/EU
Machinery Directive (MD) 89/392/EEC version 2006/42/EC
Pressure Equipment Directive (PED) 2014/68/EU
Ecodesign 2009/125/EC
To comply with these directives appropriate national & harmonised standards have been applied. These are listed on the
Declaration of Conformity, supplied with each product.
Occupancy Note
When placing a Chiller the access category for the surrounding area needs to be classied in accordance with EN 378-
1:2016 section 5.1.1. In most cases the access would be ‘Authorized Access’ as described in EN378-1:2016 Table 4.
This access level needs to be conrmed by the end user. As well as the above the location within which the product is
to be installed also needs to be dened so that the correct charge limitations can be calculated. EN 378-1:2016 section
5.3 describes the four main types of location and the hazards associated with each. Given that an air cooled Chiller is
typically an ‘Authorized Access’ installation and is most often installed in open air, ‘Class III’ location, EN378-1:2016
Table C.2 states that there is ‘No charge restriction’ for these systems using R1234ze (A2L) refrigerant.

Introduction
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TurboChill™ R1234ze Air Cooled and FreeCool
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Contents
Warranty, Commissioning & Maintenance 2
ChillerGuard™ 2
Customer Services 2
Warranty 3
Health and Safety 4
Personal Refrigerant Leak Detector 4
Manual Handling 4
Pressure Equipment Directive 4
Safe Operating Limits 5
Environmental Considerations 6
Nomenclature 12
Range Layout 14
Unit Overview 16
Unit Components 18
Refrigeration 18
Turbocor Compressor 19
Condenser 20
Electrical 21
Condenser Fans 23
Waterside 24
Controls 30
Mechanical 34
Design Features & Information 36
Pipework Design 36
Refrigeration Schematic Single Circuit 36
Specic Heat Capacity (SHC) 37
Minimum System Water Volume Calculations 37
Typical Part Load Efciencies 39
Water System 42
Grooved & Clamped Type Connection 42
Standard Recommended Installation 42
Water Systems and Recommended Flow Schemes 43
Flow Schemes 43
Pressure Relief Valve Discharge Piping 44

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Technical Data TCC (R) 48
TCC11R04G-01, TCC11R06G-01, TCC11R08G-01 48
TCC12R08G-04, TCC12R10G-04 50
TCC12R12G-04, TCC12R14G-04 52
TCC22R08G-14, TCC22R10G-14, TCC22R12G-14 54
TCC22R14G-14, TCC23R12G-17, TCC23R14G-17 56
TCC23R16G-17, TCC23R18G-17, TCC24R16G-18 58
TCC24R18G-18, TCC24R20G-18 60
TCC24R22G-18, TCC24R24G-18 62
Technical Data TCC (X) 64
TCC11X04G-01, TCC11X06G-01, TCC11X08G-01 64
TCC12X08G-04, TCC12X10G-04 66
TCC12X12G-04, TCC12X14G-04 68
TCC22X08G-14, TCC22X10G-14, TCC22X12G-14 70
TCC22X14G-14, TCC23X12G-17, TCC23X14G-17 72
TCC23X16G-17, TCC23X18G-17, TCC24X16G-18 74
TCC24X18G-18, TCC24X20G-18 76
TCC24X22G-18, TCC24X24G-18 78
Sound Data - TCC 80
TCC - EC Fans 80
Technical Data - TCF (R) 82
TCF11R06G-07, TCF11R08G-07 82
TCF12R08G-09, TCF12R10G-05 84
TCF12R12G-05, TCF12R14G-05 86
TCF22R10G-22, TCF22R12G-22, TCF22R14G-22 88
TCF23R12G-24, TCF23R14G-24 90
TCF23R16G-25, TCF23R18G-25 92
TCF24R16G-26, TCF24R18G-26, TCF24R20G-26 94
TCF24R22G-27, TCF24R24G-27 96
Technical Data TCF (X) 98
TCF11X06G-07, TCF11X08G-07 98
TCF12X08G-09, TCF12X10G-05 100
TCF12X12G-05, TCF12X14G-05 102
TCF22X10G-22, TCF22X12G-22, TCF22X14G-22 104
TCF23X12G-24, TCF23X14G-24 106
TCF23X16G-25, TCF23X18G-25 108
TCF24X16G-26, TCF24X18G-26, TCF24X20G-26 110
TCF24X22G-27, TCF24X24G-27 112
Sound Data - TCF 114
TCF - EC Fans 114
Hydronic Data 116
TCC Waterside Pressure Drop kPa (100% Water) 116
TCF Waterside Pressure Drop kPa (20% Ethylene Glycol) 117
Evaporator Pressure Drop - 100% Water 119
Evaporator Pressure Drop - 20% Ethylene Glycol 121
Strainer Pressure Drop - 100% Water 123
Strainer Pressure Drop - 20% Ethylene Glycol 123
Contents

Introduction
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Installation Data 124
Air Cooled Masses & Centre of Gravity (C of G) 124
Freecool Masses & Centre of Gravity (C of G) 125
Point Loadings - Air Cooled 126
Unit Lifting 130
General Arrangement Drawings 132
4 Fan single Circuit 132
Positioning 147
Airow & Maintenance Clearances 147
Anti Vibration Mounting (Optional) 148
Interconnecting Wiring 150
Power Quality & Harmonics 152
Liquid Level Sensor 153
Pre Start Checks 154
pCO5+ Built In Display and Keypad 155
Monitoring 155
Unit Operation 156
Restarting the Unit 156
Changing the Setpoint 157
Enabling Pumps 158
Maintenance 159
General Inspections 159
Electrical Inspection 160
Refrigeration 161
Waterside 162
Controls 163
System 164
Troubleshooting 165
Alarms 167
Alarm Menu Display 167
Pump Alarms 174
Contents

Introduction
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Chiller Technical Manual 7752785 V1.12.0_10_2018
Appendix - Ecodesign 175
Technical Data - TCC R 176
TCC11R04G-01, TCC11R06G-01, TCC11R08G-01 176
TCC12R08G-04, TCC12R10G-04 177
TCC12R12G-04, TCC12R14G-04 178
TCC22R08G-14, TCC22R10G-14, TCC22R12G-14 179
TCC22R14G-14, TCC23R12G-17, TCC23R14G-17 180
TCC23R16G-17, TCC23R18G-17, TCC24R16G-18 181
TCC24R18G-18, TCC24R20G-18 182
TCC24R22G-18, TCC24R24G-18 183
Technical Data - TCC X 184
TCC11X04G-01, TCC11X06G-01, TCC11X08G-01 184
TCC12X08G-04, TCC12X10G-4 185
TCC12X12G-04, TCC12X14G-04 186
TCC22X08G-14, TCC22X10G-14, TCC22X12G-14 187
TCC22X14G-14, TCC23X12G-17, TCC23X14G-17 188
TCC23X16G-17, TCC23X18G-17, TCC22X16G-18 189
TCC24X18G-18, TCC24X20G-18 190
TCC24X22G-18, TCC24X24G-18 191
Technical Data - TCF R 192
TCF11R06G-07, TCF11R08G-07 192
TCF12R08G-09, TCF12R10G-05 193
TCF12R12G-05, TCF12R14G-05 194
TCF22R10G-22, TCF22R12G-22, TCF22R14G-22 195
TCF23R12G-24, TCF23R14G-24 196
TCF23R16G-25, TCF23R18G-25 197
TCF24R16G-26, TCF24R18G-26, TCF24R20G-26 198
TCF24R22G-27, TCF24R24G-27 199
Technical Data - TCF X 200
TCF11X06G-07, TCF11X08G-07 200
TCF12X08G-09, TCF12X10G-05 201
TCF12X12G-05, TCF12X14G-05 202
TCF22X10G-22, TCF22X12G-22, TCF22X14G-22 203
TCF23X12G-24, TCF23R14G-24 204
TCF23X16G-25, TCF23X18G-25 205
TCF24X16G-26, TCF24X18G-26, TCF24X20G-26 206
TCF24X22G-27, TCF24X24G-27 207