AIREDALE ULTIMA 2000 User manual

AIACE
INSTALLATION, OPERATING
& MAINTENANCE MANUAL
Ultima 2000
Air Cooled Screw Liquid Chiller
250 - 650 kW

Chillers
ULTIMA 2000
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2Installation & Maintenance Manual : 903-099 IM E 05/00
About Airedale Products & Customer Services asTM
Airedale participates in Eurovent Certification as a founder member. The Eurovent
Certification programme verifies product performance by managing random independent
testing of certified products.
STD
We participate in certification programmes for Air Conditioners, Chillers and Fan Coil
units, which enable consultants, specifiers and End Users to compare and select
products with assurance that the catalogue data is accurate.
STD
EUROVENT
All new products are tested by Eurovent before being Certified. For certified products only
the Eurovent symbol appears alongside the certified product performance data.
STD
THE ENVIRONMENT -
R407C – THE NATURAL
REPLACEMENT FOR
R22
Protecting the environment is a priority and we take care to ensure our products are
developed and manufactured with this in mind. Airedale introduced R407C refrigerant in
1992 and now has the most extensive in-field experience in the air conditioning industry.
R407C is offered on all Airedale products and all new products are developed to provide
optimum efficiency with this refrigerant ensuring maximum customer choice.
STD
WARRANTY,
COMMISSIONING &
MAINTENANCE
The equipment carries the Airedaleunit parts and labour warranty in respect of non-
consumable parts, for a period of 12 months from the date of despatch. Commissioning
will be carried out by Airedale International Air Conditioning Ltd or an approved Airedale
commissioning company.
CHILLERS
ONLY
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.
ukonly
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
our Training Co-ordinator.
STD
For further assistance, please e-mail: [email protected] or telephone:
ST
D
CUSTOMER SERVICES UK Sales Enquiries...........................Tel: + 44 (0) 113 238 7789 & 7799
International Enquiries.....................Tel: + 44 (0) 113 239 1000
Spares Enquiries...............................Tel: + 44 (0) 113 238 7723 & 7727
Airedale Service.................................Tel: + 44 (0) 113 238 7704, 7746 & 7748
Training Enquiries.............................Tel: + 44 (0) 113 238 7738
For information, visit us at our Web Site: www.airedale.co.uk
ST
D
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.
STD
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.
STD
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.
STD
2000 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
ST
D

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Contents
GENERAL STATEMENT
Safety Page 4
EMC Page 4
Warranty Page 5
GENERAL DESCRIPTION
Unit Identification Page 6
Introduction Page 6
Standard Features Page 6
Optional Extras - Energy Saving Page 7
Optional Extras - General Page 8
INSTALLATION DATA
Dimensions & Weights Page 9
Point Loadings Page 9
Unit Lifting Page 10
Centre of Gravity Page 10
Positioning Page 11
Water System Data Page 12
Glycol Data Page 13
Electrical Data Page 14
CONTROLS
Control Scheme Features Page 18
Operation Page 19
Setting Up Page 20
Viewing Unit Operating Status Page 21
Adjusting Customer Control Settings Page 23
COMMISSIONING DATA
General Data Page 25
Mechanical Data Page 25
Water System Data Page 26
Electrical Data Page 27
COMMISSIONING PROCEDURE
Pre Commissioning Checklist Page 29
Commissioning Checklist Page 31
MAINTENANCE
General Maintenance Page 32
Compressor Maintenance Page 33
Refrigeration Page 33
Electrical Page 33
PARTS IDENTIFICATION
Spares Page 34

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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.
std
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.
std
CAUTION 1Service and maintenance of Airedale equipment should only be carried out
by Technically trained competent personnel. new
CAUTION 2When 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.
new
3Also ensure that there are no other power feeds to the unit such as fire alarm
circuits, BMS circuits etc std
4Electrical 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.
std
5Refrigerant 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.
std
6A full hazard data sheet in accordance with COSHH regulations is available
should this be required. std
EMC STATEMENT In accordance with CE marking requirements, all Airedale products are tested for EMC
emissions and susceptibility to European Standards EN 50081-1 and
EN 50082-1 respectively.
new
To ensure trouble-free operation of all electronic equipment, the operating environment
must comply with the same EN standards.Failure to ensure the environment meets this
standard could affect the operation of the equipment.
new

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Warranty new
Please refer to theOrder Acknowledgement for details of the warranty package.
Inclusions Warranty will cover parts and labour for a period of 12 months.
Warranty cover will commence from the date of invoice unless an alternative date is
requested in writing.
Airedale will accept warranty commencing dates from completion of commissioning or on
date of contract completion up to a maximum of 6 months from date of delivery, subject to
the equipment being properly protected and serviced in the period between delivery and
hand over.
Airedale will provide labour costs for replacement of part failed under warranty conditions
subject to the following:
•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.
•When warranty is accepted, following inspection of the faulty component, a credit
note will be issued against an invoice raised in line with the acknowledgement.
•Should warranty be refused the invoice raised against the acknowledgement
becomes payable on normal terms.
•Airedale reserve 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.
Exclusions Warranty may be refused for the following reasons:
•Misapplication of product or component.
•Incorrect site installation.
•Incomplete commissioning documentation.
•Inadequatesite installation.
•Inadequatesitemaintenance.
•Damage caused by mishandling.
General Dead on arrival or manufacturing defects are the responsibility of Airedale and should be
reported immediately.
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.

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General Description asTM
UNIT IDENTIFICATION AIR COOLED SCREW LIQUID CHILLER
USC Ultima Screw Chiller
250 - 650 Model Size (Expressed as Nominal Cooling in kW)
D- Dual Circuit - Standard Chiller
DQ- Dual Circuit - Quiet Chiller
DSQ- Dual Circuit - Super Quiet Chiller
8, 12 or 16
Number of Fans
Example USC300D-8
INTRODUCTION The Airedale range of Ultima air cooled liquid chillers covers the nominal capacity range
250kW to 650kW in 27 model sizes including Standard D, Quiet DQ and
Super QuietDSQ variations.
asTM
Attention has been placed on maximising the unit’s performance while keeping the sound
levels and footprint to an absolute minimum. asTM
REFRIGERANTS The range has been designed and optimised for operation with the ozone benign
R407C refrigerant. asTM
The Standard Ultima chiller comes complete with: asTM
•Head Pressure Control - fans are individually switched by a Microprocessor
STANDARD CHILLER
- D •Evaporator Trace Heating
•Quiet Fans
•Single Screw Compressors
•Shell & Tube Evaporator
•Dual Independent Refrigeration Circuits
With the benefits of the Standard range, the Quiet chiller is supplied with an acoustic
package, which incorporates: asTM
QUIET CHILLER
- DQ •Acoustically lined compressor enclosures
•3phase Head Pressure Controllers, which modulate the fan speeds collectively to
maintain a constant condensing pressure with minimum fan speeds.
SUPER QUIET CHILLER
- DSQ With the benefits of the Standard range, the Super Quiet chiller is supplied with a Quiet
acoustic package, which incorporates the following to become one of the quietest
chillers available:
asTM
•Acoustically lined compressor enclosures
•Reduced speed 680 rpm condenser fans
•3phase Head Pressure Controllers, which modulate the fan speeds collectively to
maintain a constant condensing pressure with minimum fan speeds.
•The use of enhanced performance condenser coils on the DSQ Quiet Package
enables a chiller capacity similar to the D and DQmodels to be maintained.

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General Description
REFRIGERATION Each refrigeration circuit is supplied with the following: asTM
•Full operating charge of R407C
•Liquid injection oil cooling circuit fitted to each compressor as standard with sight
glass, strainer and non-return valve
•Thermostatic expansion valve with external equaliser
•Liquid line ball valve
•Discharge line ball valve
•Liquid line solenoid valve
•Large capacity filter drier with replaceable cores
•Liquid line sight glass
•Low pressure switch with manual reset
•High pressure switch with manual reset
•Suction and liquid pressure transducers
•Pressure relief valve with integral rupture disc and indicator gauge
CONTROLS Microprocessor controller to provide between 6 to 8 stages of capacity control (dependant
uponmodel size) as standard.The controller incorporates full Building Management
System capabilities, full details can be found in theControls section.
asTM
ELECTRICAL A weatherproof electrical power and controls panel is situated at the end of the unit
and contains: asTM
•Individual mains power compartments for each refrigeration circuit
•Separate door locking electrical isolation for each mains compartment
•Emergency Stop fitted to controls compartment door
•Separate, fully accessible, controls compartment, allowing adjustment of control
set points whilst the unit is operational
•Dedicated bus-bar chamber for connection of incoming 3 phase and earth mains
powersupply
•Circuit breakers for protection of all major unit components
•Phase Rotation Relay also incorporating loss of phase protection
•The electrical power and control panel is wired to the latest European standards
and codes of practice
OPTIONAL EXTRAS - ENERGY SAVING asTM
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.
Electronic Expansion
Valves Electronic expansion valves differ to the normal thermostatic expansion valves in their
ability to maintain control of the suction superheat at reduced head pressures. This can
lead to significant energy savings particularly at minimum loading and low
ambienttemperatures.
Modulating Head
Pressure Control (-20°C)
Model D Only
A 3
phase head pressure controller which modulates t
he fan speed to maintain a constant
condensing pressure can be fitted on request.

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General Description
OPTIONAL EXTRAS - GENERAL new
•
Anti Vibration Mounts
Loose Item •Flow Switch
•Condenser Fan Discharge
Air Plenum
Instructions supplied with item
•Sequence Controller Refer toSequence Controller Manualprovided
with this option
•Epoxy Coated Condenser
Coils
Factory Fitted
•Coil Guards
•Dual Pressure Relief Valve
•Electronic Expansion Valve
•Modem Link Refer toAiredale for further details
•Closed Transition Star/Delta
Compressor Start Refer toCommissioning Section for details
Optional Unit Cover •Commissioning
•Chillerguard® Health Check
•Chillerguard® Maintenance
For details and a competitive quotation, contact
Airedale Service.

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Installation Data asTM
DIMENSIONS &
WEIGHTS Note: Water connections shown are standard, other handing options are available
upon request.
A85
2595
852200
B
HJ
GEDC F
2100
Electrical Panels
with Mains
Isolator
AcousticEnclosure
(DQ & DSQ Only)
P1 P2 P3 P4
P5 P6 P7 P8
20mm Ø Mounting Holes
(located on the underside of
the base frame)
90 90
Water Connections:
USC250-8 to USC350-12 = DN150 PN16
USC400-12 to USC650-16 = DN200 PN16
50
50
Dimensions
A B C D EFGHJ
USC250DSQ-8 to
USC300DSQ-8 mm 4040 460 435 1120 (1) (1) 655 1837 1753
USC350DSQ-12 mm 5740 460 400 1410 1465 1880 585 2198 1753
USC400DSQ-12 to
USC500DSQ-12 mm 5740 475 400 1410 1465 1880 585 2213 1723
USC575DSQ-16 to
USC650DSQ-16 mm 7440 525 400 2000 1645 2810 585 2522 1723
Point Loadings & Total Weights
P1 P2 P3 P4 P5 P6 P7 P8 Machine Operational
USC250DSQ-8
kg
680
540
(1)
340
680
540
(1)
340
3120
3208
USC275DSQ-8
kg
690
550
(1)
340
680
540
(1)
340
3140
3228
USC300DSQ-8
kg
690
550
(1)
340
690
550
(1)
340
3160
3248
USC350DSQ-12
kg
655
680
540
255
615
640
510
245
4140
4217
USC400DSQ-12
kg
655
680
540
255
655
680
540
255
4260
4383
USC450DSQ-12
kg
675
700
540
255
655
680
540
255
4300
4416
USC500DSQ-12
kg
675
700
540
255
675
700
540
255
4340
4449
USC575DSQ-16
kg
885
915
650
365
780
800
650
365
5410
5550
USC650DSQ-16
kg
885
915
650
365
885
915
650
365
5630
5770
(1) Only 6 fixing and loading points to this model.
(2) For AV mount selection on D and DQmodels, use the DSQ data provided.

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Installation Data asTM
UNIT LIFTING •Employ lifting specialists. IM133
•Local codes and regulations relating to the lifting of this type of equipment should
be observed. asTM
•Use the appropriate spreader bars/lifting slings with the holes/lugs provided. IM135
•Attach lifting chains to the 4 lifting lugs provided, each chain must be capable of
lifting the whole chiller. asTM
•Lifting hole/lug dimension: 40mm IM136
•Lift the unit slowly and evenly. IM134
•If the unit is dropped, it should immediately be checked for damage and reported
to Airedale Service. IM120
CAUTION Only use lifting points provided. asTM
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.
IM118
LIFTING DIMENSIONS &
CENTRE OF GRAVITY
400 LK
M
2330
C of G 1
P1 P2 P3
P5 P6 P7 P8
C of G 2
P4
KLM (min) C of G1 C of G2
USC250D-8 to
USC300D-8 mm 2465 1175 3200 1460 1100
USC350D-12 mm 3420 1920 3500 2150 1100
USC400D-12 to
USC500D-12 mm 3420 1920 3500 2130 1100
USC575D-16 to
USC650D-16 mm 5100 1940 5100 2780 1100

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Installation Data
POSITIONING The installation position should be selected with the following points in mind: IM019
•Position on a stable and even base, levelled to ensure that the compressor
operates correctly. IM121
•Levelling should be to +/- 5mm asTM
•Where vibration transmission to the building structure is possible, fit spring anti-
vibration mounts and flexible water connections. IM137
•Observe airflow and maintenance clearances. IM139
•Pipework and electrical connections are readily accessible. IM057
•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. IM122
•Within a side enclosed installation, the fan MUST be higher than the
enclosing structure. IM142
•Figures in brackets indicate airflow and maintenance clearances for side-enclosed
or multiple chiller applications. asTM
•Ensure there are no obstructions directly above the fans. IM140
•Allow free space above the fans to prevent air recirculation. asTM
CAUTION Ensure the unit is completely level and secured prior to connecting services. new
1.2m (2.4)
1.2m (2.4)
1.2m (2.4)
1.2m (2.4)
Louvred Wall with 50%
Free Area

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Installation Data
WATER SYSTEM DATA Chilled water pipework and ancillary components must be installed in accordance with: IM144
•National and Local Water supply company standards. IM145
•The manufacturer's instructions are followed when fitting ancillary components. IM146
•The system water is treated to prevent corrosion and algae forming. IM147
•In ambients of 0°C and below and when water supply temperatures of +5°C are
required, the necessary concentration of Glycol or use of an electrical trace heater
is added where static water can be expected.
asTM+
mods
•The schematic is referred to as a guide to ancillary recommendations. asTM
CAUTION No liability for externally connected pipework will be regarded by Airedale
International Air Conditioning Ltd. new
The water flow commissioning valve set is not shown in the diagram, as the valve can be
fitted elsewhere within the Chilled Water circuit. asTM
P
T
BYPASS CIRCUIT
(For Flushing)
SHUT OFF
VALVES
BINDER
POINTS
CHILLER
STRAINER
TEMPERATURE
GAUGES
PRESSURE
GAUGES
FLEXIBLE
CONNECTIONS
AUTO AIR
VENT (At
Highest Point)
FLOW
SWITCH
PUMP PUMP
STRAINER
T
P
OUT
IN
asTM
The recommended requirements to allow commissioning to be carried out correctly are: new
•The inclusion of Binder Point To Allow Temperature and pressure readings new
Component
Recommended
Requirements •A flow switch or pressure differential switch fitted adjacent to the water outlet side
of the Chiller new
•An 80-mesh strainer fitted prior to the evaporator inlet new
•A water-flow commissioning valve set fitted to the system new
•In multiple chiller installations, 1 commissioning valve set is required per chiller new
•Air vents are to be installed at all high points and where air is likely to be trapped
at intermediate points. new
•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. new
•Isolating valves should be installed adjacent to all major items of equipment for
ease of maintenance. new
•Balancing valves can be installed if required to aid correct system balancing. new
•All chilled water pipework must be insulated and vapour sealed to
avoid condensation. new
•If several units are installed in parallel adjacent to each other, reverse return
should be applied to avoid unnecessary balancing valves. IM149
Pump Statement When installing circulating water pumps or equipmentcontaining them, the following rules
should be applied: new
•Ensure the system is filled with water then vented and the pump primed with water
before running the pump. This is required as the pump bearings and mechanical
seal faces are cooled by the pumped liquid.
new
•To avoid cavitation the NPSH (Net Positive Suction Head) and a safety margin of
0.5m head must be available at the pump inlet during operation. new
Pressure Testing When all the pipework has been connected in the system, proceed as follows: new
•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.
new
When the pressure remains at the operating pressure for 1 hour, the system can be
considered leak free. new
CAUTION Although a pressure of 1.5 x working pressure is adequate for testing purposes,
most local water authorities require 2 x working pressure. new

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Installation Data
WATER SYSTEM DATA IM144
Filling
CAUTION It is recommended that the system be flushed prior to filling to remove debris left
in the water pipework between the strainer and cooler to avoid serious damage to
the tubes in the cooler.
new
During filling the system should be vented at all high points. new
Once the system has been completely vented all vents should be closed. new
To prevent air locking in the system it is advisable to fill the systems from the lowest
point, ie drain point on pipework. new
If auto air vents are used then we strongly recommend an auto pressurisation unit be
fitted to the system. new
asTM
Model USC250…-8 USC275…-8 USC300…-8 USC350…-12 USC400…-12
Connections
Water Inlet / Outlet - Evap (2) in
DN 150
DN 150
DN 150
DN 150
DN200
Water Drain/Bleed - Evap in
1/2
1/2
1/2
1/2
1/2
Water System
Min. System Water Volume (3) L
1782
1960
2138
2608
3014
Max. System Test Pressure Bar
10
10
10
10
10
asTM
Model
USC450…-12
USC500…-12
USC575…-16
USC650…-16
Connections
Water Inlet / Outlet - Evap (2) in
DN200
DN200
DN200
DN200
Water Drain/Bleed - Evap in
1/2
1/2
1/2
1/2
Water System
Min. System Water Volume (3) L
3294
3624
4253
4564
Max. System Test Pressure Bar
10
10
10
10
(2) Flanged to PN16. asTM
(3) For minimum system volume calculations, refer to theTechnical Manual.new
GLYCOL DATA 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. asTM
Ethylene Glycol Nominal Correction Factors
Glycol in System /
Freezing Point ºC 10% / -4°C 20% / -9°C 30% / -15°C 40% / -23°C
Cooling Duty
0.98
0.97
0.95
0.93
Input Power
0.99
0.98
0.96
0.95
Water Flow
0.99
0.99
0.99
1.00
Pressure Drop
Multiply by
0.99
0.99
0.99
1.00
Propylene Glycol Nominal Correction Factors
Glycol in System /
Freezing Point ºC 10% / -2°C 20% / -6°C 30% / -12°C 40% / -20°C
Cooling Duty 0.97 0.95 0.91 0.88
Input Power
0.99
0.98
0.96
0.95
Water Flow
0.98
0.97
0.95
0.95
Pressure Drop
Multiply by
0.99
0.99
0.98
0.98

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Installation Data
ELECTRICAL DATA IM024
General •As standard the equipment is designed for 400V, 3 phase, 3 wire 50Hz and a
permanent 230V, 1 phase, 50Hz supply, to all relevant IEE regulations, British
standards and IEC requirements.
IM023
•Ensure correct phase rotation. new
CAUTION •A fused and isolated electrical supply of the appropriate phase, frequency and
voltage should be installed. new
•The control voltage to the interlocks is 24V. Always size the low voltage interlock
and protection cabling for a maximum voltage drop of 2V. new
CAUTION •Wires should be capable of carrying the maximum load current under non-
fault conditions at the stipulated voltage. new
•Avoid large voltage drops on cable runs, particularly low voltage wiring. new
•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 theWiring Diagram supplied with each unit.
new
CAUTION A separately fused, locally isolated, permanent single phase and neutral supply is
required for the compressor sump heater, evaporator trace heating and
controlcircuits.
new
Interlocks & Protection
Always electrically interlock the operation of the chiller with the pump interlocks
and
water
flow switch for safety reasons.Failure to do this will invalidate the chiller warranty. new
CAUTION Do not rely solely on the BMS to protect the chiller against low flow conditions. An
evaporator interlock and flow switch MUST be fitted. new
Interconnecting Wiring For full control panel component layout, refer toParts Identification.new
L1 ç
L2 çMains Incoming Supply
L3 ç400V/3PH/50HZ
Eç
L4 çPermanent Supply
Nç230V/1PH/50HZ
Eç
502 è
503 çEvaporator Pump Interlock 24VAC
503 è
504 çEvaporator Pump Water Flow Switch 24VAC
502 èRemote ON/OFF 24VAC
505 ç
800 è0V DC
801 è24V DC
803 çRemote Setpoint Adjustment 1 to 10v dc.
573 çCircuit 1 Volt Free Alarm Common
574 èVolt Free Alarm N/O
575 èVolt Free Alarm N/C
576 çCircuit 2 Volt Free Alarm Common
577 èVolt Free Alarm N/O
USC250…-12 to
USC650…-16
578 èVolt Free Alarm N/C
EL1
(Red) L2 (Yellow) L3 (Blue)
Cable Entry
Side/Base
Cable Entry
Side/Base
seeTM

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Installation Data
ELECTRICAL DATA asTM
Model USC250...-8 USC275...-8 USC300...-8
Unit Data (1)
Nominal Run Amps (2) A
164
176
188
Maximum Start Amps A
275
287
344
Permanent Supply VAC 230 V 1 PH 50 Hz
Mains Supply VAC 400 V 3 PH 50 Hz
Recommended Permanent
Fuse Size A
16
16
16
Recommended Mains Fuse
Size A
200
250
250
Maximum Permanent
Incoming Cable Size mm² 4mm² Terminal
Maximum Mains Incoming
Cable Size mm² Direct to Bus Bar
Control Circuit VAC 24V / 230VAC
Evaporator
Trace Heater Rating W
175
200
200
Condenser Fan - Per Fan
Full Load Amps A
1.75
1.75
1.75
Locked Rotor Amps A
6.20
6.20
6.20
Motor Rating kW
0.98
0.98
0.98
Compressor - Per Compressor
Motor Rating kW
43
50 + 43
50
Nominal Run Amps (2) A
75
87 + 75
87
Crankcase Heater Rating kW
150
150
150
Start Amps (3)
193
250 + 193
250
Type Of Start Star / Delta
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps (2) A
150
160
170
Maximum Start Amps (3) A
275
287
344
Recommended Mains Fuse A
200
200
250
Compressor Nominal Run
Amps - Per Compressor A
68
78 + 68
78
Closed Transition Start
Nominal Run Amps (2) A
164
176
188
Maximum Start Amps A
275
287
344
Recommended Mains Fuse A
200
250
250
Compressor Nominal Run
Amps - Per Compressor A
75
87 + 75
87
SUPER QUIET DSQ All data as above except:
Condenser Fan - Per Fan
Full Load Amps A
1.15
1.15
1.15
Locked Rotor Amps A
2.10
2.10
2.10
Motor Rating kW
0.70
0.70
0.70
(1) Refers to standard speed fans. EN001
(2) Based at 12/7°C water and 30°C ambient EN008
(3) Starting amps refers to the Star connection only. EN004

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ULTIMA 2000
Chillers
16 Installation & Maintenance Manual : 903-099 IM E 05/00
Installation Data
ELECTRICAL DATA asTM
Model USC350...-12 USC400...-12 USC450...-12
Unit Data (1)
Nominal Run Amps (2) A
222
249
279
Maximum Start Amps A
375
373
403
Permanent Supply VAC 230 V 1 PH 50 Hz
Mains Supply VAC 400 V 3 PH 50 Hz
Recommended Permanent
Fuse Size A
16
16
16
Recommended Mains Fuse
Size A
315
315
355
Maximum Permanent
Incoming Cable Size mm² 4mm² Terminal
Maximum Mains Incoming
Cable Size mm² Direct to Bus Bar
Control Circuit VAC 24V / 230VAC
Evaporator
Trace Heater Rating W
200
200
200
Condenser Fan - Per Fan
Full Load Amps A
1.75
1.75
1.75
Locked Rotor Amps A
6.20
6.20
6.20
Motor Rating kW
0.98
0.98
0.98
Compressor - Per Compressor
Motor Rating kW
68 + 50
68
87 + 68
Nominal Run Amps (2) A
114 + 87
114
144 + 114
Crankcase Heater Rating kW
150
150
150
Start Amps (3)
248 + 250
248
316 + 248
Type Of Start Star / Delta
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps (2) A
201
225
252
Maximum Start Amps (3) A
375
373
403
Recommended Mains Fuse A
250
315
315
Compressor Nominal Run
Amps - Per Compressor A
102 + 78
102
129 + 102
Closed Transition Start
Nominal Run Amps (2) A
222
249
279
Maximum Start Amps A
375
373
403
Recommended Mains Fuse A
315
315
355
Compressor Nominal Run
Amps - Per Compressor A
114 + 87
114
144 + 114
SUPER QUIET DSQ All data as above except:
Condenser Fan - Per Fan
Full Load Amps A
1.15
1.15
1.15
Locked Rotor Amps A
2.10
2.10
2.10
Motor Rating kW
0.70
0.70
0.70
(1) Refers to standard speed fans. EN001
(2) Based at 12/7°C water and 30°C ambient EN008
(3) Starting amps refers to the Star connection only. EN004

ULTIMA 2000
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Installation & Maintenance Manual : 903-099 IM E 05/00 17
Installation Data
ELECTRICAL DATA asTM
Model USC500...-12 USC575...-16 USC650...-16
Unit Data (1)
Nominal Run Amps (2) A
309
353
390
Maximum Start Amps A
471
511
484
Permanent Supply VAC 230 V 1 PH 50 Hz
Mains Supply VAC 400 V 3 PH 50 Hz
Recommended Permanent
Fuse Size A
16
16
16
Recommended Mains Fuse
Size A
400
450
500
Maximum Permanent
Incoming Cable Size mm² 4mm² Terminal
Maximum Mains Incoming
Cable Size mm² Direct to Bus Bar
Control Circuit VAC 24V / 230VAC
Evaporator
Trace Heater Rating W
250
250
250
Condenser Fan - Per Fan
Full Load Amps A
1.75
1.75
1.75
Locked Rotor Amps A
6.20
6.20
6.20
Motor Rating kW
0.98
0.98
0.98
Compressor - Per Compressor
Motor Rating kW
87
107 + 87
107
Nominal Run Amps (2) A
144
181 + 144
181
Crankcase Heater Rating kW
150
150
150
Start Amps (3)
316
289 + 316
289
Type Of Start Star / Delta
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps (2) A
279
319
352
Maximum Start Amps (3) A
471
511
484
Recommended Mains Fuse A
355
400
450
Compressor Nominal Run
Amps - Per Compressor A
129
162 + 129
162
Closed Transition Start
Nominal Run Amps (2) A
309
353
390
Maximum Start Amps A
471
511
484
Recommended Mains Fuse A
400
450
500
Compressor Nominal Run
Amps - Per Compressor A
144
181 + 144
181
SUPER QUIET DSQ All data as above except:
Condenser Fan - Per Fan
Full Load Amps A
1.15
1.15
1.15
Locked Rotor Amps A
2.10
2.10
2.10
Motor Rating kW
0.70
0.70
0.70
(1) Refers to standard speed fans. EN001
(2) Based at 12/7°C water and 30°C ambient EN008
(3) Starting amps refers to the Star connection only. EN004

Chillers
ULTIMA 2000
Chillers
18 Installation & Maintenance Manual : 903-099 IM E 05/00
Controls
CONTROL SCHEME FEATURES asTM
General Airedale recognises that all chiller applications are different but fall mainly into 2
application categories; Variable Supply Temperature and Constant Supply Temperature.
The onboard microprocessor has the capability of satisfying either control requirement as
illustrated below.Using the Airedale Variable Supply Temperature control scheme,
energy savings are available when compared with previous schemes and that of the
Constant Supply Temperature application.
Variable Supply Temperature control schemes offer energy savings where the supply
water temperature is not critical to its operation.
Selection of the best application control scheme can be made via a software switch in the
microprocessor during initial commissioning.
Examples based on Models USC250...-8 to USC500…-12 having 6 Stages
of Cooling
Variable Supply
Temperature Control
6
7
8
9
10
11
12
13
14
WATER TEMPERATURE °C
20% 40% 55% 70% 85% 100% Chiller
Capacity %
Cooling Stage
Sequence
1 2 3 4 5 6
Return Water Temperature
Supply Water Temperature
Compressor Off
Mean Value
Constant Supply
Temperature Control
6
7
8
9
10
11
12
13
14
0 2 4 6 8 10 12 14
Supply Water Temperature
Return Water Temperature
Chiller
Capacity %
Cooling Stage
Sequence
20%
40%
55%
70%
85%
100%
1
2
3
4
5
6
WATER TEMPERATURE °C
CAUTION Prior to enabling the unit, the mode of operation should be selected, refer to
Adjusting Customer Control Settings - Constant Supply Control.new

ULTIMA 2000
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Installation & Maintenance Manual : 903-099 IM E 05/00 19
Controls new
OPERATION
Display Keypad
Visual
Alarm
Alarm Mute
On/Off
(Not used)
Audible
Alarm
Flashing
Cursor
4 Customer
Pre-Programmable
Displays only
I/O
1
3
2
4
!
X
I/P 1 RETURN TEMPERATURE
11.8 DegC
External
2 Row LCD
Cursor Movement, use to:
View Operating Status &
Adjust Customer Settings
new
Access, Navigation &
Adjustment The display is used for Viewing Unit Operating Status andAdjusting Customer
Control Settings by allowing the operator access to a series of Display Pages. Viewing
information is unrestricted, however set up and adjustment requires password entry, refer
to Password Protection.
new
Use the cursor to direct you through theDisplay Pages, use the / keys to place the
cursor to the top left of the display and use / keys to scroll through available pages. new
When the desired page is selected, toAdjust Customer Control Settings, place the
cursor under the item to change using the / keys and then increase/decrease the
value by using the / keys.
new
Password Protection To guard against unauthorised adjustments, a password is required to gain access. new
FACTORY SET PASSWORD PIN NUMBER: 4648(or Customer chosen number). new
Once protected, using aSoftware Knob for example, use the following instructions to
make a change: new
1Select the desiredSoftware Knob display. new
2Attempt to change theSoftware Knob value which will result in the display
“5*** Enter your PIN”new
3To enter thePIN number, place the cursor under each of the 4 digits represented
as “5***” and select the desired numbers using the / keys. new
4Following entry of the last digit there will be a short delay, then access will be
made available. new
The display will automatically Time Out after 2 minutes following the last keystroke
/cursor movement to prevent unauthorised access. new
CAUTION The display “EDIT INHIBITED” will appear if the PIN entered is invalid or excessive
time is taken to enter the PIN. Check and re-enter the PIN number to clear. new
PAGE TITLE SCREEN DISPLAYS new
Status Page “Status”
Display Pages
(Listed in Sequence) Real Time Clock “Time”
Sensor Inputs “Sens”
Digital Sensors “Digin”
Software Knobs “Knob”
Software Switches “Switch”
Drivers “Driver”
Time Zones “Zone”
Optimum Start/Stop “Oss” - NOT USED
Calendar “Calendr”
Alarms “Alarm”
Auto Dial Option
“DIALLER” - NOT USED

Chillers
ULTIMA 2000
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20 Installation & Maintenance Manual : 903-099 IM E 05/00
Controls
SETTING UP Always start from theStatus page. new
Real Time Clock Time 9:16 Tue 23 May 0
On by 0 hour on 0 ? back on 0 ?
new
To set , move the cursor under the number or month you wish to change and increase or
decrease by using the / keys as required. new
CAUTION Line 2, refers to seasonal time changes which must only be programmed on one
unit within a network. new
Time Zones Zone 1 STD OPERATING TIMES Next Fri
0:00 to 24:00 24:00 to 24:00 24:00 to 24:00
on 0 ?
new
The programme provides 3 factory set periods, which provide 24 hour per day continuous
operation and can be altered to suit. The unit will be factory set for continuous operation
and will not normally require further adjustment.
new
Set up
1Position the cursor under the time value(s) to change and increase or decrease by
using the / keys as required. new
2Move the cursor to the period type eg “Next” and select as follows:
“Every” - will operate during the programme times every week.
“Next” - will operate on the next occurrence of the times set and then revert to
“Every”.
new
Calendar Calendr 1Free 0 ? - 0 ? Zone 1 Unocc new
The Calendar offers 20 holiday dates, programmable as individual days or periods of up
to 99 days. The unit will be factory set for no holiday shut down and will not normally
require further adjustment.
new
Holidays must be programmed at least 7 days before the actual holiday date. new
CAUTION
Set up
1Position cursor under the calendar number egCalendr 1,to select the first set-up
period. new
2Move the cursor to period type eg “Free” and select as follows:
“Free” - holiday will not occur
“
Next”
- holiday displayed will activate at next occurrence only and then “
Free”
after
“Every” - holiday will occur every year.
new
3Move to the start day eg“0”, scroll through 1-31 days as required. new
4Move to the start month eg“?”, select month. new
5Repeat 3 & 4 for the end date. new
6”Zone” and ”Unocc” are not used. new
7Repeat the above for each period. new
new
Pre-Programmable Keys The keys numbered1, 2, 3 and 4can provide quick access to 4 customer
pre-programmed items such as frequently monitored or changed displays. new
Set up
1Select the required display and position the cursor under the value or setting
number. new
2Press Key 1 and hold down. Initially the display will revert to the previously
programmed page. After 5 seconds the display will revert to the new selection. new
3Repeat steps 1 and 2 for Keys 2, 3and 4.new
Technical Support A full Controls Manual is available on request, please contact Airedale Services.new