AIREDALE Ultima Compact FreeCool Series Maintenance and service guide

COVER
R407C
Free Cooling Chiller
75 kW - 450 kW
Ultima Compact FreeCool
INSTALLATION &
MAINTENANCE

ULTIMA COMPACT FREECOOL
Chillers
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ABOUT AIRED ALE
About Airedale Products & Customer Services
WARRANTY
All AIAC products or parts (non consumable) supplied for installation within the UK mainland and
commissioned by an AIAC 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 AIAC for installation within the UK or for Export that are properly
commissioned in accordance with AIAC standards and specification, not commissioned by an AIAC
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 AIAC standards or specification
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 AIAC 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 confirmed as valid under the given
installation and operating conditions, the Company will provide the appropriate warranty coverage (as
detailed above) attributable to the rectification of any affected Airedale equipment supplied (excluding
costs for any specialist access or lifting equipment that must be ordered by the customer).
Any spare part supplied by Airedale under warranty shall be warranted for the unexpired period of the
warranty or 3 months from delivery, whichever period is the longer.
To be read in conjunction with the Airedale Conditions of Sale - Warranty and Warranty Procedure,
available upon request.
CAUTION
Warranty cover is not a substitute for maintenance. Warranty cover is conditional to maintenance
being carried out in accordance with the recommendations provided during the warranty period.
Failure to have the maintenance procedures carried out will invalidate the warranty and any liabilities
by Airedale International Air Conditioning Ltd.
SPARES
A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our
Spares department on request.
TRAINING
As well as our comprehensive range of products, Airedale offers a modular range of Refrigeration
and Air Conditioning Training courses, for further information please contact Airedale.
CUSTOMER SERVICES
For further assistance, please e-mail: [e-mail] or telephone:
Customer Service s
UK Sales Enquiries
+ 44 (0) 113 238 7789
[e-mail]
International Enquiries
+ 44 (0) 113 239 1000
[e-mail]
Spares Hot Line
+ 44 (0) 113 238 7878
[e-mail]
Airedale Service
+ 44 (0) 113 239 1000
[e-mail]
Technical Support
+ 44 (0) 113 239 1000
[e-mail]
Training Enquiries
+ 44 (0) 113 239 1000
[e-mail]
For information, visit us at our Web Site: www.airedale.com
LegalN otic es
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
DQ\SXUSRVHRWKHUWKDQWKHSXUFKDVHU¶VSHUVRQDOXVHZLWKRXWWKHH[SUHVVZULWWHQSHUPLVVLRQRIAIAC Ltd.
¤2013 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.

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CONTENTS
Contents
General Statement.................................................................................................................. 4
Warranty .................................................................................................................................. 5
General Description ............................................................................................................... 6
Unit Identification ................................................................................................................... 6
Standard Features ................................................................................................................. 7
Optional Extras ±General...................................................................................................... 8
Installation Data...................................................................................................................... 9
Dimensions ............................................................................................................................ 9
Weights, Point Loadings & Centre of Gravity (C of G) ......................................................... 11
Unit Lifting ............................................................................................................................ 13
Anti vibration mounting (optional)......................................................................................... 14
Positioning ........................................................................................................................... 15
Water System ...................................................................................................................... 16
Standard Recommended Installation ................................................................................... 16
Water System ±General Specification................................................................................. 19
Glycol Data .......................................................................................................................... 20
Electrical .............................................................................................................................. 21
Interconnecting Wiring ......................................................................................................... 22
Electrical Data...................................................................................................................... 23
Controls................................................................................................................................. 29
Temperature control............................................................................................................. 29
General Description ............................................................................................................. 30
Operation ............................................................................................................................. 30
Setting up............................................................................................................................. 31
Viewing Unit Operating Status ............................................................................................. 32
Alarms.................................................................................................................................. 33
Commissioning Data............................................................................................................ 34
Operating Limits................................................................................................................... 34
Oil & Refrigerant Charges.................................................................................................... 34
Waterside Pressure Drops ................................................................................................... 35
Pump Packages................................................................................................................... 38
Operational Sequence ......................................................................................................... 40
Commissioning Procedure.................................................................................................. 41
Pre Commissioning Checklist .............................................................................................. 41
Commissioning Checklist ..................................................................................................... 43
Maintenance.......................................................................................................................... 44
General Maintenance........................................................................................................... 44
Compressor Maintenance .................................................................................................... 45
Shut Down Periods .............................................................................................................. 45
Parts Identification ............................................................................................................... 46

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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 Installation, service and maintenance of Airedale equipment should only be
carried out by technically trained competent personnel.
CAUTION
2 When working with any air conditioning units ensure that the electrical isolator
is switched off prior to servicing or repair work and that there is no power to
any part of the equipment.
3 Also ensure that there are no other power feeds to the unit such as fire alarm
circuits, BMS circuits etc
4 Electrical installation commissioning and maintenance work on this equipment
should be undertaken by competent and trained personnel in accordance with local
relevant standards and codes of practice.
5 Refrigerant used in this range of products is classified under the COSHH regulations
as an irritant, with set Occupational Exposure Levels (OEL) for consideration if this
plant is installed in confined or poorly ventilated areas.
6 A full hazard data sheet in accordance with COSHH regulations is available should
this be required.
SPARES
For ease of identification when ordering spares or contacting Airedale about your unit,
please quote the unit type, unit serial number and the date of manufacture, which can be
found on the unit serial plate.
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.
SERIAL PLATE
The serial plate can be located to the inside of the control panel door, refer to Parts
Identification, on page 46.
UK Office + 44 113 2391000 + 44 113 2507219
Unit/Gerät/Unite UCFC75D-2/1
Serial/Serie/Serie 81543668-001 (63091072)
Manufactured/Hergestellt/Fabriqué 24/01/2007
Supply/Spannung/Alimentation 400 V 3 PH 50 Hz
Fuse/Hauptsicherung/Fusibles
Test Pressure
Prüfdruck
3UHVVLRQG¶HVVDL
Refrigerant & Charge
Kältemittel und Füllung
Refrigerant & Charge
Max. operating pressure
Betriebsdruck (Maximal)
Pression de marche (Maximum)
N.B. No: 0086
www.airedale.com

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Warranty
GENERAL
To be read in conjunction with Airedale International Air Conditioning Ltd standard
Conditions of Sale and any related quotation.
7KHHTXLSPHQWFDUULHV$LUHGDOH¶VVWDQGDUG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.
WARRANTY IS ONLY
VALID IN THE EVENT
THAT:
1 In the period between delivery and commissioning the equipment:
ois properly protected & serviced
owater flow safety devices are in place and fully operational
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.
PROCEDURE
xThe 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.
xShould warranty be accepted, following inspection of the faulty component, a credit
note will be issued against the invoice raised in line with the acknowledgement.
xShould warranty be refused the invoice raised against the acknowledgement
becomes payable on normal terms.
xAiredale 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.
EXCLUSIONS
Warranty may be refused for the following reasons:
xMisapplication of product or component
xIncorrect site installation
xIncomplete commissioning documentation
xInadequate site installation
xInadequate site maintenance
xDamage caused by mishandling
xReplaced part being returned damaged without explanation
xUnnecessary delays incurred in return of defective component
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.
RETURNS ANALYSIS
All faulty components returned under warranty are analysed on a monthly basis as a
means of verifying component and product reliability as well as supplier performance. It is
important that all component failures are reported correctly.

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General Description
UNIT IDENTIFICATION
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
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.
$WWHQWLRQKDVEHHQSODFHGRQPD[LPLVLQJWKHXQLW¶VFRROLQJDQGHQHUJ\SHUIRUPDQFHZKLOHkeeping the footprint to an absolute minimum.
CE DIRECTIVE
Airedale certify that the equipment detailed in this manual conforms with the following
EC Directives:
Electromagnetic Compatibility Directive (EMC)
2004/108/EC
Low Voltage Directive (LVD)
2006/95/EC
Machinery Directive (MD)
89/392/EEC in the version
2006/42/EC
Pressure Equipment Directive (PED)
97/23/EC
To comply with these directives appropriate national & harmonised standards have been
applied. These are listed on the Declaration of Conformity, supplied with each product.
REFRIGERANTS
The range has been designed and optimised for operation with the ozone benign
R407C refrigerant.
CONSTRUCTION
The base is fabricated from galvanised steel to ensure a rigid, durable,
weatherproof construction.
Unit panels are manufactured from galvanised sheet steel coated with epoxy baked
powder paint to provide a durable and weatherproof finish.
Standard unit colour is Light Grey (RAL 7035).
Compressors and evaporator are mounted on a rigid galvanised heavy-duty sub frame.
Fully weatherproofed electrical panels are situated at one end of the unit. Access to the
compressors is via end panels adjacent to the electrical control panel.
A set of 4 collared eye bolts to BS4278 are supplied.
Discharge Air Plenum -
Condenser Fan
Constructed from galvanised sheet steel coated with epoxy baked powder paint, this
plenum directs discharge air vertically, thus limiting a degree of air re-circulation and
provides a degree of acoustic reduction in the horizontal plane; factory fitted. For details
please contact Airedale.
Standard unit colour is Light Grey (RAL 7035).

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General Description
STANDARD FEATURES
Standard Chiller
- D
The Standard Ultima Compact FreeCool chiller comes complete with:
x
Microprocessor Control with BMS capability
xCondenser Coil & integral Free Cooling Coil Assembly
xPlate Evaporator
xEvaporator Pad Heater
xMultiple Scroll Compressors
xDual Independent Refrigeration Circuits
xIntelligent Head Pressure Control
xCompressor Enclosures
xElectronic Expansion Valve (EEV)
x3 way modulating valve to control free cooling operation
xButterfly shut off valve for free cooling coil isolation to allow for maintenance
xWater Flow Switch & Water Filter
xSickle Bladed fans with Long Bellmouth 900 rpm
xCondenser Fan Discharge Plenum
xConnections for External Trace Heating (240V/500W available)
xA set of 4 collared eye bolts to BS4278
With all the features of the Standard range, the Quiet and Super Quiet chillers are
available with additional features:
Quiet Chiller - DQ
xFan speed reduced to 750 rpm
Super Quiet Chiller -
DSQ
xFan speed reduced to 570 rpm
xAcoustically lined compressor compartment
xEnhanced Refrigeration Condenser Coils
Controls
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;
xBuilding Management Systems
xNetworking
xSequencing (Master/Slave and Run/Standby)
to meet all your system requirements, please specify at order.
For further details, refer to Controls, on page 29.
Electrical
Dedicated weatherproof electrical power and controls panels are situated at the end of the
unit and contain:
xEmergency Stop fitted to controls compartment door
xSeparate, fully accessible, controls compartment, allowing adjustment of control set
points whilst the unit is operational
xCircuit breakers for protection of all major unit components
xSeparate door locking electrical isolation for each mains compartment
xElectrical terminals for external evaporator pipework trace heating (230V/500W)
are provided.
CAUTION
A fused and isolated electrical supply of the appropriate phase, frequency and
voltage should be installed.
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, on
page 22.

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General Description
OPTIONAL EXTRAS ±GENERAL
Loose Item
xAnti Vibration Mounts
Instructions supplied with
item
xChiller Sequence Manager
CAUTION
It is only possible to set up sequencing following completion of interconnecting
communication wiring. Airedale Service can arrange Sequence setup on request.
Factory Fitted
xExtended Discharge Air Plenum - Condenser Fan
xCorrosion Resistant Coated Coils
xCoil Guards
xPower Factor Correction
xBMS Interface Card
xSingle Pressure Relief Valve (UCFC75 - 450)
xDual Pressure Relief Valve (UCFC180 - 450)
xR407C Leak Detection System
xElectronic Soft Start
xFlushing Bypass Kit
xIn Line Pump Packages including Flushing Bypass Kit
xEvaporator Differential Pressure Sensor
xRemote Setpoint Adjust
xControl Panel Low Ambient Protection
xAlternative Refrigerant (Outside EU)
Optional Unit Cover
xCommissioning
For details and a competitive quotation,
contact Airedale Service.
xChillerguard® Maintenance(1)
(1) UK Mainland Sites

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Installation Data
DIMENSIONS
IMPORTANT
The following information is for general guidance; refer to the certified drawings
provided for installation.
Single Row Fans - /1
UCFC75 - UCFC150
A
2000
1300
50 50
E
2
3
B
D
C
1250
25
25
4
25
300
1 7
500
5
6
500
425225
20
6
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
A
2000
1300
50
50
E
2
3
B D C
1250 25
25
4
25
300
1
7
500
5
6
500
425
225
20
6
Model D
A
B
C
D
E
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
A
B
C
D
E
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
A
B
C
D
E
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
(1)
Have only 4 fixing and 4 point loadings.

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Installation Data
DIMENSIONS
IMPORTANT
The following information is for general guidance; refer to the certified drawings
provided for installation.
Double Row Fans - /2
UCFC160 - UCFC450
A 2200
50 50
D
2
3
1
350
C
B
2150
25
25
4
25 25
7
500
5
E
6
1100
20
2180
975 630
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
A
2200
50
50
D
2
3
1
350 CB
2150 25
25
4
25
25
7
500
5
E
6
1100
20
2180
975
630
Model D
A
B
C
D
E
UCFC160D - UCFC225D
mm
3800
1350
1475
(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
1350
1475
(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.

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Installation Data
WEIGHTS, POINT LOADINGS & CENTRE OF GRAVITY (C OF G)
Single Row Fans - /1
UCFC75 - UCFC150
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.
(3)
Operating weight includes refrigerant charge and system water volume.

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Installation Data
WEIGHTS, POINT LOADINGS & CENTRE OF GRAVITY (C OF G)
Double Row Fans - /2
UCFC160 - UCFC450
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
605
605
350
350
(1)
(1)
255
255
2420
1100
1335
UCFC180D-6/2
kg
645
645
360
360
(1)
(1)
260
260
2530
1100
1310
UCFC200D-6/2
kg
645
645
365
365
(1)
(1)
260
260
2540
1100
1315
UCFC225D-6/2
kg
695
695
375
375
(1)
(1)
265
265
2670
1100
1285
UCFC250D-8/2
kg
715
715
455
455
(1)
(1)
380
380
3100
1100
1760
UCFC275D-8/2
kg
735
735
475
475
(1)
(1)
390
390
3200
1100
1765
UCFC300D-8/2
kg
750
750
480
480
(1)
(1)
395
395
3250
1100
1760
UCFC330D-10/2
kg
695
695
465
465
435
435
370
370
3930
1100
2135
UCFC360D-10/2
kg
695
695
465
465
435
435
370
370
3930
1100
2135
UCFC400D-12/2
kg
720
720
535
535
510
510
445
445
4420
1100
2715
UCFC450D-12/2
kg
740
740
545
545
520
520
450
450
4510
1100
2700
Model DQ
P1
P2
P3
P4
P5
P6
P7
P8
Operating
Weight
C of G1
(mm)
C of G2
(mm)
UCFC160DQ-6/2
kg
665
665
385
385
(1)
(1)
260
260
2620
1100
1305
UCFC180DQ-6/2
kg
700
700
405
405
(1)
(1)
265
265
2740
1100
1295
UCFC200DQ-6/2
kg
700
700
405
405
(1)
(1)
265
265
2740
1100
1295
UCFC225DQ-8/2
kg
745
745
515
515
(1)
(1)
380
380
3280
1100
1750
UCFC250DQ-8/2
kg
755
755
520
520
(1)
(1)
380
380
3310
1100
1740
UCFC275DQ-10/2
kg
670
670
455
455
425
425
360
360
3820
1100
2140
UCFC300DQ-10/2
kg
690
690
460
460
425
425
360
360
3870
1100
2120
UCFC330DQ-12/2
kg
810
810
545
545
485
485
435
435
4550
1100
2590
UCFC360DQ-12/2
kg
810
810
545
545
485
485
435
435
4550
1100
2590
UCFC400DQ-14/2
kg
850
850
605
605
565
565
505
505
5050
1100
3020
UCFC450DQ-14/2
kg
885
885
610
610
565
565
505
505
5130
1100
2980
Model DSQ
P1
P2
P3
P4
P5
P6
P7
P8
Operating
Weight
C of G1
(mm)
C of G2
(mm)
UCFC160DSQ-8/2
kg
690
690
430
430
(1)
(1)
400
400
3040
1100
1810
UCFC180DSQ-8/2
kg
710
710
450
450
(1)
(1)
415
415
3150
1100
1815
UCFC200DSQ-8/2
kg
715
715
455
455
(1)
(1)
415
415
3170
1100
1810
UCFC225DSQ-10/2
kg
655
655
435
435
415
415
350
350
3710
1100
2140
UCFC250DSQ-10/2
kg
655
655
435
435
420
420
355
355
3730
1100
2150
UCFC275DSQ-12/2
kg
705
705
500
500
485
485
440
440
4260
1100
2720
UCFC300DSQ-12/2
kg
720
720
505
505
485
485
440
440
4300
1100
2700
UCFC330DSQ-16/2
kg
840
840
660
660
625
625
575
575
5400
1100
3345
UCFC360DSQ-16/2
kg
840
840
660
660
625
625
575
575
5400
1100
3345
UCFC400DSQ-16/2
kg
850
850
670
670
635
635
580
580
5470
1100
3340
UCFC450DSQ-16/2
kg
870
870
680
680
645
645
585
585
5560
1100
3330
(1)
Have only 6 fixing and 6 point loadings.
(2)
Based on standard unit, for units fitted with pump options, please contact Airedale.
(3)
Operating weight includes refrigerant charge and system water volume.

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ULTIMA COMPACT FREECOOL
Chillers
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Installation & Maintenance : 6259584 02/2013
Installation Data
UNIT LIFTING
xEmploy lifting specialists
xLocal codes and regulations relating to the lifting of this type of equipment should
be observed
xUse the appropriate spreader bars/lifting slings (provided by others) with the
holes/lugs provided
xAttach individual lifting chains to each of the lifting eye bolts/lifting lugs provided;
each individual chain must be capable of lifting the whole unit
IMPORTANT
Do not use 1 chain between 2 lifting points to avoid load shift.
Only use lifting points provided.
xChains/slings MUST NOT interfere with the casing or fan assembly to avoid damage
xLift the unit slowly and evenly
IMPORTANT
If the unit is dropped, it should immediately be checked for damage and reported
to Airedale.
LIFTING DIMENSIONS
E
D
A
C
B
A
B
C
D
E
2 FANS /1 Row
mm
290
1900
585
2500
1450
3 FANS /1 Row
mm
290
2015
1320
2500
1450
4 FANS /1 Row
mm
290
2870
1315
3000
1450
6 FANS /2 Rows
mm
465
2195
1140
2500
2350
8 FANS /2 Rows
mm
465
2560
1625
2500
2350
10 FANS /2 Rows
mm
465
3135
1900
3500
2350
12 FANS /2 Rows
mm
465
3610
2275
3500
2350
14 FANS /2 Rows
mm
465
4385
2350
4000
2350
16 FANS /2 Rows
mm
465
5035
2550
5000
2350

ULTIMA COMPACT FREECOOL
Chillers
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Chillers
Installation & Maintenance : 6259584 02/2013
Installation Data
ANTI VIBRATION MOUNTING (OPTIONAL)
Spring Type
Each mount is coloured to indicate the different loads, refer to AV selection sheet
supplied separately for correct allocation.
Dimensions
B
A
C
D
E
F
E
A(1)
B
C
D
E
FØ
UCFC 75 ±150
(2)
mm
136
110
180
148
16
11
UCFC 160 - 450
(3)
mm
180
130
225
186
20
16
(1) Unloaded dimension
(2) 2 spring type
(3) 4 spring type
Components
2
1
6a
5
6b
10
9
8
7
3
4
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
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.
Pad Type
Components/Installation
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

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Installation Data
POSITIONING
The installation position should be selected with the following points in mind:
xPosition on a stable and even base, levelled to ensure that the compressor
operates correctly
xLevelling should be to +/- 5mm
xWhere vibration transmission to the building structure is possible, fit spring anti-
vibration mounts and flexible water connections
xObserve airflow and maintenance clearances
xPipework and electrical connections are readily accessible
xWhere multiple units are installed, due care should be taken to avoid the discharge
air from each unit adversely affecting other units in the vicinity
xWithin a side enclosed installation, the fan MUST be higher than the
enclosing structure
xFigures in brackets indicate airflow and maintenance clearances for side-enclosed or
multiple chiller applications
xEnsure there are no obstructions directly above the fans
xAllow free space above the fans to prevent air recirculation
CAUTION
Prior to connecting services, ensure that the equipment is installed and
completely level.
Airflow & Maintenance
Clearances:
1 = 1.0m (2.0m)
2 = 1.0m (1.8m)
1
2
2
1

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Chillers
Installation & Maintenance : 6259584 02/2013
Installation Data
WATER SYSTEM
Chilled water pipework and ancillary components must be installed in accordance with:
xNational and Local Water supply company standards
xThe manufacturer's instructions are followed when fitting ancillary components
xThe system water is treated to prevent corrosion and algae forming
xGlycol required as standard, with the correction concentration to suit the lowest
ambient the equipment will experience
xThe 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 separately.
The water flow commissioning valve set is not shown in the diagram, as the valve can be
fitted elsewhere within the chilled water circuit.
STANDARD RECOMMENDED INSTALLATION
General
The following diagram illustrates the minimum component installation requirements. A
wide range of optional extras are available to suit various applications, please refer to
Optional Extras ±General, on page 8 for details.
CAUTION
The following installation recommendations should be adhered to. Failure to do
this may invalidate the chiller warranty.
T
T
FS
M
P
P
5
2
6
3
4
7
1
TT
M
P
P
2
1
3
4
4
1 Flushing By Pass Leg
2 Pump
3 )LOWHU´
4 Pressure Sensor
CAUTION
Full design water flow MUST be maintained at all times. Variable water volume is
NOT recommended and will invalidate warranty.
CAUTION
The correct operation of the flow switch is critical if the chiller warranty is to
be valid.
CAUTION
Following components are fitted within the chiller unit as standard:
xTemperature Sensors
xDrain Point
xAuto Air Vent
xFlow Switch
x20 Mesh Inlet Filter

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Installation Data
WATER SYSTEM
Component
Recommended
Requirements
The recommended requirements to allow commissioning to be carried out correctly are:
xThe inclusion of Binder Points adjacent to the flow and return connections, to allow
temperature and pressure readings
xA flow switch or equivalent, fitted adjacent to the water outlet side of the Chiller
xA water-flow commissioning valve set fitted to the system
xIn multiple chiller installations, 1 commissioning valve set is required per chiller
xAir vents are to be installed at all high points and where air is likely to be trapped at
intermediate points
xDrain 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
xIsolating valves should be installed adjacent to all major items of equipment for ease
of maintenance
xBalancing valves can be installed if required to aid correct system balancing
xAll chilled water pipework must be insulated and vapour sealed to
avoid condensation
xIf several units are installed in parallel adjacent to each other, reverse return should
be applied to avoid unnecessary balancing valves
Pump Statement
When installing circulating water pumps or equipment containing them, the following rules
should be applied:
xEnsure the system is filled with water 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
xTo 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
CAUTION
Where pumps are installed by others, a timer MUST be installed to ensure that the
pumps run for at least 3 minutes after a remote off signal is received by the chiller.
Interlocks & Protection
Always electrically interlock the operation of the chiller with the pump controls for
safety reasons.
CAUTION
Failure to will invalidate the chiller warranty.
Do not rely solely on the BMS to protect the chiller against low flow conditions.
An evaporator pump interlock MUST be directly wired to the chiller, refer to
Interconnecting Wiring, on page 22.

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Installation & Maintenance : 6259584 02/2013
Installation Data
WATER SYSTEM
Pressure Testing
When all the pipework has been connected in the system, proceed as follows:
xEnsure all shut off and control valves are fully open
xPressurise system to the operating pressure, hold for 1 hour (a gradual fall in
pressure shown on the gauge indicates a leak)
xLeaks should be found and repaired and the unit pressure tested for a further hour
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.
All free-cooling units should use minimum 20% glycol concentration.
RECORD
Record on commissioning sheet provided once completed.
Filling
CAUTION
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.
All free cooling units should use a MINIMUM 20% glycol concentration.
With auto-pressurisation system, regularly monitor the glycol concentration to
ensure it does not fall below the minimum 20%.
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.

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Installation Data
WATER SYSTEM ±GENERAL SPECIFICATION
UCFC75D-2/1
UCFC100D-2/1
UCFC125D-3/1
UCFC150D-3/1
UCFC160D-6/2
Connections
Water Inlet / Outlet
PN16 DN65
PN16 DN65
PN16 DN65
PN16 DN65
PN16 DN80
Water Drain / Bleed
in
1/2
1/2
1/2
1/2
1/2
Water System
Min. System Water Volume
(1)
l
377
469
419
727
717
Max. System Press
Bar
10
10
10
10
10
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(2) & (3)
In Line Pump
Single Head or Run/Standby
Nom External Head - Standard
kPa
143
109
145
122
187
Nom External Head - Larger
kPa
184
150
190
185
254
Twin Head
Nom External Head - Standard
kPa
100
82
88
89
184
Nom External Head - Larger
kPa
146
125
133
152
254
UCFC180D-6/2
UCFC200D-6/2
UCFC225D-6/2
UCFC250D-8/2
UCFC275D-8/2
Connections
Water Inlet / Outlet
PN16 DN80
PN16 DN80
PN16 DN80
PN16 DN80
PN16 DN100
Water Drain / Bleed
in
1/2
1/2
1/2
1/2
1/2
Water System
Min. System Water Volume
(1)
l
645
715
811
1156
1004
Max. System Press
Bar
10
10
10
10
10
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(2) & (3)
In Line Pump
Single Head or Run/Standby
Nom External Head - Standard
kPa
169
160
151
136
163
Nom External Head - Larger
kPa
236
226
217
201
228
Twin Head
Nom External Head - Standard
kPa
166
156
147
130
157
Nom External Head - Larger
kPa
235
225
215
199
225
UCFC300D-8/2
UCFC330D-10/2
UCFC360D-10/2
UCFC400D-12/2
UCFC450D-12/2
Connections
Water Inlet / Outlet
PN16 DN100
PN16 DN100
PN16 DN100
PN16 DN100
PN16 DN100
Water Drain / Bleed
in
1/2
1/2
1/2
1/2
1/2
Water System
Min. System Water Volume
(1)
l
1374
1168
1122
1337
1395
Max. System Press
Bar
10
10
10
10
10
OPTIONAL EXTRAS - ALL MODELS
Water Pump
(2) & (3)
In Line Pump
Single Head or Run/Standby
Nom External Head - Standard
kPa
151
138
121
125
108
Nom External Head - Larger
kPa
218
206
190
196
182
Twin Head
Nom External Head - Standard
kPa
144
129
110
109
87
Nom External Head - Larger
kPa
213
198
180
181
161
(1)
For minimum system volume calculation method, refer to Technical Manual.
(2)
Based on 12/7°C water temperature and 35°C ambient with a 20% Ethylene Glycol Water Concentration.
(3)
Based on D Model, for DQ & DSQ details, please contact Airedale.

ULTIMA COMPACT FREECOOL
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Installation & Maintenance : 6259584 02/2013
Installation Data
GLYCOL DATA
For a given percentage of glycol in the system there are correction factors that need to
be applied, the following tables can be used as a guide.
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
Catalogue Data x by:
1.00
0.98
0.96
Input Power
1.00
0.98
0.97
Water Flow
1.00
1.09
1.12
Pressure Drop
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
Catalogue Data x by:
0.98
0.94
0.91
Input Power
1.00
0.98
0.97
Water Flow
1.00
0.99
0.99
Pressure Drop
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 Technical Manual)
146.1
x 0.98
30%
Ethylene
Glycol =
143.2 kW
Input kW
(refer to Technical Manual)
54.1
x 0.98
53.0 kW
Flow l/s
calculated
(DX Mechanical Cooling kW)
7.49
x 1.09
8.16 l/s
T x 3.9
Pressure Drop kPa
(refer to Waterside Pressure Drops, on page 35)
146
x 1.29
188 kPa
CAUTION
Waste glycol needs to be handled responsibly, recycled or turned over to professional
personnel for correct disposal. Most anti-freeze manufacturers recommend that used
anti-freeze be collected and disposed according to Local Legislation. Waste glycol
should NOT be drained onto the ground, rainwater drainage system or natural waters.
If the glycol contains heavy metals or other contaminants from gas or oil, the level of
hazard posed by the glycol is increased and could be characterised as
hazardous waste.
STEPS IF GLYCOL IS RELEASED/SPILLED
Small spill - soak up with absorbent material.
Large spill - contain spill and pump to suitable container for disposal.