AIREDALE Ultima FreeCool User manual

INSTALLATION, OPERATING &
MAINTENANCE MANUAL
Ultima FreeCool
Free-Cooling Chiller
200 – 750 kW

ULTIMA FREECOOL Chillers
Chillers
2 Installation & Maintenance Manual : 903-125 IM E 05/04/A
About Airedale Products & Customer Services
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty for a period
of 12 months from the date of commissioning or 18 months from the date of despatch, which ever
is the sooner. (Excludes the cost of any specialist access or lifting equipment.) Commissioning will
be carried out by Airedale International Air Conditioning Ltd or an approved Airedale
commissioning company.
To further protect your investment in Airedale products, we have introduced Airedale Service, who
can provide full commissioning services, comprehensive maintenance packages and service cover
24 hours a day, 365 days a year (UK mainland). For a free quotation contact Airedale Service or
your local Sales Engineer.
All Airedale products are designed in accordance with EU Directives regarding prevention of build up
of water, associated with the risk of contaminants such as Legionella.
Where applicable, effective removal of condensate is achieved by gradient drainage to outlets and
where used, humidification systems produce sterile, non-toxic steam during normal operation.
WARRANTY,
COMMISSIONING &
MAINTENANCE
For effective prevention of such risk it is necessary that the equipment is maintained in accordance
with Airedale recommendations.
CAUTION Warranty cover is not a substitute for Maintenance. Warranty cover is conditional to
maintenance being carried out in accordance with the recommendations provided during the
warranty period. Failure to have the maintenance procedures carried out will invalidate the
warranty and any liabilities by Airedale International Air Conditioning Ltd.
SPARES A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our
Spares department on request.
TRAINING As well as our comprehensive range of products, Airedale offers a modular range of Refrigeration
and Air Conditioning Training courses, for further information please contact Airedale.
AIAC Ltd endeavours to ensure that the information in this document is correct and fairly stated, but
none of the statements are to be relied upon as a statement or representation of fact. AIAC Ltd does
not accept liability for any error or omission, or for any reliance placed on the information contained
in this document.
The development of Airedale products and services is continuous and the information in this
document may not be up to date. It is important to check the current position with AIAC Ltd at the
address stated. This document is not part of a contract or licence unless expressly agreed.
No part of this document may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying, recording, or information storage and retrieval systems, for
any purpose other than the purchaser's personal use, without the express written permission of
AIAC Ltd.
2004 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
CUSTOMER SERVICES For further assistance, please e-mail: [email protected]om or telephone:
UK Sales Enquiries + 44 (0) 113 238 7789 [email protected]
International Enquiries + 44 (0) 113 239 1000 [email protected]
Spares Hot Line + 44 (0) 113 238 7878 [email protected]
Airedale Service + 44 (0) 113 239 1000 [email protected]
Technical Support + 44 (0) 113 239 1000 [e-mail]
Customer Services
Training Enquiries + 44 (0) 113 239 1000 [email protected]
For information, visit us at our Web Site: www.airedale.com

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 3
Contents
GENERAL STATEMENT 4
Safety 4
WARRANTY 5
GENERAL DESCRIPTION 6
Unit Identification 6
Standard Features 6
Optional Extras - Energy Saving 8
Optional Extras - General 8
INSTALLATION DATA 9
Dimensions 9
Point Loading & Centre of Gravity 10
Weights 11
Unit Lifting 12
Anti Vibration Mounting 13
Positioning 14
Water System Data 15
Standard Recommended Installation 15
Glycol Data 17
Electrical Data 18
Interconnecting Wiring 19
CONTROLS 23
Control Scheme Features 23
Operation 24
Setting Up 25
Viewing Unit Operating Status 26
Alarms 27
COMMISSIONING DATA 28
General Data 28
Mechanical Data 28
Waterside Pressure Drops 29
Electrical Data 31
COMMISSIONING PROCEDURE 33
Pre Commissioning Checklist 33
Commissioning Checklist 35
MAINTENANCE 36
General Maintenance 36
Compressor Maintenance 37
Shut Down Periods 37
Unit Schematic 38
PARTS IDENTIFICATION 40
Spares 40

ULTIMA FREECOOL Chillers
Chillers
4 Installation & Maintenance Manual : 903-125 IM E 05/04/A
General Statement
IMPORTANT The information contained in this manual is critical to the correct operation and
maintenance of the unit and should be read by all persons responsible for the installation,
commissioning and maintenance of this Airedale unit.
SAFETY The equipment has been designed and manufactured to meet international safety
standards but, like any mechanical/electrical equipment, care must be taken if you are to
obtain the best results.
CAUTION 1 Service and maintenance of Airedale equipment should only be carried out
by Technically trained competent personnel.
CAUTION 2 When working with any air conditioning units ensure that the electrical
isolator is switched off prior to servicing or repair work and that there is no
power to any part of the equipment.
3 Also ensure that there are no other power feeds to the unit such as fire alarm
circuits, BMS circuits etc
4 Electrical installation commissioning and maintenance work on this equipment
should be undertaken by competent and trained personnel in accordance with
local relevant standards and codes of practice.
5 Refrigerant used in this range of products is classified under the COSHH
regulations as an irritant, with set Occupational Exposure Levels (OEL) for
consideration if this plant is installed in confined or poorly ventilated areas.
6 A full hazard data sheet in accordance with COSHH regulations is available
should this be required.

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 5
Warranty
GENERAL To be read in conjunction with Airedale International Air Conditioning Ltd standard
Conditions of Sale and any related quotation.
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty
for a period of 12 months from the date of commissioning or 18 months from the date of
despatch, which ever is the sooner. Commissioning must be carried out by Airedale or an
approved Airedale company.
1 The equipment is properly protected & serviced in the period between delivery
and commissioning.
WARRANTY IS ONLY
VALID IN THE EVENT
THAT: 2 The equipment is serviced & maintained by Airedale or an approved Airedale
company in accordance with the Installation & Maintenance manual provided,
during the Warranty Period.
In the event of a problem being reported, Airedale will cover the full cost of rectification
(excluding costs for any specialist access or lifting equipment) if warranty is valid under
these conditions.
Any spare part supplied by Airedale under the warranty shall be warranted for the
unexpired period of the warranty or 3 months from delivery whichever period is the
longer, with the exception of compressors on which a further 12 months warranty
is granted.
PROCEDURE •The on site contractor or service company place an official order on Airedale for
the replacement part including site labour if required. Airedale will acknowledge
this order with detailed prices for components, travel and labour rates.
•Should warranty be accepted, following inspection of the faulty component, a
credit note will be issued against the invoice raised in line with the
acknowledgement.
•Should warranty be refused the invoice raised against the acknowledgement
becomes payable on normal terms.
•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.
•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.
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.

ULTIMA FREECOOL Chillers
Chillers
6 Installation & Maintenance Manual : 903-125 IM E 05/04/A
General Description
FREE-COOLING CHILLER
UFC Ultima FreeCool
200 – 750 Model Size (Expressed as Nominal Cooling in kW)
D- Double Circuit - Standard Chiller
DQ- Double Circuit - Quiet Chiller
DSQ- Double Circuit - Super Quiet Chiller
8 - 20 Number of Fans
UNIT IDENTIFICATION
Example UFC200D-8
INTRODUCTION The Airedale range of Ultima FreeCool air cooled liquid chillers covers the cooling
capacity range 200kW to 750kW in 39 model sizes incorporating Standard D, Quiet DQ
and Super Quiet DSQ variations.
Attention has been placed on maximising the unit’s cooling and energy performance while
keeping the sound, vibration levels and footprint to an absolute minimum.
Airedale certify that the equipment detailed in this manual conforms with the following
EC Directives:
Electromagnetic Compatibility Directive (EMC) 89/336/EEC
Low Voltage Directive (LVD) 73/23/EEC
Machinery Directive (MD) 89/392/EEC in the version 98/37/EC
CE DIRECTIVE
Pressure Equipment Directive (PED) 97/23/EC
To comply with these directives appropriate national & harmonised standards have been
applied. These are listed on the Declaration of Conformity, supplied with each product.
REFRIGERANTS The range has been designed and optimised for operation with the ozone benign
R407C refrigerant.
STANDARD FEATURES
The Standard Ultima FreeCool chiller comes complete with:
•Microprocessor Controlled
•Condenser Coil & integral Free-cooling Coil Assembly
•Shell & Tube Evaporator with integral trace heating
•Single Screw Compressors
•Dual Independent Refrigeration Circuits
•Dual Circuit Electrical Isolator for maintenance
•Refrigeration Head Pressure Control
•Variable Speed Fans
•Compressor Enclosures
•Electronic Expansion Valve (EEV)
•3 Way and Modulating Water Valve
•Water Flow Switch
•Dual Maintainable Pressure Relief Valve
•Sickled Bladed fans with Long Bellmouth 1200 rev/min
Standard Chiller
- D
•Connections for External Trace Heating (240V/500W available)
With all the features of the Standard range, the Quiet and Super Quiet chillers are
available with additional features:
Quiet chiller
- DQ
•Fan speed reduced to 900 rev/min
•Fan speed reduced to 680 rev/min
•Acoustically lined compressor compartment
Super Quiet Chiller
- DSQ
•Discharge Line Mufflers

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 7
General Description
STANDARD FEATURES
Each refrigeration circuit is supplied with the following:
•Full operating charge of R407C
•Liquid injection oil cooling circuit fitted to each compressor as standard with filter,
sight glass, strainer and non-return valve
•Electronic expansion valve
•Liquid line ball valve
•Discharge line ball valve
•Discharge line mufflers (DSQ MODELS ONLY)
•Large capacity filter drier with replaceable cores
•Liquid line sight glass
•Low pressure switch with manual reset via microprocessor controller
•High pressure switch with manual reset
•Suction and liquid pressure transducers
•Dual Pressure relief valve with integral rupture disc and indicator gauge offering
easy maintenance complying with Pressure Regulations
Refrigeration
•Valves for refrigeration head pressure control in simultaneous Free Cooling and
Mechanical cooling mode
Each water glycol circuit is supplied with the following:
•Water Flow switch
•3 way modulating valve to control free-cooling operation
•Strategically placed automatic air vents
•Strategically placed drain valves
•Butterfly shut off valves for Free-cooling coil isolation to allow for maintenance
•Pressure transducers across evaporator to monitor water pressure drop
Water / Glycol
•Inlet water filter 1/16” mesh
Controls microprocessor controlled providing 6-8 stages of mechanical cooling
(Depending on model size), modulating condenser fans and valve to offer 0-100% free-
cooling when ambients permit. The controller incorporates full Building Management
System capabilities, full details can be found in the Controls section.
Weatherproof electrical power and control panels are situated at the end of the unit
and contain:
•Individual mains power compartments for each refrigeration circuit
•Separate door locking electrical isolation for each mains compartment
•Dedicated control panel and isolator for fans and integral pumps (when fitted)
Electrical
•Emergency Stop fitted to controls compartment door
CAUTION The Emergency Stop MUST NOT be used to stop the chiller other than in the event
of an emergency.
•Separate, fully accessible, controls compartment, allowing safe adjustment of
microprocessor set points whilst the unit is operational
•Dedicated bus-bar chamber for connection of incoming 3-phase and earth mains
power supply
•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
Mains supply is 3 phase and a neutral is not required.

ULTIMA FREECOOL Chillers
Chillers
8 Installation & Maintenance Manual : 903-125 IM E 05/04/A
General Description
OPTIONAL EXTRAS - ENERGY SAVING
Power Factor Correction When applied to the motors of each compressor, the compressor power factor is
controlled to a minimum operating value of 0.95 at the full operating capacity. This
satisfies many supply authorities that may impose surcharges on equipment with power
factor less than 0.95.
Closed Transition
Star/Delta Compressor
Start
Closed transition Star/Delta starting can be incorporated to avoid high transient
changeover current peaks when the compressor motor is switched over from Star to
Delta. Refer to the Commissioning Data section for a detailed description.
OPTIONAL EXTRAS - GENERAL
•Anti Vibration Mounts
•Condenser Fan Discharge
Air Plenum
Instructions supplied with item
Loose Item
•De-aeration
•Epoxy Coated Condenser
Coils
•Coil Guards
•Closed Transition Star/Delta
Compressor Start
Refer to Compressor Start-Up Information for
details
•Run & Standby
Power Supply
•Power Factor Correction
•Pumps
•Sequence Control
•BMS Interface Card
•Leak Detection Kit
•Flushing Bypass Loop
Factory Fitted
•Flushing Bypass Loop &
Regulating Valve
•Commissioning
•Chillerguard® Health Check
Optional Unit Cover
•Chillerguard® Maintenance
For details and a competitive quotation, contact
Airedale Service.

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 9
Installation Data
DIMENSIONS
A
2320
220085 8590 90
1590
365
B D E F GC
2100 5050
22
Mains Electric
Isolator
Mains Cable
Entry
Controls
Panel
20mm Ø
Mounting Holes Water Connections
UFC200 - 400 = DN100 PN16
UFC450 - 650 = DN125 PN16
UFC700 - 750 = DN150 PN16
C of G1
C of G2
P1 P3 P5 P7 P9
P2 P4 P6 P8 P10
270
800
D Models ABCD E FG
UFC200D-8 mm 4945 760 1850 1850 - - 485
UFC225D-8 mm 4945 760 1850 1850 - - 485
UFC250D-8 mm 4945 760 1850 1850 - - 485
UFC275D-8 mm 4945 760 1850 1850 - - 485
UFC300D-8 mm 4945 760 1850 1850 - - 485
UFC350D-10 mm 5795 760 1550 1450 1550 - 485
UFC400D-10 mm 5795 760 1550 1450 1550 - 485
UFC450D-12 mm 6645 760 1800 1800 1800 - 485
UFC500D-12 mm 6645 760 1800 1800 1800 - 485
UFC575D-14 mm 7670 610 1100 1725 1920 1830 485
UFC650D-14 mm 7670 610 1100 1725 1920 1830 485
UFC700D-18 mm 9370 585 1100 2400 2400 2375 460
UFC750D-18 mm 9370 585 1100 2400 2400 2375 460
DQ Models ABCD E FG
UFC200DQ-8 mm 4945 760 1850 1850 - - 485
UFC225DQ-8 mm 4945 760 1850 1850 - - 485
UFC250DQ-8 mm 4945 760 1850 1850 - - 485
UFC275DQ-8 mm 4945 760 1850 1850 - - 485
UFC300DQ-8 mm 4945 760 1850 1850 - - 485
UFC350DQ-12 mm 6645 760 1800 1800 1800 - 485
UFC400DQ-12 mm 6645 760 1800 1800 1800 - 485
UFC450DQ-14 mm 7670 610 1100 1725 1920 1830 485
UFC500DQ-14 mm 7670 610 1100 1725 1920 1830 485
UFC575DQ-16 mm 8520 610 1100 2375 2120 1830 485
UFC650DQ-16 mm 8520 610 1100 2375 2120 1830 485
UFC700DQ-18 mm 9370 585 1100 2400 2400 2375 460
UFC750DQ-18 mm 9370 585 1100 2400 2400 2375 460

ULTIMA FREECOOL Chillers
Chillers
10 Installation & Maintenance Manual : 903-125 IM E 05/04/A
Installation Data
DIMENSIONS (CONT.)
DSQ Models ABCDE FG
UFC200DSQ-8 mm 4945 760 1850 1850 - - 485
UFC225DSQ-8 mm 4945 760 1850 1850 - - 485
UFC250DSQ-8 mm 4945 760 1850 1850 - - 485
UFC275DSQ-10 mm 5795 760 1550 1450 1550 - 485
UFC300DSQ-10 mm 5795 760 1550 1450 1550 - 485
UFC350DSQ-14 mm 7670 610 1100 1725 1920 1830 485
UFC400DSQ-14 mm 7670 610 1100 1725 1920 1830 485
UFC450DSQ-16 mm 8520 610 1100 2375 2120 1830 485
UFC500DSQ-16 mm 8520 610 1100 2375 2120 1830 485
UFC575DSQ-18 mm 9370 585 1100 2400 2400 2375 460
UFC650DSQ-18 mm 9370 585 1100 2400 2400 2375 460
UFC700DSQ-20 mm 10220 585 1100 2400 2800 2825 460
UFC750DSQ-20 mm 10220 585 1100 2400 2800 2825 460
CAUTION 8 Lifting points on 20 fan models.
Mounting Holes x 20mm Ø Quantity
8 Fan Unit 6
10 Fan Unit 8
12 Fan Unit 8
14 Fan Unit 10
16 Fan Unit 10
18 Fan Unit 10
20 Fan Unit 10
POINT LOADING &
CENTRE OF GRAVITY
Please contact Airedale.

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 11
Installation Data
WEIGHTS
STANDARD D UFC200D-8 UFC225D-8 UFC250D-8 UFC275D-8 UFC300D-8
Weight - Machine kg 3340 3360 3380 3480 3670
Weight - Operating kg 3940 3960 3980 4070 4310
QUIET DQ UFC200DQ-8 UFC225DQ-8 UFC250DQ-8 UFC275DQ-8 UFC300DQ-8
Weight - Machine kg 3270 3290 3310 3410 3600
Weight - Operating kg 3870 3890 3910 4000 4240
SUPER QUIET DSQ UFC200DSQ-8 UFC225DSQ-8 UFC250DSQ-8 UFC275DSQ-10 UFC300DSQ-10
Weight - Machine kg 3270 3290 3310 3780 3980
Weight - Operating kg 3870 3890 3910 4500 4750
STANDARD D UFC350D-10 UFC400D-10 UFC450D-12 UFC500D-12 UFC575D-14
Weight - Machine kg 4130 4170 4870 5000 5490
Weight - Operating kg 4890 4920 5860 5980 6570
QUIET DQ UFC350DQ-12 UFC400DQ-12 UFC450DQ-14 UFC500DQ-14 UFC575DQ-16
Weight - Machine kg 4410 4440 5170 5290 5760
Weight - Operating kg 5300 5320 6290 6390 6970
SUPER QUIET DSQ UFC350DSQ-14 UFC400DSQ-14 UFC450DSQ-16 UFC500DSQ-16 UFC575DSQ-18
Weight - Machine kg 4820 4850 5560 5690 6140
Weight - Operating kg 5840 5860 6810 6920 7480
STANDARD D UFC650D-14 UFC700D-18 UFC750D-18
Weight - Machine kg 5560 6630 7000
Weight - Operating kg 6690 7990 8450
QUIET DQ UFC650DQ-16 UFC700DQ-18 UFC750DQ-18
Weight - Machine kg 5830 6470 6840
Weight - Operating kg 7090 7830 8290
SUPER QUIET DSQ UFC650DSQ-18 UFC700DSQ-20 UFC750DSQ-20
Weight - Machine kg 6210 6860 7220
Weight - Operating kg 7600 8350 8800

ULTIMA FREECOOL Chillers
Chillers
12 Installation & Maintenance Manual : 903-125 IM E 05/04/A
Installation Data
•Employ lifting specialists.
•Local codes and regulations relating to the lifting of this type of equipment
should be observed.
•Use the appropriate spreader bars/lifting slings with the holes/lugs provided.
•Attach lifting chains to the 4 lifting lugs provided, each chain must be capable of
lifting the whole chiller.
•Lifting hole/lug dimension: 40mm
•Lift the unit slowly and evenly.
UNIT LIFTING
•If the unit is dropped, it should immediately be checked for damage and reported
to Airedale Service.
CAUTION Only use lifting points provided.
The unit should be lifted from the base and where possible, with all packing and
protection in position. If any other type of slinging is used, due care should be taken to
ensure that the slings do not crush the casework or coil.
8 – 18 Fans
J
2300
HK
L
20 Fans
JH K
L
J
5000mm Min
2300
HJKL(min)
8 FANS mm 425 3150 1370 3200
10 FANS mm 425 3480 1890 3500
12 FANS mm 425 4105 2115 4200
14 FANS mm 1100 4035 2535 4200
16 FANS mm 1100 4885 2535 5000
18 FANS mm 1075 5585 2660 5800
LIFTING DIMENSIONS
20 FANS (8 lifting points) mm 1125 2850 2775 5000

Date: 18/10/05
Airedale International Air Conditioning Ltd
Leeds Road, Rawdon, Leeds. LS19 6JY England
Tel: + 44 (0) 113 239 1000 Fax: + 44 (0) 113 250 7219
E-mail: [email protected] Website: www.airedale.com
TECHNICAL UPDATE
MANUAL AFFECTED: TECHNICAL & INSTALLATION
ULTIMA: UCC/UCCU 30-450
UCFC/URAC/UWC75-450
UFC/USC200-750
MANUAL PART NO: 901-108 TM E 02/05/A
CHANGE: ANTI-VIBRATION MOUNT (SPRING TYPE) SPECIFICATION &
INSTALLATION INSTRUCTIONS:
COMPONENTS:
1 Locating Screw
2 Retaining Nut & Washer
3 Levelling Screw
4 Levelling Lock Nut
5 Retaining Studs
6a Upper Retaining Nuts
6b Lower Retaining Nuts
7 Spring assembly
8 Pressure Plate
9 Top Plate
10 Bolting-down holes
2
1
6a
5
6b
10
9
8
7
34
DIMENSIONS:
A(1) BCDEFØ
UCC30-70
UCC75, 80, 100, 125 & 150
UCCU30-70
UCCU75, 80, 100, 125 & 150
UCFC75-150
2 SPRING
136 110 180 148 16 11
UCC110, 130, 160-450
UCCU110, 130, 160-450
UCFC160-450
UFC200-750
URAC75-450
USC200-750
UWC75-450
4 SPRING
180 130 225 186 20 16
B
A
C
D E
F
E
(1) Unloaded dimension
(2) Refer to relevant Loose Parts Instructions sheet for positioning of each mount.
INSTALLATION 1 Locate and secure mount using bolting down holes (10) in base plate.
2 Ensure mounts are located in line with the unit base.
3 If applicable, remove compressor enclosure covers to allow access to mount fixing holes in
the unit base.
4 Lock the upper retaining nuts (6a) to the underside of the top plate (9) before a load is
applied.
5 Remove retaining nut and washer (2), lower the unit onto the mounts and replace retaining
nut and washer.
6 Beginning with the mount with the largest deflection, adjust the height of each mount using
the levelling screw (3).
CAUTION Mountings must be adjusted incrementally in turn. Do not fully adjust 1 mount at a time as
this may overload and damage springs.
7 When all mounts are level, lock each into place using the levelling lock nut (4).
8 Lock all retaining nuts (6a and 6b) to the extreme ends of the retaining studs (5).
CAUTION Do not connect any services until all anti vibration mounts have been fully adjusted.

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 13
Installation Data
1 Locate and secure mount using bolting down holes provided in base plate.
2 Ensure mounts are located in line with the chiller base.
3 If applicable remove compressor enclosure covers to allow access to AV fixing
points on the chiller base.
4 Position the machine using the centrally located stud, which allows the machine to
be bolted down securely.
5 Loosen transit bolts and turn nut 3 clockwise until top plate 6 lifts clear of support
posts. Tighten lock nut 4 when machine is at desired height and level.
ANTI VIBRATION
MOUNTING
CLS Type (Optional)
6 Adjust and lock nuts on transit bolts such that a small (3-5mm) gap is left between
washer and grommet. Refer diagram below.
Mountings must be adjusted incrementally in turn. Do not adjust 1 mount at a time
as this may overload and damage springs.
CAUTION
Do not connect any services until all anti vibration mounts have been
fully adjusted.
20 20
20
20
100
14 Ø
BASE PLATE
TOP PLATE
100
200
ELEVATION
1
2
3 4
5
6
7
8
9
10
11
1
2
13
13
5
M16 STUD
M16 STUD
180-210
= =
==
COMPONENTS
1 High deflection steel spring
2 Spring pressure plate
3 Height adjusting nut
4 Locking nut
5 Load bearing supports
6 Load bearing top plate
7 High frequency isolation pad
8 10 dia holding down bolt holes
9 High frequency isolation grommets
10 Steel spring location rings
11 Transportation/restraining bolts
12 Machine frame
13 Machine holding stud/nuts

ULTIMA FREECOOL Chillers
Chillers
14 Installation & Maintenance Manual : 903-125 IM E 05/04/A
Installation Data
POSITIONING The installation position should be selected with the following points in mind:
•Position on a stable and even base, levelled to ensure that the compressor
operates correctly.
•Levelling should be to +/- 5mm
•Where vibration transmission to the building structure is possible, fit spring anti-
vibration mounts and flexible water connections.
•Observe airflow and maintenance clearances.
•Pipework and electrical connections are readily accessible.
•Where multiple units are installed, due care should be taken to avoid the
discharge air from each unit adversely affecting other units in the vicinity.
•Within a side enclosed installation, the fan MUST be higher than the
enclosing structure.
•Figures in brackets indicate airflow and maintenance clearances for side-enclosed
or multiple chiller applications.
•Ensure there are no obstructions directly above the fans.
•Allow free space above the fans to prevent air recirculation.
CAUTION Ensure the unit is completely level and secured prior to connecting services.
2.0m (3.0)
2.0m (3.0)
2.0m (3.0)
2.0m (3.0)

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 15
Installation Data
Chilled water pipework and ancillary components must be installed in accordance with:
•National and Local Water supply company standards.
•The manufacturer's instructions are followed when fitting ancillary components.
•The system liquid is treated to prevent corrosion and algae forming.
WATER SYSTEM DATA
•Glycol required as standard, with the correction concentration to suit the lowest
ambient the equipment will experience
CAUTION The unit water connections are NOT designed to support external pipework,
pipework should be supported during installation.
CAUTION No liability for externally connected pipework will be regarded by Airedale
International Air Conditioning Ltd.
STANDARD RECOMMENDED INSTALLATION
CAUTION The following installation recommendations should be adhered to. Failure to do
this could invalidate the chiller warranty.
The water flow commissioning valve set is not shown in the diagram, as the valve can be
fitted elsewhere within the Chilled Water circuit.
PT
BYPASS CIRCUIT
(
For Flushin
g)
SHUT OFF
V
ALVES
TEMPERATURE
GAUGES
PRESSURE
GAUGES
FLEXIBLE
CONNECTIONS
A
UTO AIR
VENT (At
Highest Point)
PUMP PUMP
STRAINER
T
P
OUT
IN
DE-AERATER
(
O
p
tional Extra
)
The recommended requirements to allow commissioning to be carried out correctly are:
•A water-flow commissioning valve set fitted to the system
•In multiple chiller installations, 1 commissioning valve set is required per chiller
•Air vents are to be installed at all high points and where air is likely to be trapped
at intermediate points.
•Drain points are to be installed at all low points in the system and in particular
adjacent to the unit for maintenance to be carried out.
•Isolating valves should be installed adjacent to all major items of equipment for
ease of maintenance.
•Balancing valves can be installed if required to aid correct system balancing.
•All chilled water pipework must be insulated and vapour sealed to
avoid condensation.
Recommended Minimum
Component
Requirements
•If several units are installed in parallel adjacent to one another, reverse return
should be applied to avoid unnecessary balancing valves.
When installing circulating water pumps or equipment containing them, the following rules
should be applied:
•Ensure the system is filled with liquid then vented and the pump primed with water
before running the pump. This is required as the pump bearings and mechanical
seal faces are cooled by the pumped liquid.
Pump Statement
•To avoid cavitation the NPSH (Net Positive Suction Head) incorporating a safety
margin of 0.5m head must be available at the pump inlet during operation.
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.

ULTIMA FREECOOL Chillers
Chillers
16 Installation & Maintenance Manual : 903-125 IM E 05/04/A
Installation Data
WATER SYSTEM DATA
When all the pipework has been connected in the system, proceed as follows:
Pressure Testing
•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.
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.
CAUTION All free-cooling units should use minimum 20% glycol concentration.
Filling
CAUTION It is recommended that the whole system 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 tubes in the cooler.
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.
Auto air vents are fitted, Airedale strongly recommends an auto pressurisation unit be
fitted to the system.
Model UFC200D-8 UFC225D-8 UFC250D-8 UFC275D-8 UFC300D-8
Connections
Water Inlet / Outlet - Unit (4) DN100 DN100 DN100 DN100 DN100
Water Drain/Bleed - Evap in 1/2 1/2 1/2 1/2 1/2
Water System
Min. System Water Volume (5) l 1454 1577 1750 1915 2074
Max. System Operating Press Bar 10 10 10 10 10
Model UFC350D-10 UFC400D-10 UFC450D-12 UFC500D-12 UFC575D-14
Connections
Water Inlet / Outlet - Unit (4) DN100 DN100 DN125 DN125 DN125
Water Drain/Bleed - Evap in 1/2 1/2 1/2 1/2 1/2
Water System
Min. System Water Volume (5) l 2398 2606 3046 3413 3967
Max. System Operating Press Bar 10 10 10 10 10
Model UFC650D-14 UFC700D-18 UFC750D-18
Connections
Water Inlet / Outlet - Unit (4) DN125 DN150 DN150
Water Drain/Bleed - Evap In 1/2 1/2 1/2
Water System
Min. System Water Volume (5) l 4392 4135 3726
Max. System Operating Press Bar 10 10 10
(4) Flanged to PN16.
(5) For minimum system volume refer to the Technical Manual - Design Features & Information - Minimum Volume
Calculations section.

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 17
Installation Data
GLYCOL DATA
CAUTION All free-cooling units should use minimum 20% glycol concentration.
Ethylene Glycol Nominal Correction Factors
Glycol in System / Freezing Point ºC 20% / -9°C 30% / -15°C 40% / -23°C
Cooling Duty 1.00 0.98 0.96
Input Power 1.00 0.98 0.97
Water Flow 1.00 1.02 1.05
Pressure Drop
x by
1.00 1.15 1.31
Propylene Glycol Nominal Correction Factors
Glycol in System / Freezing Point ºC 20% / -6°C 30% / -12°C 40% / -20°C
Cooling Duty 1.00 0.96 0.93
Input Power 1.00 0.98 0.97
Water Flow 1.00 0.98 0.98
Pressure Drop
x by
1.00 1.13 1.25
Example UFC500D-12 operating at 7/12, 30°C Ambient, 30% Ethylene Glycol
Cooling kW (484.9) (refer to Technical Manual)x 0.98 475.2 kW
Input kW (194.0) (refer to Technical Manual)x 0.98 190.1 kW
Flow l/s ( 24.2) (calculated: 4xT
kW)Cooling(DX
∆)x 1.02 24.7 l/s
Pressure Drop kPa(122.0) (refer to Waterside Pressure Drops)x 1.15
30% Ethylene
Glycol =
140.3 kPa
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.
I
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.
CAUTION
Large spill - contain spill and pump to suitable container for disposal.

ULTIMA FREECOOL Chillers
Chillers
18 Installation & Maintenance Manual : 903-125 IM E 05/04/A
Installation Data
ELECTRICAL DATA
General •As standard the equipment is designed for 400V, 3 phase, 3 wire 50Hz and a
separate permanent 230V, 1 phase, 50Hz supply, to all relevant IEE regulations,
British standards and IEC requirements.
•Ensure correct phase rotation.
CAUTION
•A fused and isolated electrical supply of the appropriate phase, frequency and
voltage should be installed.
•The control voltage to the interlocks is 24V. Always size the low voltage interlock
and protection cabling for a maximum voltage drop of 2V.
CAUTION •Wires should be capable of carrying the maximum load current under non-
fault conditions at the stipulated voltage.
•Avoid large voltage drops on cable runs, particularly low voltage wiring.
•Once the connecting pipework is complete the electrical supply can be connected
by routing the cable through the appropriate casing hole and connecting the
cables, refer to the Wiring Diagram supplied with each unit.
CAUTION A separately fused, locally isolated, permanent single phase and neutral supply
MUST BE FITTED for the compressor sump heater, evaporator trace heating and
control circuits, FAILURE to do so could INVALIDATE WARRANTY.
CAUTION The Emergency Stop MUST NOT be used to stop the chiller other than in the event
of an emergency.
Interlocks & Protection Always electrically interlock the operation of the chiller with the pump controls for safety
reasons. Failure to do this will invalidate the chiller warranty.
Do not rely solely on the BMS to protect the chiller against low flow conditions.
CAUTION
An evaporator pump interlock MUST be directly wired to the chiller, refer to
Interconnecting Wiring diagram.

Chillers ULTIMA FREECOOL
Chillers
Installation & Maintenance Manual : 903-125 IM E 05/04/A 19
Installation Data
INTERCONNECTING WIRING
No Pumps L1 !"Mains incoming supply 400V/3PH/50Hz
L2 !"
L3 !"
E!"
L4 !" Separate Permanent Supply 230V/1PH/50Hz
N1 !"
E!"
11 !#External Trace Heating Connections
N!"240V/500W max
502 !# (1)Evaporator Pump Interlock 24VAC
503 !"
502 !# Unit Remote On/Off 24VAC
505 !"
502 !# Setback Setpoint Temperature switch
507 !"
573 !"
Circuit 1 Volt Free Common Alarm
574 !# Volt Free Alarm N/O
575 !# Volt Free Alarm N/C
576 !"
Circuit 2 Volt Free Common Alarm
577 !# Volt Free Alarm N/O
UFC200 – UFC750
578 !# Volt Free Alarm N/C
CAUTION (1) MUST be directly wired to the chiller to validate warranty.
With Pumps L1 !"Mains incoming supply 400V/3PH/50Hz
L2 !"
L3 !"
E!"
L4 !"Separate Permanent Supply 230V/1PH/50Hz
N1 !"
E!"
11 !#External Trace Heating Connections
N!"240V/500W max
502 !#Pump/s Remote On/Off 24VAC
506 !"
502 !#Unit Remote On/Off 24VAC
505 !"
502 !#Setback Setpoint Temperature switch
507 !"
573 !"Circuit 1 Volt Free Common Alarm
574 !#Volt Free Alarm N/O
575 !#Volt Free Alarm N/C
576 !"Circuit 2 Volt Free Common Alarm
577 !#Volt Free Alarm N/O
UFC200 – UFC750
578 !#Volt Free Alarm N/C