AIREDALE Ultima Remote Air Cooled Installation guide

INSTALLATION, OPERATING &
MAINTENANCE MANUAL
Ultima Remote Air Cooled
Air Cooled Chiller
75kW - 450kW

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About Airedale Products & Customer Services
WARRANTY,
COMMISSIONING &
MAINTENANCE
The equipment carries Airedale’s standard Parts (non consumable) & Labour warranty for a period
of 12 months from the date of commissioning or 18 months from the date of despatch, which ever
is the sooner. (Excludes the cost of any specialist access or lifting equipment.) Commissioning will
be carried out by Airedale International Air Conditioning Ltd or an approved Airedale
commissioning company.
To further protect your investment in Airedale products, we have introduced Airedale Service, who
can provide full commissioning services, comprehensive maintenance packages and service cover
24 hours a day, 365 days a year (UK mainland). For a free quotation contact our Airedale Service or
your local Sales Engineer.
All Airedale products are designed in accordance with EU Directives regarding prevention of build up
of water, associated with the risk of contaminants such as Legionella.
Where applicable, effective removal of condensate is achieved by gradient drainage to outlets and
where used, humidification systems produce sterile, non-toxic steam during normal operation.
For effective prevention of such risk it is necessary that the equipment is maintained in accordance
with Airedale recommendations.
CAUTION
Warranty cover is not a substitute for Maintenance. Warranty cover is conditional to
maintenance being carried out in accordance with the recommendations provided during the
warranty period. Failure to have the maintenance procedures carried out will invalidate the
warranty and any liabilities by Airedale International Air Conditioning Ltd.
SPARES
A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our
Spares department on request.
TRAINING
As well as our comprehensive range of products, Airedale offers a modular range of Refrigeration
and Air Conditioning Training courses, for further information please contact Airedale.
CUSTOMER SERVICES
For further assistance, please e-mail: [e-mail] or telephone:
CUSTOMER SERVIC ES
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
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.
2013 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.

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Contents
GENERAL STATEMENT 4
WARRANTY 5
GENERAL DESCRIPTION 6
Unit Identification 6
Introduction 6
Standard Features 6
Optional Extras –Energy Saving 7
Optional Extras –General 8
INSTALLATION DATA 9
Dimensions 9
Point Loadings, Weights & Centre of Gravity (C of G) 10
Unit Lifting 11
Anti Vibration Mounting - Optional 12
Positioning 13
Refrigeration System 14
Pipework Installation - Good Practices 15
Water System 16
Glycol Data 18
Electrical data 19
Interconnecting Wiring 19
Electrical Data 20
CONTROLS 23
Control Scheme Features 23
Operation 24
Setting up 25
Viewing Unit Operating Status 26
Alarms 27
COMMISSIONING DATA 28
Operating Limits 28
Mechanical Data 28
Waterside Pressure Drops 29
Operational Sequence 30
COMMISSIONING PROCEDURE 31
Pre Commissioning Checklist 31
Commissioning Checklist 33
MAINTENANCE 34
General Maintenance 34
Compressor Maintenance 35
Shut Down Periods 35
PARTS IDENTIFICATION 36
Spares 36

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General Statement
IMPORTANT
The information contained in this manual is critical to the correct operation and
maintenance of the unit and should be read by all persons responsible for the installation,
commissioning and maintenance of this Airedale unit.
SAFETY
The equipment has been designed and manufactured to meet international safety
standards but, like any mechanical/electrical equipment, care must be taken if you are to
obtain the best results.
CAUTION
1 Service and maintenance of Airedale equipment should only be carried out
by Technically trained competent personnel.
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.

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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.
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.
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
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 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:
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.

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General Description
UNIT IDENTIFICATION
REMOTE AIR COOLED LIQUID CHILLER
URAC
Ultima Remote Air Cooled Chiller
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
Example
URAC250DQ
INTRODUCTION
The Airedale range of Ultima Remote Air Cooled liquid chillers covers the nominal
capacity range 75kW to 450kW in 45 model sizes incorporating Standard D, Quiet DQ
and Super Quiet DSQ variations.
Attention has been placed on maximising the unit’s performance while keeping the sound
and vibration levels and footprint to an absolute minimum.
The range has been specifically designed for plant room installations.
A matching range of Air Cooled Condensers is available to complement the Remote Air
Cooled Liquid Chiller, please refer to Airedale.
CE DIRECTIVE
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
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
Standard Chiller
- D
The Standard Ultima Air Cooled Remote Chiller comes complete with:
Microprocessor Control
Evaporator Pad Heater
Multiple Scroll Compressors
Plate Evaporator
Connections to Remote Condenser
Dual Independent Refrigeration Circuits
Electronic Expansion Valve(s)
Connections for External Trace Heating (240V/500W available)
A set of 4 M24 collared eye bolts to BS4278
Quiet Chiller
- DQ
With the benefits of the Standard range, the Quiet chiller is supplied with an acoustic
package, which incorporates:
Compressor enclosure lined with Acoustic material
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:
Compressor enclosure lined with 40mm Acoustic material

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General Description
STANDARD FEATURES
Refrigeration
Each refrigeration circuit is supplied with the following:
Holding charge of nitrogen
Electronic expansion valve
Liquid line ball valve
Discharge line ball valve
Large capacity filter drier with replaceable cores
Liquid line sight glass
Low pressure switch with manual reset via microprocessor controller
High pressure switch with manual reset
Suction and liquid pressure transducers
Pressure relief valve with integral rupture disc and indicator gauge
Controls
As standard, the microprocessor controller can provide 4 or 6 stages of
capacity control, dependent upon model type.
Optionally, the controller is designed to provide capabilities for;
Building Management Systems
Networking
Sequencing (Master/Slave and Run/Standby)
to meet all your system requirements, please confirm at time of order.
Unit initial set up details can be found in the Controls section.
Electrical
Dedicated weatherproof electrical power and controls panels are situated at the end of
the unit and contain:
Separate, fully accessible, controls compartment, allowing adjustment of control
set points whilst the unit is operational
Circuit breakers for protection of all major unit components
Separate, permanent supply for controls/trace heating, 230v/50Hz/1ph
The electrical power and control panel is wired to the latest European standards
and codes of practice
Separate door locking electrical isolation for each mains compartment
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.

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General Description
OPTIONAL EXTRAS –GENERAL
Loose Item
Anti Vibration Mounts
Loose Parts Instructions provided
Victaulic Counterpipe Kit
Flow Switch
Water Filter
Factory Fitted
Sequence Control
(CAUTION : It is only possible to set up sequencing following
completion of interconnecting communication wiring. Airedale Service can
arrange Sequence setup on request.)
BMS Interface Card
Dual Pressure Relief Valve
Leak Detection Kit (DQ & DSQ Only)
Electronic Soft Start
Alternative Refrigerant (Outside EU)
OPTIONAL UNIT COVER
Commissioning
For details and a competitive quotation, contact
Airedale Service.
Chillerguard® Maintenance

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Installation Data
DIMENSIONS
20mm Ø
Mounting Holes
A
B
C
K
L
M
N
P1
P2
P3
P4
C of G2
C of G1
Mains Electric
Isolator
Mains Cable
Entry
Controls
Panel
Water Connections - Victualic Type
URAC 75 - 200 65mm
URAC 225 - 450 80mm
50
50
Evaporator
Water Out
Evaporator
Water in
E
D
H
H
G
F
Refrigeration
Connections
(Refer to Mechanical
Data)
J
J
Model Size
A
B
C
D
E
F
G
H
J
K
L
M
N
URAC75
mm
1800
760
1850
383
397
200
220
280
380
710
462
876
462
URAC100
mm
1800
760
1850
383
397
200
220
280
380
710
462
876
462
URAC125
mm
1800
760
1850
383
397
200
220
280
380
710
462
876
462
URAC150
mm
2000
760
1850
380
397
200
220
280
380
710
462
1076
462
URAC175
mm
2000
760
1850
380
397
200
220
280
380
710
462
1076
462
URAC200
mm
2000
760
1850
380
397
200
220
280
380
710
462
1076
462
URAC225
mm
2000
760
1850
268
628
200
220
280
380
710
462
1076
462
URAC240
mm
3200
900
1900
256
628
500
250
250
450
850
970
1730
500
URAC250
mm
2000
760
1850
268
628
200
220
280
380
710
462
1076
462
URAC300
mm
3200
900
1900
256
628
500
250
250
450
850
970
1730
500
URAC330
mm
3200
900
1900
256
628
500
250
250
450
850
970
1730
500
URAC360
mm
3200
900
1900
256
628
500
250
250
450
850
970
1730
500
URAC400
mm
3200
900
1900
256
628
500
250
250
450
850
970
1730
500
URAC450
mm
3200
900
1900
256
628
500
250
250
450
850
970
1730
500
VICTAULIC TYPE
FITTING
The unit water services are designed to accept a Victaulic type fitting as illustrated.
Optional Counter Pipe Kit
suitable for Victaulic Type
water connection

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Installation Data
POINT LOADINGS, WEIGHTS & CENTRE OF GRAVITY (C OF G)
Model D
P1
P2
P3
P4
Operating
Weight
C of G1 (mm)
C of G2 (mm)
URAC75D
kg
165
165
230
230
790
380
710
URAC100D
kg
175
175
240
240
830
380
710
URAC125D
kg
180
180
250
250
860
380
710
URAC150D
kg
255
255
340
340
1190
380
820
URAC175D
kg
275
275
370
370
1290
380
820
URAC200D
kg
300
300
390
390
1380
380
820
URAC225D
kg
315
315
410
410
1450
380
820
URAC240D
kg
560
560
210
210
1540
450
1442
URAC250D
kg
330
330
430
430
1520
380
820
URAC270D
kg
610
610
230
230
1680
450
1444
URAC300D
kg
660
660
250
250
1820
450
1445
URAC330D
kg
680
680
270
270
1900
450
1462
URAC360D
kg
710
710
280
280
1980
450
1459
URAC400D
kg
750
750
310
310
2120
450
1476
URAC450D
kg
800
800
340
340
2280
450
1486
Model DQ
P1
P2
P3
P4
Operating
Weight
C of G1 (mm)
C of G2 (mm)
URAC75DQ
kg
170
170
235
235
810
380
360
URAC100DQ
kg
180
180
248
248
855
380
710
URAC125DQ
kg
190
190
250
250
880
380
360
URAC150DQ
kg
260
260
355
355
1230
380
420
URAC175DQ
kg
285
285
378
378
1325
380
420
URAC200DQ
kg
305
305
405
405
1420
380
820
URAC225DQ
kg
325
325
420
420
1490
380
420
URAC240DQ
kg
580
580
230
230
1620
450
1461
URAC250DQ
kg
340
340
438
438
1555
380
820
URAC270DQ
kg
630
630
250
250
1760
450
1461
URAC300DQ
kg
680
680
270
270
1900
450
1462
URAC330DQ
kg
700
700
280
280
1960
450
1464
URAC360DQ
kg
730
730
300
300
2060
450
1474
URAC400DQ
kg
770
770
320
320
2180
450
1478
URAC450DQ
kg
820
820
350
350
2340
450
1488
Model DSQ
P1
P2
P3
P4
Operating
Weight
C of G1 (mm)
C of G2 (mm)
URAC75DSQ
kg
175
175
248
248
845
380
710
URAC100DSQ
kg
190
190
255
255
890
380
700
URAC125DSQ
kg
195
195
263
263
915
380
710
URAC150DSQ
kg
270
270
363
363
1265
380
820
URAC175DSQ
kg
290
290
390
390
1360
380
820
URAC200DSQ
kg
310
310
418
418
1455
380
820
URAC225DSQ
kg
330
330
433
433
1525
380
820
URAC240DSQ
kg
580
580
230
230
1620
450
1461
URAC250DSQ
kg
345
345
450
450
1590
380
820
URAC270DSQ
kg
630
630
260
260
1780
450
1475
URAC300DSQ
kg
680
680
270
270
1900
450
1462
URAC330DSQ
kg
710
710
290
290
2000
450
1472
URAC360DSQ
kg
730
730
300
300
2060
450
1474
URAC400DSQ
kg
780
780
330
330
2220
450
1484
URAC450DSQ
kg
820
820
360
360
2360
450
1498
1
For C of G diagram refer to Unit Lifting.

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Installation Data
UNIT LIFTING
Employ lifting specialists.
Local codes and regulations relating to the lifting of this type of equipment should
be observed.
Use the lifting eye bolts/lifting lugs provided.
Attach lifting chains to the 4 lifting eye bolts/lifting lugs provided, each chain and
eye bolt must be capable of lifting the whole chiller.
Use the appropriate spreader bars/lifting slings with the holes/lugs provided.
Lift the unit slowly and evenly.
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.
P
R
S
P1
P2
P3
P4
C of G2
C of G1
V
T
LIFTING DIMENSIONS
P
R
S
T
V
URAC 75 - 125
mm
370
1060
370
2100
850
URAC 150 - 250
mm
370
1260
370
2100
850
URAC 240 - 450
mm
885
1900
415
2100
990

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Installation Data
ANTI VIBRATION MOUNTING - OPTIONAL
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
3
4
DIMENSIONS:
B
A
C
D
E
F
E
A(1)
B
C
D
E
FØ
UCC30-70
2 SPRING
136
110
180
148
16
11
UCC75, 80, 100, 125 & 150
UCCU30-70
UCCU75, 80, 100, 125 & 150
UCFC75-150
UCC110, 130, 160-450
4 SPRING
180
130
225
186
20
16
UCCU110, 130, 160-450
UCFC160-450
UFC200-750
URAC75-450
USC200-750
UWC75-450
(1) Unloaded dimension
(2) Refer to relevant Loose Parts Instructions sheet for positioning of each mount.
INSTALLATION
1 Locate and secure mount using bolting down holes (10) in base plate.
2 Ensure mounts are located in line with the unit base.
3 If applicable, remove compressor enclosure covers to allow access to mount fixing holes in
the unit base.
4 Lock the upper retaining nuts (6a) to the underside of the top plate (9) before a load is
applied.
5 Remove retaining nut and washer (2), lower the unit onto the mounts and replace retaining
nut and washer.
6 Beginning with the mount with the largest deflection, adjust the height of each mount using
the levelling screw (3).
CAUTION
Mountings must be adjusted incrementally in turn. Do not fully adjust 1 mount at a time as
this may overload and damage springs.
7 When all mounts are level, lock each into place using the levelling lock nut (4).
8 Lock all retaining nuts (6a and 6b) to the extreme ends of the retaining studs (5).
CAUTION
Do not connect any services until all anti vibration mounts have been fully adjusted.

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Installation Data
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.
CAUTION
Prior to connecting services, ensure that the equipment is installed and
completely level.
C
A
500
500
Controls
Panel
Inlet /
Outlet
B
Model Size
A
B
C
URAC75 –URAC125
mm
1800
760
760
URAC150 –URAC250 (Ex. 240)
mm
2000
760
760
URAC240 –URAC450 (Ex. 250)
mm
3200
900
900

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Installation Data
REFRIGERATION SYSTEM
Pressure Testing
When installation is complete, fill the system with dry nitrogen to the required PED
pressure, (Airedale recommends 27/40 bar ). Record the pressure over a period of time.
If there is any reduction in pressure, trace the leak and repair before conducting a further
pressure test.
Evacuation
Evacuation for systems operating on R407C(or optional R22) refrigerant should be
carried out as follows (for other refrigerants refer to Airedale for advice):
1 The procedure should be carried out using a high vacuum pump. The pump
should be connected to the high and low pressure sides of the system via a gauge
manifold fitted with compound gauges. A high vacuum gauge should be fitted to
the system at the furthest point from the vacuum pump.
2 Triple evacuation should be used to ensure that all contaminants are removed or
at least reduced to significantly low proportions.
3 The vacuum pump should be operated until a pressure of 1.5 torr (200 Pa)
absolute pressure is reached, at which time the vacuum pump should be stopped
and the vacuum broken with oxygen free Nitrogen until the pressure rises
above zero.
4 The above operation should be repeated a second time.
5 The system should then be evacuated a third time but this time to 0.5 torr absolute
pressure and broken with the correct refrigerant, until pressures equalise between
the charging bottle and the System.

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Installation Data
PIPEWORK INSTALLATION - GOOD PRACTICES
Oil Traps
For long vertical rises in discharge lines, it is essential that oil traps are located every 6m
to ensure proper oil movement / entrapment. In addition there should be an oil trap at the
exit of the chiller before a vertical riser is applied (see example below).
Pipe Supports
The following table identifies the maximum
distance between pipe supports on vertical
and horizontal pipe runs.
Pipe O/D (inches)
Support distance (m)
3/8 - 5/8
2.0
7/8 - 1 1/8
2.5
1 3/8 - 2.0
3.0
Horizontal Sections
It is good practice to ensure a slight gradient toward the compressor in the direction of
the refrigerant flow for suction lines running horizontal. This assists oil return to the
compressor. A gradient of approximately 1:200 (0.5%) shall be used.
Condenser above Chiller
Condenser below Chiller
6m
Chiller
t
Condenser(s)
t
Condenser(s)
Chiller
Discharge Line
Liquid
1
‘U’ oil traps to be installed at 6m intervals on suction line only.
2
Diagrams show 1 circuit only.
It is the responsibility of the installing contractor/site engineer to check the pipe sizes/refrigerant charge is correct
for each system installation and application.
Split systems may require additional oil which should be added to the low side of each compressor.
Design should be in accordance with accepted refrigeration practice to ensure good oil return to the compressor(s)
under all normal operating conditions.

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Installation Data
WATER SYSTEM
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 water is treated to prevent corrosion and algae forming.
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.
The schematic is referred to as a guide to ancillary recommendations.
CAUTION
The unit water connections are NOT designed to support external pipework,
pipework should be supported during installation.
The water flow commissioning valve set is not shown in the diagram, as the valve can be
fitted elsewhere within the chilled water circuit.
Component
Recommended
Requirements
The recommended requirements to allow commissioning to be carried out correctly are:
The inclusion of Binder Points adjacent to the flow and return connections, to allow
temperature and pressure readings.
A flow switch or equivalent, fitted adjacent to the water outlet side of the Chiller.
CAUTION
The correct operation of the flow switch is critical if the chiller warranty is to be valid.
A 20 mesh strainer fitted prior to the evaporator inlet.
A water-flow commissioning valve set fitted to the system.
In multiple chiller installations, 1 commissioning valve set is required per chiller
Air vents are to be installed at all high points and where air is likely to be trapped at
intermediate points.
Drain points are to be installed at all low points in the system and in particular
adjacent to the unit for maintenance to be carried out.
Isolating valves should be installed adjacent to all major items of equipment for ease
of maintenance.
Balancing valves can be installed if required to aid correct system balancing.
All chilled water pipework must be insulated and vapour sealed to
avoid condensation.
If several units are installed in parallel adjacent to each other, reverse return should
be applied to avoid unnecessary balancing valves.
Standard Recommended Installation (Parts Supplied By Others)
BYPASS CIRCUIT
(For Flushing)
SHUT OFF
VALVES
TEMPERATURE
GAUGES
PRESSURE
GAUGES
FLEXIBLE
CONNECTIONS
PUMP
PUMP
STRAINER
T
P
OUT
IN
DE-AERATER
(Optional Extra)
FILTER
20 Mesh
AUTO AIR
VENT (At
Highest Point)
DRAIN
(At Lowest Point)
FS
FLOW
SWITCH
T
P
CAUTION
Constant water flow MUST be maintained. Variable water volume is NOT
recommended.

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Installation Data
WATER SYSTEM
Pressure Testing
When all the pipework has been connected in the system, proceed as follows:
Ensure all shut off and control valves are fully open.
Pressurise system to the operating pressure, hold for 1 hour (a gradual fall in
pressure shown on the gauge indicates a leak).
Leaks should be found and repaired and the unit pressure tested for a
further hour.
When the pressure remains at the operating pressure for 1 hour, the system can be
considered leak free.
CAUTION
Although a pressure of 1.5 x working pressure is adequate for testing purposes,
most local water authorities require 2 x working pressure.
Filling
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.
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.
If auto air vents are used then we strongly recommend an auto pressurisation unit be
fitted to the system.
URAC75
URAC100
URAC125
URAC150
URAC175
Connections - Evaporator
Suits “Victaulic” type Coupling & Pipe Assembly
Water Inlet / Outlet
mm / (in)
65 (2 1/2”)
65 (2 1/2”)
65 (2 1/2”)
65 (2 1/2”)
65 (2 1/2”)
Connections –Condenser
Discharge Line (brazed)
in
1 1/8
1 1/8
1 3/8
1 5/8
1 5/8
Liquid Line (brazed)
in
7/8
7/8
1 1/8
1 3/8
1 3/8
Water System - Evaporator
Min. System Water Volume
(1)
l
358
489
625
755
696
Max. System Press
Bar
10
10
10
10
10
URAC200
URAC225
URAC240
URAC250
URAC270
Connections - Evaporator
Suits “Victaulic” type Coupling & Pipe Assembly
Water Inlet / Outlet
mm / (in)
80 (3”)
80 (3”)
80 (3”)
80 (3”)
80 (3”)
Connections –Condenser –CCT1
Discharge Line (Brazed)
in
1 5/8
1 5/8
1 5/8
1 5/8
1 5/8
Liquid Line (Brazed)
in
1 3/8
1 3/8
1 3/8
1 3/8
1 3/8
Connections –Condenser –CCT2
Discharge Line (Brazed)
in
N/A
N/A
1 5/8
N/A
1 5/8
Liquid Line (Brazed)
in
N/A
N/A
1 3/8
N/A
1 3/8
Water System - Evaporator
Min. System Water Volume
(1)
l
991
890
763
1235
995
Max. System Press
Bar
10
10
10
10
10
URAC300
URAC330
URAC360
URAC400
URAC450
Connections - Evaporator
Suits “Victaulic” type Coupling & Pipe Assembly
Water Inlet / Outlet
mm / (in)
80 (3”)
80 (3”)
80 (3”)
80 (3”)
80 (3”)
Connections –Condenser –CCT1
Discharge Line (Brazed)
in
1 5/8
2 1/8
2 1/8
2 1/8
2 1/8
Liquid Line (Brazed)
in
1 3/8
1 5/8
1 5/8
1 5/8
1 5/8
Connections –Condenser –CCT2
Discharge Line (Brazed)
in
1 5/8
1 5/8
2 1/8
2 1/8
2 1/8
Liquid Line (Brazed)
in
1 3/8
1 3/8
1 5/8
1 5/8
1 5/8
Water System - Evaporator
Min. System Water Volume
(1)
l
1029
1289
1286
1498
1539
Max. System Press
Bar
10
10
10
10
10
(1)
For minimum system volume, refer to the Technical Manual.

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Installation Data
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.
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
x by
0.98
0.97
0.95
0.93
Input Power
0.99
0.98
0.96
0.95
Water Flow
0.99
1.02
1.04
1.07
Pressure Drop
1.05
1.20
1.38
1.57
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
x by
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
1.08
1.17
1.31
1.45
Example
URAC250D operating at 7/12°C water temperature & 45°C dew point, 20% Ethylene
Glycol
Cooling kW (287.3) (refer to Technical Data)
x 0.97
20% Ethylene
Glycol =
278.7 kW
Input kW (77.2) (refer to Technical Data)
x 0.98
75.7 kW
Flow l/s (13.7) (calculated:
4.19xT kW)Cooling(DX 
)
x 1.02
14.0 l/s
Pressure Drop kPa (47.0) (refer to Waterside Pressure
Drops)
x 1.20
56.4 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.

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Installation & Maintenance : 6259535 IM E 02/2013
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.
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.
Interlocks & Protection
Always electrically interlock the operation of the chiller with the pump controls and water
flow switch.
These safety devices prevent the chiller operating with low water flow which can cause
serious damage.
CAUTION
Failure to install both safety devices will invalidate the chiller warranty.
CAUTION
Do not rely solely on the BMS to protect the chiller against low flow conditions.
An evaporator pump interlock and flow switch MUST be directly wired to the
chiller, refer to Interconnecting Wiring diagram.
INTERCONNECTING
WIRING
L1


L2


L3


E


Mains incoming supply 400V/3PH/50Hz
L4


N1


E


Separate Permanent Supply 230V/1PH/50Hz
2


External Trace Heater Connections
N


240V/500W max.
502


(1)
Evaporator Pump Interlock 24VAC
503


504


(1)
Evaporator Pump Water Flow Switch 24VAC
506


502


Unit Remote On/Off 24VAC
505


502


Setback Setpoint Temperature switch
507


502


Remote Pump Interlock 24VAC
522


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
578


Volt Free Alarm N/C
RX-

RX+

AireLan Network Connections
URAC75 - URAC450
GND

CAUTION
(1) MUST be directly wired to the chiller to validate warranty.

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Installation & Maintenance : 6259535 IM E 02/2013
Installation Data
ELECTRICAL DATA
URAC75
URAC100
URAC125
URAC150
URAC175
Unit Data
Nominal Run Amps
(1)
A
46
57
65
80
90
Maximum Start Amps
(2)
A
134
170
216
258
290
Permanent Supply
VAC
230V 1PH 50Hz
Mains Supply
VAC
400V 3PH 50Hz
Rec Permanent Fuse Size
A
16
16
16
16
16
Rec Mains Fuse Size
A
63
80
100
125
125
Max Permanent Incoming Cable
Size
mm²
4 mm² terminals
Max Mains Incoming Cable Size
mm²
70 (direct to MCCB)
Control Circuit
VAC
24V/230VAC
Evaporator
Pad Heater Rating
W
40
40
40
80
100
External Trace Heating
Available (fitted by others)
W
500
500
500
500
500
Compressor - Per Compressor
Quantity
4
4
4
4
2+2
Motor Rating
kW
5.3
7.3
9.1
10.9
10.9/14.4
Nominal Run Amps
(1)
A
11.5
14.2
16.3
20.0
20.0/25.2
Crankcase Heater Rating
W
70.0
70.0
70.0
70.0
70.0/120.0
Start Amps
(2)
99
127
167
198
198/225
Type Of Start
Direct on line
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
(1)
A
41
51
58
72
81
Maximum Start Amps
(2)
A
130
165
211
252
283
Recommended Mains Fuse
A
63
80
100
100
125
Compressor Nominal Run
Amps - Per Compressor
A
10.3
12.7
14.6
17.9
17.9/22.5
Electronic Soft-Start
Nominal Run Amps
(1)
A
46
57
65
80
90
Maximum Start Amps
(2)
A
90
119
149
179
200
Recommended Mains Fuse
A
63
80
100
125
125
(1)
Based at 12/7°C water and 45°C dew point
(2)
Starting amps refers to the direct on line connections.