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COVER
OptiChill
Air Cooled Screw Chiller
500 kW - 1100 kW
R134a
INSTALLATION
& MAINTENANCE
OPTICHILL
Chillers
AB OUT AIR ED AL E
About Airedale Products & Customer Services
WARRANTY,
COMMISSIONING &
MAINTENANCE
The equipment carries the Airedale unit parts and labour warranty in respect of non-consumable
parts, 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, Airedale Service 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.
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: [email protected] or telephone:
Custom er Services
UK Sales Enquiries
International Enquiries
Spares Hot Line
Airedale Service
Technical Support
Training Enquiries
+ 44 (0) 113 238 7789
+ 44 (0) 113 239 1000
+ 44 (0) 113 238 7878
+ 44 (0) 113 239 1000
+ 44 (0) 113 239 1000
+ 44 (0) 113 239 1000
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
For information, visit us at our Web Site: www.airedale.com
Legal Notices
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.
 2012 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.
2
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
CONTENT S
Contents
General Statement
4
Warranty
5
General Description
6
Unit identification
Introduction
Features
Optional extras
6
6
7
10
Dimensional Data
12
Standard Units
Units fitted with optional pump package
Plenum options
12
14
16
Installation Data
17
Weights, point loadings & centre of gravity (C of G) - no pumps
Weights - with optional pumps (guidance)
Unit Lifting
Anti vibration mounting (optional)
Positioning
Water system
Grooved & clamped type connection
Refrigeration schematic
Standard recommended installation
Glycol data
Pumps options
Mechanical data - high efficiency
Mechanical data - high efficiency plus
Electrical
Interconnecting wiring
Electrical data - high efficiency
Electrical data - high efficiency plus
Controls
17
19
20
21
22
23
23
24
24
26
27
28
28
30
31
32
36
38
Temperature control
General description
Operation
Setting up
Viewing unit operating status
Alarms
Commissioning Data
General data
Oil & refrigerant charges - high efficiency
Oil & refrigerant charges - high efficiency plus
Waterside pressure drop (kPa)
Pump packages (optional extras)
Electrical data
Pre commissioning checklist
Commissioning checklist
Maintenance
General maintenance
Compressor maintenance
Parts Identification
38
39
39
40
41
42
43
43
44
44
46
47
50
52
54
55
56
57
58
Chillers
Installation & Maintenance : 6564868 09/2012
3
OPTICHILL
Chillers
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
The 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 58.
UK Office
Unit/Gerät/Unite
Serial/Serie/Serie
OPC500HED-8
81543668-001 (63091072)
Manufactured/Hergestellt/Fabriqué
Supply/Spannung/Alimentation
24/01/2007
400 V 3 PH 50 Hz
Fuse/Hauptsicherung/Fusibles
25.0 A
Test Pressure
Prüfdruck
Pression d’essai
27.0 BAR
Refrigerant & Charge
Kältemittel und Füllung
Refrigerant & Charge
Max. operating pressure
Betriebsdruck (Maximal)
Pression de marche (Maximum)
N.B. No: 0086
www.airedale.com
4
 + 44 113 2391000
Chillers
Installation & Maintenance : 6564868 09/2012
 + 44 113 2507219
Chillers
OPTICHILL
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:
o is properly protected & serviced
o water flow safety devices are in place and fully operational
2
The equipment is serviced and 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.
Chillers
Installation & Maintenance : 6564868 09/2012
5
OPTICHILL
Chillers
General Description
UNIT IDENTIFICATION
OPC
OPC
OptiChill Screw Chiller
500 - 1100
Model Size (Expressed as Nominal Cooling in kW)
HED
HEDQ
HE+D
HE+DQ
High Efficiency - Dual Circuit
High Efficiency - Dual Circuit - Quiet
High Efficiency Plus - Dual Circuit
High Efficiency Plus - Dual Circuit - Quiet
8 - 20
Number of Fans
INTRODUCTION
800
HED
12
The Airedale range of OptiChill air cooled liquid screw chillers covers the nominal
capacity range 500kW to 1100kW in 13 models sizes.
Each model size is offered in High Efficiency (HE) or High Efficiency Plus (HE+) and
available as Standard (D) or Quiet (DQ) sound level variations to meet a wide range
of applications.
Attention has been placed on offering a low energy high output performance and flexible
product, while keeping the sound and 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)
Low Voltage Directive (LVD)
Machinery Directive (MD)
Pressure Equipment Directive (PED)
89/336/EEC
73/23/EEC
89/392/EEC in the version 98/37/EC
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
6
The range has been designed and optimised for operation with ozone benign
R134a refrigerant.
Chillers
Installation & Maintenance : 6564868 09/2012
● Standard
○ Optional Extra
HEDQ
High Efficiency - Quiet
HE+D
High Efficiency Plus
HE+DQ
High Efficiency Plus - Quiet
-
●
-
●
●
●
●
●
●
●
●
●
Standard Size
Larger Size
Standard Size
Larger Size
●
●
-
●
●
●
●
-
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
- Not available
7
Construction
Acoustically lined compressor enclosure
Standard Height Condenser Fan Discharge Plenum (300mm)
Extended Condenser Fan Discharge Plenum (800mmm)
Evaporator / Waterside
Shell & Tube evaporator with immersion heater & thermostat
Grooved water connections and counter pipe assembly
Flow switch
Waterside Differential Pressure Switch
Pumps - Fixed Speed
Low Energy Pumps - Variable Speed incorporating Electronic Flow Metering System
Condenser
Condenser Coils - Enhanced
Corrosion Resistant Condenser Coils
Coil Guards
Head Pressure Control - Voltage Regulated
Head Pressure Control - Electronically Commutated (EC) Regulated
Low speed Axial condenser fan with Sickle blades
Extra Low speed Axial condenser fan with Sickle blades
Refrigeration
Twin screw compressors with low current Star/Delta Start
Dual independent refrigeration circuits
Electronic Expansion Valve (EEV)
Economiser with dedicated EEV
Maintainable Dual Pressure relief valve assembly
Discharge line mufflers and noise traps
Liquid line sight glass
Liquid and Discharge line ball valves
Large capacity filter drier with replaceable cores
Manual reset HP/LP Switch (LP via microprocessor)
Suction and liquid pressure transducers
Anti Vibration Mounts
Leak Detection System
Electrical
Emergency stop
Individual door isolated mains power compartments for each refrigeration CCT, fans & pump option
Dedicated bus-bar chamber for incoming 3-phase & earth mains power supply
Closed transition Star/Delta Start
Connections for External Trace Heating
Power Factor Correction
Controls
Microprocessor Controller
Energy Manager
Electronic compressor protection module with phase & rotation protection
Phase Rotation Protection
Sequence Control - Chiller Sequence Manager
Remote Setpoint Adjust 0-10 V Signal
BMS interface Card
-
-
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
OPTICHILL
Chillers
Installation & Maintenance : 6564868 08/2008
HED
High Efficiency
Chillers
FEATURES
OPTICHILL
Chillers
General Description
STANDARD FEATURES
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.
STANDARD FEATURES
Compressor
Twin screw semi hermetic compressors comprising:









Electronic Protection Module featuring:
Motor, discharge gas and oil monitoring
Rotation direction protection
Phase failure protection
Low current Star/Delta Start
Internal pressure relief
Discharge non return valve
Oil separator
Oil sight glass
Oil heater
Slide valve stepped capacity control
Suction gas motor cooling
The compressors are mounted to the rigid galvanised heavy duty sub-frame with the use
of vibration reducing isolation.
Liquid injection is not required under normal operating conditions, leading to an increase
in cooling and efficiency
Closed transition Star/Delta compressor start is available as an optional extra.
Refrigeration
8
Each refrigeration circuit is supplied with the following:

Full operating charge of R134a

Electronic Expansion Valves (EEV)

Discharge line ball valve

Liquid line ball valve

Large capacity filter drier with replaceable cores

Liquid line sight glass

Low pressure switch with Auto reset

High pressure switch with manual reset

Suction and liquid pressure transducers

Discharge line mufflers (DQ Models)
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
General Description
STANDARD FEATURES
As standard, the
capacity control.
Controls
microprocessor controller can provide 8 stages of
Optionally, the controller is designed to provide capabilities for;


Building Management Systems (BMS)
Sequencing (Master/Slave and Run/Standby)
to meet all your system requirements, please specify at order.
Unit initial set up details can be found in the Controls section.
CAUTION
When adding to an existing network, please consult Airedale to ensure
strategy compatibility.
A weatherproof electrical power and controls panel is situated at the end of the unit
and contains:
Electrical







CAUTION
Individual mains power compartments for each
refrigeration circuit
refer to
Separate door locking electrical isolation for each
Interconnecting wiring,
mains compartment
on page 31
Dedicated bus-bar chamber for connection of incoming 3phase and earth mains power supply
Emergency Stop fitted to controls compartment door
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
Phase rotation relay incorporating phase loss protection (compressor module)
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 31.
Separate 230V permanent supply is required for the controls and safety features.
Electrical terminals for external evaporator pipework trace heating (230V/500W)
are provided.
For further electrical information refer to Installation Data, on page 30.
Chillers
Installation & Maintenance : 6564868 09/2012
9
OPTICHILL
Chillers
General Description
OPTIONAL EXTRAS



Loose Item


Factory Fitted















Power Factor Correction
Electronically Commutated (EC)
Fan Motor
Energy Manager
Pump - Inverter Driven - Variable
Speed for Constant Water Flow
Pump - ac Motor - Fixed Speed
Corrosion Resistant Coated Coils
Coil Guards
Discharge Air Plenum Condenser Fan
Extended Discharge Air Plenum Condenser Fan
Maintainable Dual Pressure
Relief Valve
R134a Leak Detection System
Closed Transition Star/Delta
Compressor Start
Evaporator Differential
Pressure Sensor
Remote Setpoint Adjust
BMS Interface Card
Commissioning
Chillerguard® Maintenance(1)
(1)
10
-
Instructions supplied with item
It is only possible to set up a sequencing following completion of interconnecting
communication wiring. Airedale Service can arrange sequence setup on request
(UK Mainland).
CAUTION
Optional Unit Cover
Anti Vibration Mounts
Flow Switch
Chiller Sequence Manager
UK Mainland Sites
Chillers
Installation & Maintenance : 6564868 09/2012
- Standard feature to HEDQ, HE+D &
HE+DQ
Assembly Instructions supplied with item
-
Refer to Commissioning Data, on page 50
for details
For details and a competitive quotation,
contact Airedale Service.
Chillers
OPTICHILL
Notes:
Chillers
Installation & Maintenance : 6564868 09/2012
11
OPTICHILL
Chillers
Dimensional Data
The following information is for general guidance; refer to the certified drawings
provided for installation.
IMPORTANT
STANDARD UNITS
8 - 10 Fan Units (mm)
(8)
(9)
50
2100
(10)
50
500
(10)
H
G1
G1
L
(2)
(1)
(3)
(3)
A
(1)
(6)
(4)
(5)
(6)
(7)
D
90
90
F
E
B
C
12 - 20 Fan Units (mm)
(8)
(9)
50
2100
(10)
50
500
G1
(10)
H
G2
J
(2)
(1)
(3)
(3)
A
(1)
(6)
(4)
(5)
(7)
(6)
90
D
90
12
F
E
B
Chillers
Installation & Maintenance : 6564868 09/2012
C
K
L
Chillers
OPTICHILL
Dimensional Data
HIGH EFFICIENCY - STANDARD UNITS
OPC500HED8
OPC525HED8
OPC550HED8
OPC600HED10
OPC650HED10
OPC700HED12
OPC750HED12
OPC800HED12
OPC850HED12
OPC900HED14
OPC950HED14
OPC1000HED16
OPC1100HED16
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
C
4675
4675
4675
5675
5675
7100
7100
7100
7100
8100
8100
9100
9100
D
460
460
460
460
510
510
510
510
510
510
510
510
510
E
1056
1056
1056
1556
1582
2730
2730
2730
2304
2304
2304
3304
3304
F
2412
2412
2412
2412
2360
2360
2360
2360
3210
3210
3210
3210
3210
G1
1250
1250
1250
1750
1750
1850
1850
1850
1850
2000
2000
2875
2875
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H
1250
1250
1250
1250
1250
1200
1200
1200
1200
1400
1400
1400
1400
J
N/A
N/A
N/A
N/A
N/A
1175
1175
1175
1175
1400
1400
1400
1400
K
N/A
N/A
N/A
N/A
N/A
1775
1775
1775
1775
2000
2000
2325
2325
L
425
425
425
425
425
600
600
600
600
800
800
600
600
(10)
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
OPC500HEDQ10
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
OPC650HEDQ10
OPC700HEDQ14
OPC750HEDQ14
OPC800HEDQ14
OPC850HEDQ14
OPC900HEDQ16
OPC950HEDQ16
OPC1000HEDQ18
OPC1100HEDQ18
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
C
5675
5675
5675
5675
5675
8100
8100
8100
8100
9100
9100
10100
10100
D
460
460
460
460
460
510
510
510
510
510
510
510
510
E
1556
1556
1556
1556
1556
2730
2730
2304
2304
3304
3304
3304
3304
F
2412
2412
2412
2412
2412
2360
2360
3210
3210
3210
3210
3210
3210
G1
1750
1750
1750
1750
1750
2000
2000
2000
2000
2875
2875
3000
3000
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H
1250
1250
1250
1250
1250
1400
1400
1400
1400
1400
1400
1400
1400
J
N/A
N/A
N/A
N/A
N/A
1400
1400
1400
1400
1400
1400
1400
1400
K
N/A
N/A
N/A
N/A
N/A
2000
2000
2000
2000
2325
2325
3000
3000
L
425
425
425
425
425
800
800
800
800
600
600
800
800
(10)
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
HIGH EFFICIENCY PLUS - STANDARD UNITS
OPC500HE+D8
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
OPC650HE+D10
OPC700HE+D12
OPC750HE+D12
OPC800HE+D14
OPC850HE+D14
OPC900HE+D16
OPC950HE+D18
OPC1000HE+D18
OPC1100HE+D18
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
C
4675
5675
5675
5675
5675
7100
7100
8100
8100
9100
10100
10100
10100
D
510
510
510
510
510
510
510
510
510
510
510
510
510
E
1082
1582
1582
1582
1157
2304
2304
2304
2304
3304
3304
3304
3304
F
2360
2360
2360
2360
3210
3210
3210
3210
3210
3210
3210
3210
3210
G1
1250
1750
1750
1750
1750
1850
1850
2000
2000
2875
3000
3000
3000
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H
1250
1250
1250
1250
1250
1200
1200
1400
1400
1400
1400
1400
1400
J
N/A
N/A
N/A
N/A
N/A
1175
1175
1400
1400
1400
1400
1400
1400
K
N/A
N/A
N/A
N/A
N/A
1775
1775
2000
2000
2325
3000
3000
3000
L
425
425
425
425
425
600
600
800
800
600
800
800
800
(10)
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
OPC500HE+DQ12
OPC525HE+DQ12
OPC550HE+DQ12
OPC600HE+DQ12
OPC650HE+DQ12
OPC700HE+DQ14
OPC750HE+DQ16
OPC800HE+DQ16
OPC850HE+DQ18
OPC900HE+DQ20
OPC950HE+DQ20
OPC1000HE+DQ20
OPC1100HE+DQ20
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
2200
C
7100
7100
7100
7100
7100
8100
9100
9100
10100
11100
11100
11100
11100
D
510
510
510
510
510
510
510
510
510
510
510
510
510
E
2730
2730
2730
2730
2730
2304
3304
3304
3304
4304
4304
4304
4304
F
2360
2360
2360
2360
2360
3210
3210
3210
3210
3210
3210
3210
3210
G1
1850
1850
1850
1850
1850
2000
2875
2875
3000
2000
2000
2000
2000
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
2000
2000
2000
2000
H
1200
1200
1200
1200
1200
1400
1400
1400
1400
1400
1400
1400
1400
J
1175
1175
1175
1175
1175
1400
1400
1400
1400
1400
1400
1400
1400
K
1775
1775
1775
1775
1775
2000
2325
2325
3000
2700
2700
2700
2700
L
600
600
600
600
600
800
600
600
800
1100
1100
1100
1100
(10)
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Mains Electric Isolator(s), for unit isolation refer to (6).
Emergency Stop.
Mains Electric Panel(s), for unit isolation refer to (6).
Microprocessor Control Panel.
Compressor Enclosure (DQ Models Only).
Mains Cable Entry to Busbar, unit incoming mains isolation supplied by others.
Busbar Chamber.
Lifting Lugs (removable).
20mm Ø Mounting Holes:
8 - 10
Fan Unit
x8
12 - 18 Fan Unit
x 10
20
Fan Unit
x 12
Water Connections.
Chillers
Installation & Maintenance : 6564868 09/2012
13
OPTICHILL
Chillers
Dimensional Data
The following information is for general guidance; refer to the certified drawings
provided for installation.
IMPORTANT
UNITS FITTED WITH OPTIONAL PUMP PACKAGE
8 - 12 Fan Units (mm)
(8)
(9)
50
2100
(1)
50
(10)
(10)
500
H
G1
J
K
L
(12)
275
(2)
(1)
(3)
(3)
(1)
(11)
A
(6)
(4)
(5)
(7)
(6)
D
E
90
90
F
370
2200
C1
B
1400
C
Pump package assembly and connecting evaporator pipework supplied loose.
IMPORTANT
14 - 20 Fan Units (mm)
(8)
(9)
50
2100
(1)
(10)
50
500
G1
G2
(10)
H
J
K
(12)
L
(2)
(1)
(3)
(3)
A
(1)
(6)
(4)
(5)
(7)
(6)
D
90
90
2000
(11)
F
E
370
C
B
IMPORTANT
14
Connecting evaporator pipework supplied loose.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Dimensional Data
HIGH EFFICIENCY - WITH OPTIONAL PUMP PACKAGE
OPC500HED8
OPC525HED8
OPC550HED8
OPC600HED10
OPC650HED10
OPC700HED12
OPC750HED12
OPC800HED12
OPC850HED12
OPC900HED14
OPC950HED14
OPC1000HED16
OPC1100HED16
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
C
6075
6075
6075
7075
7075
8500
8500
8500
8500
8100
8100
9100
9100
C1
4675
4675
4675
5675
5675
7100
7100
7100
7100
N/A
N/A
N/A
N/A
D
460
460
460
460
510
510
510
510
510
510
510
510
510
E
1056
1056
1056
1556
1582
2730
2730
2730
2304
2304
2304
3304
3304
F
4300
4300
4300
4800
4770
5050
5050
5050
5477
5075
5075
5075
5075
G1
1250
1250
1250
1750
1750
1850
1850
1850
1850
2000
2000
2875
2875
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H
1250
1250
1250
1250
1250
1200
1200
1200
1200
1400
1400
1400
1400
J
N/A
N/A
N/A
N/A
N/A
1175
1175
1175
1175
1400
1400
1400
1400
K
N/A
N/A
N/A
N/A
N/A
1775
1775
1775
1775
2000
2000
2325
2325
L
1550
1550
1550
1550
1550
1725
1725
1725
1725
800
800
600
600
(10)
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
OPC500HEDQ10
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
OPC650HEDQ10
OPC700HEDQ14
OPC750HEDQ14
OPC800HEDQ14
OPC850HEDQ14
OPC900HEDQ16
OPC950HEDQ16
OPC1000HEDQ18
OPC1100HEDQ18
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
C
7075
7075
7075
7075
7075
8100
8100
8100
8100
9100
9100
10100
10100
C1
5675
5675
5675
5675
5675
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
D
460
460
460
460
460
510
510
510
510
510
510
510
510
E
1556
1556
1556
1556
1556
2730
2730
2304
2304
3304
3304
3304
3304
F
4800
4800
4800
4800
4800
4650
4650
5075
5075
5075
5075
6075
6075
G
1750
1750
1750
1750
1750
2000
2000
2000
2000
2875
2875
3000
3000
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H
1250
1250
1250
1250
1250
1400
1400
1400
1400
1400
1400
1400
1400
J
N/A
N/A
N/A
N/A
N/A
1400
1400
1400
1400
1400
1400
1400
1400
K
N/A
N/A
N/A
N/A
N/A
2000
2000
2000
2000
2325
2325
3000
3000
L
1550
1550
1550
1550
1550
800
800
800
800
600
600
800
800
(10)
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN150 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
HIGH EFFICIENCY PLUS - WITH OPTIONAL PUMP PACKAGE
OPC500HE+D8
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
OPC650HE+D10
OPC700HE+D12
OPC750HE+D12
OPC800HE+D14
OPC850HE+D14
OPC900HE+D16
OPC950HE+D18
OPC1000HE+D18
OPC1100HE+D18
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
C
6075
7075
7075
7075
7075
8500
8500
8100
8100
9100
10100
10100
10100
C1
4675
5675
5675
5675
5675
7100
7100
N/A
N/A
N/A
N/A
N/A
N/A
D
510
510
510
510
510
510
510
510
510
510
510
510
510
E
1082
1582
1582
1582
1157
2304
2304
2304
2304
3304
3304
3304
3304
F
4274
4770
4770
4770
5200
5477
5477
5075
5075
5075
6075
6075
6075
G
1250
1750
1750
1750
1750
1850
1850
2000
2000
2875
3000
3000
3000
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H
1250
1250
1250
1250
1250
1200
1200
1400
1400
1400
1400
1400
1400
J
N/A
N/A
N/A
N/A
N/A
1175
1175
1400
1400
1400
1400
1400
1400
K
N/A
N/A
N/A
N/A
N/A
1775
1775
2000
2000
2325
3000
3000
3000
L
1550
1550
1550
1550
1550
1725
1725
800
800
600
800
800
800
(10)
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
OPC500HE+DQ12
OPC525HE+DQ12
OPC550HE+DQ12
OPC600HE+DQ12
OPC650HE+DQ12
OPC700HE+DQ14
OPC750HE+DQ16
OPC800HE+DQ16
OPC850HE+DQ18
OPC900HE+DQ20
OPC950HE+DQ20
OPC1000HE+DQ20
OPC1100HE+DQ20
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
A
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
2600
B
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
2570
C
8500
8500
8500
8500
8500
8100
9100
9100
10100
11100
11100
11100
11100
C1
7100
7100
7100
7100
7100
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
D
510
510
510
510
510
510
510
510
510
510
510
510
510
E
2730
2730
2730
2730
2730
2304
3304
3304
3304
4304
4304
4304
4304
F
5050
5050
5050
5050
5050
5075
5075
5075
6075
6075
6075
6075
6075
G
1850
1850
1850
1850
1850
2000
2875
2875
3000
2000
2000
2000
2000
G2
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
2000
2000
2000
2000
H
1200
1200
1200
1200
1200
1400
1400
1400
1400
1400
1400
1400
1400
J
1175
1175
1175
1175
1175
1400
1400
1400
1400
1400
1400
1400
1400
K
1775
1775
1775
1775
1775
2000
2325
2325
3000
2700
2700
2700
2700
L
1725
1725
1725
1725
1725
800
600
600
800
1100
1100
1100
1100
(10)
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Mains Electric Isolator(s), for unit isolation refer to (6).
Emergency Stop.
Mains Electric Panel(s), for unit isolation refer to (6).
Microprocessor Control Panel.
Compressor Enclosure (DQ Models Only).
Mains Cable Entry to Busbar, unit incoming mains isolation supplied by others.
Busbar Chamber.
Lifting Lugs (removable).
20mm Ø Mounting Holes:
8 - 10
Fan Unit
x 8 + 2 (Pump Package)
12
Fan Unit
x 10 + 2 (Pump Package)
Water Connections.
Pump package including connecting evaporator pipework.
Pump Controls Panel, for unit isolation refer to (6).
14 - 18 Fan Unit
20
Fan Unit
x 10
x 12
Chillers
Installation & Maintenance : 6564868 09/2012
15
OPTICHILL
Dimensional Data
PLENUM OPTIONS
Standard Discharge Plenum Option (mm)
2600
Extended Discharge Plenum Option (mm)
3100
(1)
16
For plenum weights, please contact Airedale.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
Chillers
OPTICHILL
Installation Data
WEIGHTS, POINT LOADINGS & CENTRE OF GRAVITY (C OF G) - NO PUMPS
High Efficiency
2
1
L1
L2
L3
L4
= (C of G)
R1
R2
R3
R4
1
2
L1
L2
L3
L4
L5
L6
= C of G
R1
R2
R3
R4
R5
R6
OPC500HED8
OPC525HED8
OPC550HED8
OPC600HED10
OPC650HED10
OPC700HED12
OPC750HED12
OPC800HED12
OPC850HED12
OPC900HED14
OPC950HED14
OPC1000HED16
OPC1100HED16
L1
650
660
660
750
760
760
810
810
820
820
830
900
900
L4
470
470
470
370
380
760
810
810
820
860
870
910
910
Point Loadings (kg)
L5
L6
R1
R2
(1)
(1) 830 860
(1)
(1) 830 870
(1)
(1) 830 870
(1)
(1) 920 1080
(1)
(1) 1010 1190
360
(2) 950 800
380
(2) 1010 840
390
(2) 1010 850
390
(2) 1070 890
370
(2) 1040 1130
380
(2) 1050 1140
490
(2) 1130 1140
490
(2) 1130 1140
R3
850
850
860
950
1040
1040
1100
1100
1170
1240
1250
1260
1260
R4
590
590
590
450
500
950
1010
1010
1070
1100
1110
1140
1140
R5
(1)
(1)
(1)
(1)
(1)
450
480
480
510
480
480
610
610
R6
(1)
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
Operating
Weight (kg)
5600
5640
5650
6170
6570
7530
8000
8020
8330
8900
8990
9490
9490
C of G (mm)
1
1220
1220
1220
1205
1245
1220
1215
1215
1235
1225
1225
1220
1220
2
2225
2225
2230
2495
2515
3130
3230
3225
3250
3510
3525
4290
4295
OPC500HEDQ10
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
OPC650HEDQ10
OPC700HEDQ14
OPC750HEDQ14
OPC800HEDQ14
OPC850HEDQ14
OPC900HEDQ16
OPC950HEDQ16
OPC1000HEDQ18
OPC1100HEDQ18
L1
L2
L3
L4
800 940 820 390
800 940 830 390
800 950 830 400
800 950 830 400
810 950 830 400
790 860 940 830
840 910 1000 880
850 930 1010 900
850 930 1010 900
930 940 1040 940
940 950 1050 950
970 1040 1110 1010
970 1050 1110 1010
Point Loadings (kg)
L5
L6
R1
R2
(1)
(1) 960 1130
(1)
(1) 960 1140
(1)
(1) 970 1140
(1)
(1) 970 1140
(1)
(1) 970 1140
360
(2) 970 1050
390
(2) 1020 1110
390
(2) 1070 1170
390
(2) 1070 1170
510
(2) 1160 1170
510
(2) 1170 1180
540
(2) 1180 1280
540
(2) 1190 1280
R3
990
1000
1000
1000
1000
1150
1210
1270
1280
1290
1300
1360
1360
R4
470
470
480
480
480
1020
1080
1130
1130
1170
1180
1240
1240
R5
(1)
(1)
(1)
(1)
(1)
450
470
490
490
630
630
660
670
R6
(1)
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
Operating
Weight (kg)
6500
6530
6570
6570
6580
8420
8910
9210
9220
9780
9860
10390
10420
C of G (mm)
1
1200
1200
1200
1195
1195
1205
1200
1220
1220
1215
1210
1205
1205
2
2520
2520
2520
2520
2525
3440
3510
3525
3525
4295
4305
4485
4485
(1)
(2)
(3)
(4)
L2
L3
680 670
690 680
690 680
880 770
900 790
630 830
680 880
680 880
690 900
890 970
900 980
910 1000
910 1000
Only 8 fixing and loading points to this model.
Only 10 fixing and loading points to this model.
Based on standard unit, for units fitted with options, please contact Airedale.
Operating weight includes refrigerant charge and system water volume.
Chillers
Installation & Maintenance : 6564868 09/2012
17
OPTICHILL
Chillers
Installation Data
WEIGHTS, POINT LOADINGS & CENTRE OF GRAVITY (C OF G) - NO PUMPS
High Efficiency Plus
2
1
L1
L2
L3
L4
= (C of G)
R1
R2
R3
R4
1
2
L1
L2
L3
L4
L5
L6
= C of G
R1
R2
R3
R4
R5
R6
OPC500HE+D8
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
OPC650HE+D10
OPC700HE+D12
OPC750HE+D12
OPC800HE+D14
OPC850HE+D14
OPC900HE+D16
OPC950HE+D18
OPC1000HE+D18
OPC1100HE+D18
L1
L2
L3
670 700 690
760 890 780
760 890 780
760 900 790
770 910 800
770 640 840
820 690 900
810 880 960
810 880 960
890 900 990
920 990 1050
920 1000 1050
920 1000 1060
L4
480
370
370
370
380
770
820
850
850
900
960
960
960
Point Loadings (kg)
L5
L6
R1
R2
(1)
(1) 920 960
(1)
(1) 1000 1180
(1)
(1) 1000 1180
(1)
(1) 1010 1180
(1)
(1) 1070 1260
360
(2) 1010 840
390
(2) 1060 890
370
(2) 1030 1120
370
(2) 1030 1120
480
(2) 1120 1130
510
(2) 1140 1230
520
(2) 1140 1240
520
(2) 1150 1240
R3
940
1030
1040
1040
1110
1100
1160
1220
1230
1240
1310
1310
1310
R4
650
490
490
500
530
1010
1060
1090
1090
1130
1190
1190
1200
R5
(1)
(1)
(1)
(1)
(1)
480
510
470
470
610
640
640
640
R6
(1)
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
Operating
Weight (kg)
6010
6500
6510
6550
6830
7820
8300
8800
8810
9390
9940
9970
10000
C of G (mm)
1
1265
1245
1245
1245
1270
1245
1235
1230
1230
1220
1215
1215
1215
2
2225
2510
2515
2515
2530
3160
3250
3520
3520
4280
4480
4480
4480
OPC500HE+DQ12
OPC525HE+DQ12
OPC550HE+DQ12
OPC600HE+DQ12
OPC650HE+DQ12
OPC700HE+DQ14
OPC750HE+DQ16
OPC800HE+DQ16
OPC850HE+DQ18
OPC900HE+DQ20
OPC950HE+DQ20
OPC1000HE+DQ20
OPC1100HE+DQ20
L1
L2
L3
L4
740 620 810 740
750 630 820 750
750 630 820 750
750 630 820 750
750 630 820 750
800 870 950 840
920 930 1030 930
920 930 1030 930
950 1020 1080 990
560 640 1090 1060
570 640 1100 1070
570 640 1100 1070
570 640 1100 1080
Point Loadings (kg)
L5
L6
R1
R2
350
(2) 930 780
360
(2) 940 780
360
(2) 940 790
360
(2) 940 790
360
(2) 940 790
370
(2) 1020 1110
500
(2) 1150 1160
500
(2) 1150 1160
530
(2) 1160 1260
910 590 690 770
920 600 690 780
920 600 690 780
920 600 690 780
R3
1020
1020
1030
1030
1030
1210
1280
1280
1330
1320
1330
1340
1340
R4
930
940
940
940
940
1070
1160
1160
1210
1290
1300
1310
1310
R5
440
450
450
450
450
470
620
620
650
1110
1120
1120
1120
R6
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
720
730
730
730
Operating
Weight (kg)
7360
7440
7460
7460
7460
8710
9680
9680
10180
10750
10850
10870
10880
C of G (mm)
1
1220
1220
1220
1220
1220
1225
1215
1215
1210
1205
1200
1200
1200
2
3215
3215
3220
3215
3220
3455
4300
4295
4480
5265
5280
5275
5280
(1)
(2)
(3)
(4)
18
Only 8 fixing and loading points to this model.
Only 10 fixing and loading points to this model.
Based on standard unit, for units fitted with options, please contact Airedale.
Operating weight includes refrigerant charge and system water volume.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Installation Data
WEIGHTS - WITH OPTIONAL PUMPS (GUIDANCE)
CAUTION
Due to the number of different pump options available, the following table is
provided as a guide to the MAXIMUM weight of models with optional pumps fitted.
Once selection has been made, it is important to consult Airedale for the specific
details at time of enquiry to ensure lifting and support arrangements are sufficient.
Point Loadings and AV selection will be provided separately.
OPC750HED12
OPC800HED12
OPC850HED12
OPC900HED14
8210
8610
8220
8630
8400
8940
8943
9483
9023 9550 9570
9573 10090 10090
kg
kg
6182
6422
6202
6462
6232
6472
6722
6992
7006
7426
7976
8386
8522
8922
8532
8942
8712
9252
9250
9790
9330 9874 9894
9880 10414 10414
OPC500HEDQ10
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
OPC650HEDQ10
OPC700HEDQ14
OPC750HEDQ14
OPC800HEDQ14
kg
kg
6795
7035
6825
7065
6845
7105
6855
7105
6907
7157
8607
8997
9110
9520
9290
9820
kg
kg
7082
7322
7112
7352
7132
7392
7142
7392
7186
7436
8886
9276
9422 9602 9612 10150 10240 10784 10804
9832 10132 10142 10670 10750 11314 11344
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
OPC650HE+D10
OPC700HE+D12
OPC750HE+D12
OPC800HE+D14
OPC850HE+D14
kg
kg
6125
6545
6635
7035
6665
7045
6675
7085
6887
7407
7867
8397
8390
8910
8870
9410
8880
9420
kg
kg
6412
6832
6922
7322
6952
7332
6962
7372
7166
7686
8146
8676
8702
9222
9182
9722
9192 9730 10310 10364 10384
9732 10280 10830 10894 10924
OPC525HE+DQ12
OPC550HE+DQ12
OPC600HE+DQ12
OPC650HE+DQ12
OPC700HE+DQ14
OPC750HE+DQ16
OPC800HE+DQ16
OPC1100HED16
OPC700HED12
7697
8107
kg
kg
7525
7895
7555
7975
7585
7995
7595
7995
7647
8037
8767 9760 9770 10270 10813 10903 10940 10970
9287 10290 10290 10790 11333 11433 11470 11480
kg
kg
7812
8182
7842
8262
7872
8282
7882
8282
7926
8316
9046 10072 10082 10582 11120 11210 11264 11294
9566 10602 10602 11102 11640 11740 11794 11804
OPC950HEDQ16
OPC1100HEDQ18
OPC650HED10
6727
7147
OPC1000HEDQ18
OPC600HED10
6435
6705
OPC950HED14
OPC550HED8
5945
6185
OPC900HEDQ16
OPC525HED8
5915
6175
OPC850HEDQ14
OPC500HED8
5895
6135
OPC500HE+D8
Single Pump Option
Weight - Machine
Weight - Operating
Run/Standby Pump Option
Weight - Machine
Weight - Operating
kg
kg
OPC500HE+DQ12
Single Pump Option
Weight - Machine
Weight - Operating
Run/Standby Pump Option
Weight - Machine
Weight - Operating
OPC1000HED16
High Efficiency
9300 9843 9933 10460 10480
9830 10363 10443 10990 11020
Single Pump Option
Weight - Machine
Weight - Operating
Run/Standby Pump Option
Weight - Machine
Weight - Operating
(1)
OPC1100HE+D18
OPC1000HE+D18
OPC950HE+D18
OPC900HE+D16
OPC1100HE+DQ20
OPC1000HE+DQ20
OPC950HE+DQ20
9423 10003 10040 10060
9973 10523 10570 10600
OPC900HE+DQ20
Single Pump Option
Weight - Machine
Weight - Operating
Run/Standby Pump Option
Weight - Machine
Weight - Operating
OPC850HE+DQ18
High Efficiency Plus
Machine weight includes refrigerant charge; operating weight includes refrigerant charge and water volume.
Chillers
Installation & Maintenance : 6564868 09/2012
19
OPTICHILL
Chillers
Installation Data
UNIT LIFTING




IMPORTANT
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 (provided by others) with the
holes/lugs provided
Attach individual lifting chains to each of the lifting eye bolts/lifting lugs provided;
each individual chain must be capable of lifting the whole unit
Do not use 1 chain between 2 lifting points to avoid load shift.
Only use lifting points provided.



IMPORTANT
Lifting hole/lug dimension: 40mm
Chains/slings MUST NOT interfere with the casing or fan assembly to avoid damage
Lift the unit slowly and evenly
If the unit is dropped, it should immediately be checked for damage and reported
to Airedale.
LIFTING DIMENSIONS
8 - 10 Fan
2300
A1
C
B
12 - 20 Fan
A2
2300
A1
B
C
C
8 FAN
10 FAN
12 FAN
14 FAN
16 FAN
18 FAN
20 FAN
IMPORTANT
20
mm
mm
mm
mm
mm
mm
mm
A1 (Min)
4000
4000
4000
5000
5000
6000
7000
A2 (Min)
N/A
N/A
5000
5000
5000
5000
5000
B
520
846
520
520
520
520
520
For models with optional pumps fitted, a separate instruction will be provided.
Chillers
Installation & Maintenance : 6564868 09/2012
C
3200
3500
4000
4650
5000
5650
6650
Chillers
OPTICHILL
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
mm
(1)
(2)
A(1)
180
B
130
C
225
D
186
E
20
FØ
16
Unloaded dimension
For models with optional pumps fitted, please consult
Airedale.
A
F
B
D
E
E
C
Components
2
1
9
6a
5
3
4
8
7
6b
1
2
3
4
5
6a
6b
7
8
9
10
Locating Screw
Retaining Nut & Washer
Levelling Screw
Levelling Lock Nut
Retaining Studs
Upper Retaining Nuts
Lower Retaining Nuts
Spring assembly
Pressure Plate
Top Plate
Bolting-down holes
10
Installation
1
2
3
4
5
6
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
8
CAUTION
Locate and secure mount using bolting down holes (10) in base plate.
Ensure mounts are located in line with the unit base.
If applicable, remove compressor enclosure covers to allow access to mount fixing
holes in the unit base.
Lock the upper retaining nuts (6a) to the underside of the top plate (9) before a load
is applied.
Remove retaining nut and washer (2), lower the unit onto the mounts and replace
retaining nut and washer.
Beginning with the mount with the largest deflection, adjust the height of each mount
using the levelling screw (3).
When all mounts are level, lock each into place using the levelling lock nut (4).
Lock all retaining nuts (6a and 6b) to the extreme ends of the retaining studs (5).
Do not connect any services until all anti vibration mounts have been
fully adjusted.
Pad Type
Components/Installation
2
2
1
5
3
3
64
7
1
2
3
4
5
6
7
M16 Bolt (Not Supplied)
Washer (Not Supplied)
Fixing Pad 506-063
A V Pad 506-062
2 x M16 Nut (Not Supplied)
Unit Base
Unit Mounting Plinth
Chillers
Installation & Maintenance : 6564868 09/2012
21
OPTICHILL
Chillers
Installation Data
POSITIONING
CAUTION
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 antivibration 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

Increase airflow and maintenance clearances for side-enclosed or multiple
unit applications

Ensure there are no obstructions directly above the fans

Allow free space above the fans to prevent air recirculation
Prior to connecting services, ensure that the equipment is installed and
completely level.
AIRFLOW &
MAINTENANCE
CLEARANCES
(1)
(1)
1300mm / (2600mm)
Application
Single unit
Side-enclosed or multiple units
22
Chillers
Installation & Maintenance : 6564868 09/2012
Distance from Overall Base Dimension
1300mm
2600mm
Chillers
OPTICHILL
Installation Data
WATER SYSTEM
CAUTION
GROOVED & CLAMPED
TYPE CONNECTION
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

In ambients of 0°C and below, where static water can be expected, or when water
supply temperatures of +5°C or below is required, the necessary concentration of
Glycol or use of an electrical trace heater must be included

The schematic is referred to as a guide to ancillary recommendations
The unit water connections are NOT designed to support external pipework,
pipework MUST be supported separately.
1
Place Grooved Ends Together
2
Locate Rubber Gasket

Note that an expansion gap of 5mm is
shown here

The gasket should be checked for
compatability and damage prior
to installation
A thin coat of sealing lubricant should
be applied to both the inside and
outside mating surfaces
Slip the gasket fully onto one of the
pipe ends, align the second pipe and
slide the gasket into place


3
Place Clamp over Gasket

Wrap the 2-halves of the clamp over

the gasket
Ensure the gasket fits snugly within the
grooved recess within the inside of the 
clamp and that the clamp
mates correctly

4
Secure Clamp
Tightend the bolts incrementally and
evenly at both sides until a leak free
seal is formed
The gasket should not be visible
beneath the clamp when the bolts are
properly tightened
Chillers
Installation & Maintenance : 6564868 09/2012
23
OPTICHILL
Chillers
Installation Data
3
REFRIGERATION
SCHEMATIC
4
2
5
A
7
A2
1
6
A1
8
9
1
2
3
4
5
6
Screw compressor
Muffler (DQ Only)
Ball Valve - Discharge
Ball Valve - Liquid
Sight Glass
Filter driver - Replaceable core
7
8
9
A
A1
A2
Solenoid valve
EEV
Evaporator
Economiser Circuit
EEV
Heat exchanger
STANDARD RECOMMENDED INSTALLATION
(Parts Supplied by Others)
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, on page 10 for details.
GENERAL
CAUTION
The following installation recommendations should be adhered to. Failure to do
this will invalidate the chiller warranty.
(2)
(3)
P
T
(5)
T
(6)
(4)
(1)
P
(1)
(2)
(3)
(4)
(5)
(6)
CAUTION
Flexible connections
Pressure gauges
Temperature gauges
Binder points
De-aerator (optional extra)
Auto air vent (at highest point)
(9)
(11)
(7)
(8)
(7)
(8)
(9)
(10)
(11)
(12)
(12)
(10)
Strainer (optional extra)
Flow switch
Shut off valves
Bypass circuit (for flushing)
Pump
Pump strainer
Full design water flow MUST be maintained at all times. Variable water volume is
NOT recommended and will invalidate warranty
The correct operation of the flow proving device is critical if the chiller warranty is
to be valid.
Following components are fitted within the chiller unit as standard:

Temperature Sensors

Drain Point

Auto Air Vent
24
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Installation Data
WATER SYSTEM
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 unit Chiller

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

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
Pump Statement
When installing circulating water pumps or equipment containing them, the following rules
should be applied:


Interlocks & Protection
CAUTION
Ensure the system is filled with liquid 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
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
Always electrically interlock the operation of the chiller with the pump controls and flow
proving device for safety reasons.
Failure to install safety devices will invalidate the chiller warranty.
Do not rely solely on the BMS to protect the chiller against low flow conditions.
An evaporator pump interlock and flow proving device MUST be directly wired to
the chiller, refer to Interconnecting wiring, on page 31.
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.
RECORD
Record on commissioning sheet provided once completed.
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.
Filling




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
Chillers
Installation & Maintenance : 6564868 09/2012
25
OPTICHILL
Chillers
Installation Data
GLYCOL DATA
CAUTION
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.
The source data must be at 100% Water for the correction factors to be valid.
Ethylene Glycol Nominal Correction Factors
Glycol in System / Freezing Point ºC
Output (kW)
Compressor Input (kW)
x
Water Flow (l/s)
Pressure Drop (kPa)
10% / -4°C
0.98
0.99
0.99
1.05
20% / -9°C
0.97
0.98
1.02
1.20
30% / -15°C
0.95
0.96
1.04
1.38
40% / -23°C
0.93
0.95
1.07
1.57
20% / -6°C
0.95
0.98
0.97
1.17
30% / -12°C
0.91
0.96
0.95
1.31
40% / -20°C
0.88
0.95
0.95
1.45
Propylene Glycol Nominal Correction Factors
Glycol in System / Freezing Point ºC
Output (kW)
Compressor Input (kW)
x
Water Flow (l/s)
Pressure Drop (kPa)
10% / -2°C
0.97
0.99
0.98
1.08
Model Ref.
Ambient:
Fluid
Inlet Fluid Temp.
Outlet Fluid Temp.
Example
Output (kW)
Compressor Input (kW)
Water Flow (l/s)
Pressure Drop (kPa)
=
Input (kW) - TFP {283.1 - {14 x 1.7}} =
Output
4.19 x ΔT
Plot from curve (refer to Waterside
pressure drop (kPa), on page 46)
Where:
Output
Compressor Input
TFP
(Total Fan Power)
Water Flow
ΔT
CAUTION
= OPC800HE+D14
= 35°C
= 20% Ethylene Glycol
= 7°C
= 12°C (5°C T)
100% Water
841.2
259.3
Multiplier Corrected Figure
x 0.97
=
816.0 kW
x 0.98
=
254.1 kW
40.2
x 1.02
=
40.8 l/s
33.1
x 1.20
=
39.7 kPa
= (kW) Output (kW), refer to Technical Manual
= (kW) Input (kW) refer to Technical Manual (-) Minus TFP
= (kW) Quantity of Fans to unit x Fan Motor Size
= (l/s) ALWAYS USE 100% water SHC of 4.19
= (°C) Difference of Entering Water and Leaving Water temperature
Waste glycol needs to be handled responsibly, recycled or turned over to professional
personnel for correct disposal. Most anti-freeze manufacturers recommend that used antifreeze 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.
26
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Installation Data
PUMPS OPTIONS
CAUTION
Full design water flow MUST be maintained at all times. Variable water volume is
NOT recommended and will invalidate warranty.
A variety of pump options to suit a wide range of applications is available:
Factory fitted in line as a single pump or run/standby configuration and available in
standard and larger nominal external head pressures.
Factory fitted run/standby pumps have a shut off valve to the inlet and a non return valve
to the outlet enabling one pump to be maintained without interrupting chiller flow.
Supplied with electrical switchgear and isolating valve as standard.
Run/standby pumps may be rotated manually to ensure even pump usage and prolong
component life.
For performance curves, please refer to Commissioning Data, on page 47.
The pump motor speed can be supplied as fixed or variable:
Standard - ac Motor Fixed Speed
The standard ac electric motors are 400Vac / 50Hz / 3ph and fixed speed.
Inverter Driven Motor Variable Speed for
constant water flow
Flow is monitored by the onboard electronic flow meter to maintain the exact requirement
of the application, thus saving pump input power whilst providing optimum chilled water
flow control.
The option of an onboard variable speed drive combined with the electronic flow metering
system offers an exceptional combination of simple commissioning and
optimised efficiency.
Flow Schemes:
A
B
C
D
Single Head Pump - Standard ac Motor - Fixed Speed
Run/Standby Pump - Standard ac Motor - Fixed Speed
Single Head Pump - Inverter Driven Motor - Variable Speed with electronic flow
metering system
Run/Standby Pump - Inverter Driven Motor - Variable Speed with electronic
flow metering system
5
1
1
1
5
4-20 mA
6
6
0-10V
4
2a
4
1
2a
2b
3
0-10V
2b
2b
2a
A
4-20 mA
1
3
3
3
3
1
1
1
1
B
Shut off valve
Pump
Pump & Inverter
Liquid Strainer
C
D
4
5
6
Non Return Valve
Electronic Flow Meter
Microprocessor
Chillers
Installation & Maintenance : 6564868 09/2012
27
OPTICHILL
Chillers
Installation Data
MECHANICAL DATA - HIGH EFFICIENCY
OPC500HED8
Connections
Water Inlet / Outlet
Water Drain / Bleed
Water System
Min. System Water Volume
Max. System Operating Pressure
OPTIONAL EXTRAS
Water Pump - ac Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
Water Pump - Inverter Driven Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
in
DN150 PN16
1/2
l
bar
1764
10
(1)
1849
10
1934
10
OPC650HED10
DN200 PN16
1/2
2079
10
2260
10
56
94
76
179
67
155
87
174
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
Grooved type Coupling & Pipe Assembly
DN150 PN16
DN150 PN16
DN150 PN16
1/2
1/2
1/2
OPC650HEDQ10
In Line Pump - Fixed Speed Motor
kPa
kPa
70
107
kPa
kPa
124
124
OPC500HEDQ10
Connections
Water Inlet / Outlet
Water Drain / Bleed
Water System
Min. System Water Volume
Max. System Operating Pressure
OPTIONAL EXTRAS
Water Pump - ac Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
Water Pump - Inverter Driven Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
OPC525HED8
OPC550HED8
OPC600HED10
Grooved type Coupling & Pipe Assembly
DN150 PN16
DN150 PN16
DN150 PN16
1/2
1/2
1/2
in
DN150 PN16
1/2
l
bar
1750
10
(1)
66
63
104
100
In Line Pump - Variable Speed Motor
120
120
1832
10
117
117
1915
10
DN150 PN16
1/2
2001
10
2087
10
60
97
56
159
71
159
67
155
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
Grooved type Coupling & Pipe Assembly
DN200 PN16
DN200 PN16
DN200 PN16
1/2
1/2
1/2
OPC650HE+D10
In Line Pump - Fixed Speed Motor
kPa
kPa
71
108
kPa
kPa
124
124
67
64
105
101
In Line Pump - Variable Speed Motor
121
121
118
118
MECHANICAL DATA - HIGH EFFICIENCY PLUS
OPC500HE+D8
Connections
Water Inlet / Outlet
Water Drain / Bleed
Water System
Min. System Water Volume
Max. System Operating Pressure
OPTIONAL EXTRAS
Water Pump - ac Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
Water Pump - Inverter Driven Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
in
DN200 PN16
1/2
l
bar
1825
10
(1)
(1)
kPa
kPa
87
124
kPa
kPa
140
140
in
DN200 PN16
1/2
l
bar
1850
10
(1)
2164
10
2297
10
78
116
89
192
89
177
100
187
OPC525HE+DQ12 OPC550HE+DQ12 OPC600HE+DQ12
Grooved type Coupling & Pipe Assembly
DN200 PN16
DN200 PN16
DN200 PN16
1/2
1/2
1/2
OPC650HE+DQ12
83
81
121
118
In Line Pump - Variable Speed Motor
137
137
1947
10
135
135
2044
10
DN200 PN16
1/2
2139
10
2234
10
79
116
76
179
90
177
87
175
In Line Pump - Fixed Speed Motor
kPa
kPa
86
123
kPa
kPa
140
140
Based on 12/7°C water temperature and 35°C ambient.
28
2067
10
In Line Pump - Fixed Speed Motor
OPC500HE+DQ12
Connections
Water Inlet / Outlet
Water Drain / Bleed
Water System
Min. System Water Volume
Max. System Operating Pressure
OPTIONAL EXTRAS
Water Pump - ac Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
Water Pump - Inverter Driven Motor
Single Head or Run/Standby
Nom External Head Single - Standard
Nom External Head Single - Larger
1967
10
DN200 PN16
1/2
Chillers
Installation & Maintenance : 6564868 09/2012
84
81
121
119
In Line Pump - Variable Speed Motor
137
137
135
135
Chillers
OPTICHILL
OPC700HED12
OPC750HED12
DN200 PN16
1/2
DN200 PN16
1/2
2475
10
2637
10
OPC800HED12
OPC850HED12
OPC900HED14
Grooved type Coupling & Pipe Assembly
DN200 PN16
DN200 PN16
DN200 PN16
1/2
1/2
1/2
2779
10
2977
10
3171
10
OPC950HED14
OPC1000HED16
OPC1100HED16
DN200 PN16
1/2
DN200 PN16
1/2
DN200 PN16
1/2
3302
10
3518
10
3669
10
81
172
76
167
98
164
108
167
103
226
99
222
OPC950HEDQ16
OPC1000HEDQ18
OPC1100HEDQ18
DN200 PN16
1/2
DN200 PN16
1/2
DN200 PN16
1/2
3231
10
3434
10
3581
10
83
174
78
169
100
166
109
169
105
228
101
224
OPC950HE+D18
OPC1000HE+D18
OPC1100HE+D18
DN200 PN16
1/2
DN200 PN16
1/2
DN200 PN16
1/2
3412
10
3567
10
3722
10
78
170
75
166
97
163
105
165
102
224
98
221
In Line Pump - Fixed Speed Motor
81
173
77
168
72
164
81
168
76
163
71
159
OPC700HEDQ14
OPC750HEDQ14
DN200 PN16
1/2
DN200 PN16
1/2
2437
10
2594
10
88
84
179
175
In Line Pump - Variable Speed Motor
87
174
111
170
OPC800HEDQ14
OPC850HEDQ14
OPC900HEDQ16
Grooved type Coupling & Pipe Assembly
DN200 PN16
DN200 PN16
DN200 PN16
1/2
1/2
1/2
2785
10
2928
10
3109
10
In Line Pump - Fixed Speed Motor
82
174
78
169
92
183
82
169
77
164
91
178
OPC700HE+D12
OPC750HE+D12
DN200 PN16
1/2
DN200 PN16
1/2
2519
10
2698
10
89
85
180
177
In Line Pump - Variable Speed Motor
88
175
112
172
OPC800HE+D14
OPC850HE+D14
OPC900HE+D16
Grooved type Coupling & Pipe Assembly
DN200 PN16
DN200 PN16
DN200 PN16
1/2
1/2
1/2
2891
10
3040
10
3226
10
In Line Pump - Fixed Speed Motor
97
188
100
191
90
181
96
184
99
187
89
176
OPC700HE+DQ14
OPC750HE+DQ16
DN200 PN16
1/2
DN200 PN16
1/2
2480
10
2693
10
87
83
178
174
In Line Pump - Variable Speed Motor
86
173
109
169
OPC800HE+DQ16 OPC850HE+DQ18 OPC900HE+DQ20 OPC950HE+DQ20 OPC1000HE+DQ20 OPC1100HE+DQ20
Grooved type Coupling & Pipe Assembly
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
DN200 PN16
1/2
1/2
1/2
1/2
1/2
1/2
2840
10
3030
10
3201
10
3337
10
3486
10
3636
10
80
172
77
168
99
165
107
167
104
226
100
223
In Line Pump - Fixed Speed Motor
97
189
93
185
91
182
97
184
93
180
90
177
87
83
178
175
In Line Pump - Variable Speed Motor
86
173
110
170
Chillers
Installation & Maintenance : 6564868 09/2012
29
OPTICHILL
Chillers
Installation Data
ELECTRICAL

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
The control voltage to the interlocks is 24V, always size the low voltage interlock and
protection cabling for a maximum voltage drop of 2V
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
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
The unit isolators DO NOT isolate the incoming mains supply, but isolate the
individual electrical panels. Isolate REMOTELY the mains incoming supply to the
BUSBAR chamber prior to maintenance or repair work.
CAUTION
ALL work MUST be carried out by technically trained competent personnel.
The Emergency Stop MUST NOT be used to stop the chiller other than in the event
of an emergency.
A fused and isolated electrical supply of the appropriate phase, frequency and
voltage should be installed.
Wires should be capable of carrying the maximum load current under non-fault
conditions at the stipulated voltage.
A separately fused, locally isolated, permanent single phase and neutral supply
MUST BE FITTED for the compressor oil heater, evaporator trace heating and
control circuits, FAILURE to do so will INVALIDATE WARRANTY.
To reduce down time, if possible support the above supply with a UPS.
Ensure correct phase rotation.
Refer also to Interlocks & Protection, on page 25.
30
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Installation Data
INTERCONNECTING WIRING










Mains incoming supply 400V/3PH/50Hz
(N2 only required for Power Meter Option)






Separate Permanent Supply 230V / 1PH +N / 50Hz




External Trace Heating Connections
230V/500W max
502
507




(1) Remote Pump Interlock 24VAC
502
505




(1) Evaporator Pump Water Flow Switch 24VAC
502
504




Unit Remote On/Off 24VAC
502
506




Setback Setpoint Temperature switch
581
580
582






NonCritical
Alarm
Volt Free Common Alarm
Volt Free Alarm N/O
Volt Free Alarm N/C
591
590
592






Critical
Alarm
Volt Free Common Alarm
Volt Free Alarm N/O
Volt Free Alarm N/C
RX-/TxRX+/Tx+
GND






L1
L2
L3
N2
E
L4
N1
E
11
N
OPC500 - OPC1100
CAUTION
Network Connections
(1) MUST be directly wired to the chiller to validate warranty.
Chillers
Installation & Maintenance : 6564868 09/2012
31
OPTICHILL
Chillers
Installation Data
IMPORTANT
The following information is for general guidance; refer to the certified drawings
provided for installation.
ELECTRICAL DATA - HIGH EFFICIENCY
Standard Chiller - D
Unit Data
Nominal Run Amps
Maximum Start Amps
Rec Mains Fuse Size
Mains Supply
Max Mains Incoming Cable Size
Permanent Supply
Rec Permanent Fuse Size
Max Permanent Incoming Cable Size
Control Circuit
Evaporator
Immersion Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Standard AC Type
Full Load Amps
Locked Rotor Amps
Motor Size
Optional EC Type
Full Load Amps
Motor Size
Compressor - Per Compressor
Quantity
Motor Size
Nominal Run Amps
Oil Heater Rating
Start Amps
Type Of Start
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
Maximum Start Amps
Recommended Mains Fuse
Compressor Nom Run Amps - Per
Compressor
Closed Transition
Nominal Run Amps
Maximum Start Amps
Recommended Mains Fuse
Compressor Nom Run Amps - Per
Compressor
Water Pump - ac Motor
Single Head or Run/Standby - Standard
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Single Head or Run/Standby - Larger
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Water Pump - Inverter Driven Motor
Single Head or Run/Standby - Standard
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Single Head or Run/Standby - Larger
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
(1)
(2)
32
(1)
(2)
(1)
(2)
OPC500HED8
OPC525HED8
OPC550HED8
OPC600HED10
OPC650HED10
A
A
A
VAC
mm²
VAC
A
mm²
VAC
291
461
400
308
521
450
325
538
450
400 V 3 PH 50 Hz
Direct to Bus Bar
230 V 1 PH 50 Hz
16
16
4mm² Terminal
24V / 230VAC
347
589
450
361
604
500
16
16
W
100
100
100
100
100
W
500
500
500
500
500
8
8
8
10
10
A
A
kW
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
A
kW
3.9
2.2
3.9
2.56
3.9
2.2
3.9
2.56
3.9
2.56
kW
A
W
A
1+1
74.5 / 74.5
130.4 / 130.4
300
300 / 300
1+1
83.4 / 74.5
147.3 / 130.4
300
360 / 300
1+1
83.4 / 83.4
147.3 / 147.3
300
360 / 360
Star - Delta
1+1
91.8 / 83.4
161.5 / 147.3
300
404 / 360
1+1
91.8 / 91.8
161.5 / 161.5
300
404 / 404
16
(1)
(2)
A
A
A
A
257
444
400
117 / 117
270
504
450
132 / 117
284
517
450
132 / 132
304
569
450
145 / 132
317
381
500
145 / 145
(1)
(2)
A
A
A
A
291
461
400
130.4 / 130.4
308
521
450
147.3 / 130.4
325
538
450
147.3 / 147.3
347
589
450
161.5 / 147.3
361
604
500
161.5 / 161.5
(1)
A
A
kW
A
300
400
4.0
8.9
317
450
4.0
8.9
334
450
4.0
8.9
356
450
4.0
8.9
370
500
4.0
10.6
(1)
A
A
kW
A
306
400
7.5
14.4
322
450
7.5
14.4
339
450
7.5
14.4
361
500
7.5
14.4
382
500
11.0
21.0
(1)
A
A
kW
A
302
400
5.5
11.0
319
450
5.5
11.0
336
450
5.5
11.0
358
450
5.5
11.3
372
500
5.5
11.3
(1)
A
A
kW
A
302
400
5.5
11.0
319
450
5.5
11.0
336
450
5.5
11.0
362
450
7.5
15.0
376
500
7.5
15.0
Based at 12/7°C water and 35°C ambient with standard AC type fans.
Starting amps refers to the Star connection only with standard AC type fans.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
OPC700HED12
OPC750HED12
OPC800HED12
394
643
560
419
668
560
444
697
630
16
16
16
100
100
100
500
500
12
OPC850HED12
OPC900HED14
470
723
630
400 V 3 PH 50 Hz
Direct to Bus Bar
230 V 1 PH 50 Hz
16
4mm² Terminal
24V / 230VAC
OPC950HED14 OPC1000HED16 OPC1100HED16
512
851
710
546
886
710
576
957
750
597
979
750
16
16
16
16
100
100
100
100
100
500
500
500
500
500
500
12
12
12
14
14
16
16
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.8
11
1.8
3.9
2.56
3.9
2.56
3.9
2.56
3.9
2.56
3.9
2.56
3.9
2.56
3.9
2.56
3.9
2.56
1+1
109.2 / 91.8
186.6 / 161.5
300
436 / 404
1+1
109.2 / 109.2
186.6 / 186.6
300
436 / 436
1+1
126.5 / 109.2
212.2 / 186.6
300
465 / 436
1+1
1+1
162.5 / 162.5
143.1 / 126.5
212.2 / 212.2
246.5 / 212.2
300
300
465 / 465
586 / 465
Star - Delta
1+1
143.1 / 143.1
246.5 / 246.5
300
586 / 586
1+1
156.4 / 143.1
268.3 / 246.5
300
650 / 586
1+1
156.4 / 156.4
268.3 / 268.3
300
650 / 650
351
621
560
167 / 145
377
648
560
167 / 167
404
677
630
190 / 167
430
703
630
190 / 190
463
831
710
221 / 190
488
857
710
246.5 / 246.5
516
928
750
268.3 / 246.5
536
948
750
240 / 240
394
643
560
186.6 / 161.5
419
668
560
186.6 / 186.6
444
697
630
212.2 / 186.6
470
723
630
212.2 / 212.2
512
851
710
246.5 / 212.2
546
886
710
246.5 / 246.5
576
957
750
268.3 / 246.5
597
979
750
268.3 / 268.3
404
560
5.5
10.6
429
560
5.5
10.6
455
630
5.5
10.6
481
630
5.5
10.6
522
710
5.5
10.6
557
710
5.5
10.6
586
750
5.5
10.6
612
750
7.5
14.4
415
560
11.0
21.0
440
560
11.0
21.0
465
630
11.0
21.0
491
630
11.0
21.0
533
710
11.0
21.0
567
710
11.0
21.0
597
750
11.0
21.0
618
750
11.0
21.0
405
560
5.5
11.3
430
560
5.5
11.3
456
630
5.5
11.3
481
630
5.5
11.3
527
710
7.5
14.7
561
710
7.5
14.7
590
750
7.5
14.7
612
750
7.5
14.7
409
560
7.5
15.0
440
560
11.0
21.4
466
630
11.0
21.4
491
630
11.0
21.4
533
710
11.0
21.4
568
710
11.0
21.4
604
750
15.0
28.0
625
750
15.0
28.0
Chillers
Installation & Maintenance : 6564868 09/2012
33
OPTICHILL
Chillers
Installation Data
IMPORTANT
The following information is for general guidance; refer to the certified drawings
provided for installation.
ELECTRICAL DATA - HIGH EFFICIENCY
Quiet Chiller - DQ
Unit Data
Nominal Run Amps
Maximum Start Amps
Rec Mains Fuse Size
Mains Supply
Max Mains Incoming Cable Size
Permanent Supply
Rec Permanent Fuse Size
Max Permanent Incoming Cable Size
Control Circuit
Evaporator
Immersion Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Full Load Amps
Motor Size
Compressor - Per Compressor
Quantity
Motor Size
Nominal Run Amps
Oil Heater Rating
Start Amps
Type Of Start
OPTIONAL EXTRAS
Power Factor Correction
Nominal Run Amps
Maximum Start Amps
Recommended Mains Fuse
Compressor Nom Run Amps - Per
Compressor
Closed Transition
Nominal Run Amps
Maximum Start Amps
Recommended Mains Fuse
Compressor Nom Run Amps - Per
Compressor
Water Pump - ac Motor
Single Head or Run/Standby - Standard
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Single Head or Run/Standby - Larger
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Water Pump - Inverter Driven Motor
Single Head or Run/Standby - Standard
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Single Head or Run/Standby - Larger
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
(1)
(2)
34
(1)
(2)
(1)
(2)
OPC500HEDQ10
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
OPC650HEDQ10
A
A
A
VAC
mm²
VAC
A
mm²
VAC
277
446
400
294
506
450
311
523
450
400 V 3 PH 50 Hz
Direct to Bus Bar
230 V 1 PH 50 Hz
16
16
4mm² Terminal
24V / 230VAC
325
567
450
339
582
500
16
16
W
100
100
100
100
100
W
500
500
500
500
500
A
kW
10
3.9
2.2
10
3.9
2.56
10
3.9
2.56
10
3.9
2.56
10
3.9
2.56
kW
A
W
A
1+1
74.5 / 74.5
130.4 / 130.4
300
300 / 300
1+1
83.4 / 74.5
147.3 / 130.4
300
360 / 300
1+1
83.4 / 83.4
147.3 / 147.3
300
360 / 360
Star - Delta
1+1
91.8 / 83.4
161.5 / 147.3
300
404 / 360
1+1
91.8 / 91.8
161.5 / 161.5
300
404 / 404
16
(1)
(2)
A
A
A
A
242
429
400
113 / 113
256
489
450
127 / 113
269
503
450
127 / 127
282
547
450
139 / 122
295
559
500
139 / 139
(1)
(2)
A
A
A
A
277
446
400
130.4 / 130.4
294
506
450
147.3 / 130.4
311
523
450
147.3 / 147.3
325
567
450
161.5 / 147.3
339
582
500
161.5 / 161.5
(1)
A
A
kW
A
286
400
4.0
8.9
303
450
4.0
8.9
319
450
4.0
8.9
334
450
4.0
8.9
348
500
4.0
10.6
(1)
A
A
kW
A
291
400
7.5
14.4
308
450
7.5
14.4
325
450
7.5
14.4
339
500
7.5
14.4
360
500
11.0
21.0
(1)
A
A
kW
A
288
400
5.5
11.0
305
450
5.5
11.0
322
450
5.5
11.0
336
450
5.5
11.3
350
500
5.5
11.3
(1)
A
A
kW
A
288
400
5.5
11.0
305
450
5.5
11.0
322
450
5.5
11.0
340
450
7.5
15.0
354
500
7.5
15.0
Based on 12/7°C water temperature and 35°C ambient.
Starting amps refers to the Star connection only.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
OPC700HEDQ14
OPC750HEDQ14
OPC800HEDQ14
370
620
560
396
645
560
421
674
630
16
16
16
100
100
100
500
500
14
3.9
2.56
OPC850HEDQ14
OPC900HEDQ16
447
700
630
400 V 3 PH 50 Hz
Direct to Bus Bar
230 V 1 PH 50 Hz
16
4mm² Terminal
24V / 230VAC
OPC950HEDQ16 OPC1000HEDQ18 OPC1100HEDQ18
484
824
710
519
858
710
544
925
710
565
947
750
16
16
16
16
100
100
100
100
100
500
500
500
500
500
500
14
3.9
2.56
14
3.9
2.56
14
3.9
2.56
16
3.9
2.56
16
3.9
2.56
18
3.9
2.56
18
3.9
2.56
1+1
109.2 / 91.8
186.6 / 161.5
300
436 / 404
1+1
109.2 / 109.2
186.6 / 186.6
300
436 / 436
1+1
126.5 / 109.2
212.2 / 186.6
300
465 / 436
1+1
1+1
162.5 / 162.5
143.1 / 126.5
212.2 / 212.2
246.5 / 212.2
300
300
465 / 465
586 / 465
Star - Delta
1+1
143.1 / 143.1
246.5 / 246.5
300
586 / 586
1+1
156.4 / 143.1
268.3 / 246.5
300
650 / 586
1+1
156.4 / 156.4
268.3 / 268.3
300
650 / 650
328
598
560
166 / 139
354
624
560
166 / 166
381
653
630
192 / 166
407
680
630
192 / 192
435
804
710
217 / 192
460
829
710
217 / 217
484
896
750
238 / 217
504
916
750
238 / 238
370
620
560
186.6 / 161.5
396
645
560
186.6 / 186.6
421
674
630
212.2 / 186.6
447
700
630
212.2 / 212.2
484
824
710
246.5 / 212.2
519
858
710
246.5 / 246.5
544
925
710
268.3 / 246.5
565
947
750
268.3 / 268.3
381
560
5.5
10.6
406
560
5.5
10.6
432
630
5.5
10.6
457
630
5.5
10.6
495
710
5.5
10.6
529
710
5.5
10.6
554
750
5.5
10.6
580
750
7.5
14.4
391
560
11.0
21.0
417
560
11.0
21.0
442
630
11.0
21.0
468
630
11.0
21.0
505
710
11.0
21.0
540
710
11.0
21.0
565
750
11.0
21.0
586
750
11.0
21.0
382
560
5.5
11.3
407
560
5.5
11.3
432
630
5.5
11.3
458
630
5.5
11.3
499
710
7.5
14.7
533
710
7.5
14.7
558
750
7.5
14.7
580
750
7.5
14.7
385
560
7.5
15.0
417
560
11.0
21.4
443
630
11.0
21.4
468
630
11.0
21.4
506
710
11.0
21.4
540
710
11.0
21.4
572
750
15.0
28.0
593
750
15.0
28.0
Chillers
Installation & Maintenance : 6564868 09/2012
35
OPTICHILL
Chillers
Installation Data
IMPORTANT
The following information is for general guidance; refer to the certified drawings
provided for installation.
ELECTRICAL DATA - HIGH EFFICIENCY PLUS
Standard Chiller - D & Quiet Chiller - DQ
Unit Data
Nominal Run Amps
Maximum Start Amps
Rec Mains Fuse Size
Mains Supply
Max Mains Incoming Cable Size
Permanent Supply
Rec Permanent Fuse Size
Max Permanent Incoming Cable Size
Control Circuit
Evaporator
Immersion Heater Rating
External Trace Heating
Available (fitted by others)
Condenser Fan - Per Fan
Quantity
Full Load Amps
Motor Size
Compressor - Per Compressor
Quantity
Motor Size
Nominal Run Amps
Oil Heater Rating
Start Amps
Type Of Start
QUIET DQ
Condenser Fan - Per Fan
Quantity
Full Load Amps
Motor Size
OPTIONAL EXTRAS - ALL MODELS
Power Factor Correction
Nominal Run Amps
Maximum Start Amps
Recommended Mains Fuse
Compressor Nom Run Amps - Per
Compressor
Closed Transition
Nominal Run Amps
Maximum Start Amps
Recommended Mains Fuse
Compressor Nom Run Amps - Per
Compressor
Water Pump - ac Motor
Single Head or Run/Standby - Standard
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Single Head or Run/Standby - Larger
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Water Pump - Inverter Driven Motor
Single Head or Run/Standby - Standard
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
Single Head or Run/Standby - Larger
Unit Nominal Run Amps
Recommended Mains Fuse
Motor Size
Full Load Amps
(1)
(2)
36
(1)
(2)
(1)
(2)
OPC500HE+D8
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
OPC650HE+D10
A
A
A
VAC
mm²
VAC
A
mm²
VAC
288
458
400
312
524
450
329
541
450
400 V 3 PH 50 Hz
Direct to Bus Bar
230 V 1 PH 50 Hz
16
16
4mm² Terminal
24V / 230VAC
343
585
450
357
600
500
16
16
W
100
100
100
100
100
W
500
500
500
500
500
A
kW
8
3.9
2.56
10
3.9
2.56
10
3.9
2.56
10
3.9
2.56
10
3.9
2.56
kW
A
W
A
1+1
74.5 / 74.5
130.4 / 130.4
300
300 / 300
1+1
83.4 / 74.5
147.3 / 130.4
300
360 / 300
12
3.9
2.56
12
3.9
2.56
12
3.9
2.56
12
3.9
2.56
12
3.9
2.56
16
1+1
1+1
1+1
83.4 / 83.4
91.8 / 83.4
91.8 / 91.8
147.3 / 147.3
161.5 / 147.3
161.5 / 161.5
300
300
300
360 / 360
404 / 360
404 / 404
Star - Delta
OPC500HE+DQ12 OPC525HE+DQ12 OPC550HE+DQ12 OPC600HE+DQ12 OPC650HE+DQ12
All data as above except:
A
kW
(1)
(2)
A
A
A
A
254
440
400
113 / 113
274
507
450
127 / 113
287
521
450
127 / 127
300
565
450
139 / 127
313
577
500
139 / 139
(1)
(2)
A
A
A
A
288
458
400
130.4 / 130.4
312
524
450
147.3 / 130.4
329
541
450
147.3 / 147.3
343
585
450
161.5 / 147.3
357
600
500
161.5 / 161.5
(1)
A
A
kW
A
297
400
4.0
8.9
321
450
4.0
8.9
337
450
4.0
8.9
352
450
4.0
8.9
366
500
4.0
10.6
(1)
A
A
kW
A
302
400
7.5
14.4
326
450
7.5
14.4
343
450
7.5
14.4
357
500
7.5
14.4
378
500
11.0
21.0
(1)
A
A
kW
A
299
400
5.5
11.0
323
450
5.5
11.0
340
450
5.5
11.0
354
450
5.5
11.3
368
500
5.5
11.3
(1)
A
A
kW
A
299
400
5.5
11.0
323
450
5.5
11.0
340
450
5.5
11.0
358
450
7.5
15.0
372
500
7.5
15.0
Based on 12/7°C water temperature and 35°C ambient.
Starting amps refers to the Star connection only.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
OPC700HE+D12
OPC750HE+D12
OPC800HE+D14
389
638
560
414
663
560
446
699
630
16
16
16
100
100
100
500
500
12
3.9
2.56
1+1
109.2 / 91.8
186.6 / 161.5
300
436 / 404
OPC850HE+D14
OPC900HE+D16
OPC950HE+D18
OPC1000HE+D18
OPC1100HE+D18
513
853
710
554
894
710
576
958
750
598
980
750
16
16
16
16
100
100
100
100
100
500
500
500
500
500
500
12
3.9
2.56
14
3.9
2.56
14
3.9
2.56
16
3.9
2.56
18
3.9
2.56
18
3.9
2.56
18
3.9
2.56
1+1
109.2 / 109.2
186.6 / 186.6
300
436 / 436
1+1
126.5 / 109.2
212.2 / 186.6
300
465 / 436
1+1
143.1 / 143.1
246.5 / 246.5
300
586 / 586
1+1
156.4 / 143.1
268.3 / 246.5
300
650 / 586
1+1
156.4 / 156.4
268.3 / 268.3
300
650 / 650
OPC700HE+DQ14 OPC750HE+DQ16
All data as above except:
OPC800HE+DQ16
1+1
1+1
162.5 / 162.5
143.1 / 126.5
212.2 / 212.2
246.5 / 212.2
300
300
465 / 465
586 / 465
Star - Delta
OPC850HE+DQ18 OPC900HE+DQ20
472
725
630
400 V 3 PH 50 Hz
Direct to Bus Bar
230 V 1 PH 50 Hz
16
4mm² Terminal
24V / 230VAC
OPC950HE+DQ20 OPC1000HE+DQ20 OPC1100HE+DQ20
14
3.9
2.56
16
3.9
2.56
16
3.9
2.56
18
3.9
2.56
20
3.9
2.56
20
3.9
2.56
20
3.9
2.56
20
3.9
2.56
346
616
560
166 / 139
373
643
560
166 / 166
406
679
630
192 / 166
432
705
630
192 / 192
464
833
710
217 / 192
496
865
710
217 / 217
516
929
750
238 / 217
536
949
750
238 / 238
389
638
560
186.6 / 161.5
414
663
560
186.6 / 186.6
446
699
630
212.2 / 186.6
472
725
630
212.2 / 212.2
513
853
710
246.5 / 212.2
554
894
710
246.5 / 246.5
576
958
750
268.3 / 246.5
598
980
750
268.3 / 268.3
399
560
5.5
10.6
425
560
5.5
10.6
457
630
5.5
10.6
483
630
5.5
10.6
524
710
5.5
10.6
565
710
5.5
10.6
587
750
5.5
10.6
612
750
7.5
14.4
410
560
11.0
21.0
435
560
11.0
21.0
467
630
11.0
21.0
493
630
11.0
21.0
534
710
11.0
21.0
575
710
11.0
21.0
597
750
11.0
21.0
619
750
11.0
21.0
400
560
5.5
11.3
425
560
5.5
11.3
458
630
5.5
11.3
483
630
5.5
11.3
528
710
7.5
14.7
569
710
7.5
14.7
591
750
7.5
14.7
613
750
7.5
14.7
404
560
7.5
15.0
435
560
11.0
21.4
468
630
11.0
21.4
493
630
11.0
21.4
534
710
11.0
21.4
576
710
11.0
21.4
604
750
15.0
28.0
626
750
15.0
28.0
Chillers
Installation & Maintenance : 6564868 09/2012
37
OPTICHILL
Chillers
Controls
TEMPERATURE
CONTROL
Airedale recognises that all chiller applications are different but fall mainly into 2
application categories; Variable Supply Temperature and Constant Supply Temperature.
The onboard microprocessor has the capability of satisfying either control requirement as
illustrated below. Using the Airedale Variable Supply Temperature control scheme,
energy savings are available when compared with previous schemes and that of the
Constant Supply Temperature application.
Variable Supply Temperature control schemes offer energy savings where the supply
water temperature is not critical to its operation.
Selection of the best application control scheme can be made via a soft switch in the
microprocessor during initial commissioning.
The microprocessor maintains the set supply Chilled Water temperature by sensing the
return and supply water temperatures and ambient air temperature to adjust the
compressor loading and water valve position as required.
Variable Supply
Temperature Control
14
Water Temperature °C
13
12
1
11
10
2
9
3
8
7
4
6
1
(20%)
2
(40%)
3
(50%)
4
(60%)
5
(70%)
6
(80%)
7
(90%)
8
(100%)
7
(90%)
8
(100%)
Cooling Stages / Unit Capacity %
14
Constant Supply
Temperature Control
Water Temperature °C
13
12
1
11
10
9
3
8
7
6
1
(20%)
2
(40%)
3
(50%)
4
(60%)
5
(70%)
6
(80%)
Cooling Stages / Unit Capacity %
1
2
3
4
CAUTION
Return Water Temperature
Mean Value
Supply Water Temperature
Compressor Off
Factory set to Variable Supply Temperature Control unless otherwise stated
at order.
Only when the mode selection has been set can the unit be enabled.
38
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Controls
GENERAL
DESCRIPTION
The
microprocessor controller offers powerful analogue and digital control to
meet a wide range of monitoring and control features including a real time clock and
Industry standard communication port and network connections.
The controller’s inbuilt display is used for viewing the unit operating status and making
adjustments to control parameters by allowing the operator access to a series of
display pages.
Also featured are a visual alarm and the facility to adjust and display control settings by
local operator for information and control.
6
DISPLAY/KEYPAD
5
4
3
7
1
2
1
UP/DOWN KEYS - To change Adjustable Fields & Scrolls up & down
available Menus
2
ENTER -Selects Menus & Moves Cursor to Adjustable Fields Green LED
3
ESC - Green LED lit when Operating Page displayed, Returns to Operating Page
Screen when pressed
4
PROGRAM - Opens the Available Menus
5
ALARM - Red LED Indicates Alarm Present
6
4 ROW LCD DISPLAY
7
CURSOR (FLASHING) Top Left Position = “HOME” Indicates adjustable Fields
OPERATION
Navigation
The display is used for Viewing Unit Operating Status and Adjusting Customer
Control Settings by allowing the operator access to a series of Menus & sub-menus.
Viewing information is unrestricted, however set up and adjustment requires password
entry, refer to Password Protection, on page 40.
Prg
Initially, use the
key to access Menus, the symbol will appear top right and the
first menu will appear in CAPITALS, these indicators shows which menu is selected.
Use the
open the menu.
keys to move the indicator
Use the
key to move the flashing cursor
keys to change the values.
Press the
the
to
to adjustable fields and the
key to move the cursor to the next field or Home.
When the cursor is Home either use the
Esc
to the desired menu and press
keys to scroll to next sub-menu or
to exit and return to the Standard Operating page.
Chillers
Installation & Maintenance : 6564868 09/2012
39
OPTICHILL
Chillers
Controls
OPERATION
Standard Operating
Page
The following Menus can be accessed from the Operating Page, it is recommended that
Password Protection
To guard against unauthorised adjustments, a password is required to gain access to
certain menus as defined below.
the display is always returned to the Operating Page by using the
Esc
key
FACTORY SET PASSWORD PIN NUMBER: 4648 (or Customer chosen number).
When a password is requested use the
access the page.
Menus
(Listed in Sequence)
keys to enter the number and
Menu
Description
Password
Unit On/Off
Enable or Disable the unit
Displays hours run for compressors and pumps (if
fitted). Also includes Electronic Expansion Valves (if
fitted).
Display last 100 alarms in chronological order.
Displays current status on digital and analogue
inputs and outputs.
Allows adjustment of real time clock, time zones
Allows setpoint adjustment, includes supply
temperature setpoint and unit temperature
differential.
Allows selection of setpoint limits, enables unit on/off
from display, remote on/off and remote pump on/off.
Factory use only.
Open Access
Maintenance
Alarm Log
Input/Output
Clock
Setpoint
User
Manufacturer
to
Default 4648
Open Access
Open Access
Default 4648
Default 4648
Default 4648
Airedale Only
SETTING UP
Unit On/Off
Esc
By pressing the
and
simultaneously for approximately 5 seconds, the unit
operation will stop or start. The unit can also be enabled through the Unit On/Off menu.
Real Time Clock
The units leave the factory set, however follow the Navigation instructions if necessary.
Time Zones
The programme provides 3 On/Off periods per day, 7 days per week. The unit is factory
set for continuous operation.
Technical Support
For further details, please contact Airedale.
40
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Controls
VIEWING UNIT OPERATING STATUS
Status Menu
Allows access to view operating status of Digital and Analogue Inputs and Outputs.
Using the Navigation instructions, the following Sub-Menus shown in sequence can
be accessed:
Digital Inputs
ID1
ID2
ID3
ID4
ID5
ID6
ID7
ID8
ID9
ID10
ID11
ID12
ID13
ID14
ID15
ID16
ID17
ID18
Phase Rotation (Optional)
Emergency Stop
Evaporator Flow Switch
Remote On/Off (Optional)
Compressor 1 Contactor Status
Circuit 1 Low Pressure Switch
Compressor 1 Overload
Circuit 1 Isolator Status
Circuit 1 Discharge Gas Thermostat
Compressor 2 Contactor Status
Circuit 2 Low Pressure Switch
Compressor 2 Overload
Circuit 2 Isolator Status
Circuit 2 Discharge Gas Thermostat
Pump 1 Contactor Status (Optional)
Pump 2 Contactor Status (Optional)
Remote Pump Enable
Summer / Winter Setpoint Enable
Analogue Inputs
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
Circuit 1 Discharge Temperature
Circuit 1 Liquid Pressure
Refrigerant Leak Detector (Optional)
Return Water Temperature (Optional)
Supply Water Temperature
Circuit 2 Liquid Pressure
Evaporator Differential Pressure (Optional)
Circuit 2 Discharge Temperature
Not Used
Ambient Temperature (Optional)
Digital Outputs
NO1
NO2
NO3
NO4
NO5
NO6
NO7
NO8
NO9
NO10
NO11
NO12
NO13
NO14
NO15
NO16
NO17
NO18
Compressor 1 Line Contactor
Compressor 1 Star Contactor
Compressor 1 Delta Contactor
Compressor 1 Economiser Solenoid Valve
Compressor 1 CR1 Solenoid Valve
Compressor 1 CR2 Solenoid Valve
Compressor 1 CR3 Solenoid Valve
Non-Critical Alarm
Compressor 2 Line Contactor
Compressor 2 Star Contactor
Compressor 2 Delta Contactor
Compressor 1 CR4 Solenoid Valve
Critical Alarm
Compressor 2 CR3 Solenoid Valve
Compressor 2 CR4 Solenoid Valve
Compressor 2 Economiser Solenoid Valve
Compressor 2 CR1 Solenoid Valve
Compressor 2 CR2 Solenoid Valve
Analogue Outputs
Y1
Y2
Y3
Y4
Y5
Y6
Not Used
Circuit 1 Condenser Fan Speed Controller
Circuit 2 Condenser Fan Speed Controller
Pump 1 Contactor (Optional)
Pump 2 Contactor (Optional)
Not Used
Chillers
Installation & Maintenance : 6564868 09/2012
41
OPTICHILL
Chillers
Controls
ALARMS
The controller logs and allows viewing of the last 100 conditions recorded in descending
chronological order.
1
2
3
Alarm Handling
1
A Red LED behind the Alarm
alarms, simply press the
2
1
2
5
3
4
5
Alarm Label
Alarm Status: Alarm Active
or Alarm Cleared
Time of Alarm
Alarm Log
Date of Alarm
key will light in the event of an alarm. To view the
key and the
keys to scroll through.
Auto reset alarms will clear following this first depression of the Alarm
however the Red LED behind the Alarm
requires some form of manual reset.
COMMON ALARMS
4
key. If
key remains illuminated, the unit
3
For manual reset alarms, isolate the affected circuits before further investigation.
4
To reset or delete the alarms displayed in the alarm screen, simply press
again.
Outlined below is a selection of Common Alarms, a full list is available, please
contact Airedale.
Phase Rotation or MCCB A normally closed contact. When Phase Rotation is incorrect all controller outputs are
de-activated.
Emergency Stop
A normally open contact. On closing, all controller outputs are de-activated.
Evaporator Flow Failure
A normally closed contact. On opening, all controller outputs are de-activated.
Low Supply
Temperature
Supply Water Temperature Low Limit alarm is generated when the supply water
temperature falls below the low limit value set. All controller outputs are de-activated.
INDIVIDUAL CIRCUIT
ALARMS
Outlined below is a selection of Individual Circuit Alarms, a full list is, please
contact Airedale.
Electronic Expansion
Valve Failure
This indicates that the electronic expansion valve controller has detected an
operating problem.
Low Suction Pressure
When the suction pressure sensor value falls below the value set by the low suction level
for a period exceeding 1 minute (or 3 minutes on compressor start-up), a visual alarm will
be generated at the in-built display and the relevant compressor will be de-activated.
High Liquid Pressure
When the liquid pressure reaches 14.6 barg, the relevant circuit will be switched off and
an alarm activated, this can only be rectified by manual reset via the microprocessor.
Compressor Status
A normally closed contact when the compressor is operating. If this contact remains open
for a period of 5 seconds during operation of the compressor, a visual alarm is generated
and the relevant compressor will be de-activated. This alarm comprises of compressor
motor protection module, discharge gas thermostat and safety high pressure switch.
42
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Commissioning Data
GENERAL DATA
Operating limits
(For 100% Water)
Standard Unit
Minimum Ambient Air DB °C
Maximum Ambient Air DB °C at Full Load Operation
Maximum Ambient Air DB °C at Reduced Load Operation
Minimum Leaving Water Temperature °C
Maximum Return Water Temperature °C
Minimum / Maximum ΔT
1
2
-20°C
40°C
45°C
+5°C
+20°C
4°C / 8°C
For conditions outside those quoted, please refer to Airedale.
For minimum ambient, it is assumed that adequate freeze protection is fitted.
Chillers
Installation & Maintenance : 6564868 09/2012
43
OPTICHILL
Chillers
Commissioning Data
OIL & REFRIGERANT CHARGES - HIGH EFFICIENCY
OPC500HED8
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Pre Charged
Charge (Total)
l
1+1
22 + 22
kg
85 + 85
OPC500HEDQ10
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Pre Charged
Charge (Total)
l
kg
1+1
22 + 22
100 + 100
OPC525HED8
OPC550HED8
OPC600HED10
Screw - Twin
1+1
1+1
1+1
19 + 22
19 + 19
19 + 19
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
90 + 85
90 + 90
105 + 105
OPC525HEDQ10
OPC550HEDQ10
OPC600HEDQ10
Screw - Twin
1+1
1+1
1+1
19 + 22
19 + 19
19 + 19
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
105 + 100
105 + 105
105 + 105
OPC650HED10
1+1
19 + 19
115 + 115
OPC650HEDQ10
1+1
19 + 19
105 + 105
OIL & REFRIGERANT CHARGES - HIGH EFFICIENCY PLUS
OPC500HE+D8
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Pre Charged
Charge (Total)
Compressor
Quantity
Oil Charge Volume (Total)
Oil Type
Refrigeration
Refrigerant Control
Refrigerant Pre Charged
Charge (Total)
44
l
1+1
22 + 22
kg
90 + 90
l
kg
OPC525HE+D10
OPC550HE+D10
OPC600HE+D10
Screw - Twin
1+1
1+1
1+1
19 + 22
19 + 19
19 + 19
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
115 + 105
115 + 115
115 + 115
OPC650HE+D10
1+1
19 + 19
120 + 120
OPC500HE+DQ12 OPC525HE+DQ12 OPC550HE+DQ12 OPC600HE+DQ12 OPC650HE+DQ12
Screw - Twin
1+1
1+1
1+1
1+1
1+1
22 + 22
19 + 22
19 + 19
19 + 19
19 + 19
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
125 + 125
130 + 125
130 + 130
130 + 130
130 + 130
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
OPC700HED12
OPC750HED12
OPC800HED12
1+1
35 + 19
1+1
35 + 35
1+1
35 + 35
130 + 130
130 + 130
130 + 130
OPC700HEDQ14
OPC750HEDQ14
OPC800HEDQ14
1+1
35 + 19
1+1
35 + 35
1+1
35 + 35
145 + 145
145 + 145
155 + 155
OPC700HE+D12
OPC750HE+D12
OPC800HE+D14
1+1
35 + 19
1+1
35 + 35
1+1
35 + 35
135 + 135
140 + 140
155 + 155
OPC700HE+DQ14
OPC750HE+DQ16
OPC800HE+DQ16
1+1
35 + 19
1+1
35 + 35
1+1
35 + 35
155 + 155
170 + 170
170 + 170
OPC850HED12
OPC900HED14
Screw - Twin
1+1
1+1
35 + 35
35 + 35
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
135 + 135
160 + 155
OPC950HED14
OPC1000HED16
OPC1100HED16
1+1
35 + 35
1+1
35 + 35
1+1
35 + 35
160 + 160
180 + 180
180 + 180
OPC850HEDQ14 OPC900HEDQ16
Screw - Twin
1+1
1+1
35 + 35
35 + 35
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
155 + 155
180 + 170
OPC950HEDQ16 OPC1000HEDQ18 OPC1100HEDQ18
OPC850HE+D14 OPC900HE+D16
Screw - Twin
1+1
1+1
35 + 35
35 + 35
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
155 + 155
180 + 170
OPC950HE+D18 OPC1000HE+D18 OPC1100HE+D18
OPC850HE+DQ18 OPC900HE+DQ20
Screw - Twin
1+1
1+1
35 + 35
35 + 35
Ester Oil
Dual Circuit
Electronic Expansion Valve (EEV)
R134a
185 + 185
215 + 205
OPC950HE+DQ20 OPC1000HE+DQ20 OPC1100HE+DQ20
1+1
35 + 35
1+1
35 + 35
1+1
35 + 35
180 + 180
195 + 195
195 + 195
1+1
35 + 35
1+1
35 + 35
1+1
35 + 35
195 + 195
195 + 195
195 + 195
1+1
35 + 35
1+1
35 + 35
1+1
35 + 35
215 + 215
215 + 215
215 + 215
Chillers
Installation & Maintenance : 6564868 09/2012
45
OPTICHILL
Chillers
Commissioning Data
WATERSIDE PRESSURE DROP (KPA)
Full design water flow MUST be maintained at all times. Variable water volume is
NOT recommended and will invalidate warranty.
CAUTION
140
2
1
Waterside Pressure Drop (kPa)
120
100
3
80
4
60
40
20
70
65
60
55
50
45
40
35
30
25
20
15
0
Waterflow (l/s)
OPC500
OPC525
OPC550
OPC600
OPC650
OPC700
OPC750
OPC800
OPC850
OPC900
OPC950
OPC1000
OPC1100
(1)
(2)
46
HED
1
1
1
1
2
2
2
2
3
3
3
3
3
HEDQ
1
1
1
1
1
2
2
3
3
3
3
3
3
HE+D
2
2
2
2
3
3
4
3
3
3
3
3
3
HE+DQ
2
2
2
2
2
3
3
3
3
3
3
3
3
Chiller pressure drop refers to standard unit only. For pump options, please contact Airedale.
For glycol solutions, please refer to Glycol data, on page 26.
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
Commissioning Data
PUMP PACKAGES (OPTIONAL EXTRAS)
Use the formula below and the graphs provided to calculate the External Head Available:
Example
Model Ref.
Ambient:
Fluid
Inlet Fluid Temp.
Outlet Fluid Temp.
Pump Selection
Fluid Flow l/s
= OPC800HE+D14
= 35°C
= 100% Water
= 7°C
= 12°C (5°C T)
= Single Standard Head - Standard ac Motor - Fixed Speed Option
= 40.0 l/s
EHA (kPa) =
External Head Available
EHA (kPa) =
Total Pump Head Available
Unit Waterside Pressure Drop
EHA (kPa) =
123 - 33
EHA (kPa) =
90 kPa
Chillers
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47
OPTICHILL
Chillers
Commissioning Data
PUMP PACKAGES (OPTIONAL EXTRAS)
ac Motor - Fixed Speed Option
Total Pump Head Available (kPa)
130
1
120
110
100
90
80
10
15
20
25
30
35
Waterflow (l/s)
Total Pump Head Available (kPa)
250
2
200
150
3
4
100
50
10
20
30
40
50
60
70
Waterflow (l/s)
HE / HE+
OPC500
OPC525
OPC550
OPC600
OPC650
OPC700
OPC750
OPC800
OPC850
OPC900
OPC950
OPC1000
OPC1100
48
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Installation & Maintenance : 6564868 09/2012
Standard Head
1
1
1
1
1
4
4
4
4
4
4
4
3
Single Head
Larger Head
3
3
3
3
2
2
2
2
2
2
2
2
2
Chillers
OPTICHILL
Commissioning Data
PUMP PACKAGES (OPTIONAL EXTRAS)
Inverter Driven Motor - Variable Speed Option
Total Pump Head Available (kPa)
240
1
220
200
2
180
160
140
120
10
15
20
25
30
35
40
Waterflow (l/s)
Total Pump Head Available (kPa)
300
3
250
4
200
5
150
6
100
50
0
10
20
30
40
50
60
70
Waterflow (l/s)
HE / HE+
OPC500
OPC525
OPC550
OPC600
OPC650
OPC700
OPC750
OPC800
OPC850
OPC900
OPC950
OPC1000
OPC1100
Single Head
Standard Head
2
2
2
6
6
6
6
6
6
5
5
5
5
Larger Head
2
2
2
1
1
1
4
4
4
4
4
3
3
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49
OPTICHILL
Chillers
Commissioning Data
ELECTRICAL DATA
L1
L1
Compressor Start-Up
Information
L2
L2
L3
L3
PE
PE
Key:
A
B
C
D
E
3
MCCB1
2 4 6
4
MCB8
1 3 5
Power Factor Correction
Capacitor
Compressor
Phase Rotation Relay
Closed Transition Start
Optional Extra
Power Factor Correction
Optional Extra
L1 L L3
2
E
D
1 3 5
CP9
1 3
5
2 4
6
5
2 4
6
CP3
CP1
2 4 6
1 3
2 4 6
1 3 5
MCB12 2 4 6
CP2 2 4 6
1
1 3
C
14
2 4
12
6
E
A
3
2
M1
3~
1
3
3
N
L
N
7
8
9
N
B
Starting Sequence (StarDelta Starting)
CP5
On
CP1
On
CP5
Off
2 Sec ± 1(1)
Star
(1)
50
CP3
On
< 40 ms
Delta
0.7 seconds when Closed Transition optional extra selected.
Chillers
Installation & Maintenance : 6564868 09/2012
PRR1 L1 L2 L3
5
OL1
A
3 5
293
294
1 3 5
292
CP7
11
Chillers
OPTICHILL
Commissioning Data
OPERATIONAL SEQUENCE
Refrigerant Charge
Liquid refrigerant should be charged into the condenser before compressor starting to
ensure that refrigerant is present at compressor start-up.
Compressor Oil Heater
The mains supply to the compressor oil heater should be switched on at least 8 hours
prior to compressor starting to avoid refrigerant migration.
CAUTION
A separately fused, locally isolated, permanent single phase and neutral supply
MUST BE FITTED for the compressor oil heater, evaporator trace heating and
control circuits, FAILURE to do so could INVALIDATE WARRANTY.
To reduce down time, if possible support the above supply with a UPS.
Pre-Start-Up Check
Before compressor start-up, make sure that an oil level is showing in the compressor
sight glass, and that all refrigerant ball valves are opened, including the liquid
injection line.
Checks at Compressor
Start-up
As soon as the compressor starts, make sure that the solenoid valve for liquid injection
opens, and that the suction and liquid/discharge pressure gauges are showing low and
high pressures respectively.
CAUTION
If there is no liquid present or no differential pressure occurs, isolate immediately.
Check phase rotation by connecting pressure gauges to the suction and
discharge ports.
Capacity Control
4 Stage capacity control
CONTROL RELAY
START / STOP
25% CAPACITY
50% CAPACITY
75% CAPACITY
100% CAPACITY
1





2





3





4





 Solenoid Valve De-energized
 Solenoid Valve Energized
 Solenoid Valve intermittent (10 sec on / off)
Adding Refrigerant
Additional refrigerant should be added to the system via 1/4” Schrader connection on the
expansion line.
Pump Down
Never shut the liquid injection solenoid valve during or before pump down.
Never pump down without the low pressure trip and high discharge temperature switches
being operative.
UNLOADING PROTECTION
Head Pressure
The microprocessor has inbuilt protection against nuisance trips. If the head pressure
rises above 13.2barg the compressor will unload to 75% and remain unloaded until the
head pressure drops below 11.2barg.
Low Pressure
If low pressure drops below the microprocessor setting, the compressor will unload to
75%, if low pressure persists for 1 minute, the circuit will be switched off and sound
an alarm.
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51
OPTICHILL
Chillers
Commissioning Procedure
To be read in conjunction with the commissioning sheets provided, items highlighted
should be recorded.
GENERAL
CAUTION
Please ensure all documents have been completed correctly and return to Airedale
Technical Support immediately to validate warranty.
PRE COMMISSIONING CHECKLIST
CAUTION
ALL work MUST be carried out by Technically Trained competent personnel.
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
The unit isolators DO NOT isolate the incoming mains supply, but isolate the
individual electrical panels. Isolate REMOTELY the mains incoming supply to the
BUSBAR chamber prior to maintenance or repair work.
The door interlocking MCCB should be in the OFF position and the auxiliary alarm
contact from the MCCB should be linked out.
Ensure all items listed in the Pre commissioning section are complete.
RECORD

















CAUTION
The unit should be visually inspected and any damage noted
Secure commissioning gauges to the high side of the system, check for a
positive charge
Check tightness of electrical components and properly terminated
Check that the remote on/off switch (if fitted) is in the off position
With the MCBs in the off position measure the incoming voltage
Check Phase Rotation
Check voltage at permanent supply
Measure and record the primary (230V) and secondary (24V) voltages at each of the
transformers, adjust tapping if necessary and record on the commissioning document
Check all timer settings are correct
Check compressor oil heater (ensure this is switched on for a minimum of 8 hours
prior to the unit operation)
Check oil level of each compressor
Check water filter is fitted
Check design water flow is available
Check flow switch and pump interlocks are fitted to the water system and wired
directly to the chiller and functioning correctly
Switch on the controls and individual circuits, primary and secondary, MCBs to the
ON position, at this stage the control display panel should be illuminated
Record Optional Extras
Record Controller Data
Disable remote ON/OFF to ensure the unit does not start unintentionally.
The chiller will not start until microprocessor control SWITCH 1 is in the ON
position. DO NOT SWITCH TO ON AT THIS STAGE
52
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Chillers
OPTICHILL
Commissioning Procedure
PRE COMMISSIONING CHECKLIST
Adjust the water temperature supply and return set points (if necessary) to call for 100%
cooling (refer to Controls, on page 39).

Ensure all KNOBS and SWITCHES are adjusted to suit the design requirements
(refer to Controls, on page 39)

To switch the unit ON, use the microprocessor keypad as follows:
Press
CAUTION
Prg
, press
, press
, press
& finally
There will always be a delay between the enabling of the unit and the energising of
the compressor contactors, anything between 1 to 2 minutes. Be patient.
Check that there is a 2 seconds delay between the Star and Delta contactor energising on
each circuit.
CAUTION
CAUTION
This delay period would be 0.7 seconds in Closed Transition Starting.

Check capacity control timing as detailed previously

Check that each circuit trips on low pressure, the alarm should appear within
3 minutes

The alarm will be recognised at the display circuit trip, to clear the alarms refer to
Alarm Handling, on page 42
Prior to the chiller compressors being allowed to start, the Water Flow Fail and
Pump Interlock features MUST both be proven to work correctly.
To check the water flow fail safety protection is working satisfactorily:
RECORD


Reduce the flow rate to 75% of design and ensure that the evaporator pressure or
flow protection switch trips at this flow rate, adjust as necessary
With compressors off, ensure this alarm is recognised as “Water Flow Fail” at the
display and disengages the circuits operation immediately, restore flow rate to the
design and check the alarm has self-cleared
To check the pump interlock safety feature works satisfactorily:
RECORD

Switch off the chiller water pump and check the interlock wiring connections at the
chiller are open circuit

To switch the unit OFF, use the microprocessor keypad as follows:
Press

CAUTION
Prg
, press
, press
, press
& finally
Fully open all liquid line and discharge service ball valves on each circuit
Re-instate both the liquid injection and liquid line solenoid valves.
Remove the link from the MCCB for the auxiliary alarm contact.
Fully open all liquid line and discharge service ball valves on each circuit.
Chillers
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53
OPTICHILL
Chillers
Commissioning Procedure
COMMISSIONING CHECKLIST
The following should be carried out with a load on the system; otherwise the unit is likely
to short cycle. The following tests are to be carried out on 1 circuit at a time.

Switch the door interlocking MCCB to the ON position but again only on the circuit
which is to be tested

Adjust the water temperature supply and return set points to match the
system requirements

To switch the unit ON, use the microprocessor keypad as follows:
Press
Prg
, press
, press
, press
& finally

Check liquid injection solenoid valve is energised and sight glass is clear

Check pressures at suction and discharge ports for correct phase rotation
CAUTION
If there is no liquid present or no differential pressure occurs, isolate immediately.
RECORD



CAUTION
RECORD
Check the unloading solenoids operate in the correct sequence - refer to
Commissioning Data, on page 51
Measure and record the compressor amps once the compressors are fully loaded
and then at each of the unloading stage
Measure and record full speed amps of each condenser
The microprocessor LP setting is adjustable via the micro display. It is
recommended that this setting be 0.6 bar below the equipment freezing point of the
cooling medium ie for water (no glycol) LP micro settings is 3.2barg.

Ensure that the low water temperature safety cuts out at the correct setting +/- 0.5°C,
to clear the alarms refer to Alarm Handling, on page 42

For water (no glycol) application, the recommended setting is 3°C below the design
supply water temperature (to a minimum of 3°C)



Check the liquid line sight glass is clear and dry
Check the superheat setting adjust the expansion valve to maintain a superheat
setting of 5 - 8°C at all operating loads
Check and record the following:
Suction and discharge pressures
Liquid, discharge and suction line temperature
Water inlet and outlet temperature

Ensure the above are all within the design parameters

Repeat as follows for each circuit:

To switch the unit OFF, use the microprocessor keypad as follows:
Press

Prg
, press
, press
, press
& finally
To switch the unit ON, repeat above
The unit is now commissioned and will provide many years of trouble free operation
providing the following maintenance schedule is followed.
54
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Chillers
OPTICHILL
Maintenance
CAUTION
WARNING
ALL work MUST be carried out by technically trained competent personnel.
The equipment contains live electrical and moving parts, ISOLATE prior to
maintenance or repair work.
The unit isolators DO NOT isolate the incoming mains supply, but isolate the
individual electrical panels. Isolate REMOTELY the mains incoming supply to the
BUSBAR chamber prior to maintenance or repair work.
The door interlocking MCCB should be in the OFF position and the auxiliary alarm
contact from the MCCB should be linked out.
WARNING
Power Factor Correction - Optional Extra
Allow Discharge time and short circuit the capacitor before handling! This applies
to any flying leads directly attached to the capacitor terminals.
IMPORTANT
UK MAINLAND - The Chiller Maintenance Record and supporting maintenance
documents MUST be complete and available on request to validate warranty.
The Chiller Maintenance Record is located within the unit control panel.
IMPORTANT
Ensure relevant F-Gas Regulation checks are carried out at the appropriate period.
Chillers
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55
OPTICHILL
Chillers
Maintenance
The maintenance schedule indicates the time period between maintenance operation.
GENERAL
MAINTENANCE
3 MONTHS
ACTION
NOTES
REFRIGERATION Check the following and compare results with
commissioning records:

Suction and discharge readings

Head pressure control is maintained

Pressure relief indicator gauge

Check each circuit sight glass for dryness and
bubbles for indication of leaks

Check compressor oil level and
shell/sump temperature
 Visually inspect the unit for oil patches
Investigate and rectify variations
SYSTEM
Check the following against the commissioning
records:

Control settings

Alarm log for unusual occurrences

Chilled water control maintains
design temperature

Chilled water flow is within design limits of
zero to plus 10%

Concurrently ensure chilled water pump and
flow switch operate efficiently, and that
interlocks function correctly

Operation of waterflow switch and pump
interlock
Investigate and adjust as necessary.
Finally!
Record operating conditions.
FABRIC
Visually inspect the unit for general wear and tear,
treat metalwork.
Rust should be inhibited, primed and touched
up with matching paint (available from
Airedale or your Distributor).
Visually inspect pipe and pipework insulation.
Repair/rectify as necessary.
Clean evaporator water strainer.
At first maintenance visit and then as
frequently as necessary (12 months).
Remember to re-cap the Schrader
connections!
Investigate and repair possible leaks
Clean condenser coils. Do not steam clean use
Do not damage fins and comb out if
detergent and stiff bristled brush. For heavy dirt,
necessary.
use either a high pressure water or chemical hose.
Visually check the following:

Pipework clamps are secure

Tightness and condition of fan and
compressor mounts

Anti-Vibration mounts fixings (if fitted)
Finally!
56
Ensure control panel lids and access panels have
been correctly replaced and securely fastened
in position.
Chillers
Installation & Maintenance : 6564868 09/2012
Secure/tighten as necessary.
Chillers
OPTICHILL
Maintenance
GENERAL MAINTENANCE
6 MONTHS
ACTION
NOTES
Repeat 3 month checks plus the following:
SYSTEM
Check evaporator heater and low ambient
thermostat are set to activate at 4.0ºC.
Remember to re-cap the Schrader
connections!
12 MONTHS
ACTION
NOTES
Repeat 6 month checks plus the following:
SYSTEM
Check safety devices cut out the compressor at the
correct settings.
REFRIGERATION Check glycol concentration if appropriate.
Leak test all refrigerant joins and inspect all
water connections.
ELECTRICAL
Adjust as necessary.
Rectify as necessary.
Tighten all electrical terminals.
COMPRESSOR
MAINTENANCE
SHUT DOWN PERIODS
Periodic maintenance and inspection of this equipment is necessary to prevent premature
failure, the following periodic inspections should be carried out by period or hourly use
which ever is sooner.
1 Year
Measure compressor motor insulation.
7,500 Hours or 4 Years
Inspect compressor oil.
20,000 Hours or 4 Years
Inspect oil filter, suction filter, check valve and pressurerelief valve.
For periods of winter shut down the following precautions are recommended:

Close the liquid and discharge ball valve

Cap service ports

Turn off electrical circuits

Drain the water from the chiller evaporator via the evaporator drain plug
Chillers
Installation & Maintenance : 6564868 09/2012
57
OPTICHILL
Chillers
Parts Identification
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.
The serial plate can be located inside Item 31.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
31
30
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
58
Suction Pressure Transducer
Low Pressure Switch
HP Switch
Liquid Line Sight Glass
Discharge Line Ball Valve
Discharge NRV
Discharge Schrader Connection
Discharge Thermostat Switch
Compressor
Liquid Line Ball Valve
Liquid Line Filter Drier
Electronic Expansion Valve Controller
Microprocessor Controller
Phase Rotation Relay
Bus bar Chamber 3 phase Mains Incoming
Closed Transition Starting Resistor Pack (Optional Extra)
Condenser Fan Motor Protection Circuit Breakers
Modulating Head Pressure Controller - AC Standard Fans only
Timers
Door Interlocking Circuit Isolator
Star Delta Contactors
Incoming Customer Terminals
Evaporator
Water Connection
Electronic Expansion Valve (EEV)
Liquid Line
Mains Electrics & Controls Panels
Fan & Motor Assemblies - AC Motor Standard, EC Motor Optional
Condenser Coils
Control Panel (Serial Plate to inside)
Mains Panel Circuit 2
Emergency Stop
Incoming Customer Mains Access Points
Suction Port
Compressor Electrical Terminal Box
Unloading Solenoid Valve 1
Discharge Line
Unloading Solenoid Valve 2
Unloading Solenoid Valve 4
Oil Level Sight Glass
Compressor Feet/Resilient Pads
Unloading Solenoid Valve 3
Oil Sump Draw Point
Sump Heater
Economiser Circuit
Economiser EEV
Liquid Line Solenoid Valve
Economiser Liquid Transducer
Economiser Plate Heat Exchanger
Chillers
Installation & Maintenance : 6564868 09/2012
Chillers
OPTICHILL
16
17
18
5
19
6
1
12
7
2
8
20
6
13
21
14
22
3
4
9
23
10
25
9
26
24
15
11
27
28
29
30
31
32
20
15
33
33
9
45
37
34
35
33
36
38
39
40
41
42 44
46 47
48
49
43
Chillers
Installation & Maintenance : 6564868 09/2012
59
W here to Fin d U s
Head Office:
Airedale International Air Conditioning Ltd
Leeds Road
Rawdon
Leeds LS19 6JY
United Kingdom
Tel:
Fax:
e-mail:
website:
LITER ATUR E ORDER COD E
PART NO:
6564868 (IM E)
6564868 (IM E)
ISSUE
08/2008
09/2012
+44 (0) 113 239 1000
+44 (0) 113 250 7219
[email protected]
www.airedale.com
UT AIRED AL E