air cooled liquid chiller installation, commissioning

YCAJ
AIR COOLED LIQUID CHILLER
INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE
STYLE E
REFRIGERANT TYPE: R22, R134a, R407C
WITH: V4-4 REV6 SOFTWARE AND HIGHER
V4C-2 REV6 SOFTWARE AND HIGHER
035L02203-100 Rev. 5
(10/03)
GB
035L02203-100 Rev. 5
I-i
TABLE OF CONTENTS
1
2
3
SUPPLIER INFORMATION
4
INSTALLATION
1.1 Introduction
1.1
4.1 Location Requirements
4.1
1.2 Warranty
1.1
4.2 Location Clearances
4.2
1.3 Safety
1.1
4.3 Vibration Isolator Installation & Dimensions 4.2
1.4 Responsibility for Safety
1.1
4.4 Pipework Connection
4.3
1.5 About this Manual
1.2
4.5 Water Treatment
4.5
1.6 Misuse of Equipment
1.2
4.6 Pipework Arrangement
4.5
1.7 Emergency Shutdown
1.3
4.7 Connection Types & Sizes
4.6
1.8 Safety Labels
1.3
4.8 Refrigerant Relief Valve Piping
4.7
1.9 Material Safety Data
1.5
4.9 Ductwork Connection
4.8
4.10 Electrical Connection
4.9
4.11 Power Wiring
4.9
4.12 Power Section Volt Free Contacts
4.10
4.13 Logic Section Connections
4.11
4.14 Power and Control Panel Layout
4.12
4.15 Power Supply Connections
4.13
4.16 Connection Schematic
4.14
PRODUCT DESCRIPTION
2.1 Introduction
2.1
2.2 Compressors
2.1
2.3 Cooler
2.2
2.4 Air Cooled Condensers
2.2
2.5 Refrigerant Circuits
2.2
2.6 Power and Control Panels
2.2
2.7 Options and Accessories
2.3
2.8 Nomenclature
2.5
TRANSPORTATION, HANDLING
AND STORAGE
6
3.1 Delivery and Storage
3.1
3.2 Inspection
3.1
3.3 Moving the Chiller
3.1
3.4 Lifting Weights
3.2
3.5 Shipping Brackets
3.2
(10/03)
5
COMMISSIONING
5.1 Preparation
5.1
5.2 First Time Start-up
5.3
UNIT OPERATION
6.1 General Description
6.1
6.2 Start-up
6.1
6.3 Normal Running and Cycling
6.1
6.4 Compressor Capacity Control
6.2
6.5 Discharge Pressure Fan Control
6.2
6.6 Heat Recovery Operation
6.2
6.7 Shutdown
6.2
I-ii
7
8
035L02203-100 Rev. 5
MAINTENANCE
9
TECHNICAL DATA
7.1 General Requirements
7.1
9.1 Flow Rate/Pressure Drop Charts
9.1
7.2 Daily Maintenance
7.1
9.2 Operating Limitations
9.3
7.3 Scheduled Maintenance
7.2
9.3 Physical Data
9.6
7.4 Vessels In-Service Inspection
7.3
9.4 Electrical Data
9.8
9.5 Clearances
9.12
9.6 Dimensions
9.13
TROUBLE SHOOTING
8.1 Competent Persons Trouble
Shooting Guide
8.1
9.7 Lifting Weights
9.17
8.2 Compressor Components
8.3
9.8 Weight Distribution And Isolator Positions
9.18
8.3 Fan Control Sequencing
8.4
9.9 Process and Instrumentation Diagrams
9.23
8.4 Sensor Calibration Charts
8.4
9.10 Component Locations
9.25
8.5 Electronic Expansion Valve Calibration
8.5
8.6 Electronic Expansion Valve
Trouble Shooting
8.6
10
11
SPARE PARTS
10.1 Recommended Spares
10.1
10.2 Compressor Top Head Rebuild Kit
10.1
DE-COMMISSIONING, DISMANTLING
AND DISPOSAL
11.1 General
11.1
(10/03)
035L02203-100 Rev. 5
1
SUPPLIER INFORMATION
1.1
Introduction
York YCAJ-Series Air Cooled Liquid Chillers are
manufactured to the highest design and construction
standards to ensure high performance, reliability and
adaptability to all types of air conditioning installations.
The unit is intended for cooling water or glycol solutions
(and heating water in the case of heat recovery models)
and is not suitable for purposes other than those
specified in this manual.
1- 1
The initial start of the unit must be carried out by trained
personnel from an Authorised York Service Centre.
Only genuine York approved spare parts, oils and
refrigerants must be used.
All the scheduled maintenance operations detailed in
this manual must be performed at the specified times by
suitably trained and qualified personnel.
This manual and the Operating Instructions for the Micro
Based Control System contain all the information
required for correct installation and commissioning of
the unit, together with operating and maintenance
instructions. The manuals should be read thoroughly
before attempting to operate or service the unit.
Failure to satisfy any of these conditions will
automatically void the warranty.
All procedures detailed in the manuals, including
installation, commissioning and maintenance tasks
must only be performed by suitably trained and qualified
personnel.
YCAJ-Series Chillers are designed and built within an
EN ISO 9001 accredited design and manufacturing
organisation and, within the limits specified in this
manual, are in conformity with the essential health and
safety requirements of the following European Union
Directives:
The manufacturer will not be liable for any injury or
d a m a g e c a u s e d by i n c o r r e c t i n s t a l l a t i o n ,
commissioning, operation or maintenance resulting
from a failure to follow the procedures and instructions
detailed in the manuals.
1.2
Warranty
1.3
Safety
Standards for Safety
Machinery Directive (89/392/EEC)
Low Voltage Directive (73/23/EEC)
EMC Directive (89/336/EEC)
York International Limited warrants all equipment and
materials against defects in workmanship and materials
for a period of one year from initial start-up, or eighteen
months from delivery (whichever occurs first) unless
extended warranty has been agreed as part of the
contract.
Refrigeration equipment built at York Basildon conforms
to the applicable essential safety requirements of
Pressure Equipment Directive 97/23/EC and bear CE
marking.
The warranty is limited to free replacement and shipping
of any faulty part, or sub-assembly which has failed due
to poor quality or manufacturing errors. All claims must
be supported by evidence that the failure has occurred
within the warranty period, and that the unit has been
operated within the designed parameters specified.
Every care has been taken in the design and
manufacture of York Chillers to ensure that they meet
the safety requirements listed in the previous paragraph.
However, the individual operating or working on any
machinery is primarily responsible for:
All warranty claims must specify the unit model, serial
number and order number. These details are printed on
the unit identification plate.
The unit warranty will be void if any modification to the
unit is carried out without prior written approval from
York International.
For warranty purposes, the following conditions must be
satisfied:
(10/03)
1.4
Responsibility for Safety
Personal safety, safety of other personnel, and the
machinery
Correct utilisation of the machinery in accordance with
the procedures detailed in this manual.
1- 2
1.5
035L02203-100 Rev. 5
About this Manual
The following symbols are used in this document to alert
the reader to areas of potential hazard.
A Warning is given in this document to
identify a hazard which could lead to
personal injury. Usually an instruction will
be given, together with a brief explanation
and the possible result of ignoring the
instruction.
A Caution identifies a hazard which could
lead to damage to the machine, damage to
other equipment and/or environmental
pollution. Usually an instruction will be given,
together with a brief explanation and the
possible result of ignoring the instruction.
A Note is used to highlight additional
information which may be helpful to you but
w h e r e th e r e a r e n o s p e c i a l s a f e t y
implications.
The contents of this manual include suggested best
working practices and procedures. These are issued for
guidance only, they do not take precedence over the
above stated individual responsibility and/or local safety
regulations.
This manual and any other document supplied with the
unit, are the property of YORK which reserves all rights.
They may not be reproduced, in whole or in part, without
prior written authorisation from an authorised YORK
representative.
1.6
Misuse of Equipment
Suitability for Application
Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage to
the equipment.
Mechanical Strength
The unit is not designed to withstand loads or stresses
from adjacent equipment, pipework or structures.
Additional components must not be mounted on the unit.
Any such extraneous loads may cause structural failure
and may result in injury to the operator, or damage to the
equipment.
General Access
There are a number of areas and features which may be
a hazard and potentially cause injury when working with
the unit unless suitable safety precautions are taken. It is
important to ensure access to the unit is restricted to
suitably qualified persons who are familiar with the
potential hazards and precautions necessary for safe
operation and maintenance of equipment containing
high temperatures, pressures and voltages.
Pressure Systems
Each unit has two independent pressure systems
comprising the compressor, air cooled condenser coils,
cooler vessel and interconnecting copper pipework.
Each system contains refrigerant vapour and liquid
under pressure, release of which can be a danger and
cause injury. The user should ensure that care is taken
during installation, operation and maintenance to avoid
damage to the pressure system. No attempt should be
made to gain access to the component parts of the
pressure system other than by suitably trained and
qualified personnel.
The unit is intended for cooling (and heating) water or
glycol solutions and is not suitable for purposes other
than those specified in these instructions. Any use of the
equipment other than its intended use, or operation of
the equipment contrary to the relevant procedures may
result in injury to the operator, or damage to the
equipment.
The unit must not be operated outside the design
parameters specified in this manual.
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035L02203-100 Rev. 5
1- 3
Electrical
1.7
The unit must be ear thed. No installation or
maintenance work should be attempted on electrical
equipment without first switching off, isolating and
locking-off the main power supply and any control
supplies. Work on live equipment must only be
carried-out by suitably trained and qualified personnel.
No attempt should be made to gain access to internals
of the control panel, wiring or other electrical enclosures
during normal operation of the unit.
In case of emergency the control panel is fitted with an
emergency stop switch which, when operated, removes
the electrical supply from the control system and the
microprocessor controller. A facility is available to
connect a remote emergency stop device for the same
purpose. The emergency stop switch can be pad-locked
in the off position.
Emergency Shutdown
Rotating Parts
Fan guards must be fitted at all times and not removed
unless the main power supply has been isolated. If
ductwork is to be fitted, requiring the wire fan guards to
be removed, alternative safety measures must be taken
to protect against the risk of injury from rotating fans.
Sharp Edges
The finning on the air cooled condenser coils has sharp
metal edges. Reasonable care should be taken when
working in contact with the coils to avoid the risk of minor
abrasions and lacerations. The use of gloves is
recommended.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
non-toxic, non-flammable and non-corrosive, and pose
no special safety hazards. Use of gloves and safety
glasses are, however, recommended when working on
the unit. Build up of refrigerant vapour, from a leak for
example, does pose a risk of asphyxiation in confined or
enclosed spaces and attention should be given to good
ventilation. For more comprehensive information on
safety precautions for use of refrigerants and oils, refer
to the Materials Safety Data tables provided.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods (e.g.
steam cleaning) should not be used on any part of the
pressure system as this may cause operation of the
pressure relief device(s). Detergents and solvents which
may cause corrosion should also be avoided.
PULL TO
PAD-LOCK
1.8
Safety Labels
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may
exist.
White symbol on blue
background
For safe operation - read the
Instructions first
Black symbol on yellow
background
Warning: This machine may
start automatically without
prior warning
Black symbol on yellow
background
Warning: Hot surface
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035L02203-100 Rev. 5
Black symbol on yellow
background
Warning: Safety relief valve
may discharge gas or liquid
without prior warning
Black symbol on yellow
background
Warning: Isolate all
electrical sources of supply
before opening or removing
the cover, as lethal voltages
may exist
Black symbol on yellow
background
General attention symbol
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035L02203-100 Rev. 5
1.9
1- 5
Material Safety Data
Refrigerant Data:
Safety Data
R22, R407C, R134a
Toxicity
Low.
In contact with skin
Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by
skin absorption. R22 may be slightly irritant and liquid has a degreasing effect.
Thaw affected areas with water. Remove contaminated clothing carefully - may
adhere to skin in case of freeze burns. Wash affected areas with plenty of warm
water. If symptoms occur (irritation or blistering) obtain medical attention.
In contact with eyes
Vapour has no effect. Liquid splashes or spray may cause freeze burns.
Immediately irrigate with eyewash solution or clean water for at least 10
minutes. Obtain immediate medical attention.
Ingested
Highly unlikely to occur -but should this occur freeze burn will occur. Do not
induce vomiting. Provided patient is conscious, wash mouth with water and give
about 250 ml (0.5 pint) to drink. Obtain immediate medical attention.
Inhalation
R22 High levels of vapour
concentration initially produce
stimulation and then depression of the
central nervous system causing
headaches and giddiness and may
lead to unconsciousness. Can prove
suddenly fatal if the exposure has
been severe.
R407C, R134a High atmospheric
concentrations may lead anaesthetic
effect, including loss of consciousness.
Very high exposures may cause an
abnormal heart rhythm and prove
suddenly fatal.
At higher concentration there is a danger from asphyxiation due to reduced
oxygen content of atmosphere. Remove patient to fresh air, keep warm and at
rest. Administer oxygen if necessary. Apply artificial respiration if breathing has
ceased or shows signs of failing. In event of cardiac arrest apply external
cardiac massage. Obtain immediate medical attention.
Further medical advice
Symptomatic and supportive therapy is indicated. Cardiac sensitisation has
been described which may, in the presence of circulating catecholamines such
as adrenalin, give rise to cardiac arrhythmias and subsequent arrest following
exposure to high concentrations.
Long term exposure
R22 A lifetime inhalation study in rats
and mice give a small excess in
salivary gland tumours in male rats
only at 50,000 ppm. 10,000 ppm
showed no effect. This information
suggests that R22 does not represent
a carcinogenic hazard to humans.
R407C, R134a A lifetime inhalation
study in rats has shown that exposure
to 50,000 ppm resulted in benign
tumours of the testis. This is not
considered to be of relevance to
humans exposed to concentrations at
or below the occupational exposure
limit.
Occupational exposure
limits
R22 Recommended limit : 1000 ppm
v/v - 8 hr TWA 1250 ppm v/v - 12 hr
TWA.
R407C, R134a Recommended limit:
1000 ppm v/v - 8 hr TWA.
Stability
R22 Unstable.
R407C, R134a Not specified.
Conditions to avoid
Use in presence of naked flames, red hot surfaces and high moisture levels.
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035L02203-100 Rev. 5
Hazardous reactions
May react violently with sodium, potassium, barium and other alkali and alkaline
earth metals. Incompatible materials : Magnesium and alloys containing more
then 2% magnesium.
Hazardous decomposition
products
R22 Halogen acids formed by thermal
decomposition.
General precautions
Avoid inhalation of high concentrations of vapours. Atmospheric concentrations
should be minimised and kept as low as reasonably practicable below the
occupational exposure limit. The vapour is heavier than air and collects at low
level and in confined areas. Ventilate by extraction at lowest levels.
Respiratory protection
Where doubt exists on atmospheric concentration, HSE approved breathing
apparatus should be worn. This should be self contained or of the long breather
type.
Storage
Keep containers dry and in a cool place away from fire risk, direct sunlight, and
all sources of heat such as radiators. Keep at temperatures not exceeding
45°C.
Protective clothing
Wear overalls, impervious gloves and goggles/face protection.
Spill/leak procedure
Ensure suitable personal protective clothing and respiratory protection is worn.
Provided it is safe to do so, isolate the source of the leak. Allow small spillages
to evaporate provided there is suitable ventilation.
Large spillages : Ventilate area. Contain spillages with sand, earth or any
suitable absorbent material. Prevent liquid from entering drains, sewers,
basements and work pits since vapour may create a suffocating atmosphere.
Disposal
Best to recover and recycle. If this is not possible, destruction is to be in an
approved facility which is equipped to absorb and neutralise acids and other
toxic processing products.
Fire extinguishing data
R22 Non-flammable
Containers
Fire exposed containers should be kept cool with water sprays. Containers may
burst if overheated.
Fire fighting protective
equipment
Self contained breathing apparatus and protective clothing must be worn in fire
conditions.
R407C, R134a Halogen acids by
thermal decomposition and hydrolysis.
R407C. R134a Non-flammable at
atmospheric conditions.
Refrigerant Oil Data
Safety Data
York “C” Oil
York “H” Oil
Classification
Non-hazardous
In contact with skin
Minimally irritating. No first aid necessary. Exercise reasonable personal
cleanliness including cleansing exposed skin areas several times daily with
soap and water. Launder soiled work clothes at least weekly.
In contact with eyes
As with most foreign materials flush
with plenty of eyewash solution or
clean water.
Flush eyes with eyewash solution or
clean water for 15 minutes and consult
a physician.
Ingested
Non-toxic. No first aid considered
necessary.
May cause nausea and diahorrhea.
Obtain immediate medical attention.
Inhalation
If oil mist is inhaled, remove to fresh air and consult a physician.
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035L02203-100 Rev. 5
1- 7
Occupational exposure
limits
Recommended limit : 5 mg/cubic
metre of oil mist in air for 8 hr daily
exposure.
Not determined.
Stability
Stable.
Stable but hygroscopic -store in sealed
containers.
Conditions to avoid
None Specified.
Strong oxidisers, caustic or acid
solutions, excessive heat. May
degrade some paints and rubber
materials.
Hazardous decomposition
Oxides of carbon, aldehydes and
ketones, combustion products of
nitrogen, sulphur.
Not fully. Analogous compounds
evolve carbon monoxide, carbon
dioxide and other unidentified
fragments when burned. Burning fluid
may evolve irritating/noxious fumes.
Respiratory protection
Use in well ventilated areas.
Use in well ventilated areas - ventilate
locally.
Protective clothing
Not necessary but goggles or face
shield recommended.
Goggles or face shield should be
worn. Gloves not necessary, but
recommended, especially for
prolonged exposure.
Spill / Leak procedure
Wear suitable protective equipment, especially goggles. Stop source of spill.
Use absorbent materials to soak up fluid (i.e. sand, sawdust, and commercially
available materials).
Disposal
Incinerate the oil and all associated wastes in an approved facility in
accordance with local laws and regulations governing oily wastes.
Fire extinguishing data
Flash point over 180°C. Use water
spray, dry chemical, carbon dioxide or
alcohol foam. Water or foam may
cause frothing.
Flash point over 300°C. Use dry
chemical, carbon dioxide or foam.
Spraying water on hot or burning
liquid, may cause frothing or
splashing.
If a leak or spill has not ignited use water spray to disperse the vapours and to
provided protection for persons attempting to stop the leak.
Containers
Fire exposed containers should be kept cool with water sprays.
Fire fighting protective
equipment
Self contained breathing apparatus should be worn in fire conditions.
(10/03)
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035L02203-100 Rev. 5
Thermal & Acoustic Materials Data
Health Hazard & First Aid
Toxicity Index <10 to NES713 Issue 3 (1991) : Non-hazardous,
non-toxic. No first aid necessary.
Stability / Reactivity
Stable.
Handling / Use / Disposal
No special handling precautions required. Dispose of according to local
laws and regulations governing non-biodegradable non-hazardous solid
wastes.
Fire & Explosion
Flammability rating Class 1 to BS 476 pt 7 : Non-flammable. If forced to
burn, combustion products are typically over 95% carbon dioxide and
carbon monoxide.
(10/03)
035L02203-100 Rev. 5
2
PRODUCT DESCRIPTION
2.1
Introduction
2- 1
York YCAJ-Series Air Cooled Liquid Chillers are
designed for water or water-glycol cooling. Heat
recovery models provide simultaneous chilled and
warm water to satisfy cooling, heating and domestic hot
water requirements.
All models are designed to be located outside on the
roof of a building or at ground level. YCAJ-Series
Chillers are packaged in one or two condenser modules.
All models are delivered completely assembled with all
interconnecting refrigerant piping and internal wiring,
ready for field installation.
Prior to delivery each unit is pressure tested, evacuated
and fully charged with refrigerant, and includes an initial
oil charge. After assembly a full run test is performed
with water flowing through the cooler to verify that each
refrigeration circuit operates correctly.
The unit base and framework are fabricated using
heavy-gauge galvanised steel which is zinc phosphate
pre-treated and powder coated to minimise corrosion.
Key
2.2
Compressors
Each unit is fitted with two semi-hermetic, reciprocating
compressors. The compressor motors are refrigerant
gas cooled, with integral temperature sensing solid state
overload protection in each phase. The motor terminal
boxes are manufactured to prevent ingress of dust and
water to IP54. Starting is by part-winding or star delta.
Compressor Housing
The compressor housing is cast iron. It contains:
removable cylinder heads with internal muffling, suction
and discharge service valves, crankcase sight glass
and heater, oil and suction strainers, and internal relief
valve conforming to ASHRAE/ANSI Standard 15 Safety
Code.
1
2
3
4
5
6
7
8
9
Condenser Fan
Condenser - System 1
Compressor - System 1
Compressor - System 2
Control Panel - Power Section - System 1
Control panel - Power Section -System 2
Control Panel - Logic Section
Cooler
Heat Recovery Condenser (Option)
Compressor Lubrication
The lubrication is force-fed by a reversible oil pump
which supplies oil to all crankshaft and bearing surfaces
through a fine mesh stainless steel filter.
Capacity Control
Capacity control is provided by solenoid-actuated
capacity control valves, controlled by the Micro Based
Control System. This method efficiently and effectively
matches unit capacity to low load conditions as
required.
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035L02203-100 Rev. 5
2.4
Key
1
2
3
4
5
6
7
8
9
10
11
2.3
Condenser Fan
Condenser - System 1
Condenser - System 2
Compressor -System 1
Compressor - System 2
Control Panel - Power Section - System 1
Control panel - Power Section - System 2
Control Panel - Logic Section
Cooler
Heat Recovery Condenser - System 1
(Option)
Heat Recovery Condenser - System 2
(Option)
Cooler
The dual-circuit shell-and-tube cooler is of the direct
expansion type, with refrigerant in the tubes and chilled
liquid flowing through the baffled shell.
The water baffles are constructed from galvanised steel
to minimise corrosion. The removable heads allow
access to the internally enhanced, seamless copper
tubes. Vent and drain connections are included.
The cooler is equipped with heater mats controlled by
the Micro Based Control System. The heaters provide
freeze protection down to -29°C.
Air Cooled Condensers
Coils
The condenser coils are manufactured from seamless
copper tubes arranged in staggered rows, mechanically
expanded into fins. Integral subcooling is included.
Fans
The condenser fan blades are high efficiency,
aerofoil-type directly driven by independent motors and
positioned for vertical discharge. The fan guards are
constructed of heavy gauge steel wire which are hot dip
galvanised to minimise corrosion. All fan blades are
statically balanced for vibration free operation.
The fan motors are fully enclosed. The motor bearings are
double sealed and are permanently lubricated.
2.5
Refrigerant Circuits
Two complete, independent, refrigerant circuits are
supplied on each YCAJ unit. All unit piping is
manufactured from ACR copper with brazed joints. Each
liquid line includes: a shut-off valve with charging port,
sight glass with moisture indicator, thermal expansion
valve (direct acting, maximum operating pressure),
solenoid valve and filter. Each suction line and liquid line
from expansion valve to the cooler are insulated with
flexible, closed cell, foam insulation.
2.6
Power and Control Panels
All controls and motor starting equipment necessary for
the unit operation are located in galvanised steel
enclosures manufactured to IP55 weather protection.
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035L02203-100 Rev. 5
The power and logic sections are fully factory wired and
function tested during manufacture. Components are
mounted on galvanised steel back plates in separate
power or control compartments, each having a separate
galvanised steel access door. All doors are hinged and
lockable, and include door stays.
Control Panel - Power Sections
2- 3
Common Input Supply + Mains Isolation
Fa c t o r y fi t t e d d o o r i n t e r lo cke d is o l a t o r s
(switch-disconnector-fuse type), one per power section,
plus interconnecting wiring and terminals to allow
connection at a single point. Available with B.S. or D.I.N.
fuses. A gland plate extension box is included with this
option to allow additional space for cable spreading.
Each power section contains two 380/400V power
groups. One group is formed by the compressor
contactors and incoming terminals, the other by fan
contactors, overloads and fuses. A 220/230V control
group is formed by control fuses, residual current
device, compressor timer, compressor current
transformer and relay boards.
Low Ambient Kit
Control Panel - Logic Section
A high efficiency refrigerant to water condenser can be
provided to recover rejected heat into a hot water
system.
A door with a perspex viewing window is located on the
exterior of the logic section to house the Micro Based
Control System keypad and display. The logic control
compartment contains the microprocessor board,
power supply board, optical isolation board and, if fitted,
electronic expansion valve controllers. For details refer
to the Operating Instructions for the Micro Based
Control System supplied with the chiller.
2.7
Options and Accessories
This accessory is factory fitted and includes all
necessary components to allow chiller operation down
to -18°C condenser air intake.
Heat Recovery Kit
YCAJ 4 fan models (R22/R407C models 44MR7 to
77XT9 and R134a models 44MR7 to 99ST9) have one
condenser fitted to refrigerant system 1.
YCAJ 8 fan models (R22/R407C models 77SU7 to
99XW9 and R134a models 98AW9 to 99AW9) have two
condensers fitted, one to each refrigerant system. Hot
water leaving temperature controls are supplied for all
heat recovery models.
3-Wire Kit (Mandatory on CE units)
Condenser Coil - Corrosion Protection
A 3-wire kit comprising a control transformer and
associated wiring can be supplied to allow the control
voltage to be internally derived on sites where there is
no neutral connection available.
Mains Isolation (Mandatory on CE units)
Fa c t o r y fi t t e d d o o r i n t e r lo cke d is o l a t o r s
(switch-disconnector-fuse type), one per power section.
Available with B.S. or D.I.N. fuses.
Condenser coils can be supplied with the following fin
materials and finishes for corrosion protection, but
YORK cannot recommend which option is the most
suitable not knowing the environmental conditions at the
installation site. The final choice of fin material and finish
must be the responsibility of the customer or his
Consulting Engineer based on their experience and
knowledge of the application.
Aluminium Finning Material
Copper Finning Material
Epoxy pre-coated aluminium finning Material (Black fin)
Blygold coated aluminium condenser coils
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035L02203-100 Rev. 5
Wire Mesh Guards
Sequence Commander
Units can be supplied fitted with wire mesh guards
mounted on the exterior of the unit to protect condenser
coils from accidental damage.
A Sequence Commander allows control of common
liquid leaving temperature from up to four units
operating in parallel (each unit requires an additional
printed circuit board fitted to interface with the Sequence
Commander).
High Static Pressure Fans
Factory fitted fans with extra static pressure capability
permitting addition of louvres, ductwork, attenuators,
etc.
VBG 20 Compliance Kit
Acoustic Kits
Factory fitted T.Ue.V. approved mechanical high
pressure cut-out switches (two per system) as required
to comply with some pressure vessel safety codes.
Phase I kit comprises factory fitted low noise fans.
Flange Kits
Phase II kit comprises low noise fans, compressor
acoustic enclosure, discharge line gas mufflers and
acoustic lagging.
Units can be supplied with all liquid connections fitted
with flanges to BS 4504 (ISO 7005 - NP 10). Companion
flanges can also be supplied to the same standard.
Electronic Expansion Valve
Flow Switch
Electronic expansion valves and controls instead of
thermally operated valves for improved efficiency. This
option is only available for R22 and R134a models.
Switch suitable for up to 10 barg pressure and having
gold plated contacts suitable for low voltage/current for
protection of the unit against loss of water flow. This, or
an equivalent switch, must be fitted in the liquid outlet
pipe of each heat exchanger.
Mechanical Gauge Kit
Factory fitted mechanical dial gauges for discharge,
suction and oil pressure (one set per compressor) in
addition to electronic pressure display.
Anti-vibration Mounts
Set of level adjustable spring vibration isolator mounts
with mounting holes for fixing to foundations.
Star/Delta Compressor Starting
Lifting Lug Set
Compressors fitted with star/delta wound motors and
contactors for reduced current starting.
Microprocessor Contact Isolator Kit
Additional printed circuit board which allows customer
volt-free contacts to be located more than 7.5m from
panel connections.
Required for YCAJ 4 fan models (R22/R407C models
44MR7 to 77XT9 and R134a models 44MR7 to 99ST9).
The lifting lug set comprises four lifting lugs for locating
in the unit base frame and extending out to provide
shackle points clear of the unit sides for safe, correct
lifting.
Printer
EMS Offset Card
Additional printed circuit board which allows alternative
signals to be used from the customers Energy
Management System (EMS) to perform remote
temperature set-point offset function.
Hand held printer for obtaining print-outs of the unit
operating and history data from the Micro Based Control
System.
(10/03)
035L02203-100 Rev. 5
2.8
2- 5
Nomenclature
YC A J 7 5 M T 7 A GSi HR 50 P E
Design Level (Style)
YORK Chiller
Air Cooled
Type of Starter:
P = Part Wind
SD = Star Delta
Semi-Hermetic Compressor
Compressor Code (System 1)
Voltage Code:
50 = 380/400-3-50
Compressor Code (System 2)
Heat Recovery (Option)
Evaporator Code
Gold Standard Intelligent
Condenser Code
Refrigerant Code:
- = R22, A = R134a
B = R407c
Fan Code
Compressor Codes:
4 = PC43
5 = PC44
6 = PC63
7 = PC64
8 = PC83
9 = PC84
(10/03)
Evaporator Codes:
M = DXC 1408A
N = DXC 1408B
S = DXC 1608A
A = DXC 1808A
X = DXC 2008A
Condenser Codes:
R = 4 Fan - 3 Row
S = 4 Fan - 4/3 Row
T = 4 Fan - 4 Row
U = 8 Fan - 3 Row
W = 8 Fan - 4 Row
Fan Codes:
7 = 3 hp (standard)
9 = 5 hp (standard)
2- 6
035L02203-100 Rev. 5
Range of Models
R22 / R407C Models
4 Fan Units
8 Fan Units
YCAJ 44MR7
YCAJ 77SU7
YCAJ 55MR7
YCAJ 87SU7
YCAJ 55ST7
YCAJ 97SU7
YCAJ 65NS7
YCAJ 98XU7
YCAJ 66ST9
YCAJ 99XU7
YCAJ 76ST9
YCAJ 99XW9
YCAJ 77XT9
R134a Models
4 Fan Units
8 Fan Units
YCAJ 44MR7
YCAJ 98AW9
YCAJ 55MR7
YCAJ 99AW9
YCAJ 75MS7
YCAJ 77MT7
YCAJ 88ST7
YCAJ 98ST9
YCAJ 99ST9
Related Drawings
Units with Opto Board 025L02777-000
Models
Product
Drawings:
Wiring
Diagrams:
Standard Units
Heat Recovery Units
Schematic
Connection
Customer Wiring
Heat Recovery Wiring
Legend
4 Fan Units
R22 / R407C : 44MR7 -77XT9
R134a : 44MR7 - 99ST9
035L02178-000
035L02179-000
035L02341-001
035L02342-001
035L02343-001
035L02348-001
035L02110-001
8 Fan Units
R22 / R407C : 77SU7 - 99XW9
R134a : 98AW9 - 99AW9
035L02180-000
035L02181-000
035L02344-001
035L02345-001
035L02343-001
035L02349-001
035L02110-001
(10/03)
035L02203-100 Rev. 5
3
TRANSPORTATION, HANDLING
AND STORAGE
3.1
Delivery and Storage
To ensure consistent quality and maximum reliability,
each YCAJ-Series Chiller is tested and inspected
before leaving the factory. YCAJ-Series Chillers are
shipped as completely assembled units containing
refrigerant under pressure. Units are shipped without
export crating unless this has been specified on the
Sales Order.
If the chiller is to be put into storage, prior to installation,
the following precautions should be observed:
3.2
Do not store where exposed to ambient air temperatures
exceeding 45°C (R22 and R134a models) or 42°C
(R407C models).
The finned heat exchangers should be covered to
protect the fins from potential damage and corrosion,
particularly where building work is in progress.
The unit should be stored in a location where there is
minimal activity in order to limit the risk of accidental
physical damage.
To prevent inadvertent operation of the pressure relief
devices the unit must not be steam cleaned.
It is recommended that the control panel keys are
removed and deposited with a responsible person
on-site.
It is recommended that the unit is periodically inspected
during storage.
(10/03)
Inspection
Remove any transit packing and inspect the unit to
ensure that all components have been delivered and
that no damage has occurred during transit. If any
damage is evident, it should be noted on the carrier’s
freight bill and a claim entered in accordance with the
instructions given on the advice note.
Major damage must immediately be reported to your
local York representative.
3.3
Ensure that all openings, such as water connections,
are securely capped.
3- 1
Moving the Chiller
YCAJ-Series Chillers are designed to be lifted using
lifting lugs and cables. A spreader bar or frame 2.4
metres wide should be used in order to prevent damage
to the unit from the lifting chains:
3- 2
035L02203-100 Rev. 5
The unit must only be lifted by the base frame
at the points provided.
Two Module Units
Eight fan units are provided with lifting eyes extending
from the sides of the base frame which can be attached
to directly using shackles or safety hooks:
Never move the unit on rollers, or lift the unit
using a fork-lift truck.
Care should be taken to avoid damaging the
condenser cooling fins when moving the unit.
Prior to moving the chiller ensure that the installation site
is suitable for installing the unit, and is capable of
supporting the weight of the unit and all associated
services.
Single Module Units
Four fan units are provided with four square holes in the
base frame which accept the accessory lifting lug set
(part number 026L00309-000) which bolts through the
base frame to allow shackles or safety hooks to be
attached:
Open hooks should not be used
3.4
Lifting Weights
For details of weights and weight distribution refer to
section 9.
3.5
Shipping Brackets
Each unit is delivered with two shipping brackets on
each module which must be removed once the unit is
mounted on its foundations. The brackets are typically
galvanised steel sections, one running diagonally
across the side of the module, and one shorter bracket
at the back of the module.
Open hooks should not be used
(10/03)
035L02203-100 Rev. 5
4
INSTALLATION
4.1
Location Requirements
To achieve optimum performance and trouble-free
service, it is essential that the proposed installation site
meets with the location and space requirements for the
model being installed. For dimensions, weight and
space requirements, including service access details,
refer to Section 9.
It is important to ensure that the minimum service
access space is maintained for cleaning and
maintenance purposes.
The unit should not be installed directly on
flammable materials, such as wooden
structures or roof’s.
4- 1
On rooftop locations, choose a place with adequate
structural strength to safely support the entire operating
weight of the unit and service personnel. The unit can be
mounted on a concrete slab, similar to ground floor
locations, or on steel channels of suitable strength. The
channels should be spaced at the same centres as the
vibration mounting holes in the unit base frame and
must be at least 120 mm wide at the contact points. This
will allow vibration isolators to be fitted if required.
Standard units are fitted with multi-blade cooling fans
with a maximum external static pressure capability of 20
Pascal (Pa). Optional low speed fans with a maximum
capability of only 10 Pa, or high static pressure fans with
a maximum capability of 125 Pa may be fitted. Any
ductwork or attenuators fitted to the unit must not have a
total static pressure resistance, at full unit airflow,
exceeding the capability of the fans installed in the unit.
Outdoor Installations
Indoor Installations
YCAJ-Series Chillers can be installed at ground level, or
on a suitable rooftop location. In both cases an adequate
supply of air is required. Avoid locations where the
sound output and air discharge from the unit may be
objectionable.
The unit can be installed in an enclosed plant room
providing the floor is level and of suitable strength to
support the full operating weight of the unit and service
personnel. It is essential that there is adequate
clearance for airflow to the unit. The discharge air from
the top of the unit must be ducted away to prevent
recirculation of air within the plant room. If common
ducts are used for fans, non-return dampers must be
fitted to the outlet from each fan. Common ducts should
not be used on a four fan (single module) unit fitted with
the optional low ambient kit as these units use fans in the
reverse direction in some modes of operation.
The location should be selected for minimum sun
exposure and away from boiler flues and other sources
of airborne chemicals that could attack the condenser
coils and steel parts of the unit.
If located in an area which is accessible to unauthorised
persons, steps must be taken to prevent access to the
unit by means of a protective fence. This will help to
prevent the possibility of vandalism, accidental damage,
or possible harm caused by unauthorised removal of
protective guards or opening panels to expose rotating
or high voltage components.
For ground level locations, the unit must be installed on a
suitable flat and level concrete base that extends to fully
support the two side channels of the unit base frame. A
one-piece concrete slab, with footings extending below
the frost line is recommended. To avoid noise and
vibration transmission the chiller should not be secured
to the building foundation.
(10/03)
The discharge ducting must be properly sized with a
total static pressure loss, together with any intake static
pressure loss, less than the available static pressure
capability for the type of fan fitted. For details refer to the
details provided in “Outdoor Installations”.
The discharge air duct usually rejects outside the
building through a louvre. The outlet must be positioned
to prevent the air being drawn directly back into the air
intake for the condenser coils as such recirculation will
affect unit performance.
4- 2
4.2
035L02203-100 Rev. 5
On heat recovery units it is advisable to allow
space, equal to the width of the unit, on at least
one side of the heat recovery condensers.
Location Clearances-refer to section 9.5
Clearances around the unit(s) are required for the
unrestricted access of airflow onto the air-cooled
condenser coils and to prevent recirculation of warm
discharge air back onto the coils. If clearance
dimensions are not maintained, airflow restriction or
recirculation will cause a loss of unit performance, an
increase in power consumption and may cause the unit
to malfunction. Consideration should also be given to
the possibility of down draughts, caused by adjacent
buildings, which may cause recirculation or uneven unit
airflow.
4.3
Vibration Isolator Installation & Dimensions
When ordered, an optional set of four or eight spring
type vibration isolators will be supplied loose with each
unit.
n
Using the Isolator tables (in Section 9), identify
each mount and its correct location on the unit.
n
Place each mount in its correct position and lower
the unit carefully onto the mounts ensuring the
locating pin on top of each mount engages in the
mounting holes in the unit base frame.
n
Transfer the unit weight evenly to the springs by
turning the mount adjusting nuts (located just
b e l o w t h e to p p l a t e o f th e m o u n t )
counter-clockwise to raise and clockwise to lower.
This should be done two turns at a time until the top
plates of all mounts are between 6 mm and 13 mm
clear of top of their housing and the unit base is
level.
For locations where significant cross winds are
expected, such as exposed roof tops, an enclosure of
solid or louvre type is recommended to prevent wind
turbulence interfering with the unit airflow.
When units are installed in an enclosure, the enclosure
height should not exceed the height of the unit. If the
enclosure is of louvred construction the same
requirement of static pressure loss applies as for ducts
and attenuators stated above.
Where accumulation of snow is likely, additional height
must be provided under the unit to ensure normal airflow
to the unit.
The clearance dimensions given are
necessary to maintain good airflow and
ensure correct unit operation. It is also
necessary to consider access requirements
for safe operation and maintenance of the unit
and control panel (600 mm wide doors). Local
health and safety regulations, or practical
considerations for service replacement of
large components, may require larger
clearances than those given below.
Dimension to louvred wall assumes 60%
minimum free area. For louvres of less free
area use dimensions for solid walls.
Pressure drop through louvred walls must not
exceed available external static pressure
capability for the type of fans fitted.
(10/03)
035L02203-100 Rev. 5
CP-2 Mounts
4.4
4- 3
Pipework Connection
General Requirements
The following piping recommendations are intended to
ensure satisfactory operation of the unit(s). Failure to
follow these recommendations could cause damage to
the unit, or loss of performance, and may invalidate the
warranty.
The maximum flow rate and pressure drop for
the cooler (and condenser if fitted) must not be
exceeded at any time. Refer to Section 9 for
details.
Mount Type Nominal Rating Spring colour Deflection at
nominal load
CP-2-27
680 kg
Orange
27 mm
CP-2-28
816 kg
Green
26 mm
CP-2-31
998 kg
Grey
21 mm
CP-2-32
1180 kg
White
19 mm
CP-2-35
1361 kg
Gold
18 mm
n
The water must enter the heat exchanger(s) by the
inlet connection. The inlet connection for the cooler
is at the same end as the refrigerant pipework
connections. The inlet connection for a heat
recovery condenser is the bottom liquid
connection.
n
A flow switch must be installed in the customer
pipework at the outlet of the heat exchanger(s) as
shown in the arrangement diagrams, and wired
back to the control panel using screened cable. For
details refer to “Electrical Connection”. This is to
prevent damage to the heat exchanger(s) caused
by the unit operating without adequate liquid flow.
Note: Free height for CP-2-35 mount is 13 mm higher than shown
CP-4 Mounts
The flow switch used must have gold plated
contacts for low voltage/current operation. Paddle
type flow switches suitable for 10 barg working
pressure and having a 1" N.P.T. connection can be
obtained from York as an accessory for the unit.
Alternatively a differential pressure switch sited
across an orifice plate may be used, preferably of
the high/low limit type.
n
Mount Type Nominal Rating Spring colour
CP-4-28
CP-4-31
1633 kg
1996 kg
Green
Grey
Key
A
Foundation Bolts
B
Free & Nominal Working Height
C
D
6 mm Acoustic Non-Skid Neoprene Pad
Adjust Height to Ensure Upper Housing
Clears Lower by 6 mm Min. 13 mm Max.
(10/03)
Deflection at
nominal load
26 mm
21 mm
The liquid pump(s) installed in the pipework
system(s) should discharge directly into the unit
heat exchanger section of the system. The
pump(s) may be controlled external to the unit - but
an override must be wired to the YCAJ control
panel so that the unit can start the pump in the
event that the liquid temperature falls below the
minimum setting. For details refer to “Electrical
Connection”.
4- 4
035L02203-100 Rev. 5
n
Pipework and fittings must be separately
supported to prevent any loading on the heat
exchanger(s). Flexible connections are
recommended which will also minimise
transmission of vibrations to the building. Flexible
connections must be used if the unit is mounted on
anti-vibration mounts as some movement of the
unit can be expected in normal operation.
n
The liquid circulation pump must be controlled by
the YCAJ-Series Chiller. This will ensure that when
the liquid temperature falls within 2 or 3°C of
freezing the pump will start. On heat recovery units
the hot water pump must be started by the
customer controls 2 or 3°C above the freezing point
of the liquid to prevent damage to the heat recovery
condenser(s) and pipework.
n
Pipework and fittings immediately adjacent to the
heat exchangers should be readily de-mountable
to enable cleaning prior to operation, and to
facilitate visual inspection of the exchanger
nozzles.
n
The heat recovery mode of the unit must not be
used as freeze protection for the hot water system.
A suitable interlock should be provided to the hot
water system flow switch to prevent heat recovery
mode being activated when the pump(s) are being
run for freeze protection purposes.
n
Each heat exchanger must be protected by a
strainer, preferably of 30 mesh, fitted as close as
possible to the liquid inlet connection, and provided
with a means of local isolation.
n
The heat exchangers are protected by heater mats
under their insulation which are supplied from the
unit control system power supply. During risk of
freezing the control system should be left switched
on to provide the freeze protection function unless
the liquid systems have been drained.
n
The heat exchanger(s) must not be exposed to
flushing velocities or debris released during
flushing. It is recommended that a suitably sized
by-pass and valve arrangement is installed to allow
flushing of the pipework system. The by-pass can
be used during maintenance to isolate the heat
exchanger without disrupting flow to other units.
n
Thermometer and pressure gauge connections
should be provided on the inlet and outlet
connections of each heat exchanger.
n
Drain and air vent connections should be provided
at all low and high points in the pipework to permit
drainage of the system, and to vent any air in the
pipes.
n
Liquid systems at risk of freezing, due to low
ambient temperatures, should be protected using
insulation and heater tape and/or a suitable glycol
solution. The liquid pump(s) must also be used to
ensure liquid is circulated when the ambient
temperature approaches freezing point. Insulation
should also be installed around the heat exchanger
nozzles.
Any debris left in the water pipework between
the strainer and heat exchanger could cause
serious damage to the tubes in the heat
exchanger and must be avoided. The
installer/user must also ensure that the quality
of the water in circulation is adequate, without
any dissolved gasses which can cause
oxidation of steel parts within the heat
exchanger(s).
Heater tape of 21 watts per metre under the
insulation is recommended, supplied
independently and controlled by an ambient
temperature thermostat set to switch on at 3°C
above the freezing temperature of the liquid.
(10/03)
035L02203-100 Rev. 5
4.5
Water Treatment
The unit performance given in the Design Guide is
based on a fouling factor of 0.044 m2 °C/kW (0.00025
2
ft hr°F/Btu). Dirt, scale, grease and certain types of
water treatment will adversely affect the heat exchanger
surfaces and therefore unit performance. Foreign matter
in the water system(s) can increase the heat exchanger
pressure drop, reducing the flow rate and causing
potential damage to the heat exchanger tubes.
Aerated, brackish or salt water is not recommended for
use in the water system(s). York recommend that a
water treatment specialist is consulted to determine that
the proposed water composition will not affect the
evaporator materials of carbon steel and copper. The pH
value of the water flowing through the heat exchangers
must be kept between 7 and 8.5.
Glycol Solutions
Recommendations of the Building Services
Research Association
Chilled Water/Glycol System
Single Heat Recovery Condenser
(Hot Water/Glycol System)
For unit operation with chilled liquid temperatures
leaving the cooler at 4°C or below, glycol solutions can
be used to help prevent freezing. Section 9, gives
recommended solution strength with water, as a
percentage by weight, for the most common types of
glycol. It is important to check glycol concentration
regularly to ensure adequate concentration and avoid
possible freeze-up in the cooler.
When using glycol solutions, pressure drops
are higher than with water. Special care must
be taken not to exceed the maximum pressure
drop allowed.
4.6
Pipework Arrangement
The following are suggested pipework arrangements for
single unit installations. For multiple unit installations,
each unit should be piped as shown.
Isolating Valve - Normally Open
Isolating Valve - Normally Closed
Flow Regulating Valve
Flow Measurement Device
Strainer
Pressure Tapping
Flow Switch
Flanged Connection
(10/03)
4- 5
4- 6
035L02203-100 Rev. 5
Twin Heat Recovery Condensers - Parallel Flow
(Hot Water/Glycol System)
4.7
Connection Types & Sizes
For connection sizes relevant to individual chiller
models refer to the Technical Specification Section.
Cooler Connections
Standard chilled liquid connections on all coolers are of
the Victaulic Groove type. Optionally, one of two types of
flanges may be fitted depending on the customer or
local Pressure Vessel Code requirements. These are
Vic-Adapter flanges, normally supplied loose, or weld
flanges which may be supplied loose or ready fitted.
Vic-Adapter and weld flange dimensions are to ISO
7005 - NP10 (BS 4504 - NP10). Dimensions are as
follows:
Standard Victaulic
Twin Heat Recovery Condensers - Series Flow
(Hot Water/Glycol System)
Nom, Size
6" (150 mm)
8" (200 mm)
OD
168,3
219,1
T
7,1-8,0
7,9-8,2
A
16
19
B
C
9,5 164
11 214
Optional Flanges
WELD FLANGE
Nom. Size
6" (150 mm)
8" (200 mm)
VIC-ADAPTOR FLANGE
PCD
240
295
T
22
24
Bolts
8 x M 20
8 x M 20
(10/03)
035L02203-100 Rev. 5
4- 7
Condenser Connections
4.8
Refrigerant Relief Valve Piping
Standard hot water connections on heat recovery
condensers (when fitted) may be female taper threaded
to BSPT, or drilled and tapped as flange connections to
ISO 7005 - NP10 (BS4504 - NP10). Optional flange
connections are available in place of the BSPT
connections and consist of a set of threaded flanges and
pipe nipples normally supplied loose. Dimensions are as
follows:
Coolers and heat recovery condenser vessels are each
protected against internal refrigerant overpressure and
fire by refrigerant relief valves. The pressure relief valve
is set at design pressure of the system and has
discharge capacity required by relevant standard. For
coolers, a pressure relief valve is mounted on each of
the main refrigerant lines connecting the cooler to the
compressors. On heat recovery condensers the
pressure relief valve is mounted on top of vessel body.
Standard Threaded
It is recommended that a piece of pipe is fitted to each
valve and directed so that when the valve is activated the
release of high pressure gas and liquid cannot be a
danger or cause injury. For indoor installations pressure
relief valves should be piped to the exterior of the
building.
The size of any pipework attached to a relief valve must
be of sufficient diameter so as not to cause resistance to
the operation of the valve. Unless otherwise specified by
local regulations, the minimum allowable internal
diameter depends on the length of pipe required and is
given by the following formula:
Nom. Size
Thread Type
2 1/2" (65 mm) 2 1/2" BSP Female Taper
3" (80 mm)
3" BSP Female Taper
D5 = 1.447 x L
Standard Flange
Where:
D = minimum pipe internal diameter in centimetres
L = length of pipe in metres
Precautions should be taken to ensure the exit of relief
valves/vent pipe remain clear of obstructions at all
times.
Nom. Size
4" (100 mm)
PCD
180
Bolts
8 x M 16
Optional Flange
Nom. Size
2 1/2" (65 mm)
3" (80 mm)
(10/03)
PCD
145
160
T
18
20
Bolts
4 x M 16
8 x M 16
4- 8
4.9
035L02203-100 Rev. 5
Ductwork Connection
General Requirements
The following ductwork recommendations are intended
to ensure satisfactory operation of the unit(s). Failure to
follow these recommendations could cause damage to
the unit, or loss of performance, and may invalidate the
warranty.
n
When ducting is to be fitted to the fan discharge it is
recommended that the duct should be the same
cross sectional area as the fan outlet and straight
for at least one metre in order to obtain static regain
from the fan.
n
Ductwork should be suspended with flexible
hangers to prevent noise and vibration being
transmitted to the structure. A flexible joint is also
recommended between the duct attached to the
fan and the next section for the same reason.
Flexible connectors should not be allowed to
concertina.
n
The unit is not designed to take structural loading.
No significant amount of weight should be allowed
to rest on the fan outlet flange, deck assemblies or
condenser coil module(s). No more than one metre
of light construction ductwork should be supported
by the unit. Where cross winds may occur, any
ductwork must be supported to prevent side
loading on the unit.
n
If the ducts from two or more fans are to be
combined into a common duct, back-flow dampers
should be fitted in the individual fan ducts. This will
prevent recirculation of air when only one of the
fans is running.
On four fan units fitted with an optional “Low
Ambient Operation Kit” two of the four
condenser fans operate in both forward and
reverse directions. The bi-directional fans are
numbers 1 & 3 and are furthest from the
control panel. For details refer to the Trouble
shooting Section. Consideration should be
given to allowing free airflow in both directions
on four fan units with this option. Back-flow
dampers should not be used.
n
Units are supplied with outlet side guards for safety
and to prevent damage to the fan blades. If these
guards are removed to fit ductwork, adequate
alternative precautions must be taken to ensure
persons cannot be harmed or put at risk from
rotating fan blades.
Connection Details and Dimensions
1 Top Flange
2 Guard
3 8 Holes, 10 mm Ø for bolt size M8, on Ø 'C'
Model and Fan Type
Standard Fans - All Models
Low Noise Fans - All Models
High Pressure Fans All Models except:
66ST9, 76ST9, 77XT9 & 99XW9
98ST9, 99ST9, 98AW9 &99AW9
High Pressure Fans - Models:
66ST9, 76ST9, 77XT9 & 99XW9
98ST9, 99ST9, 98AW9 &99AW9
All Dimensions in Millimeters
A
924
924
B
190
190
C
984
984
924
190
984
1000
190
1070
(10/03)
035L02203-100 Rev. 5
4.10 Electrical Connection
The following connection recommendations are
intended to ensure safe and satisfactory operation of the
unit(s). Failure to follow these recommendations could
cause harm to persons, or damage to the unit, and may
invalidate the warranty.
No additional controls (relays, etc.) should
be mounted in any section of the control
panel. Power and control wiring not
connected to the Control Panel should not
be run through the Control Panel. If these
precautions are not followed it could lead
to a risk of electrocution. In addition,
electrical noise could cause malfunctions,
or damage the unit and its controls.
After connection do not switch on mains
p o w e r t o t h e u n i t . S o me i n t e r n a l
components are live as soon as mains is
switched on, and this must only be done by
authorised persons.
n
The main off/on unit selector switch on the front of
the control panel has been sealed in the off position
at the factory.
This seal must remain in place
preventing running of the unit until
commissioned by authorised
personnel. If the seal has been
removed before commissioning
then it must be reported to the
Basildon Factory Quality Manager
o t h e r w i s e w a r r a n t y ma y b e
invalidated.
4.11 Power Wiring
YCAJ units are suitable for 380/400 volt,
3 phase, 50 Hz nominal supplies only.
Minimum allowable voltage 342 V.
Maximum allowable voltage 440 V.
All electrical wiring should be carried out in accordance
with local regulations. Route properly sized cables
(based on installation conditions and currents given in
electrical data tables) to site drilled holes in the Control
Panel gland plate as specified below.
In accordance with EN 60204 it is the responsibility of
the user to install overcurrent protection devices
between the supply conductors and the customer input
supply terminals on the unit.
To ensure that no eddy currents are set up in the metal
gland plate the cables forming each 3 phase power
supply must enter via the same hole in the gland plate. If
separate entries for each cable forming the 3 phase
supplies are used, the metal gland plate must be
replaced by a non-metallic gland plate, with due regard
given to sealing the panel to IP55.
All sources of supply to the unit must be
taken via a common point of isolation (not
supplied by York).
Standard Units and Units with Switch
Disconnector Fuse*
Standard units and units fitted with optional switch
disconnector fuse require two-off 3 phase separately
fused 3 wire supplies plus earth, with one supply to be
connected to each of the two system power sections of
the control panel. Also required is a separate control
supply connected to customer terminals in the centre
common power section of the panel.
All three supply cables should enter via site drilled gland
plate in the bottom of the centre common power section.
The 3 phase supplies can then be routed to their
respective input terminals in each of the power sections,
number 1 to the right and number 2 to the left.
Connect each of the two main 3 phase supplies to the
customer ter minal blocks, or optional switch
disconnector fuse, located in the two separate power
sections of the control panel using lug sizes detailed in
Section 4-15.
Connect earth wires to the main protective earth
terminals, using M10 lugs, in each power section.
On standard units connect a 220/230 V single phase
control supply to the control switch disconnector in the
centre main common power section with bare wire ends
of maximum cable size 4 mm. For details refer to the
Technical Specification Section (customer control circuit
supply data). Also connect an earth wire to the
protective earth terminal using an M4 lug.
On units fitted with a 3 wire supply option* connect two
phases (380/400 V) to the control switch disconnector in
the centre main common power section with bare wire
ends of maximum cable size 4 mm2. For details refer to
Technical Specification Section (customer control circuit
supply data). Also connect an earth wire to the
protective earth terminal using an M4 lug.
*Fitted as standard on CE units
(10/03)
4- 9
4-10
035L02203-100 Rev. 5
Units with Common Input Supply and Isolators
4.12 Power Section Volt Free Contacts
Units fitted with the common input supply option require
one 3 phase and neutral supply plus earth only. If a 3
wire mains supply option is fitted**, no neutral is
required. Under the centre power section of the control
panel is a cable spreader box which should be used to
separate the cores of large multi-core cable prior to
connection to the customer main terminal block. The
cable should enter the spreader box through a site
drilled gland plate on the bottom of the box.
All wiring to the power section volt free contacts requires
a supply, maximum 254 V, provided by the customer.
The customer must take particular care deriving the
supplies for the volt free terminals with regard to a
common point of isolation. These circuits when used
must be fed via the common point of isolation so that the
voltage is removed when the common point of isolation
to the unit is opened.
**Fitted as standard with common input supply option on
CE units
Connect the 3 phases to the main customer terminal
block located in the centre power section of the control
panel using M16 lugs. If no 3 wire supply option is fitted,
also connect neutral to the main neutral terminal block
using an M12 lug.
Connect an earth wire to the main protective earth
terminal located in the centre power section of the
control panel using an M10 lug.
In accordance with EN 60204 it is recommended that
the customer wiring to these terminals uses orange
wires. This will ensure that circuits not switched off by
t h e YC A J s u p p l y d i s c o n n e c t i n g d ev i c e a r e
distinguished by colour, so that they can easily be
identified as live even when the YCAJ disconnecting
device is off.
The YCAJ volt-free contacts are rated at 125 VA. All
inductive devices (relays) switched by the YCAJ
volt-free contacts must have their coil suppressed using
standard R/C suppressors.
Chilled Liquid Pump Starter
Control Transformer Primary Voltage Tappings
The 3-wire control transformer is mounted behind the
control panel. It is important to check that the correct
primary tapping has been used:
n
With the supply to the unit isolated remove the lid to
the transformer box.
n
Check that the tapping used conforms to the site
supply voltage. The two tappings are 342-424 V
and 360-440 V.
Remote Emergency Stop Device
If required, a remote emergency stop device can be
wired to terminals 3 and 4 in the control panel (centre
main common power section). The existing link must
first be removed. This device should be rated at 10
amps, 230V, AC-15. Terminals 3 and 4 are in a circuit
protected by a 10 amp class gG fuse.
Terminals 33 and 34 close to start chilled liquid pump.
This contact can be used as a master start/stop for the
pump in conjunction with the daily start/stop schedule. If
no schedule is set, and the customer has master control
of the pump, the YCAJ contact must be used to override
the customer master start/stop so that the York contact
can start the pump in the event of a low temperature
liquid condition.
Run Contact
Terminals 35 and 36 close to indicate that a system is
running.
Alarm Contacts
Each system has a voltage-free change over contact
which will operate to signal an alarm condition whenever
a system locks out, or there is a power failure. To obtain
system alarm signal, connect alarm circuit to volt free
terminals 31 and 32 (close on alarm) or 30 and 32 (open
on alarm) for No. 1 system and to terminals 38 and 39
(close on alarm) or 37 and 39 (open on alarm) for
No. 2 system.
(10/03)
035L02203-100 Rev. 5
4-11
4.13 Logic Section Connections
Remote Lead/Lag
All wiring to the logic section terminal block is nominal 30
Vdc and must be run in screened cable, with the screen
earthed at the panel end only. Run screened cable
separately from mains cable to avoid electrical noise
pick-up. Use the gland plate on the back of the control
panel, to connect directly into the logic section to avoid
mains cable.
If manual lead/lag control is required, closure of suitable
contacts connected to terminals 13 and 19 will cause
system 2 to operate in lead. Open contacts will cause
system 1 to be in lead.
The voltage free contacts must be suitable for 30 Vdc
(gold contacts recommended). If the voltage free
contacts form part of a relay or contactor, the coil of the
device must be suppressed using a standard R/C
suppressor. The above precautions must be taken to
avoid electrical noise which could cause a malfunction
or damage to the unit and its controls.
The length of cable to these terminals must
not exceed 7.5 m unless an optional input
isolator kit is fitted.
The optional input isolator kit uses 15 Vdc (not
30 Vdc)
Flow Switch
A chilled liquid flow switch of suitable type must be
connected to terminals 10 and 13 to provide adequate
protection against loss of liquid flow. On heat recovery
units a suitable hot liquid flow switch must also be
connected to terminals 51 and 52.
Remote Run/Stop
Remove link from terminals 11 and 14 (system 1) and
terminals 12 and 15 (system 2) and connect remote
switch(es) to provide remote run/stop control if required.
Remote Print
Closure of suitable contacts connected to terminals 18
and 13 will cause a hard copy printout of Operating
Data/Fault History to be made if an optional printer is
connected to the RS 232 port.
(10/03)
Remote Set Point Offset
Timed closure of suitable contacts connected to
terminals 13 and 17 (PWM contacts) will give remote
offset function of the chilled liquid set point if required.
This function cannot be used if “Remote Unload”
function is required.
Remote Unloading
The Micro Based Control System is capable of remote
unloading (or pull-down demand limiting) in two steps.
The first step of unloading is achieved by closing
suitable contacts connected to terminals 16 and 13. The
second step of unloading is achieved by closing suitable
contacts connected to terminals 17 and 13. Note: the
first step contacts must be closed before the second
step contacts are closed. For details of compressor load
steps given by these contacts, refer to the Micro Based
Control System Manual. This function cannot be used if
“Remote Set point Offset” is required.
4-12
035L02203-100 Rev. 5
4.14 Power and Control Panel Layout
(10/03)
035L02203-100 Rev. 5
4.15 Power Supply Connections
SYS 1 & 2
SYS 2
SYS 1 & 2
SYS 1
SYS 2
SYS 1 & 2
SYS 1
SYS 2
R22 STANDARD UNITS WITH CUSTOMER INPUT TERMINAL BLOCK
MODEL
TERMINAL BOLT SIZE
44MR7, 55MR7, 55ST7
M8
65NS7
M8
66ST9, 77XT9, 77SU7
M10
65NS7, 76ST9
M10
76ST9, 87SU7, 97AU7
M10
99XU7, 99XW9
M12
87SU7, 97AU7, 98XU7
M12
98XU7
M12
R134a STANDARD UNITS WITH CUSTOMER INPUT TERMINAL BLOCK
MODEL
TERMINAL BOLT SIZE
SYS 1 & 2
44MR7, 55MR7
M6
SYS 2
75MR7
M6
SYS 1 & 2
77MT7, 88ST7
M8
SYS 1
75MS7
M8
SYS 1 & 2
99ST9
M10
SYS 1
98ST9
M10
SYS 2
98AW9
M8 Slow Speed Fans
M10 Standard, High Speed Fans
SYS 1 & 2
99AW9
M10
SYS 1
98AW9
M10
SYS 2
98ST9
M8
R22 UNITS WITH SWITCH DISCONNECTOR FUSE (WITHOUT COMMON INPUT)
MODEL
TERMINAL BOLT SIZE
BS
SYS 1 & 2
SYS 1 & 2
SYS 1 & 2
SYS 1 & 2
SYS 2
SYS 1 & 2
SYS 1
SYS 1 & 2
SYS2
SYS 1& 2
SYS 1
SYS 2
SYS 1 & 2
SYS 1
(10/03)
44MR7
55 MR7, 55ST7, 66ST9, 77XT9,
77SU7, 99XU7, 99XW9
65NS7, 76ST9, 87SU7,
97AU7, 98XU7
M8
DIN
M10 Part Wind
M8 Star Delta
M10
M10
M10
M10
R134a UNITS WITH SWITCH DISCONNECTOR FUSE (WITHOUT COMMON INPUT)
MODEL
TERMINAL BOLT SIZE
BS
44MR7, 55MR7
M8
75MS7
M8
77MT7
M8
75MS7
M8
88ST7
M8 Slow Speed, Standard Fans
M10 High Pressure Fans
98ST9
M8 Slow SpeedFans
M10 Standard, High Pressure Fans
99ST9
M10
98ST9
M10
98AW9
M8 Slow SpeedFans
M10 Standard, High Pressure Fans
99AW9
M10
98AW9
M10
DIN
M8
M8
M10
M10
M10
M10
M10
M10
M10
M10
M10
M10
M10
M10
4-13
4-14
035L02203-100 Rev. 5
4.16 Connection Schematic
(10/03)
035L02203-100 Rev. 5
5
COMMISSIONING
5.1
Preparation
Commissioning of this unit should only be
carried out by York authorised personnel.
The Micro Based Control System Manual must be
read in conjunction with this section.
The unit switch on the front of the control panel has
been sealed in the off position at the factory. This
seal must remain in place preventing running of the
unit until commissioned by
authorised personnel. If the seal has
been
r e m ov e d
b e for e
commissioning then it must be
reported to the Basildon Factory
Quality Manager otherwise the
warranty may be invalidated.
Preparation - Power Off
The following checks should be made with the customer
supply/supplies to the unit switched off.
Inspection: Inspect unit for installation damage. If found
take action and/or repair as appropriate.
Refrigerant charge: Units are normally shipped as
standard with a full refrigerant operating charge. Check
that refrigerant pressure is present in both systems and
that no leaks are apparent. If no pressure is present a
leak test must be undertaken, the leak(s) located and
repaired. Repaired systems and units supplied with a
nitrogen holding charge must be evacuated with a
suitable vacuum pump/recovery unit as appropriate to
below 100 microns. Check the unit data plate or unit
labels for the type of refrigerant intended for use with the
unit and break the vacuum with refrigerant as follows:
Refrigerant
R22
R407c
R134a
Break vacuum from
bottle connection for:
Vapour
Liquid
Vapour
Raise system pressure
to approximately:
4.0 barg (60 psig)
4.6 barg (70 psig)
2.0 barg (30 psig)
Charging from the liquid connection on the
cylinder is necessary on R407C to ensure the
correct refrigerant mix is maintained.
(10/03)
5- 1
Do not liquid charge with static water in any of the heat
exchangers. Care must also be taken to liquid charge
slowly to avoid excessive thermal stress at the charging
point. Once the vacuum is broken, charge into the
condenser coils with the full operating charge as given
on the unit data plate and the Physical Data section of
this manual.
Valves: Open the compressor suction and discharge,
and the liquid line service valves on both systems
(CCW).
Compressor oil: Compressor lubrication systems must
be primed prior to first time start-up. Only the correct
type of oil must be used as given by unit data plate/labels
and is as follows for YCAJ standard units:
Refrigerant
R22
R407c
R134a
Compressor Oil
York grade C
York grade H
York grade H
To prime each compressor - connect a York hand oil
pump (part no. 470-10654-000) to the 1/4" compressor
oil priming valve with a length of clean hose or copper
line, but do not tighten the flare nut. Using clean oil of the
correct type, pump oil until all air has been purged from
the hose then tighten the nut. Stroke the oil pump 10
times (delivering approximately 1,5 litres) to prime the
oil system. The oil level should be between the middle of
the lower and middle of the upper sight glasses. If it is
necessary to add oil, continue to stroke the pump until
the correct level is achieved.
Fans: Check that all fans are free to rotate and are not
damaged. Ensure blades are at the same height when
rotated. Ensure fan guard is securely fixed.
Isolation/protection: Verify that all sources of electrical
supply to the unit are taken from a single point of
isolation. For units not fitted with a switch disconnector
fuse check that the maximum recommended fuse sizes
given in the Technical Data section have not been
exceeded.
Control panel: Check panel to see that it is free of
foreign materials (wire, metal chips, etc.) and clean out if
required.
Power connections: Check the customer power cables
are connected to the unit incoming terminals. Ensure
that connections of power cables within the panel to
contactors, terminal blocks or switch disconnector fuse,
and external connection to compressors are tight.
5- 2
035L02203-100 Rev. 5
Earthing: Verify that the units protective terminal(s) are
properly connected to a suitable earthing point. Ensure
that all unit internal earth connections are tight.
Overloads: Ensure that the fan overloads setting
correspond to the current drawn value shown on the unit
data plate for the type of fan fitted.
Supply voltage: Verify that the site voltage supply
corresponds to the unit requirement and is within the
limits given on the unit data plate / Operating Limitations
section.
Control Transformer: The 3-wire control transformer is
mounted behind the control panel. It is important to
check that the correct primary tapping has been used:
n
With the supply to the unit isolated remove the lid to
the transformer box.
n
Check that the tapping used conforms to the site
supply voltage. The two tappings are 342 - 424 V
and 360 -440 V.
Switch Settings: Ensure that the black handled unit
switch on the display door and the micro board system
switches S2 and S3 in the logic section are set to "0"
(OFF). Set the red handled control circuit switch
disconnector/emergency stop device on the lower
centre section door to "1" (ON). For units fitted with
switch disconnector fuse devices the two power section
doors must be closed and the devices set to "1" (ON).
The customers disconnection devices can now be set to
ON.
The machine is now live!
The unit is fitted with an under voltage relay
and it may take between 5 to 10 seconds for its
contacts to close and energise the units
electronics, including the display.
Crankcase heaters: Verify the compressor crankcase
heaters are energised. If the ambient temperature is
above 30oC the compressor crankcase heaters must be
on for at least 24 HOURS prior to start-up to ensure all
refrigerant liquid is driven out of the oil. If the ambient
temperature is below 30oC then allow 8 hours.
Water/Glycol system(s): Verify that the chilled water
system has been installed correctly, and has been
commissioned with the correct direction of water flow
through the cooler. Inlet should be at the refrigerant
pipework connection end of the cooler. Purge air from
the top of the cooler using the plugged air vent mounted
on the top of the cooler body.
On heat recovery units, verify that the hot water system
h a s b e e n i n s t a l l e d c o r r e c t l y, a n d h a s b e e n
commissioned with the correct direction of water flow
through the condenser(s). Inlet should be at the
condenser connection nearest the bottom of the vessel.
Purge air from the condenser using the plugged air vent
mounted on the top of water head. Flow rates and
pressure drops must be within the limits given in Section
9 of this manual. Operation outside of these limits is
undesirable and could cause damage. Note: pressure
drop should not be used to determine flow rate.
Flow switch(es): Verify a chilled water flow switch is
correctly fitted in the customer’s pipework on the cooler
outlet, and wired into the YCAJ control panel logic
section Opto-isolator board terminals 10 and 13 using
screened cable. On heat recovery units, also verify a hot
water flow switch is correctly fitted in the heat recovery
condenser common outlet, and wired into control board
behind the main processor board in terminals 51 and 52
using screened cable.
Temperature sensor(s): Ensure the leaving water
temperature sensor is coated with heat conductive
compound (part no. 013-00890-000) and is inserted in
the bottom of the water outlet sensor pocket of the
cooler. This sensor also acts as the freeze protection
thermostat sensor and must always be in the water
OUTLET sensor pocket. On heat recovery units also
ensure that the heat recovery thermostat sensor(s) are
installed with heat conductive compound in the leaving
hot water pipework of the condenser(s) ensuring when
two are fitted that they are fitted to the correct
condenser.
Control supply: Verify the control centre display is
illuminated behind the control screen door. If an
electronic expansion valve option is fitted, the `power to
expansion valve’ on the valve controllers (in the logic
section) should pulse to indicate the 24 volt supply is on
to these items.
HP cut-out reset: Check that the hand reset
mechanical high pressure cut-outs mounted on the unit
are reset.
(10/03)
035L02203-100 Rev. 5
5- 3
EEV controller settings (if fitted): The EKC 315A
controller uses suction temperature and pressure to
control suction superheat. The controller MUST be set
for the refrigerant used in the unit and the other control
parameters checked in accordance with the table below.
To save the changes press both buttons simultaneously.
If both buttons are not pressed the controller will revert
to displaying the actual superheat after 15 seconds.
Pushing the upper button briefly will then display an
error code.
Operating the unit with the wrong refrigerant
entered into the controller will cause damage
to the compressor.
The actual suction pressure (u 25) and temperature (u
20) can be displayed to ensure the controller is receiving
the input signals from the suction pressure transducer
and suction temperature sensor. The suction superheat
(o 17) will be displayed on the controller as the default
display parameter.
The two buttons on the controller are used to check and
set the control parameters. Press and hold the upper
button for approximately two seconds to access the
menu of parameters codes. The upper or lower buttons
can now be used to step through the parameter codes,
w h i c h a r e d i s p l aye d . P r e s s i n g b o t h bu t t o n s
simultaneously will then display the value and allow you
to change the value by pressing the upper or lower
buttons.
Description
Parameter
Setting
Units
Main switch
Thermostat mode
r 05
r 12
r 14
C-b
ON
O
Amplification factor (Kp)
n 04
4
Integration time (Tn)
n 05
60
Differentiation time (Td)
Max superheat (Max sh)
Min superheat (Min sh)
MOP
Stability
Kp min
Superheat regulation
Superheat Close
Standby temperature (TQ Kmin)
Standby temperature (TQ Kmin)
n 06
n 09
n 10
n 11
n 18
n 19
n 21
n 22
n 26
n 27
OFF
6
6
6.5
5
0.3
2
2
0
20
Valve and output signal (AO type)
Frequency
Display mode
o 09
o 12
o 17
1
50
1
Transmitter pressure min
Transmitter pressure max
Refrigerant Setting
o 20
o 21
o 30
0
13.8
20
TQ valve actuator temp.
TQ valve reference temp.
Suction temp
Actual superheat
Set superheat
Valve opening %
Suction pressure
Suction Saturated temp
u 04
u 05
u 20
u 21
u 22
u 24
u 25
u 26
E1
E 11
E 15
E 16
E 20
A 11
(10/03)
EEV sensors (if fitted): Check that the electronic
expansion valve sensor S1 is coated with heat
conductive compound (013-00890-000) and is firmly to
the bottom of the sensor pocket. Sensor S2, located on
the suction line, should also be coated in the heat
conductive compound and should be securely strapped
to the suction pipe.
Comments on Setting Up Parameters
Reference Parameters
C-b = Display in °C and bar; F-p = Display in °F and psi.
Must always be ON, which is main switch on.
Must always be O, which is superheat regulated.
Control Parameters
Should be 4 which is the suggested setting for TQ and PHTQ valves,
reduced values and the regulation becomes slower.
Increased values will give unstable operation, with fluctuating suction pressure.
Maximum setting = 8.
Should be 60 which is the suggested setting for TQ and PHTQ valves,
increased values and the regulation becomes slower.
Must always be OFF.
The maximum and minimum superheat settings MUST be the same.
The suggested setting is 6 which is 6 °C.
MOP setting for R-22 and R-407C is 6.5; MOP setting for R-134a is 4.0.
Must always be 5.
Must always be 0.3.
Must always be 2.
Must always be 2.
Must always be 0.
Must always be 20.
Miscellaneous
Must always be 1.
50 for 50Hz units; 60 for 60Hz units
1 = The actual superheat will be displayed;
2 = The valve opening will be displayed
Must always be 0, with York pressure transducer 025-29583-000, range 0 to 200psi.
Must always be 13.8, with York pressure transducer 025-29583-000, range 0 to 200psi.
2 = R-22; 3 = R-134a; 20 = R-407C.
WARNING: Wrong refrigerant selection will cause compressor damage.
Service
Actuator temperature.
Actuator reference temperature.
Temperature of suction line sensor.
Suction superheat from pressure and temperature for refrigerant selected.
Superheat setpoint.
Percentage opening of valve.
Suction pressure from pressure transducer.
Suction saturated temperature from the suction pressure for the refrigerant selected.
Error Messages
Fault in controller
Valve's actuator temperature outside its range
Cut-out suction temperature sensor
Short circuited suction temperature sensor
The input signal from suction pressure transducer on terminals 14-15
is outside the range ( PO signal)
No refrigerant has been selected
5- 4
035L02203-100 Rev. 5
Programmed options: Verify that the options factory
programmed into the Microprocessor Control Centre
are in accordance with the customers order
requirements by pressing the `Options’ key on the
keypad and reading the settings from the display. Refer
also to the Micro Based Control System Manual for
notes and explanation of messages.
Programmed settings: Ensure the system cut-out and
operational settings are in accordance with the
instructions given in the Microprocessor Control Centre
Manual and with operational requirements by pressing
the ‘Program’ key. The chilled liquid temperature control
settings need to be set according to the unit model and
required operating conditions. The following tables give
suggested settings:
Unit Capacity
Steps
Temperature range
through cooler
at full load / °C
Rate control
temperature / °C
Rate sensitivity
°C / min
Control range / °C
Anti-recycle timer
/ sec,
4
5
6, 7 or 8
4
7
4
7
4
7
4
4
4
4
4
4
3
4
3
3,5
2
3,5
1,4
2,5
1,1
2
1
1,8
600
Additional settings for units operating on glycol with a
cooler leaving temperature below 4,5oC:
Glycol leaving
-10
-7,5
-5
-2,5
temperature / °C
Leaving liquid
temperature
-14 -11,5
-9
-6,5
Cut-out / °C
Suction pressure cut-out / barg
R22
1,52 1,79 2,07 2,34
R407C
1,56 1,84 2,14 2,43
R143a
0,42 0,58 0,73 0,9
0
2,5
-4
-1,5
2,62
2,73
1,1
2,97
3,09
1,32
Start/Stop schedule: Programme the daily and holiday
start/stop by pressing the ‘Set Schedule/Holiday’ key
(see Microprocessor Control Centre Manual).
Set-point and Remote offset: Set the required leaving
chilled liquid temperature set-point and control range
(see table above for recommended control ranges). If
remote temperature reset (offset) is to be used, the
maximum reset must be programmed by pressing the
‘Remote Reset Temp’. key (see Microprocessor Control
Centre Manual).
5.2
First Time Start-up
During the commissioning period there should
be sufficient heat load to run the YCAJ unit
under stable full load operation to enable the
unit controls, and system operation to be set
up correctly and a commissioning log taken.
Read the following section in conjunction with
the Micro Based Control System Manual, then
proceed step by step as follows:
Interlocks: Verify that water is flowing through the
cooler and that heat load is present (if heat recovery
condenser(s) are fitted, do not allow water flow through
the condensers at this stage). Ensure that any remote
run interlocks are in the run position and that the run
schedule requires the unit to run or is overridden.
System switches: Place the ‘Sys 1’and ‘Sys 2’switches
on the microprocessor board to the ON position - see
operating sequence in the Microprocessor Control
Centre Manual.
Date & time: Programme the date and time by first
e n s u r i n g th a t t h e C L K j u m p e r J 1 8 o n th e
microprocessor board is in the ON position (top two
pins). Then press the ‘Clock Set Time’ key and set the
date and time (see Microprocessor Control Centre
Manual).
(10/03)
035L02203-100 Rev. 5
Start-up: Remove the locking device from the unit
switch which prevents unauthorised starting of the unit
before commissioning. Press the ‘Status’ key, then turn
the unit switch to the "1" position to start the unit (there
may be a few seconds delay before the first compressor
starts because of the anti-recycle timer). Be ready when
each compressor star ts to switch the unit off
immediately if any unusual noises or other adverse
conditions develop. Also refer to the Micro Based
Control System Manual for the normal operating
sequence of the YCAJ from start-up.
Oil pressure: When a compressor starts, press the
relevant ‘System Pressures’ key and verify that oil
differential pressure is developed immediately. If oil
pressure does not develop the automatic controls will
shut down the compressor (see the Micro Based Control
System Manual for the flow chart of the automatic oil
pressure safety system). Under no circumstances
should a restart attempt be made on a compressor
which does not develop oil pressure immediately. Switch
the unit switch to the "0" position (OFF).
Refrigerant flow: When a compressor starts a flow of
liquid refrigerant will be seen in the liquid line sight glass.
After several minutes operation, and providing a full
charge of refrigerant is in the system, the bubbles will
disappear and be replaced by a solid column of liquid.
Fan rotation: As the discharge pressure rises the
condenser fans will start as required. Verify that the fan
rotation is correct and that airflow is in the upward
direction. NOTE: on single module / four fan units fitted
with low ambient kits only, the first stage of fan operation
on each system is for the fan furthest from the control
panel to operate backwards and give downward airflow all further stages give upward airflow (see also Section
8.5 Discharge Pressure Fan Control). If fan operation is
not in the correct direction, stop the unit, switch off the
main customer disconnecting device to the unit, and
reverse (or arrange to have reversed) two of the three
main supply phases.
General operation: Check the system operating
parameters are normal by selecting the various
readouts of pressure, temperature, etc.
(10/03)
5- 5
Superheat: Check the compressor suction superheat
value only when pull down is complete and steady full
load operation has been established. It is also important
that there are no bubbles showing in the liquid line sight
glass. Suction line temperature should be measured on
the copper line about 150 mm before the compressor
service valve. Suction pressure should be measured at
the compressor service valve with a suitably calibrated
gauge. Suction superheat at the compressor should be
between 5 °C and 6 °C for R22 and R134a, and between
4 °C and 5 °C relative to the `dew’ temperature for
R407C.
Thermal expansion valve adjustment: Thermal
expansion valves are factory set and should not need
adjustment. If the superheat is out of range, however, the
expansion valve adjusting screw should be adjusted no
more than 1 turn at a time (`in’ to increase superheat,
`out’ to decrease superheat), allowing at least 10
minutes for the valve to stabilise before rechecking the
value of superheat.
Electronic expansion valve adjustment: The given
setting of Amplification Factor (Kp = 4) and
Differentiation Time (Tn = 60) should give stable
superheat control. If the superheat is oscillating more
than plus or minus 1 °C then adjustment of Kp and Tn
can be used. Decreasing Kp will give a slower reaction
and more stable operation. Increasing Tn will reduce the
oscillation of superheat and valve regulation is slower. At
start up the superheat will be high and then decrease to
the superheat setpoint. The valve should be allowed to
stabilise for at least 5 minutes between adjustments.
The superheat setpoint MUST NOT be set
below 5 °C, operating the system at low
superheats will not increase the unit capacity
and could damage the compressor.
The actual suction temperature, and pressure plus the
opening degree of the EEV valve can be displayed on
the controller, (refer to page 5-3 for further details).
Electronic expansion valve controller operation:
The indicating LED's on the front of the controller light up
when power is applied. The upper LED will indicate the
expansion valve's opening degree, a short pulse
indicates a low flow and a long pulse indicates a high
flow. The other LED will indicate when the controller
calls for refrigeration. The three lower LED's will flash if
there is an error in the regulation. In an error situation,
the error code can be displayed by pressing the upper
controller button briefly (refer to page 5-3 for further
details).
5- 6
035L02203-100 Rev. 5
Subcooling: Check the amount of subcooling leaving
the condenser coils only when pull down is complete
and steady full load operation has been established. It is
also important that all fans are running, giving full airflow
across the condenser coils. Liquid line temperature
should be measured on the copper line between the
liquid line service valve and the filter/drier. Liquid
pressure should be measured at the liquid line service
valve with a suitably calibrated gauge. Liquid subcooling
should be between 7 °C and 10 °C for R22 and R134a,
and between 6 °C and 8 °C relative to the ‘bubble’
temperature for R407C. If necessary, add or remove
refrigerant to obtain the correct level of subcooling. Do
not overcharge the unit.
Heat recovery system(s) (if fitted)
For each heat recovery condenser system:
Thermostat: Set the hot water thermostat to the
settings given in the table below for the required hot
water temperature by pressing the `set’ button and using
the `up’ and `down’ buttons within the limits of 35 °C to 55
°C (the thermostat is factory set at 52 °C leaving hot
water temperature and a differential of 3 °C).
Mode select: Starting the hot water pump will operate
the unit in heat recovery mode. Note: at full load on the
compressor, there may be nuisance trips if the
condenser leaving water temperature is below 30 °C.
Pressure regulator: Adjust the discharge pressure
regulator valve so that it begins to open at the setting
given in the table for the required hot water temperature.
The setting can be identified by a distinct gas flow noise
from the regulator as the hot water temperature and
compressor discharge pressure rise and the regulator
begins to open and reject gas to the air cooled
condenser. Note: the relative setting of the hot water
thermostat to the pressure regulator is most important
to give controlled heat recovery modulation. Incorrect
setting will give on/off heat recovery operation and
unstable operating conditions.
Required Hot
Water Leaving
Temperature / °C
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
Hot Water
Thermostat
Setting / °C
ON*
OFF
54
57
53
56
52
55
51
54
50
53
49
52
48
51
47
50
46
49
45
48
44
47
43
46
42
45
41
44
40
43
39
42
38
41
37
40
36
39
35
38
34
37
Compressor Discharge
Pessure Regulator
Setting / barg
R22
R407C
R134a
15,8
15,4
15,0
21,7
14,6
21,2
14,3
20,8
13,9
20,3
13,5
19,8
22,1
13,2
19,3
21,6
12,8
18,8
21,0
12,5
18,4
20,5
12,2
18,0
19,9
11,8
17,5
19,4
11,5
17,1
18,9
11,2
16,7
18,4
10,8
16,2
18,0
10,5
15,8
17,5
10,2
15,4
17,0
9,9
15,0
16,6
9,7
14,7
16,1
9,4
14,3
15,7
9,1
The thermostat settings given are for a water
temperature range through the condenser of 5
°C. For higher ranges (8 °C) the ‘ON’
thermostat setting should be lowered by 1 °C.
Superheat: Check the compressor suction superheat
value when the system is in full heat recovery mode and
steady full load operation has been established. It is also
important that no gas is being rejected to the air cooled
condenser as this can cause bubbles in the liquid line.
Check the superheat, and if necessary adjust the heat
recovery thermal expansion valve, as for the standard
cooling circuit.
(10/03)
035L02203-100 Rev. 5
6
UNIT OPERATION
6.1
General Description
YCAJ packaged chillers are designed to work
independently, or in conjunction with other equipment
via a York ISN building management system or other
automated control system. When operating, the unit
controls monitor the chilled liquid system temperature at
the unit and takes appropriate action to maintain this
temperature within desired limits. This action will involve
running one or both compressors at a suitable load step
to match the cooling effect of the refrigerating systems to
the heat load on the liquid system. The heat removed
from the chilled liquid is then rejected from the air cooled
condenser coils, or can optionally be recovered into a
hot water system.
The following sections give an overview of the operation
of a YCAJ unit. For detailed information, reference
should be made to the Microprocessor Control System
Manual for this product.
6.2
Start-up
Ensure the mains power to the unit and controls is on,
the microprocessor ‘Sys 1’ and ‘Sys 2’ circuit board
switches are in the `on’ position, all refrigerant service
stop valves are open (anti-clockwise), and the chilled
liquid flow has been established (unless the unit chilled
liquid pump start control is being used, in which case
just ensure the pump supply is on)
Press the ‘STATUS’ key on the keypad and then switch
theunit switch below the keypad to the ‘1’(on) position.
The controller will perform a pre-check to ensure that the
daily/holiday schedule and any remote interlocks will
allow the unit to run, that all safety cut-outs are satisfied
and that cooling load is required (i.e. that the chilled
liquid temperature is outside the set limits). Any
problems encountered by the pre-check will be
displayed if present. If no problems are present and
cooling duty is required `START SEQUENCE’ will be
displayed and after a short delay the lead compressor
will start on its first capacity step.
(10/03)
6- 1
The display will show the anti-coincidence timer status
for the lag compressor, followed by `NO COOL LOAD’
until it is called to operate by the control system.
6.3
Normal Running and Cycling
Once the unit has been started, all operations are fully
automatic. After an initial period at minimum capacity
step on the lead compressor, the control system will
adjust the unit load step depending on the chilled liquid
temperature and rate of temperature change. If high
heat load is present, the controller will increase the
number of active cylinders on the lead compressor
and/or star t-up the lag compressor (`START
SEQUENCE’ will be displayed for the lag compressor,
followed by the same sequence as for the lead
compressor).
If very little heat load is present, however, the lead
compressor will continue at minimum step, or may
simply stop again to avoid overcooling the liquid. If the
latter is the case, one compressor will restart
automatically should the liquid temperature rise
again.
When a compressor is running, discharge pressure
rises as refrigerant is pumped into the air cooled
condenser coils. This pressure is controlled by stages of
fans to ensure maximum unit efficiency whilst
maintaining sufficient pressure for correct operation of
the condensers and expansion valves.
As soon as a compressor is running the controller
monitors oil pressure, motor current, and various other
system parameters such as discharge pressure, chilled
liquid temperature, etc. Should any problems occur the
control system will immediately take appropriate action
and display the nature of the fault (see Microprocessor
Control System Manual for full details).
6- 2
6.4
035L02203-100 Rev. 5
Compressor Capacity Control
York PC Semi-Hermetic Compressors are each capable
of operating at various stages of loading to allow the
microprocessor control system to accurately match the
cooling effect of the YCAJ to the heat load on the
system. This is achieved by activating and deactivating
compressor cylinders in order to adjust the overall
refrigerant pumping capacity. All compressors have two
permanently loaded cylinders to ensure that when a
compressor is running there is always sufficient
refrigerant gas flow to cool the main drive motor.
Remaining cylinders are unloaded in pairs by energising
solenoid actuating valves which route high pressure oil
or gas (depending on model of compressor) to the
unloader mechanisms in the compressor.
6.5
6.6
Heat Recovery Operation
Where fitted, heat recovery condenser(s) allow heat
normally rejected to atmosphere to be recovered into a
hot water system. Whenever a compressor is running
due to cooling demand, an independent thermostat
checks for hot water demand and, if present, diverts
compressor discharge gas to the heat recovery
condenser. This gas supply is automatically regulated to
maintain a constant hot water temperature, with any
excess gas being sent to the air cooled condenser
section. Once the hot water demand is satisfied, the
thermostat returns the unit to `cooling only’ mode. Note:
adjustment of the hot water temperature thermostat also
requires adjustment of the pressure regulating control
valve(s) and should only be made by suitably qualified
persons.
Discharge Pressure Fan Control
6.7
Each refrigerant system has an independent air cooled
condenser section with its own cooling fans. The fans
are controlled by the Microprocessor Control Centre
and are switched on and off based on compressor
discharge pressure whenever a compressor is running.
Control is independent of compressor load status with
the fans being operated in stages to maintain the
discharge pressure within a preset range. Some options
may also cause fans to run in the reverse direction for
the first stage of control. On units fitted with heat
recovery system(s), fan control is based on the
refrigerant pressure in the air cooled condensers rather
than discharge pressure. For pressure setting values of
each stage of fan control for individual models - refer to
the Micro Base Control System Manual.
Shutdown
The unit can be stopped at any time by switching the unit
switch just below the keypad to the ‘0’ (off) position. To
stop each system with a pumpdown, first set the system
switches to ‘OFF’ and wait for a pumpdown. The
crankcase heaters will then energise to prevent the
compressor oil becoming saturated with refrigerant. If
mains power is to be switched off, e.g., for a shutdown
period, the compressor suction and discharge service
stop valves should be closed (clockwise) and, if there is
a possibility of liquid freezing due to low ambient
temperatures, the heat exchanger(s) should be drained.
(10/03)
035L02203-100 Rev. 5
7
MAINTENANCE
7.1
General Requirements
The York YCAJ range of liquid chillers have been
designed to operate continuously provided they are
regularly maintained and operated within the limitations
given in this manual. Each unit should be included in a
routine schedule of daily maintenance checks by the
operator/customer, backed up by regular service
inspection and maintenance visits by a suitably qualified
Service Engineer.
It is entirely the responsibility of the owner to provide for
these regular maintenance requirements and/or enter
into a maintenance agreement with York International
service organisation to protect the operation of the unit.
If damage or a system failure occurs due to improper
maintenance during the warranty period, York shall not
be liable for costs incurred to return the unit to
satisfactory condition.
7- 1
Operating conditions: read the operating pressures
and temperatures at the control panel using the display
keys and check that these are within the operating
limitations given this manual.
Compressor oil level: Check the compressor oil level
after the compressor has been operating on "FULL
LOAD" for approximately 15 minutes. The maximum
acceptable operating oil level is the middle of the top
sight glass and the minimum acceptable operating oil
level is the middle of the bottom sight glass. When the
compressor is operating for long periods at "PART
LOAD" the level may fall as far as the middle of the
bottom sight glass but should not fall below this level.
Do not overfill the PC style compressor with oil
as this could cause damage to the
compressor.
This maintenance section applies only to the
basic YCAJ chiller unit and may, on individual
contracts, be supplemented by additional
requirements to cover any modifications or
ancillary equipment as applicable.
The Safety Section of this manual should
be read carefully before attempting any
maintenance operations on the unit. This
section should be read in conjunction with
the Micro Based Control System Manual.
7.2
Daily Maintenance
The following maintenance checks should be carried out
on a daily basis by the operator/customer. Please note,
however, that YCAJ units are not generally user
serviceable and no attempt should be made to rectify
faults or problems found during daily checks unless
competent and equipped to do so. If in any doubt,
contact your local York Service Agent.
Unit status: press the ‘STATUS’ key on the keypad and
ensure no fault messages are displayed (refer to the
Micro Based Control System Manual for explanation of
messages and the Trouble Shooting section for courses
of action).
Refrigerant leaks: visually check the heat exchangers,
compressors and pipework for damage and gas leaks.
Airflow obstructions: check the air cooled condenser
coil intakes and adjacent areas are clear of foreign
materials or obstructions, e.g., paper, leaves, etc.
(10/03)
Maximum Acceptable Operating Oil Level
Minimum Acceptable Operating Oil Level
Refrigerant charge: when a system starts up, or
sometimes after a change of capacity step, a flow of
bubbles will be seen in the liquid line sight glass. After a
few minutes of stable operation the bubbles should clear
leaving just liquid refrigerant showing in the sight glass.
7- 2
7.3
035L02203-100 Rev. 5
Scheduled Maintenance
The maintenance operations detailed in the following table should be carried out on a regular basis by a
suitably qualified Service Engineer. It should be noted that the interval necessary between each `minor’ and
`major’ service can vary depending on, for instance, application, site conditions and expected operating
schedule. Normally a `minor’ service should be carried out every three to six months and a `major’ service once
a year. It is recommended, however, that York Service is contacted for recommendations for individual sites.
Standard Units
SERVICE SCHEDULE
Unit general:
Refrigerant systems general:
MINOR SERVICE
MAJOR SERVICE
All items under Minor Service plus:
Check thermal insulation
Check main structure
Check vibration isolators
Check paint-work
Check relief valves
Change filter/drier cores
Check fusible plugs
Check solenoid valves
Check for pipework damage
Check for leaks
Check moisture indicator
Check suction superheat
Check liquid subcooling
Compressors:
Check oil level
Check big ends
Check oil pressure
Check sump for white metal
Check unloader operation
Check suction valves and springs
Check crankcase heater
Check discharge valves and springs
Check condition of oil
Check cylinder sleeves
Check suction strainer
Check oil filter
Check pistons and rings
Change compressor oil
Evaporator:
Check water flow
Check water pH / glycol strength
Check water pressure drop
Check heater mats
Air cooled condensers:
Check for airflow obstructions
Brush fins
Check fins
Check fan motor bearings
Check fans and fan guards
Power & Control system general:
Microprocessor controls:
Check panel condition
Check all connections
Check mains and control wiring
Check compressor contactors
Check sensor locations
Check fan contactors / overloads
Check mechanical HP cut-outs
Check sensor / transducer calibration
Check emergency stop
Check motor protectors
Check residual current devices
Check contactor contacts
Check fault history
Check fan control function
Check program settings
Check ambient cut-out function
Check HP / LP cut-out functions
Check LTL cut-out function
Check pump-down function
Check low oil pressure function
Check load / unload function
(10/03)
035L02203-100 Rev. 5
7- 3
Heat Recovery Units - All items under above plus:
SERVICE SCHEDULE
MINOR SERVICE
MAJOR SERVICE
All items under Minor Service plus:
Water cooled condensers:
Check water pressure drop. Check heater mats
Check water pH / glycol strength
Controls:
Check thermostat program settings
Check pressure regulator setting
7.4
Vessels In-Service Inspection
There is no corrosion on the refrigerant side therefore in-service inspection on the refrigerant side is not necessary.
For the water side, if the water used is treated in accordance with Section 4.5, in-service inspection is not necessary.
In the design of the vessels used in the unit, a 1 mm corrosion allowance has been used to consider slight corrosion
on the water side. This allowance is sufficient to cover the lifetime of the unit.
York International believes that periodic in service proof testing (e.g.; hydro tests) is not required. However, York
International recognises that national regulations may require such testing to be conducted.
(10/03)
7- 4
035L02203-100 Rev. 5
Page Left Intentionally Blank
(10/03)
035L02203-100 Rev. 5
8
TROUBLE SHOOTING
8.1
Competent Persons Trouble Shooting Guide
8- 1
PROBLEM
POSSIBLE CAUSE
ACTION
No display on panel - unit will not
operate
Mains supply to control system off.
Switch on mains supply if safe to do so.
Emergency stop device off.
Check if control panel emergency stop switch and any
remote emergency stop devices are in the ‘OFF’ position.
Turn to ‘ON’ position (1) if safe to do so.
Undervoltage relay tripped.
Check mains supply.
No supply to -T3.
Check emergency stop switch fuses -F1 and -F4 (when
fitted).
No 24 V ac supply to power board.
Check wiring from -T3 to power board and fuse -F3.
No +12 V output from power board.
Replace power board or isolate excessive load on the
board.
No liquid flow through the cooler.
Ensure that liquid pumps are running, valves are correctly
set and flow is established.
Flow switch contacts are not made.
Check the flow switch is functional and is installed as per
the manufacturers instructions.
NO RUN PERM displayed
Note: on some systems the pump starter may be wired to
the unit and controlled to start with the unit.
OIL TEMP INHIBIT displayed
CHILLER FAULT: LOW AMBIENT
TEMP displayed
Remote cycling device open.
Check cycling devices connected to terminals 11 & 14
(SYS 1) and 12 & 15 (SYS 2) on the opto interface board
are closed.
Oil temperature has not reached
working temperature following
power-up.
Use the oil temperature display key to confirm that the oil
temperature is slowly rising. The warning message should
clear when the oil temperature has reached the correct
working temperature.
Compressor crankcase heater not
working.
Check the operation of the heater. Measure the current
drawn by the heater (should be 1A).
Liquid flooding.
Check expansion valve operation, especially during
unloading steps.
Measured temperature incorrect.
Check sensor calibration, location and wiring.
Ambient air temperature is lower than
the programmed operating limit.
Use the ‘ambient temp.’ key to display the temperature and
confirm that the displayed value is approximately correct.
The warning message should clear when the ambient air
temperature reaches the programmed operating limit.
Check the programmed settings are correct for the options
fitted to the unit.
CHILLER FAULT: HIGH AMBIENT
TEMP displayed
Measured temperature is incorrect.
Check sensor calibration, location and wiring.
Ambient air temperature is higher
than the programmed operating limit.
Use the ‘ambient temp.’ key to display the temperature and
confirm that the displayed value is approximately correct.
The warning message should clear when the ambient air
temperature falls below the programmed operating limit.
Check the programmed settings are correct for the options
fitted to the unit.
Residual heat is not being dissipated.
Check fan is operating correctly and the rotation is correct.
Check sensor calibration, location and wiring.
Measured temperature is incorrect.
(10/03)
8- 2
035L02203-100 Rev. 5
PROBLEM
POSSIBLE CAUSE
ACTION
CHILLER FAULT: LOW WATER
TEMP displayed
Leaving liquid drops below the
programmed low limit faster than the
unit can unload.
Check for restrictions in the liquid flow line.
Check the liquid flow is stable.
Unit is not unloading.
Check the electrical supply to the unloader valve
solenoids.
Check the compressor unloads correctly.
Measured temperature is incorrect.
Check sensor calibration, location and wiring.
CHILLER FAULT: LWT SENS
FAULT displayed
LWT sensor out of range.
Check sensor calibration. Check sensor wiring for
open/short circuit.
CHILLER
FAILURE
displayed
Incorrect mains supply voltage.
Check mains supply voltage is stable and within
permissible limits. Check voltage drop on compressor
start.
Discharge high pressure trip due to
poor airflow through the condenser
coils.
Check for airflow restrictions caused by blockages on
intake faces of air coils.
Check for damaged fins/return bends.
Check for correct fan operation and direction of rotation.
FAULT: POW E R
MANUAL RESET
SYS # HIGH DSCH displayed
Excessive refrigerant charge.
Check for signs of air in the refrigerant system(s).
Check sub-cooling is correct.
Check discharge transducer calibration and wiring.
Measured pressure is incorrect.
SYS # DSCH LIMITING displayed
Discharge pressure unloading due to
unit operating above load limit. See
also SYS # HIGH DSCH.
Check chilled liquid temperature is within range. Check if
ambient air temperature is above design conditions.
SYS # OIL PRESS displayed
Oil loss. Oil pump wear or failure.
Check oil level, particularly at minimum load step.
Replace oil pump.
Too much refrigerant in the oil.
Check crankcase heater operation and output (current
should be in excess of 1 amp).
Check operation of expansion valve for liquid flooding
(especially during unloading steps).
Measured pressure incorrect.
Check suction/oil pressure transducer calibration and
wiring.
Insufficient liquid flow through chiller.
Check operation of liquid pumps.
Check valves are correctly set.
Check liquid filter for blockages.
Check liquid line suction valve is operating correctly.
SYS # LOW SUCTION displayed
Badly adjusted or faulty expansion
valve.
Check superheat.
Reduced evaporator performance.
Check for fouled tube surfaces.
Low refrigerant charge.
Check refrigerant charge level.
Check for leaks.
Measured pressure incorrect.
Check suction pressure transducer calibration and wiring.
SYS # CURRENT/MP/HPX
displayed
Compressor current too high or too
low.
Check compressor mains supply, fuses, contactors and
wiring. Check mains supply voltage is within tolerance.
Measured current is incorrect.
Check for defective current transformer (resistance should
be between 58 and 68 Ohms).
Check calibration resistor is correctly fitted.
Compressor motor protector signal
failure (no MP light on opto board).
Check motor protector and wiring.
Check compressor motor.
Mechanical high pressure cut-out trip
(standard and heat recovery
systems).
Check compressor discharge valve is open.
Check cut-out setting and wiring.
Check for restricted liquid flow in heat recovery system.
Check discharge line solenoid valve operation (including
pressure regulator setting).
(10/03)
035L02203-100 Rev. 5
8- 3
PROBLEM
POSSIBLE CAUSE
ACTION
SYS # PUMPDOWN FAIL displayed
(Failure to pump down)
Liquid line solenoid valve not closed.
Check operation of valve.
Check wiring to valve.
Leak on low pressure side of system.
Measured pressure incorrect.
Check low pressure side for air/liquid leaks.
Check suction pressure transducer calibration and wiring.
High compressor motor current has
activated unloading.
See also SYS # CURRENT/MP/HPX
Check liquid temperature is within operating limits. Check if
ambient air temperature is above operating limits.
SYS # CURR LIMITING displayed
8.2
Compressor Components
Logic Section Components
PC Compressors Unloading Valves
(oil pressure actuated)
Oil Pump-end Components
AE4BC
Expansion Board (When Fitted)
APB
Power Board
AMB
Micro Board
AOIB
Opto Interface Board
YEEVC
Electronic Expansion Valve Controller
Compressor liquid injection cooling system
A
To Oil Pressure Transducer
B
Oil Pump Priming and Pressure Access Valve
C
Oil Level Sight Glasses
D
Oil Charging and Drain Valve
E
Oil Heater
F
Oil Temperature Sensor
(10/03)
On PC style 6 and 8 cylinder compressors that unload to
two operational cylinders the compressor is fitted with a
liquid injection system. This consists of solenoid valve,
filter and ball valve mounted on the side of the
compressor which controls the feed of liquid refrigerant
into the compressor’s unloaded suction plenums
through an orifice in each plenum. In some early
compressors the liquid feed was into the crankcase
through a capillary tube.
The liquid feed to the compressor is directly from the
main liquid line, on heat recovery units there are two
liquid feeds one from the main liquid line and the other
from the heat recovery liquid line. The two solenoid
valves control the liquid feed into the compressor
depending on the mode of operation.
8- 4
035L02203-100 Rev. 5
The operation of the solenoid valve(s) is controlled by
the compressor crankcase oil temperature as sensed by
the micro panel. If the oil temperature is above 60 °C and
the compressor is operating then the liquid injection
solenoid valve is energised. When the oil temperature is
below 55 °C the liquid injection solenoid valve is
de-energised, it is also de-energised when the
compressor is not operating.
8.3
Fan Control Sequencing
Four Fan Units (two refrigerant systems, each with two
fans per condenser section)
8.4
Sensor Calibration Charts
Pressure Transducers
0 - 200 psig Transducer
0 - 400 psig Transducer
Pressure psig
Voltage V dc
Pressure psig
Voltage V dc
0
0,5
0
0,5
25
1,0
50
1,0
50
1,5
100
1,5
75
2,0
150
2,0
100
2,5
200
2,5
125
3,0
250
3,0
150
3,5
300
3,5
175
4,0
350
4,0
200
4,5
400
4,5
Red wire = 5 V, Black wire = 0 V, White or Green wire = signal
Leaving Water Temperature Sensor (LWT)
and 3 k Oil Temperature Sensor*
Fan Control
Step
Standard
Units
Units fitted with a
Low Ambient Kit
STAGE 1
Fans off
Fan /1 on -backwards*
STAGE 2
Fan /2 on
Fan /2 on ( Fan /1 off )
STAGE 3
Fans /1 & /2 on
Fans /1 & /2 on
*backwards fan rotation gives airflow in a downward direction.
Eight Fan Units (two refrigerant systems, each with
four fans per condenser section)
Fan Control Step
All Units
STAGE 1
Fans /2 & /4 on
STAGE 2
Fans /2, /3 & /4 on
STAGE 3
Fans /1, /2, /3 & /4 on
Temperature °C
-10
-8
-6
-4
-2
0
2
4
6
8
10
20
30
Resistance Ω
16598
14896
13388
12047
10856
9795
8849
8005
7251
6575
5970
3748
2417
Voltage Vdc
1,45
1,57
1,69
1,80
1,93
2,05
2,17
2,30
2,42
2,54
2,66
3,22
3,69
40
1598
4,05
Microboard test points:
Leaving water: J11-7/1
Sys.1 oil temp: J11-8/2
Sys.2 oil temp: J16-6/3
Ambient Temperature Sensor
and 10 k Oil Temperature Sensor*
Temperature °C
-10
-5
0
5
10
15
20
25
30
35
40
Microboard test point:
Resistance Ω
Voltage Vdc
55330
0,97
42227
1,20
32650
1,45
25390
1,72
19900
2,00
15710
2,29
12490
2,58
10000
2,85
8057
3,11
6530
3,35
5327
3,57
Ambient Air: J11-9/3
Sys.1 oil temp: J11-8/2
Sys.2 oil temp: J16-6/3
* Two types of oil temperature sensors can be
found on the compressors, 3 kΩ or 10 kΩ. The
3 kΩ sensor is 3 kΩ at 25 °C, the 10 kΩ is 10
kΩ at 25 °C.
(10/03)
035L02203-100 Rev. 5
8.5
Electronic Expansion Valve Calibration
8- 5
Calibration Checks
(See Section 5 for Valve Adjustment)
n
Supply voltage should measure 24 Vac + 10% .
Electronic Expansion Valve and Controller base
connections
n
Actuator power circuit should measure 8 - 20
ohms.
n
Actuator temperature feedback circuit should
measure 100 ohms - 100 kohms.
On/Off
1 2 3 4 5
9 10
12 13
D1
D02
D01
A0
-BS1 and -BS2 resistance should correspond the table
below.
BUTTONS
AIB
AKS 32R
TQ
AIA
14 15 16 17 18 19 20 21 22 23 24 25 26
+
1
P3 S
2
35
36
77
78
24 V
a.c.
50/60Hz, 75VA
S2
Expansion ValveOrifice assembly
The spring in the orifice assembly is factory set and is
critical to the correct operation of the valve. The length of
the spring should be as follows:
VALVE TYPE
SPRING LENGTH `Y’
TQ 55 - 2
31,0 mm ± 0,3 mm
PHTQ 85 - 3, PHTQ 85 - 4
26,5 mm ± 0,3 mm
(10/03)
Temperature
°C
-30
-29
-28
-27
-26
-25
-24
-23
-22
-21
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
Resistance
Ω
882,2
886,2
890,1
894,0
898,0
901,9
905,9
909,8
913,7
917,7
921,6
925,5
929,5
933,4
937,3
941,2
945,2
949,1
953,0
956,9
960,9
964,8
968,7
972,6
976,5
980,4
984,4
988,3
992,2
996,1
1000
Temperature
°C
0
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
30
Resistance
Ω
1000
1003,9
1007,8
1011,7
1015,6
1019,5
1023,4
1027,3
1031,2
1035,1
1039,0
1042,9
1046,8
1050,7
1054,6
1058,5
1062,4
1066,3
1070,2
1074,0
1077,9
1081,8
1085,7
1089,6
1093,5
1097,3
1101,2
1105,1
1109,0
1112,8
1116,7
8- 6
8.6
035L02203-100 Rev. 5
Electronic Expansion Valve Trouble Shooting
PROBLEM
POSSIBLE CAUSES
ACTION
Valve
capacity low actuator hot
Insufficient liquid subcooling.
Check liquid subcooling.
Check for blocked filter drier.
Insufficient pressure drop across valve.
Check discharge pressure fan control settings.
Check for blocked filter drier.
Sensors swapped over.
Check sensors are wired correctly.
Broken or short circuited sensor cable
or sensor out of calibration / out of
position.
Check sensors are located correctly: -BS1 firmly
in bottom of cooler pocket and -BS2 strapped on
suction line.
Broken or short circuited wiring from
controller base to valve actuator.
Test wiring.
Defective NTC resistor in valve
actuator.
Check NTC resistance from controller base.
Defective actuator heater element.
Check heater resistance from controller base.
Defective NTC resistor circuit.
Check NTC resistance from controller base.
Defective controller / incorrect set-up.
Remove controller and check if valve now
closes.
Obstruction in valve orifice.
Check orifice is clean and O-ring is in place.
Broken or short circuited sensor cable
or sensor out of calibration / out of
position.
Check sensor resistance at controller base.
Check sensors are located correctly: -BS1 firmly
in bottom of cooler pocket and -BS2 strapped on
suction line.
Valve
capacity low actuator cold
Valve does
not close
(10/03)
035L02203-100 Rev. 5
9
TECHNICAL DATA
9.1
Flow Rate/Pressure Drop Charts
Cooler Water Pressure Drops
9- 1
Pressure Drop Corrections
A Correction Factor
B Mean Glycol Temperature through Cooler
C Concentration W/W
X Cooler Flow Rate
Y Nominal Pressure Drop
R22/R407C Models
44MR7
55MR7
55ST7
65NS7
66ST9
76ST9
77XT9
77SU7
87SU7
97AU7
98XU7
99XU7
99XW9
Line
A
A
C
B
C
C
E
C
C
D
E
E
E
R134a Models
44MR7
55MR7
75MS7
77MT7
88ST7
98ST9
99ST9
98AW9
99AW9
Line
A
A
A
A
C
C
C
D
D
COOLER
MODEL
1408 A
1408 B
1608 A
1808 A
2008 A
LINE ON CHART
MAX FLOW l/s
A
B
C
D
E
36,5
36,5
40,5
45,5
50,7
MAX PRESS
DROP kPa
110
98
103
116
91
When using glycol solutions, pressure drops are higher than with water. Special care must be taken not to
exceed the maximum allowed.
Pressure drops quoted are nominal values. Manufacturing variations may cause up to 15% increase.
(10/03)
9- 2
035L02203-100 Rev. 5
Heat Recovery Condenser Water Pressure Drops
R22/R407C
Models
44MR7
55MR7
55ST7
65NS7
66ST9
76ST9
77XT9
77SU7
87SU7
97AU7
98XU7
99XU7
99XW9
SYS 1
SYS 2
R134a Models
SYS 1
SYS 2
Q
Q
Q
S
S
S
S
S
T
T
T
T
T
S
S
T
T
T
T
44MR7
55MR7
75MS7
77MT7
88ST7
98ST9
99ST9
98AW9
99AW9
P
P
Q
Q
R
S
S
S
S
R
S
X Cooler Flow Rate
Y Nominal Pressure Drop
CONDENSER MODEL
BPC 44
BPC 51
BPC 60
BPC 73
BPC 98
LINE ON CHART
P
Q
R
S
T
MAX FLOW l/s
10,8
13
15,6
19
24,5
When using glycol solutions, pressure drops are higher than with water. Special care must be taken not to
exceed the maximum allowed.
Pressure drops quoted are nominal values. Manufacturing variations may cause up to 15% increase.
(10/03)
035L02203-100 Rev. 5
9.2
9- 3
Operating Limitations
General Limitations
Electrical Supply
Minimum
Maximum
Mains (380/400 V - 3 ph - 50 Hz Nominal):
342 V
440 V
Controls (220/230 V - 1 ph - 50 Hz Nominal):
198 V
254 V
Water System
Minimum
Maximum
4,5 °C
6,0 °C
12 °C
10 °C
3,3 °C
8 °C
R22 & R134a models:
R407C models:
Chilled Water Leaving Temperature:
Chilled Liquid Temperature Range Across Cooler:
Glycol System
Chilled Glycol Leaving Temperature:
Miniumum Leaving Glycol Temperature
-
12 °C
R22/R134a models
Pressure Vessel Codes:
Merkblatter (TüV), DRIRE, Raccolta(Espesi)
-6 °C
-
R407C models
Pressure Vessel Codes:
Merkblatter (TüV), DRIRE, Raccolta(Espesi)
-2 °C
-
R22/R134a/R407C models
Pressure Vessel Code:
ASME
-8 °C
-
R134a models:
R22 models:
R407C models:
35 °C
35 °C
30 °C
55 °C
52 °C
49 °C
-
10 barg
Hot Water Leaving Temperature:
Water / Glycol Pressue at Unit:
Condenser Air
Minimum
Maximum
Standard Units:
With Low Ambient Kit Fitted:
With Low Noise Fans Fitted:
-4 °C
-18 °C
-4 °C
45 °C
45 °C
42 °C
Standard Units:
With Low Noise Fans Fitted:
With High Static Pressure Fans Fitted:
-
20 Pa
10 Pa
100Pa
Minimum
Maximum
-
31,0 barg
16,2 barg
Compressor Operation
Minimum
Maximum
Compression Ratio:
Discharge Pressure:
Suction Pressure (operating):
Differential Pressure:
Oil Pressure (above suction pressure):
Oil Temperature (at oil pump suction):
Suction Gas Superheat:
Discharge Gas Temperature:
1,4 bar *
2,8 °C
-
9,5:1
27,9 barg
6,5 barg
22,5 barg
70 °C
135 °C
Entering Temperature:
External Static Loss:
Refrigerant System
High Pressure Side:
Low Pressure Side:
Design Pressure:
Note *: 1,4 bar provides bearing protection but is insufficient to operate oil pressure actuated unloading system on PC style H compressors which may require
up to 4,2 bar.
(10/03)
9- 4
035L02203-100 Rev. 5
Individual Unit Limitations
Liquid Flow Rate, System Water Content and Pressure Drop Limitations
COOLER
R143a
MODELS
System 2
Flow Rate
(l/s)
Min.
Max.
Max.
Recommende
d Min.
System
Content (l)
44MR7
7,5
36,5
110
1500
3,3
11,0
-
-
55MR7
7,5
36,5
110
1720
3,3
11,0
-
-
Flow Rate
(l/s)
MODEL
R22/
R407C
MODELS
HEAT RECOVERY CONDENSER(S)
System 1
Flow Rate
(l/s)
Press. Drop
(kPa)
Min.
Max.
Min.
Max.
55ST7
9,4
40,5
103
1850
3,3
11,0
-
-
65NS7
7,5
36,5
110
1540
5,0
19,0
-
-
66ST9
9,4
40,5
103
1460
5,0
19,0
-
-
76ST9
9,4
40,5
103
1560
5,0
19,0
-
-
77XT9
15,8
50,7
91
1700
5,0
19,0
-
-
77SU7
9,4
40,5
103
1740
5,0
19,0
5,0
19,0
87SU7
9,4
40,5
103
1860
6,5
24,5
5,0
19,0
97AU7
12,6
45,5
116
1800
6,5
24,5
6,5
24,5
98XU7
15,8
50,7
91
1860
6,5
24,5
6,5
24,5
99XU7
15,8
50,7
91
1910
6,5
24,5
6,5
24,5
99XW9
15,8
50,7
91
2020
6,5
24,5
6,5
24,5
44MR7
7,5
36,5
110
1050
2,9
10,8
-
-
55MR7
7,5
36,5
110
1200
2,9
10,8
-
-
75MS7
7,5
36,5
110
1180
3,3
11,0
-
-
77MT7
7,5
36,5
110
1160
3,3
11,0
-
-
88ST7
9,4
40,5
103
1000
4,0
15,6
-
-
98ST9
9,4
40,5
103
1140
5,0
19,0
-
-
99ST9
9,4
40,5
103
1210
5,0
19,0
-
-
98AW9
12,6
45,5
116
1370
5,0
19,0
4,0
15,6
99AW9
12,6
45,5
116
1410
5,0
19,0
5,0
19,0
Notes:
1. The maximum cooler flow rates shown are for water operation.
2. On glycol operation maximum flow value must be reduced in order to observe the maximum pressure drop limit.
3. Heat recovery condenser flow rates should also be limited between 3,6 litres/sec and 7,2 litres/sec per 100 kW heat rejection.
4. For units with twin heat recovery condensers, series or parallel flow may be used but limits for each vessels must be observed.
CONCENTRATION BY WEIGHT %
0.27
GLYCOL FACTOR AT
RECOMMENDED
CONCENTRATION
0.26
0.25
RECOMMENDED
CONCENTRATION
0.24
0.23
FREEZING
TEMPERATURE
LEAVING LIQUID TEMPERATURE °C
GLYCOL FACTOR (l/s) °C / kW
0.28
CONCENTRATION BY WEIGHT %
Factors at other concentrations for
Ethylene glycol solutions
GLYCOL FACTOR (l/s) °C / kW AT
RECOMMENDED CONCENTRATION
Recommended concentrations for
Ethylene glycol solutions
LEAVING LIQUID TEMPERATURE °C
(10/03)
035L02203-100 Rev. 5
Recommended concentrations for
Propylene glycol solutions
0.23
RECOMMENDED
CONCENTRATION
FREEZING
TEMPERATURE
CONCENTRATION BY WEIGHT %
0.24
GLYCOL FACTOR (l/s) °C / kW
CONCENTRATION BY WEIGHT %
0.25
GLYCOL FACTOR (l/s) °C / kW AT
RECOMMENDED CONCENTRATION
Factors at other concentrations for
Propylene glycol solutions
0.26
GLYCOL FACTOR AT
RECOMMENDED
CONCENTRATION
9- 5
LEAVING LIQUID TEMPERATURE °C
LEAVING LIQUID TEMPERATURE °C
Pressure drop correction factors for
Ethylene glycol solutions
Pressure drop correction factors for
Propylene glycol solutions
MEAN LIQUID TEMPERATURE °C
% CONCENTRATION
CORRECTION FACTOR
% CONCENTRATION
CORRECTION FACTOR
1.50
MEAN LIQUID TEMPERATURE °C
Correction Factors
% By Weight
10
20
30
40
50
Ethylene Glycol
Capacity Factor
Comp. Input Factor
1.045
1.020
1.020
1.010
1.000
1.000
0.970
0.990
0.940
0.980
To adjust 30% Ethylene Glycol Ratings
(10/03)
Propylene Glycol
Capacity Factor
Comp. Input Factor
1.070
1.025
1.040
1.015
1.000
1.000
0.950
0.985
0.900
0.970
9- 6
9.3
035L02203-100 Rev. 5
Physical Data
R22 and R407C
YCAJ
44MR7
55MR7
55ST7
65NS7
66ST9
76ST9
2
2
2
2
2
2
2
System No. 1
PC43-M
PC44-P
PC44-P
PC63-Q
PC63-Q
PC64-S
PC64-S
System No. 2
PC43-M
PC44-P
PC44-P
PC44-P
PC63-Q
PC63-Q
PC64-S
4+4
4+4
4+4
6+4
6+6
6+6
6+6
rpm
1450
1450
1450
1450
1450
1450
1450
l
22.8
22.8
22.8
22.8
22.8
22.8
22.8
2+2
2+2
2+2
3+2
3+3
3+3
3+3
29-58
29-58
29-58
24-47-66
20-39-55
21-40-56
20-39-55
-79-100
-79-100
-79-100
-83-100
25-50
25-50
25-50
23-43-61
-75-100
-75-100
-75-100
-80-100
Cooler DXC Model
1408A
1408A
1608A
1408A
1608A
1608A
Number of Circuits
2
2
2
2
2
2
2
135
135
150
135
150
150
205
Number of Refrigerant Circuits
Model
Compressor
Number of Cylinders
Speed
Total Oil Capacity
Number of Capacity Steps
Unit
Cooling capacity step %
Power input step %
Cooler
Water Capacity
l
Number of Condenser Modules
Condenser
20-38-54
18-37-53
2008A
1
1
1
1
1
1
11.8
11.8
11.8
11.8
11.8
11.8
Number of Tube Rows
3
3
4
4-3
4
4
4
Quantity
4
4
4
4
4
4
4
Slow Speed
(730 rpm)
m
2
Power (each)
kW
2.2
2.2
2.2
2.2
3.8
3.8
3.8
Total Airflow
29.1
29.1
27.6
28.6
33.5
33.5
33.5
Ext. Static Pressure
m3/s
Pa
20
20
20
20
20
20
20
Power (each)
kW
1.4
1.4
1.4
1.4
1.7
1.7
1.7
Total Airflow
m3/s
Pa
26.0
26.0
26.0
25.5
31.0
31.0
31.0
10.0
10.0
10.0
10.0
10.0
10.0
10.0
Ext. Static Pressure
Power (each)
kW
3.8
3.8
3.8
3.8
4.1
4.1
4.1
Total Airflow
m3/s
Pa
29.1
29.1
27.6
28.6
33.5
33.5
33.5
100
100
100
100
100
100
100
51
51
51
73
73
73
73
1
1
1
1
1
1
1
Litres
39
39
39
59
59
59
59
Standard Chiller
kg
32+32
35+35
38+38
40+37
44+44
50+44
52+52
Heat Recovery
kg
50+32
53+35
56+38
64+37
68+44
74+44
76+52
Aluminium Fins Shipping
kg
3865
3935
4170
4120
4505
4575
4840
kg
4000
4070
4320
4245
4655
4725
5045
Ext. Static Pressure
BPC Model
Heat Recovery
Quantity
Condenser
Water Volume
Operating
Weight
18-37-53
-68-84-100 -67-85-100 -68-84-100
1
High Pressure
(950 rpm)
Refrigerant
Charge
-70-85-100 -71-86-100 -70-85-100
11.8
Face Area
Standard
(950 rpm)
Fans
77XT9
Copper Fins
Shipping
Operating
Additional for Heat Recovery
kg
4235
4395
4750
4640
5085
5155
5420
kg
4460
4530
4900
4765
5235
5305
5625
kg
390
390
390
520
520
520
520
Length
mm
2960
2960
2960
2960
2960
2960
2960
Width
mm
2315
2315
2315
2315
2315
2315
2315
Height
mm
2480
2480
2480
2480
2480
2480
2480
Dimensions Length
Heat Recovery Width
Units
Height
mm
3404
3404
3404
3404
3404
3404
3404
mm
2315
2315
2315
2315
2315
2315
2315
mm
2480
2480
2480
2480
2480
2480
2480
Dimensions
Cooling Only
Units
(10/03)
9- 7
035L02203-100 Rev. 5
R22 and R407C (Continue)
YCAJ
77SU7
87SU7
97AU7
98XU7
99XU7
2
2
2
2
2
2
System No. 1
PC64-S
PC83-S
PC84-T
PC84-T
PC84-T
PC84-T
System No. 2
PC64-S
PC64-S
PC64-S
PC83-S
PC84-T
PC84-T
6+6
8+6
8+6
8+8
8+8
8+8
rpm
1450
1450
1450
1450
1450
1450
l
22.8
22.8
22.8
22.8
22.8
22.8
3+3
4+3
4+3
4+4
4+4
4+4
20-39
16-31-49
17-33-49
16-31-45
15-29-44
15-29-44
Number of Refrigerant Circuits
Model
Compressor
Number of Cylinders
Speed
Total Oil Capacity
Number of Capacity Steps
Cooling capacity step %
Unit
Power input step %
Cooler
-91-100
-90-100
-90-100
18-37
15-26-43
15-28-44
15-26-39
13-24-38
13-24-38
-58-71
-86-100
-88-100
-86-100
-86-100
Cooler DXC Model
1608A
1608A
1808A
2008A
2008A
2008A
Number of Circuits
2
2
2
2
2
2
l
150
150
175
205
205
205
2
2
2
2
2
2
m2
23.6
23.6
23.6
23.6
23.6
23.6
Face Area
-49-62-73 -49-61-73 -49-61-73
Number of Tube Rows
3
3
3
3
3
4
Quantity
8
8
8
8
8
8
Slow Speed
(730 rpm)
High Pressure
(950 rpm)
Power (each)
kW
2.2
2.2
2.2
2.2
2.2
3.8
Total Airflow
58.2
58.2
58.2
58.2
58.2
67.0
Ext. Static Pressure
m3/s
Pa
20
20
20
20
20
20
Power (each)
kW
1.4
1.4
1.4
1.4
1.4
1.7
Total Airflow
m3/s
Pa
52.0
52.0
52.0
52.0
52.0
62.0
10.0
10.0
10.0
10.0
10.0
10.0
Power (each)
kW
3.8
3.8
3.8
3.8
3.8
3.8
Total Airflow
m3/s
Pa
58.2
58.2
58.2
58.2
58.2
67.0
Ext. Static Pressure
BPC Model
Heat recovery
Quantity
Condenser
Water Volume
100
100
100
100
100
100
73 + 73
98 + 73
98 + 98
98 + 98
98 + 98
98 + 98
2
1+1
2
2
2
2
l
118
136
154
154
154
154
Standard Chiller
kg
55+62
59+62
63+62
63+71
63+71
66+74
Heat Recovery
kg
79+86
90+86
94+93
94+102
94+102
97+105
Aluminium Fins Shipping
Operating
Copper Fins
Shipping
Operating
Additional for Heat Recovery
Dimensions
Cooling Only
Units
-58-70-80 -58-69-80 -58-69-80
-56-71
Ext. Static Pressure
Weight
-62-76
-87-100
-85-100
Standard
(950 rpm)
Refrigerant
Charge
-61-75
-86-100
-53-68
Number of Condenser Modules
Fans
-55-70
-85-100
-84-100
Water Capacity
Condenser
99XW9
kg
6210
6230
6635
6795
6895
7045
kg
6360
6377
6811
7000
7100
7250
kg
7145
7165
7570
7730
7830
8635
kg
7296
7313
7747
7936
8030
8842
1315
kg
1040
1183
119
1315
1315
Length
mm
5812
5812
5812
5812
5812
5812
Width
mm
2315
2315
2315
2315
2315
2315
2480
Height
mm
2480
2480
2480
2480
2480
Dimensions Length
Heat Recovery Width
Units
Height
mm
6251
6251
6251
6251
6251
6251
mm
2315
2315
2315
2315
2315
2315
mm
2480
2480
2480
2480
2480
2480
(10/03)
9- 8
035L02203-100 Rev. 5
R134a
YCAJ
Number of Refrigerant Circuits
Model
System No. 1
System No. 2
Compressor Number of Cylinders
Speed
Total Oil Capacity
44MR7
55MR7
75MS7
77MT7
88ST7
Number of Capacity Steps
2
PC43-M
PC43-M
4+4
1450
22.8
2+2
2
PC44-M
PC44-M
4+4
1450
22.8
2+2
2
PC64-M
PC44-M
6+4
1450
22.8
3+2
2
PC64-N
PC64-N
6+6
1450
22.8
3+3
2
PC83-P
PC83-P
8+8
1450
22.8
4+4
29-58
29-58
24-47-66
21-40-56
15-29-44
Cooling capacity step %
-79-100
-79-100
-83-100
rpm
Litres
Unit
Cooler
Condenser
Fans
-
-
-
-
-90-100
25-50
25-50
23-43-61
20-38-54
13-24-38
Power input step %
-75-100
-75-100
-80-100
Cooler DXC Model
Number of Circuits
Water Capacity
Number of Condenser Models
Face Area
Number of Tube Rows
Quantity
Power (each)
Standard
Total Airflow
(950 rpm)
Ext. Static Pressure
Power (each)
Slow Speed
Total Airflow
(730 rpm)
Ext. Static Pressure
Power (each)
High Head
Total Airflow
(950 rpm)
Ext. Static Pressure
1408A
2
135
1
11.8
3
4
2.2
29.1
20
1.4
26.0
10.0
3.8
29.1
100
44
1408A
2
135
1
11.8
3
4
2.2
29.1
20
1.4
26.0
10.0
3.8
29.1
100
44
1408A
2
135
1
11.8
4+3
4
2.2
28.6
20
1.4
25.5
10.0
3.8
28.6
100
51
BPC Model
Heat Recovery
Quantity
Condenser
Water Volume
Refrigerant Standard Chiller
Heat Recovery
Charge
Weight
Aluminium Fins
Copper Fins
Dimensions
Cooling Only
Units
-71-86-100 -58-69-80
m2
kW
m3/s
Pa
kW
m3/s
Pa
kW
m3/s
Pa
Shipping
Operating
Shipping
Operating
1408A
2
135
1
11.8
4
4
2.2
27.6
20
1.4
25.0
10.0
3.8
27.6
100
51
-86-100
1608A
2
150
1
11.8
4
4
3.8
33.5
20
1.4
31.0
10.0
3.8
33.5
100
60
1
1
1
1
1
kg
mm
mm
mm
mm
34
32+32
47+32
3865
4000
4325
4460
390
2960
2315
2480
3404
34
35+35
50+35
3935
4670
4395
4518
390
2960
2315
2480
3404
39
40+37
58+37
4145
4295
4665
4815
390
2960
2315
2480
3404
39
40+40
58+40
4250
4375
4830
4955
390
2960
2315
2480
3404
51
45+45
66+45
4775
4925
4355
5505
455
2960
2315
2480
3404
mm
2315
2315
2315
2315
2315
mm
2480
2480
2480
2480
2480
Litres
Additional for Heat Recovery
Length
Width
Height
Length
Dimensions
Heat Recovery Width
Units
Height
Litres
-67-85-100 -49-61-73
kg
kg
kg
kg
kg
kg
(10/03)
035L02203-100 Rev. 5
9- 9
R134a (Continue)
YCAJ
Number of Refrigerant Circuits
Model
System No. 1
System No. 2
Compressor Number of Cylinders
Speed
Total Oil Capacity
rpm
Litres
Number of Capacity Steps
Cooling capacity step %
Power input step %
Condenser
Fans
Cooler DXC Model
Number of Circuits
Water Capacity
Number of Condenser Modules
Face Area
Number of Tube Rows
Quantity
Power (each)
Standard
Total Airflow
(950 rpm)
Ext. Static Pressure
Power (each)
Slow Speed
Total Airflow
(730 rpm)
Ext. Static Pressure
Power (each)
High Head
Total Airflow
(950 rpm)
Ext. Static Pressure
Aluminium Fins
Copper Fins
Dimensions
Cooling Only
Units
Litres
m2
kW
m3/s
Pa
kW
m3/s
Pa
kW
m3/s
Pa
99AW9
2
PC84P
PC83Q
8+8
1450
22.8
4+4
2
PC84-Q
PC84-Q
8+8
1450
22.8
4+4
16-31-45
15-29-44
16-31-45
15-29-44
-91-100
-90-100
-91-100
-90-100
15-26-39
13-24-38
15-26-39
13-24-38
-86-100
1608A
2
150
1
11.8
4
4
3.8
33.5
20
1.7
31.0
10.0
3.8
33.5
100
73
-88-100
1808A
2
175
2
23.6
4
8
3.8
67.0
20
1.7
62.0
10.0
3.8
67.0
100
73+60
-86-100
1808A
2
175
2
23.6
3
8
3.8
67.0
20
1.7
62.0
10
3.8
67.0
100
73+73
1
1
1
1
kg
mm
mm
mm
mm
59
50+50
74+45
4850
5055
5430
5635
520
2960
2315
2480
3404
59+51
63+71
87+92
6755
6905
7915
8605
975
5805
2315
2480
6251
59+59
63+71
87+95
6855
7005
8015
8165
1040
5805
2315
2480
6251
mm
2315
2315
2315
2315
mm
2480
2480
2480
2480
kg
kg
kg
kg
kg
kg
Shipping
Operating
Shipping
Operating
Additional for Heat Recovery
Length
Width
Height
Length
-88-100
1608A
2
150
1
11.8
4
4
3.8
33.5
20
1.7
31.0
10.0
3.8
33.5
100
73
59
50+45
74+45
4845
4995
5425
5575
520
2960
2315
2480
3404
Litres
Dimensions
Heat Recovery Width
Units
Height
9.4
98AW9
2
PC84-Q
PC84-Q
8+8
1450
22.8
4+4
-49-62-73 -49-61-73 -49-62-73 -49-61-73
BPC Model
Heat Recovery
Quantity
Condenser
Water Volume
Refrigerant Standard Chiller
Heat Recovery
Charge
Weight
99ST9
2
PC84P
PC83-Q
8+8
1450
22.8
4+4
-58-70-80 -58-69-80 -58-70-80 -58-69-80
Unit
Cooler
98ST9
Electrical Data
Fan Data (all values are per fan)
RUNNING Full Load Amps
LOCKED ROTOR Amps
R134a MODELS
FAN TYPE
NOMINAL
POWER kW
@ 380 V
@ 400 V
@ 380 V
@ 400 V
44MR7 - 65NS7 (4 FAN)
77SU7 - 99XU7 (8 FAN)
44MR7 - 88ST7 (4 FAN)
Low Noise
Standard
High Pressure
1,1
2,2
3,8
4
5,7
8,6
3,9
5,8
8,2
14
24,1
44
15
25,4
46,3
66ST9 - 77XT9 (4 FAN)
99XW9 (8 FAN)
98ST9 - 99ST9 (4 FAN)
98SW9 - 99AW9 ( 8 FAN)
Low Noise
Standard
High Pressure
1,7
3,8
4,1
4
8,6
7,7
4,1
8,2
7,5
24,7
44
54
26
46,3
57
R22 / R407C MODELS
(10/03)
9-10
035L02203-100 Rev. 5
Compressor Data (all values are per compressor)
RUNNING CONDITIONS
UNIT
MODEL
SYS
NO.
COMP'S
MODEL
MOTOR
CODE
NOMINAL
LOCKED ROTOR CONDITIONS
MAXIMUM
Power
Current Amps
Power
kW
@380V @400V
kW
Current Amps
STAR / DELTA
PART-WIND
FULL-WIND
Current Amps
Current Amps
Current Amps
@342V @380V @400V @380V @400V @380V @400V @380V @400V
R22/R407C - 4 Fan Models
44MR7*
44MR7*
1&2
1&2
PC43-M
PC43-P
M1
P1
49
49
85
88
84
87
58
58
125
111
100
102
96
100
153
161
281
-
296
-
382
458
402
482
55MR7
1&2
PC44-P
P2
61
105
102
74
145
127
123
153
161
338
356
458
482
55ST7
1&2
PC44-P
P2
61
105
102
74
145
127
123
153
161
338
356
458
482
65NS7
1
2
PC63-Q
PC44-P
Q1
P2
71
61
127
105
126
102
85
74
162
145
150
127
147
123
207
153
218
161
458
338
482
356
620
458
653
482
66ST9
1&2
PC63-Q
Q1
71
127
126
85
162
150
147
207
218
458
482
620
653
76ST9
1
2
PC64-S
PC63-Q
S1
Q1
88
71
156
127
156
126
106
85
205
162
190
150
184
147
247
207
260
218
549
458
578
482
742
620
781
653
77XT9
1&2
PC64-S
S1
88
156
156
106
205
190
184
247
260
549
578
742
781
R22/R407C - 8 Fan Models
77SU7
1&2
PC64-S
S2
82
145
145
98
188
176
172
247
260
549
578
742
781
87SU7
1
2
PC83-S
PC64-S
S3
S2
93
82
165
145
163
145
111
98
215
188
198
176
192
172
247
247
260
260
549
549
578
578
742
742
781
781
97AU7
1
2
PC84-T
PC64-S
T1
S2
110
83
195
147
191
147
132
100
260
192
230
178
222
174
304
247
320
260
689
549
725
578
912
742
960
781
98XU7
1
2
PC84-T
PC83-S
T1
S3
113
94
200
168
196
166
135
113
265
220
235
202
227
195
304
247
320
260
689
549
725
578
912
742
960
781
99XU7
1&2
PC84-T
T1
113
200
196
135
265
235
227
304
320
689
725
912
960
99XW9
1&2
PC84-T
T1
110
195
191
131
258
228
220
304
320
689
725
912
960
65
-
-
281
296
382
402
R134a - 4 Fan Models
44MR7
1&2
PC43-M
M2
28
56
58
35
67
63
55MR7
1&2
PC44-M
M3
36
63
65
46
87
80
80
-
-
281
296
382
402
75MS7
1
2
PC64-N
PC44-M
N1 M3
52
36
93
63
93
65
65
46
125
87
113
80
111
80
-
-
329
281
346
296
447
382
471
402
77MT7
1&2
PC64-N
N1
52
93
93
65
125
113
111
-
-
329
346
447
471
88ST7
1&2
PC83-P
P3
55
96
94
70
135
120
117
153
161
338
356
458
482
98ST9
1
2
PC84-Q
PC83-P
Q2
P3
71
54
124
94
124
92
92
69
175
133
160
118
156
115
207
153
218
161
458
338
482
356
620
458
653
482
99ST9
1&2
PC84-Q
Q2
71
124
124
92
175
160
156
207
218
458
482
620
653
R134a - 8 Fan Models
98AW9
1
2
PC84-Q
PC83-P
Q1
P4
65
51
116
90
115
89
85
65
160
128
148
112
142
108
207
153
218
161
458
338
482
356
620
458
653
482
99AW9
1&2
PC84-Q
Q1
65
116
115
85
160
148
142
207
218
458
482
620
653
Notes
* YCAJ 44 MR7 R22 compressors are fitted with different motor sizes depending on starting method.
Nominal conditions for R22 units are taken as 6 °C Leaving Chilled Water, 35 °C Ambient Air.
Nominal conditions for R143a units are taken as 6 °C Leaving Chilled Water, 30°C Ambient Air.
Maximum conditions are taken as 12°C Leaving Chilled Water, 45°C Ambient Air.
Use Maximum Amps for cable sizing.
(10/03)
035L02203-100 Rev. 5
9-11
Fuse/Switch Disconnector Current Ratings
MODEL
FAN TYPE
SYSTEM
44MR7
ALL
1&2
55MR7
55ST7
ALL
ALL
L.N/STD
H.P
ALL
L.N
STD/H.P
ALL
L.N
STD/H.P
ALL
1&2
1&2
1
1
2
1&2
1&2
1
2
2
1&2
MAXIMUM (gG) FUSE SIZE
PER SYSTEM
BS
DIN
R22/R407C - 4-FAN MODELS:
160
160
SWITCH DISCONNECTOR FUSE (Ie)
RATING
BS
DIN
200 (P.W.)
160 (S.D.)
250
250
250
250
250
250
250
315
250
250
315
250 (P.W.)
160 (S.D.)
250
250
250
250
250
250
250
400
250
250
400
200
200
200
200
200
200
65NS7
250
250
200
200
200
200
66ST9
250
250
250
250
76ST9
200
200
250
250
77XT9
250
250
R22/R407C - 8-FAN MODELS:
L.N/STD
1&2
250
250
315
400
77SU7
H.P
1&2
315
315
315
400
ALL
1
315
315
400
400
87SU7
L.N/STD
2
250
250
315
400
H.P
2
315
315
315
400
ALL
1
355
355
400
400
97AU7
L.N/STD
2
250
250
315
400
H.P
2
315
315
315
400
ALL
1
355
355
400
400
98XU7
ALL
2
315
315
400
400
99XU7
ALL
1&2
355
355
400
400
L.N
1&2
315
315
400
400
99XW9
STD/H.P
1&2
355
355
400
400
R134a - 4-FAN MODELS:
44MR7
ALL
1&2
100
100
160
160
55MR7
ALL
1&2
125
125
160
160
ALL
1
160
160
200
250
75MS7
ALL
2
125
125
160
160
77MT7
ALL
1&2
160
160
200
250
L.N/STD
1&2
200
200
200
250
88ST7
H.P
1&2
200
200
250
250
L.N
1
250
250
250
250
STD/H.P
1
250
250
315
400
98ST9
L.N
2
160
160
200
250
STD/H.P
2
200
200
250
250
L.N
1&2
250
250
250
250
99ST9
STD/H.P
1&2
250
250
315
400
R134a - 8-FAN MODELS:
L.N
1
200
200
250
250
STD/H.P
1
250
250
315
400
98AW9
L.N
2
200
200
200
250
STD/H.P
2
200
200
250
250
L.N
1&2
200
200
250
250
99AW9
STD/H.P
1&2
250
250
315
400
L.N = Low Noise Fans, STD = Standard Fans, H.P = High Pressure Fans
The maximum fuse size given:
1. Means that the conditional short-circuit current of the York (optional) switch disconnector fuse is 50KA.
2. Ensures a minimum of TYPE 1 co-ordination for contactors to EN 60947-4-1: 1992 with a conditional short-circuit current of 50KA.
3. Ensures that the ultimate allowable short-time conductor temperature under short-circuit conditions is not exceeded in accordance with EN 60204-1: 1992.
Fuses not exceeding the 5 seconds interruption current given in the table Switch Disconnector/Fuse Size must be used.
(10/03)
9-12
035L02203-100 Rev. 5
Customer Control Circuit Supply Data
4-WIRE UNITS 230 V CUSTOMER SUPPLY
CONTROL SUPPLY
INTERNAL FUSE
LOAD AT 230 V
RATING CLASS gG
MAX. CUSTOMER
FUSE RATING
3-WIRE UNITS 380/400 V CUSTOMER SUPPLY
CONTROL SUPPLY
INTERNAL FUSE
LOAD AT 380/400 V RATING CLASS aM
MAX. CUSTOMER
FUSE RATING
STANDARD UNITS
6,7
10
16
3,9
10
16
UNITS WITH HEAT
RECOVERY
9,1
12
20
5,2
10
16
Switch Disconnector Fuse/Fuse Size
SWITCH DISCONNECTOR FUSE
Ie RATING
BS 88 FUSE RANGE FOR
SWITCH DISCONNECTOR FUSE
DIN HN FUSE RANGE FOR
SWITCH DISCONNECTOR FUSE
160
A4 or max. fuse dia. 45 mm
0
200
B1 - B2
-
250
B1 - B3
1
315
B1 - B3
-
400
B1 - B4
2
FUSE RATING (A)
MAX 5 SECOND INTERRUPT
CURRENT
FUSE RATING (A)
MAX 5 SECOND INTERRUPT
CURRENT
100
500
250
1300
125
610
315
1700
160
810
355
2200
200
1000
-
-
(10/03)
035L02203-100 Rev. 5
9.5
Clearances
1.3 m
1.3 m
A
A
A
B
A
B
B
A=
1.5 m (Models YCAJ 44MR7 - 77XT9)
2 m (Models YCAJ 77SU7 - 99XW9)
B=
1.5 m (Models YCAJ 44MR7 - 77XT9)
2 m (Models YCAJ 77SU7 - 99XW9)
C=
2.5 m (Models YCAJ 44MR7 - 77XT9)
3 m (Models YCAJ 77SU7 - 99XW9)
1.3 m
A
C
B
(10/03)
A
9-13
9-14
9.6
035L02203-100 Rev. 5
Dimensions
Standard Models - Single Module/Four Fans
1
2
3
4
5
6
7
8
9
MODELS
DIMENSIONS
A
R22/
R407C
B
STD CONNECTIONS
Mounting Holes
Base
4 Mounting Holes 17.5 Dia in Base
Water Inlet
Water Outlet
Power Cable Entry
Gland Plate Extension Box Fitted With Common Input Supply Option
76 mm Square Rigging Holes
Gland Plate 235 x 286 mm
MODELS
C
44MR7
2159
273
406
150 mm (6") N.B. Victaulic
55MR7
2159
273
406
150 mm (6") N.B. Victaulic
55ST7
2108
299
432
200 mm (8") N.B. Victaulic
65NS7
2159
273
406
150 mm (6") N.B. Victaulic
66ST9
2108
299
432
200mm (8") N.B. Victaulic
76ST9
2108
299
432
200 mm (8") N.B. Victaulic
77XT9
2108
299
470
200 mm (8") N.B. Victaulic
Vibration isolators (not shown) increase unit height by approximately 176 mm.
R134a
44MR7
55MR7
75MS7
77MT7
88ST7
98ST9
99ST9
DIMENSIONS
STD CONNECTIONS
A
B
C
2159
2159
2159
2159
2108
2108
2108
273
273
273
273
299
299
299
406
406
406
406
432
432
432
150 mm (6") N.B. Victaulic
150 mm (6") N.B. Victaulic
150 mm (6") N.B. Victaulic
150 mm (6") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
(10/03)
9-15
035L02203-100 Rev. 5
Heat Recovery Models - Single Module/Four Fans
3404
2962
1
229
2248
FAN 1/1
2312
2241.4
SYSTEM 1 HEAT RECOVERY
CONDENSER
FAN 1/2
1
Mounting Holes
Base
4 Mounting Holes 17.5 Dia in Base
Water Inlet
Water Outlet
Power Cable Entry
Gland Plate Extension Box Fitted With Common Input Supply Option
76 mm Square Rigging Holes
Gland Plate 235 x 286 mm
Condenser Water Inlet
Condenser Water Outlet
1
2
3
4
5
6
7
8
9
10
11
2
FAN 2/2
35
FAN 2/1
AIR DISCHARGE
AIR DISCHARGE
9
2312
3
743
1219
580
743
1152
260
SYS 2 CONDENSERS
SYSTEM 2
CONTROL
PANEL
SYSTEM 1
AIR INTAKE
2480
2450
2263
AIR INTAKE
SYS 1 CONDENSERS
252
SYSTEM 2
COMPRESSOR
38
STANDARD
VICTAULIC
10
11
152
COOLER
F
E
C
7
B
A
4
432
2712
8
D
5
MODELS
(10/03)
R22/
R407C
44MR7
55MR7
55ST7
65NS7
66ST9
76ST9
77XT9
COOLER CONNECTIONS
DIMENSIONS
A
B
C
STD. CONNECTIONS
2159
273
406
150 mm (6") N.B. Victaulic
2159
273
406
150 mm (6") N.B. Victaulic
2108
299
432
200 mm (8") N.B. Victaulic
2159
273
406
150 mm (6") N.B. Victaulic
2108
299
432
200 mm (8") N.B. Victaulic
2108
299
432
200 mm (8") N.B. Victaulic
2108
299
470
200 mm (8") N.B. Victaulic
R134a
44MR7
2159
H.R. CONDENSER
DIMENSIONS
D
E
F
2356
438
350
2356
438
350
2356
438
350
2381
486
404
2381
486
404
2381
486
404
2381
486
404
STD. CONNECTIONS
63 mm (21/2") N.B. BSPT Female
63 mm (21/2") N.B. BSPT Female
63 mm (21/2") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
150 mm (6") N.B. Victaulic
2356
436
350
63 mm (21/2") N.B. BSPT Female
55MR7
2159
273
406
150 mm (6") N.B. Victaulic
75MS7
2159
273
406
150 mm (6") N.B. Victaulic
77MT7
2159
273
406
150 mm (6") N.B. Victaulic
88ST7
2108
299
432
200 mm (8") N.B. Victaulic
98ST9
2108
299
432
200 mm (8") N.B. Victaulic
99ST9
2108
299
432
200 mm (8") N.B. Victaulic
Vibration isolators (not shown) increase unit height by approximately 176mm.
2356
2356
2356
2381
2381
2381
436
436
436
486
486
486
350
350
350
404
404
404
63 mm (21/2") N.B. BSPT Female
63 mm (21/2") N.B. BSPT Female
63 mm (21/2") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
76 mm (3") N.B. BSPT Female
273
406
6
9-16
035L02203-100 Rev. 5
Standard Models - Two Modules/Eight Fans
1
2
3
4
5
6
7
8
MODELS
R22/
77SU7
R407C
87SU7
97AU7
98XU7
99XU7
99XW9
R134a
98AW9
99AW9
DIM A
432
432
457
470
470
470
457
457
Mounting Holes
Base
8 Mounting Holes 17.5 Dia in Base
Water Inlet
Water Outlet
Power Cable Entry
Gland Plate Extension Box Fitted With Common Input Supply Option
Gland Plate 235 x 286 mm
STD CONNECTIONS
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
Vibration isolators (not shown) increase unit height by approximately 176 mm.
(10/03)
9-17
035L02203-100 Rev. 5
Heat Recovery Models - Two Modules/Eight Fans
1
2
3
4
5
6
7
8
9
10
Mounting Holes
Base
8 Mounting Holes 17.5 Dia in Base
Water Inlet
Water Outlet
Power Cable Entry
Gland Plate Extension Box Fitted With Common Input Supply Option
Gland Plate 235 x 286 mm
Condenser Water Inlet
Condenser Water Outlet
3076
2/2 FAN
1/1 FAN
1/2 FAN
2/3 FAN
2/4 FAN
1/3 FAN
1/4 FAN
2312
2241.4
2/1 FAN
2
1
8
AIR DISCHARGE
1365
1368
1
AIR DISCHARGE
1
1365
35
3
1
B
2312
29
743
1219
743
743
1219
743
374
580
1152
SYSTEM 1
CONDENSERS
SYSTEM 2
CONDENSERS
SYSTEM 2
AIR INTAKE
SYSTEM 1
AIR INTAKE
9
10
CONTROL PANEL
SYSTEM 1
COMPRESSOR
SYSTEM 2
COMPRESSOR
F
E
2263
2480
2450
SYSTEM 1
CONDENSER
13
STANDARD
VICTAULIC
(COOLER)
152
A
D
G
COOLER
5
SYSTEM 2
CONDENSER
1678
4
2108
252
432
7
2718
C
6
SECTION 1
SECTION 2
5464
MODEL
R22/
R407C
77SU7
87SU7
97AU7
98XU7
99XU7
99XW9
R134a
98AW9
99AW9
MODEL
R22/
77SU7
R407C
87SU7
97AU7
98XU7
99XU7
99XW9
R134a
98AW9
99AW9
(10/03)
A
432
432
457
470
470
470
457
457
DIMENSIONS
B
C
D
E
F
2381
2381
466
668
548
2419
2381
466
709
548
2419
2381
466
709
548
2419
2419
497
668
497
2419
2419
497
668
497
2419
2419
497
668
497
2381
2419
466
668
548
2381
2419
466
668
548
STD COOLER CONNECTIONS
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
200 mm (8") N.B. Victaulic
G
668
626
626
668
668
668
668
668
MODEL
STD. H.R. CONDENSER CONNECTIONS
SYSTEM 1
R22 /
77SU7
63 mm (21/2") N.B. BSPT Fem.
R407C
87SU7
100 mm (4") N.B. I.S.O. Flange
97AU7
100 mm (4") N.B. I.S.O. Flange
98XU7
100 mm (4") N.B. I.S.O. Flange
99XU7
100 mm (4") N.B. I.S.O. Flange
99XW9
100 mm (4") N.B. I.S.O. Flange
R134a
98AW9
63 mm (21/2") N.B. BSPT Fem.
99AW9
63 mm (21/2") N.B. BSPT Fem.
Vibration isolators (not shown) increase unit height by approximately 176mm.
SYSTEM 2
63 mm (21/2") N.B. BSPT Fem.
63 mm (21/2") N.B. BSPT Fem.
63 mm (21/2") N.B. BSPT Fem.
100 mm (4") N.B. I.S.O. Flange
100 mm (4") N.B. I.S.O. Flange
100 mm (4") N.B. I.S.O. Flange
63 mm (21/2") N.B. BSPT Fem.
63 mm (21/2") N.B. BSPT Fem.
9-18
9.7
035L02203-100 Rev. 5
Lifting Weights
Single Module/Four Fans
STANDARD UNITS
HEAT-RECOVERY UNITS
Condenser Fin Material
Model
ALUMINIUM &
PHENOLIC COATED
44MR7
55MR7
Condenser Fin Material
COPPER
ALUMINIUM &
PHENOLIC COATED
COPPER
3865 kg
4325 kg
4215 kg
4675 kg
3935 kg
4395 kg
4285 kg
4745 kg
55ST7
4170 kg
4750 kg
4520 kg
5100 kg
65NS7
4120 kg
4640 kg
4580 kg
5100 kg
66ST9
4505 kg
5085 kg
4965 kg
5545 kg
75MS7
4145 kg
4665 kg
4495 kg
5015 kg
76ST9
4575 kg
5155 kg
5035 kg
5615 kg
77MT7
4250 kg
4830 kg
4580 kg
5160 kg
77XT9
4840 kg
5420 kg
5300 kg
5880 kg
88ST7
4775 kg
4355 kg
5170 kg
5750 kg
98ST9
4845 kg
5425 kg
5305 kg
5885 kg
99ST9
4850 kg
5430 kg
5310 kg
5890 kg
Two Modules/Eight Fans
STANDARD UNITS
Model
HEAT-RECOVERY UNITS
Condenser Fin Material
ALUMINIUM &
PHENOLIC COATED
77SU7
Condenser Fin Material
COPPER
ALUMINIUM &
PHENOLIC COATED
COPPER
6210 kg
7145 kg
7130 kg
8070 kg
87SU7
6230 kg
7165 kg
7275 kg
8205 kg
98AW9
6755 kg
7915 kg
7610 kg
8770 kg
97AU7
6635 kg
7570 kg
7680 kg
8600 kg
98XU7
6795 kg
7730 kg
7955 kg
8890 kg
99AW9
6855 kg
8015 kg
7760 kg
8915 kg
99XU7
6895 kg
7830 kg
8055 kg
8990 kg
99XW9
7045 kg
8635 kg
8205 kg
9390 kg
(10/03)
9-19
035L02203-100 Rev. 5
9.8
Weight Distribution And Isolator Positions
Standard Models (R22/R407C) - Single Module/Four Fans
WITH ALUMINIUM / PHENOLIC COATED
CONDENSER COILS
MODEL
44MR7
55MR7
55ST7
65NS7
66ST9
76ST9
77XT9
WITH COPPER FINNED CONDENSER COILS
MOUNT POSITION
MOUNT POSITION
A
B
C
D
POINT LOAD
1135
1010
980
875
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1160
1045
980
885
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1195
1080
1065
980
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1225
1080
1020
920
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1305
1170
1135
1045
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1340
1180
1160
1045
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1330
1205
1305
1205
MOUNT TYPE
CP-4-28
CP-2-35
CP-4-28
CP-2-35
TOTAL
4000
4070
4320
4245
4655
4725
5045
A
B
C
D
1250
1125
1095
990
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1275
1160
1095
1000
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1340
1225
1210
1125
CP-4-28
CP-2-35
CP-2-35
CP-2-32
1370
1225
1135
1035
CP-4-28
CP-2-35
CP-2-32
CP-2-32
1450
1315
1280
1190
CP-4-28
CP-2-35
CP-2-35
CP-2-32
1485
1325
1305
1190
CP-4-28
CP-2-35
CP-2-35
CP-2-32
1480
1350
1445
1350
CP-4-28
CP-4-28
CP-4-28
CP-4-28
TOTAL
4460
4530
4900
4765
5235
5305
5625
Point Loads are Kg OPERATING WEIGHT.
Standard Models (R134a) - Single Module/Four Fans
WITH ALUMINIUM / PHENOLIC COATED
CONDENSER COILS
MODEL
44MR7
55MR7
75MS7
77MT7
88ST7
98ST9
99ST9
WITH COPPER FINNED CONDENSER COILS
MOUNT POSITION
MOUNT POSITION
A
B
C
D
POINT LOAD
1135
1010
980
875
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1160
1045
980
885
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1240
1080
1015
960
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1235
1130
1050
960
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1400
1265
1175
1085
MOUNT TYPE
CP-4-28
CP-2-35
CP-2-35
CP-2-32
POINT LOAD
1435
1275
1200
1085
MOUNT TYPE
CP-4-28
CP-2-35
CP-2-35
CP-2-32
POINT LOAD
1450
1275
1220
1110
MOUNT TYPE
CP-4-28
CP-2-35
CP-2-35
CP-2-32
TOTAL
4000
4070
4295
4375
4925
4995
5055
A
B
C
D
1250
1125
1095
990
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1275
1160
1095
1000
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1385
1225
1130
1075
CP-2-35
CP-2-35
CP-2-32
CP-2-32
1380
1275
1195
1105
CP-2-35
CP-2-35
CP-2-32
CP-2-32
1545
1410
1320
1230
CP-4-28
CP-4-28
CP-2-35
CP-2-35
1580
1420
1345
1230
CP-4-28
CP-4-28
CP-2-35
CP-2-35
1595
1420
1365
1255
CP-4-28
CP-4-28
CP-2-35
CP-2-35
TOTAL
4460
4530
4815
4955
5505
5575
5635
Point Loads are Kg OPERATING WEIGHT.
Mount Type Nominal Rating Spring colour
CP-2-27
680 kg
Orange
CP-2-28
816 kg
Green
CP-2-31
998 kg
Grey
CP-2-32
1180 kg
White
CP-2-35
1361 kg
Gold
CP-4-28
1633 kg
Green
CP-4-31
1996 kg
Grey
Mount Ratings are Kg NOMINAL.
(10/03)
9-20
035L02203-100 Rev. 5
Heat Recovery Models (R22/R407C) - Single Module/Four Fans
WITH ALUMINIUM / PHENOLIC COATED
CONDENSER COILS
MODEL
44MR7HR
55MR7HR
55ST7HR
65NS7HR
66ST9HR
76ST9HR
77XT9HR
WITH COPPER FINNED CONDENSER COILS
MOUNT POSITION
MOUNT POSITION
A
B
C
D
POINT LOAD
1135
1205
980
1070
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1160
1240
980
1080
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1195
1275
1065
1175
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1225
1340
1020
1180
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1305
1430
1135
1305
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1340
1440
1160
1305
MOUNT TYPE
CP-2-35
CP-4-28
CP-2-32
CP-2-35
POINT LOAD
1330
1465
1305
1465
MOUNT TYPE
CP-4-28
CP-2-35
CP-4-28
CP-2-35
TOTAL
4390
4460
4710
4765
5175
5225
5565
A
B
C
D
1250
1320
1095
1185
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1275
1355
1095
1195
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1340
1420
1210
1320
CP-4-28
CP-2-35
CP-2-35
CP-2-32
1370
1485
1135
1295
CP-4-28
CP-2-35
CP-2-32
CP-2-32
1450
1575
1280
1450
CP-4-28
CP-2-35
CP-2-35
CP-2-32
1485
1385
1305
1450
CP-4-28
CP-2-35
CP-2-35
CP-2-32
1480
1610
1445
1610
CP-4-28
CP-4-28
CP-4-28
CP-4-28
TOTAL
4850
4920
5290
5285
5755
5825
6145
Point Loads are Kg OPERATING WEIGHT.
Heat Recovery Models (R134a) - Single Module/Four Fans
WITH ALUMINIUM / PHENOLIC COATED
CONDENSER COILS
MODEL
44MR7HR
55MR7HR
75MS7HR
77MT7HR
88ST7HR
98ST9HR
99ST9HR
WITH COPPER FINNED CONDENSER COILS
MOUNT POSITION
MOUNT POSITION
A
B
C
D
POINT LOAD
1135
1205
980
1070
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1160
1240
980
1080
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1240
1275
1015
1155
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1235
1325
1050
1155
MOUNT TYPE
CP-2-35
CP-2-32
CP-2-32
CP-2-31
POINT LOAD
1400
1490
1175
1315
MOUNT TYPE
CP-4-28
CP-2-35
CP-2-35
CP-2-32
POINT LOAD
1435
1535
1200
1345
MOUNT TYPE
CP-4-28
CP-2-35
CP-2-35
CP-2-32
POINT LOAD
1450
1535
1220
1370
MOUNT TYPE
CP-4-28
CP-2-35
CP-2-35
CP-2-32
TOTAL
4390
4460
4685
4765
5380
5515
5575
A
B
C
D
1250
1320
1095
1185
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1275
1355
1095
1195
CP-2-35
CP-2-32
CP-2-32
CP-2-32
1385
1420
1130
1270
CP-2-35
CP-2-35
CP-2-32
CP-2-32
1380
1470
1195
1300
CP-2-35
CP-2-35
CP-2-32
CP-2-32
1545
1635
1320
1460
CP-4-28
CP-4-28
CP-2-35
CP-2-35
1580
1680
1345
1490
CP-4-28
CP-4-28
CP-2-35
CP-2-35
1595
1680
1365
1515
CP-4-28
CP-4-28
CP-2-35
CP-2-35
TOTAL
4850
4920
5205
5345
5960
6095
6155
Point Loads are Kg OPERATING WEIGHT.
Mount Type Nominal Rating Spring colour
CP-2-27
680 kg
Orange
CP-2-28
816 kg
Green
CP-2-31
998 kg
Grey
CP-2-32
1180 kg
White
CP-2-35
1361 kg
Gold
CP-4-28
1633 kg
Green
CP-4-31
1996 kg
Grey
Mount Ratings are Kg NOMINAL.
(10/03)
9-21
035L02203-100 Rev. 5
Standard Models (R22/R407C) - Two Modules/Eight Fans
WITH ALUMINIUM / PHENOLIC COATED CONDENSER COILS
MODEL
77SU7
87SU7
97AU7
98XU7
99XU7
99XW9
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
775
788
795
916
715
766
773
832
MOUNT TYPE
CP-2-28
CP-2-31
CP-2-31
CP-2-31
CP-2-28
CP-2-28
CP-2-28
CP-2-31
POINT LOAD
777
788
796
918
716
766
780
836
MOUNT TYPE
CP-2-28
CP-2-31
CP-2-31
CP-2-31
CP-2-28
CP-2-28
CP-2-31
CP-2-31
POINT LOAD
790
807
844
964
778
848
870
910
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
798
815
852
974
805
890
919
947
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
828
846
853
978
820
904
919
952
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
847
865
872
998
838
922
938
970
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-31
CP-2-31
CP-2-32
TOTAL
6360
6377
6811
7000
7100
7250
Point Loads are Kg OPERATING WEIGHT
Standard Models (R22/R407C) - Two Modules/Eight Fans
WITH COPPER FINNED CONDENSER COILS
MODEL
77SU7
87SU7
97AU7
98XU7
99XU7
99XW9
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
892
905
912
1033
832
883
890
949
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
894
905
913
1035
833
883
896
954
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
907
924
961
1081
895
965
987
1027
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
915
932
969
1091
922
1007
1036
1064
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
945
963
970
1095
937
1021
1036
1069
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
996
1014
1021
1147
987
1071
1087
1119
MOUNT TYPE
CP-2-32
CP-2-32
CP-2-32
CP-2-32
CP-2-31
CP-2-32
CP-2-32
CP-2-32
TOTAL
7296
7313
7747
7936
8036
8442
Point Loads are Kg OPERATING WEIGHT.
Mount Type Nominal Rating Spring colour
CP-2-27
680 kg
Orange
CP-2-28
816 kg
Green
CP-2-31
998 kg
Grey
CP-2-32
1180 kg
White
CP-2-35
1361 kg
Gold
CP-4-28
1633 kg
Green
CP-4-31
1996 kg
Grey
Mount Ratings are Kg NOMINAL.
(10/03)
9-22
035L02203-100 Rev. 5
Heat Recovery Models (R22/R407C) - Two Modules/Eight Fans
WITH ALUMINIUM / PHENOLIC COATED CONDENSER COILS
MODEL
77SU7HR
87SU7HR
97AU7HR
98XU7HR
99XU7HR
99XW9HR
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
1295
788
795
916
1235
766
773
832
MOUNT TYPE
CP-2-35
CP-2-31
CP-2-31
CP-2-31
CP-2-35
CP-2-28
CP-2-28
CP-2-31
POINT LOAD
1369
788
796
918
1307
766
780
836
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-31
CP-4-28
CP-2-28
CP-2-31
CP-2-31
POINT LOAD
1379
807
844
964
1368
848
870
910
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
1456
815
852
974
1462
890
919
947
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
1486
846
853
978
1477
904
919
952
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
1505
865
872
998
1495
922
938
970
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-31
CP-2-31
CP-2-32
TOTAL
7400
7560
7990
8315
8415
8565
Point Loads are Kg OPERATING WEIGHT
Heat Recovery Models (R22/R407C) - Two Modules/Eight Fans
WITH COPPER FINNED CONDENSER COILS
MODEL
77SU7HR
87SU7HR
97AU7HR
98XU7HR
99XU7HR
99XW9HR
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
1414
905
912
1033
1354
883
890
949
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
1483
905
913
1035
1421
883
896
954
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
1498
924
961
1081
1487
965
987
1027
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1572
932
969
1091
1579
1007
1036
1064
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1602
963
970
1095
1594
1021
1036
1069
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1651
1014
1021
1147
1640
1071
1087
1119
MOUNT TYPE
CP-4-31
CP-2-32
CP-2-21
CP-2-32
CP-4-31
CP-2-32
CP-2-32
CP-2-32
TOTAL
8340
8490
8930
9250
9350
9750
Point Loads are Kg OPERATING WEIGHT.
Mount Type Nominal Rating Spring colour
CP-2-27
680 kg
Orange
CP-2-28
816 kg
Green
CP-2-31
998 kg
Grey
CP-2-32
1180 kg
White
CP-2-35
1361 kg
Gold
CP-4-28
1633 kg
Green
CP-4-31
1996 kg
Grey
Mount Ratings are Kg NOMINAL.
(10/03)
9-23
035L02203-100 Rev. 5
Standard Models (R134a) - Two Modules/Eight Fans
WITH ALUMINIUM / PHENOLIC COATED CONDENSER COILS
MODEL
98AW9
99AW9
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
821
838
842
968
791
864
868
913
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-28
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
852
869
843
969
806
881
870
915
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-28
CP-2-31
CP-2-31
CP-2-31
TOTAL
6905
7005
Point Loads are Kg OPERATING WEIGHT.
Standard Models (R134a) - Two Modules/Eight Fans
WITH COPPER FINNED CONDENSER COILS
MODEL
98AW9
99AW9
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
966
983
987
1113
936
1009
1013
1058
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
997
1014
988
1114
951
1026
1015
1060
MOUNT TYPE
CP-2-31
CP-2-31
CP-2-31
CP-2-32
CP-2-31
CP-2-32
CP-2-32
CP-2-32
TOTAL
8065
8165
Point Loads are Kg OPERATING WEIGHT.
Mount Type Nominal Rating Spring colour
Heat Recovery Models (R134a) - Two Modules/Eight Fans
CP-2-27
680 kg
Orange
CP-2-28
816 kg
Green
CP-2-31
998 kg
Grey
CP-2-32
1180 kg
White
CP-2-35
1361 kg
Gold
CP-4-28
1633 kg
Green
CP-4-31
1996 kg
Grey
Mount Ratings are Kg NOMINAL.
WITH ALUMINIUM / PHENOLIC COATED CONDENSER COILS
MODEL
98AW9HR
99AW9HR
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
1308
838
842
968
1279
864
868
913
MOUNT TYPE
CP-2-35
CP-2-31
CP-2-31
CP-2-32
CP-2-35
CP-2-31
CP-2-31
CP-2-31
POINT LOAD
1372
869
843
969
1326
881
870
915
MOUNT TYPE
CP-2-35
CP-2-31
CP-2-31
CP-2-32
CP-2-35
CP-2-31
CP-2-31
CP-2-31
TOTAL
7880
8045
Point Loads are Kg OPERATING WEIGHT.
Heat Recovery Models (R134a) - Two Modules/Eight Fans
WITH COPPER FINNED CONDENSER COILS
MODEL
MOUNT POSITION
A
B
C
D
E
F
G
H
POINT LOAD
1453
983
987
1113
1424
1009
1013
1058
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-32
CP-2-32
CP-2-32
POINT LOAD
1517
1014
988
1114
1471
1026
1015
1060
MOUNT TYPE
CP-4-28
CP-2-31
CP-2-31
CP-2-32
CP-4-28
CP-2-32
CP-2-32
CP-2-32
98AW9HR
TOTAL
9040
99AW9HR
9205
Point Loads are Kg OPERATING WEIGHT.
Mount Type Nominal Rating Spring colour
CP-2-27
680 kg
Orange
CP-2-28
816 kg
Green
CP-2-31
998 kg
Grey
CP-2-32
1180 kg
White
CP-2-35
1361 kg
Gold
CP-4-28
1633 kg
Green
CP-4-31
1996 kg
Grey
Mount Ratings are Kg NOMINAL.
(10/03)
-YLLSV
-ECH
-SHP -SHP
-EEH
COMP
S
LIC
-BMP
-SF
-TC
P
-SHP
-YLLSV
-EEH
-ECH
-TC
-BMP
-SF
-SHP
LIQUID LINE S.V.
EVAPORATOR HEATER
BALL VALVE
9.9
DV
LPC
9-24
035L02203-100 Rev. 5
Process and Instrumentation Diagrams
Cooling Circuit
(10/03)
(10/03)
-YLLSV
-YLLHR
-ECDH
-SHP
T
HTC
-SF
-ECH
-SHP -SHP
-YDHRC
-YDCVPR
-EEH
COMP
S
S
HIC
LIC
-BMP
-SF
-TC
P
EVAPORATOR HEATER
CONDENSER HEATER
BALL VALVE
-YLLSV LIQUID LINE S.V.
-YLLHR LIQUID LINE HEAT RECOVERY S.V.
-YDHRC DISCHARGE HEAT RECOVERY COND S.V.
-YDCVPR DISCHARGE TO COIL VIA PRESS REG S.V.
-EEH
-ECH
-TC
-BMP
-SF
-BHTH
-ECDH
-SHP
-SHP
035L02203-100 Rev. 5
9-25
Heat Recovery Circuit
9-26
035L02203-100 Rev. 5
9.10 Component Locations
Standard Models - Single Module/Four Fans
System Components
1
2
BAMB
System 1
CDR
System 2
Ambient
Temperature
Sensor
Oil
Temperature
Sensor
Condenser
CLR
Cooler
-BOT
COMP
Compressor
CP
-ECDH
Heat Recovery Models - Single Module/Four Fans (Additional)
Control Panel
Condenser
Heater
-ECH Crankcase
Heater
-EEH Heater Mat
Cooler
-TEV Thermostatic
Expansion
Valve
-TEVHR Thermostatic
Expansion
Valve Heat
Recovery
-YDCVPR Discharge to
Coil Via Pressure
Regulator Solenoid
Valve
-YDHRC Discharge
Heat Recovery
Condenser
Solenoid Valve
-YLLHR Liquid Line
Heat Recovery
Solenoid Valve
-YLLSV Liquid Line
Solenoid Valve
-YSBSV Starting Bypass
Solenoid Valve
-ZCMTB Compressor Motor
Terminal Box
(10/03)
9-27
035L02203-100 Rev. 5
Standard Models - Two Modules/Eight Fans
System Components
1
2
BAMB
-BOT
CDR
CLR
COMP
System 1
System 2
Ambient
Temperature
Sensor
Oil
Temperature
Sensor
Condenser
Cooler
Compressor
CP
-ECDH
Heat Recovery Models - Two Modules/Eight Fans (Additional)
Control Panel
Condenser
Heater
-ECH Crankcase
Heater
-EEH Heater Mat
Cooler
-TEV Thermostatic
Expansion
Valve
-TEVHR Thermostatic
Expansion
Valve Heat
Recovery
-YDCVPR Discharge to
Coil Via Pressure
Regulator Solenoid
Valve
-YDHRC Discharge
Heat Recovery
Condenser
Solenoid Valve
-YLLHR Liquid Line
Heat Recovery
Solenoid Valve
-YLLSV Liquid Line
Solenoid Valve
-YSBSV Starting Bypass
Solenoid Valve
-ZCMTB Compressor Motor
Terminal Box
(10/03)
9-28
035L02203-100 Rev. 5
Page Left Intentionally Blank
(10/03)
10-1
035L02203-100 Rev. 5
10
SPARE PARTS
10.1 Recommended Spares
It is recommended that the following common spare
parts are held for preventive or corrective maintenance
operations.
Other spare parts vary depending on the product model
number. Contact your local York Service Centre for
information and please quote the Chiller model number
and serial number.
Item
Designation
Part Number
Quantity
Per Panel
Pressure Transducer 200 psi
BSP, BOP
025-29583-000
4
Pressure Transducer 400 psi
BDP
025L01916-000
2
Fuse 10 Amp gG, 38 x 10 mm
F1
025L02428-000
1
Fuse 1 Amp F, 20 x 5 mm
F2
025L02438-000
1
Fuse 2.5 Amp T 20 x 5 mm
F3
025L02439-000
1
Fuse 0,5 Amp aM 38 x 10 mm
F4
025L02434-000
1
Fuse 10 Amp aM, 38 x 10 mm
F14, F15
025L02645-000
2
Sensor, Oil Temperature 3 kΩ
BOT
025L01952-000
2
Sensor, Oil Temperature 10 kΩ*
BOT
025-32966-000*
2
Sensor, Ambient Temperature
BAMB
025L01963-000
1
Sensor, Water Temperature
BLCT
025L02168-000
1
Description
* The 10 KΩ sensor listed, screws directly into
the compressor. For details of the 10 kΩ
sensor that fits into a pocket in the compressor
contact your local York Service Centre.
10.2 Compressor Top Head Rebuild Kit
It is recommended that a top head compressor rebuild is
performed after 5000 hours of compressor operation.
The top head rebuild kit consists of top head and
manifold gaskets, discharge and suction valves and
springs, valve retaining clip and self locking nut and
built-in discharge cage assembly. The tables below
detail the kit part numbers.
All Models
Compressor
Kit Part Number
4 Cylinder PC Compressor
398L00654-001
6 Cylinder PC Compressor
398L00654-002
8 Cylinder PC Compressor
398L00654-003
(10/03)
11-1
11
035L02203-100 Rev. 5
DE-COMMISSIONING, DISMANTLING
AND DISPOSAL
Never release refrigerant to the
atmosphere when emptying the
refrigerating circuits. Suitable retrieval
equipment must be used. If reclaimed
refrigerant cannot be re-used. It must be
returned to the manufacturer.
Never discard used compressor oil, as it
contains refrigerant in solution. Return
used oil to the oil manufacturer.
Unless otherwise indicated, the operations described
below can be performed by any properly trained
maintenance technician.
11.1 General
Isolate all sources of electrical supply to the unit
including any control system supplies switched by the
unit. Ensure that all points of isolation are secured in the
‘OFF’ position. The supply cables may then be
disconnected and removed. For connection points refer
to Section 4.
Remove all refrigerant from each system of the unit into
a suitable container using a refrigerant reclaim or
recovery unit. This refrigerant may then be re-used, if
appropriate, or returned to the manufacturer for
disposal. Under NO circumstances should refrigerant
be vented to atmosphere. Drain the refrigerant oil from
each system into a suitable container and dispose of
according to local laws and regulations governing the
disposal of oily wastes. Any spilt oil should be mopped
up and similarly disposed of.
Isolate the unit heat exchanger(s) from all external water
systems and drain the heat exchanger section(s) of the
system. If no isolation valves are installed it may be
necessary to drain the complete system(s).
If glycol or similar solutions have been
used in the water system(s), or chemical
additives are contained, the solution
MUST be disposed of in a suitable and safe
manner. Under NO circumstances should
any system containing glycol or similar
solutions be drained directly into domestic
waste or natural water systems.
After draining, the water pipework can be disconnected
and removed.
Packaged units can generally be removed in one piece
after disconnection as above. Any fixing down bolts
should be removed and then the unit should be lifted
from position using the points provided and equipment
of adequate lifting capacity.
Reference should be made to Section 4 for unit
installation instructions, Section 9 for unit weights and
Section 3 for handling.
Units which cannot be removed in one piece after
disconnection as above must be dismantled in position.
Special care should be taken regarding the weight and
handling of each component. Where possible units
should be dismantled in the reverse order of installation.
Residual refrigerant oil and glycol or
similar solutions may remain in some
parts of the system. These should be
mopped up and disposed of as described
above.
It is important to ensure that whilst components are
being removed the remaining parts are supported in a
safe manner.
Only use lifting equipment of adequate
capacity.
After removal from position the unit parts may be
disposed of according to local laws and regulations.
(10/03)
Italy
YORK International
20051 Limbiate (Milan)
Via Manara 2
Italia
Tel: ++39/0299450.1
Fax: ++39/0299450.860
YORK International ZAO
Alexeevskaya St. 26, Office
208
N. Novgorod,
CIS
Tel/Fax: ++7 8312/35 19 03
Roca/YORK
Av. Valdelaparra 47
28100 Alcobendas
Madrid
Spain
Tel: ++34 916 624 101
Fax: ++34 91 662 41 57
Serbia
YORK International
Representation Office
92 Maulenov Str. office 329,327
KZ-480012 Almaty
Kazakhstan
Tel: ++732 72/ 62 97 77
Fax: ++732 72/ 63 37 19
YORK International
YU Business Center
Bulevar Lenjina 10/D/I/127
YU-11070 Belgrade
Serbia
Tel: ++381 11 311 41 43
++381 11 311 91 19
Fax: ++381 11 137 694
Roca/YORK
Juventud 8
Parque Ind. PISA
41927 Mairena de Aljarafe
Seville
Spain
Tel: ++34 954 183 012
Fax: ++34 95 418 30 68
Latvia
Slovak Republic
YORK Latvia
YORK International S.I.A.
Krustpils iela 1
LV-1073 Riga
Latvia
Tel: ++371/7113068
Fax: ++371/7113067
YORK Slovensko
YORK International spol.sr.o.
Pekna cesta 6b
SK-83105 Bratislava
Slovak Republic
Tel/Fax: ++421/7/44880952,
0953, 0954, 0955
Roca/YORK
Senyera s/n
Pol. Ind. Mediterráneo Parc 28 Nave 3
46560 Massalfassar
Valencia
Spain
Tel: ++34 961 400 711
Fax: ++34 96 140 22 53
Lithuania
South Africa
Switzerland
YORK International GmbH
Representation Office
Fabijoniskiu 96
2029 Vilnius/Lithuania
Tel: ++3702 - 388337,
388339
Fax: ++3702 388112
YORK International
Johannesburg Head Office.
60 B Electron Ave.
Isando. 1600
Johannesburg
Tel: +27 11 921 7100
Fax: +27 11 921 7200
Nederland
Supremeair (YORK Service)
th
'43 11 Rd.
Kew
Johannesburg
Tel: +27 11 786 0868
Fax: +27 11 786 0876
Kazakhstan
YORK International
Tinstraat 15
Postbus 3453
4800 DL Breda
Nederland
Tel: ++31 765486800
Fax: ++31 765421800
Poland
YORK Polska
YORK INT. Sp.z.o.o.
Al. Slowianska 10
PL-01-695 Warszawa
Poland
Tel: ++4822/83 22 220
Fax: ++4822/8330303
Portugal
Roca/YORK
Estrada Outeiro de Polima
Lote 9 3 A/D
Abübada Cascais
2785 518,
S. Domingos de Rana
Portugal
Tel: ++351 21 445 0601
Fax: ++351 21 445 0598
Romania
YORK Romania
YORK International S.R.L.
6 Londra St.
1 District
RO-712171 Bucharest
Romania
Tel: ++401/2304516/2315319
2315320/2315321
Fax: ++401/2304406
Russia
YORK International ZAO
Poklonnaya, 14a
CIS-121170 Moscow
Russia
Tel: ++7095/232-2075
Fax: ++7095/232-6661
YORK International ZAO
28 Zagorodny prospect
CIS-191002
St. Petersburg
Russia
Tel: ++7812/325 4700
Fax: ++7812/325 4701
YORK International
35 Haulage Rd.
Carletonville 2500
Tel: +27 18 786 1062/3
Fax: +27 18 787 3213
YORK International
2 Cassiafield Grove
Springfield Park 4091
Durban
Tel: +27 31 579 4646
Fax: +27 31 579 1030
YORK International
5 Stepmar Building
27 Stells Rd.
Montague Gardens 7441
Cape Town
Tel: +27 21 551 3012
Fax: +27 21 551 4176
Supremair (YORK Service)
9 Henri van Rooijen St.
Eastend 9300
Bloemfontein
Tel: +27 51 432 7828
Fax: +27 51 432 2450
YORK International
118D Constantia St.
Welkom 9459
Tel: +27 57 352 3240
Fax: +27 57 352 8982
Spain
Roca/YORK
Industria 94-96
08908 Hospitalet de Llobregat
Barcelona
Spain
Tel: ++34 93 422 90 90
Fax: ++34 93 332 16 14
Roca/YORK
Hurtado de Amézaga 20, 4°
48008 Bilbao
Spain
Tel: ++34 944 162 833
Fax: ++34 94 415 49 69
YORK International
Grindelstrasse 19
CH-8303 Bassersdorf
Switzerland
Tel: ++41/1/83844-11
Fax: ++41/1/8369780
YORK International
4, Chemin des I'Esparcette
CH-1023 Crissier
Switzerland
Tel: ++41/21/6328011
Fax: ++41/21/6328013
Ukraine
YORK Ukraine
YORK International GmbH
36, Degterevskaya street
floor 7, room 723-725
Kiev/Ukraine
Tel: ++38044/219 32 89,
461 91 77, 211 09 91
Fax: ++38044/213 36 95
United Kingdom
York International
72 Buckingham Avenue
Slough
Berkshire
SL1 4PN
England
Tel: ++44 (0) 1753 693919
Fax: ++44 (0) 1753 692405
York International
14-16 St Martins Avenue
Fieldhead Business Centre
Bradford
BD7 1LG
England
Tel: ++44 (0) 1274 765300
Fax: ++44 (0) 1274 765301
York International
Unit 4
Zealley Estate
Greenhill Way
Kingsteignton
Newton Abbott
Devon
TQ12 3TD
England
Tel: ++44 (0) 1626 333734
Fax: ++44 (0) 1626 335220
York International
Gardiners Lane South
Basildon
Essex
SS14 3HE
England
Tel: ++44 (0) 1268 246000
Fax: ++44 (0) 1268 246001
York International
Unit 10
Hadrians Court
Seventh Avenue
Team Valley Trading Estate
Gateshead
Tyne & Wear NE11 0XW
England
Tel: ++44 (0) 191 491 0598
Fax: ++44 (0) 191 482 6167
York International
1 Donaldson Crescent,
Southbank Business Park
Kirkintillock
Glasgow
G66 1XF
Scotland
Tel: ++44 (0) 141 776 7576
Fax: ++44 (0) 141 777 7425
York International
Unit 1
Western Access
Guinness Road
Trafford Park
Manchester M17 1SY
England
Tel: ++44 (0) 161 848 0202
Fax: ++44 (0) 161 848 7196
York International
Unit 25
Portsmouth Enterprise Centre
Quartremaine Road
The Airport
Portsmouth
PO3 5QT
England
Tel: ++44 (0) 2392 650149
Fax: ++44 (0) 2392 650225
York International
Arden House
Marsh Lane
Hampton-In-Arden
Solihull
West Midlands
B92 0AJ
England
Tel: ++44 (0) 1675 443341
Fax: ++44 (0) 1675 442402
York International
Unit 17
Garanor Way
Royal Portbury
Bristol
BS920 7XE
England
Tel: ++44 (0) 1275 375713
Fax: ++44 (0) 1275 375714
Uzbekistan
York International
Unit 5
Swift Business Centre
Keen Road
Cardiff
CF1 5JR
Wales
Tel: ++44 292 0470619
Fax: ++44 292 0470624
European Parts Organisation
YORK International
Representation Office
C4, Place 35
UZ - 700017 Tashkent
Uzbekistan
Tel: ++998 71 137 5770
++998 71 137 5062
Fax: ++998 71 137 5055
Gardiners Lane South
Basildon
Essex
SS14 3HE
England
Tel: ++44 (0) 1268 246000
Fax: ++44 (0) 1268 246426
YORK Service and Parts Contact
Addresses
Austria
YORK Austria
Central & Eastern Europe Headquarters
Zetschegasse 3
A 1232 Wien
Austria
Tel: ++43 1 66 136 195
Fax: ++43 1 66 136 86
Azerbaijan
YORK International AO
90 M. Mansurov Str.
AZ-370004 Baku
Republic of Azerbaijan
Tel.: ++99 412/ 97 10 35
Fax: ++99 412/ 97 10 36
Belarus
YORK International AO
Leningradskaya str, 18
Minsk
Belarus
Tel/Fax: ++375/172/06 63 80
Tel/Fax: ++375/172/10 43 35
Belgium
YORK International
Prins Boudewijnlaan 1
2550 Kontich
Belgium
Tel: ++32 34510600
Fax:++32 34582444
Bulgaria
YORK Bulgaria
YORK International EOOD
10, Marko Balabanov Str.
BG-1303 Sofia
Bulgaria
Tel: ++3592/9803040,
9815780, 9817578
Fax: ++3592/9818386
Croatia
YORK International
Vrlicka 24
HR-10000 Zagreb
Croatia
Tel.: ++385/1/3843 444
++385/1/3843 851
++385/1/3840 352
Fax: ++385/1/3840 398
Czech Republic
YORK Ceska Republika
YORK International spol. sr.o.
Edisonova 27
CZ-10900 Praha 10 -Petrovice
Tel: ++420/2/721 21 111
Fax: ++420/2/721 21 100
France
YORK International
Innolac n°7
Rue du Professeur G.Jeanneney
33300 Bordeaux
France
Tel: ++33 5.57.19.06.30
Fax: ++33 5.56.69.04.96
YORK International
14 rue de Bel Air
B.P.309
44473 Carquefou Cedex
France
Tel: ++33 2.40.30.62.93
Fax: ++33 2.40.30.22.66
YORK International
114-126 Avenue d'Alfortville
94607 Choisy-le-Roi Cedex
France
Tel: ++33 1.45.12.10.30
Fax: ++33 1.48.52.59.34
YORK International
Widdersdorfer Straße 215
50825 Köln
Germany
Tel: ++49/221/498750
Fax: ++49/221/4987539
YORK International
31 rue Wilson
69150 Decines- Charpieu
France
Tel: ++33 4.72.02.62.50
Fax: ++33 4.72.05.30.01
YORK International
6 Bis rue Chalutier-La-Tanche
56100 Lorient
France
Tel: ++33 3.20.87.61.62
Fax: ++33 2.97.83.83.80
YORK International
Rue de la Longuerais
ZA des Landelles
35520 Melesse
France
Tel: ++33 2.99.66.01.87
Fax: ++33 2.99.66.92.73
YORK International
15 rue des Combattants d'Extrême Orient
13700 Marignane
France
Tel: ++33 4.42.77.04.60
Fax: ++33 4.42.15.08.99
YORK International
78 Avenue de Laon
02200 Soissons
France
Tel: ++33 3.23.59.65.55
Fax: ++33 3.23.59.65.56
YORK International
Gottlieb-Daimler-Strasse 6
68165 Mannheim
Germany
Tel: ++49/621/468-532
Fax: ++49/621/468-680
YORK International
Rue A.Fruchard - Z.I. Jean Prouvé
54320 Maxeville
France
Tel: ++33 3.83.32.49.83
Fax: ++33 3.83.32.43.16
YORK International
8 rue de l'Artisanat
67120 Dupigheim
France
Tel: ++33 3.88.48.22.50
Fax: ++33 3.88.48.22.51
YORK International
Geisenhausener Straße 6
81379 München
Germany
Tel: ++49/89/78048
Fax: ++49/89/7804844
YORK International
14 rue de Constantine
62200 Boulogne Sur-Mer
France
Tel: ++33 3.21.83.17.70
Fax: ++33 3.21.83.11.02
YORK International
Z.A. du Prieuré
37530 Poce Sur Cisse
France
Tel: ++33 2.47.23.29.23
Fax: ++33 2.47.23.25.50
YORK International
Edisonstraße 60
90431 Nürnberg
Germany
Tel: ++49/911/961750
Fax: ++49/911/9617544
YORK International
102 Bd de Strasbourg
49300 Cholet
France
Tel: ++33 2.41.29.13.73
Fax: ++33 2.41.29.13.80
YORK International
Avenue Lavoisier
Z.I. de Villemilan
91320 Wissous
France
Tel: ++33 1.60.11.88.76
Fax: ++33 1.60.11.90.16
YORK International
Mainzer Straße 29
66111 Saarbrücken
Germany
Tel: ++49/681/67494
Fax: ++49/681/66243
YORK International
3 rue du Moros
29900 Concarneau
France
Tel: ++33 2.98.60.52.10
Fax: ++33 2.98.60.52.11
YORK International
Parc du Talou - 7 rue A.Legras
76200 Dieppe
France
Tel: ++33 2.32.14.41.50
Fax: ++33 2.32.14.41.51
YORK International
44 rue Gambetta
17260 Gemozac
France
Tel: ++33 5.46.95.87.80
Fax: ++33 5.46.94.56.41
YORK International
Z.I. du Vern
29230 Landivisiau
France
Tel: ++33 2.98.68.21.52
Fax: ++33 2.98.68.90.91
YORK International
4 rue du Grand Fief
85150 Vaire
France
Tel: ++33 2.51.33.70.83
Fax: ++33 2.51.33.70.85
Germany
YORK International
Paradiesstraße 210
12526 Berlin
Germany
Tel: ++49/30/6797190
Fax: ++49/30/67971944
YORK International
Hafenstraße 100
45356 Essen
Germany
Tel: ++49/201/364000
Fax: ++49/201/3640041
YORK International
Fuggerstraße 1
04158 Leipzig - Wiederitzsch
Germany
Tel: ++49/341/566630
Fax: ++49/341/5666333
YORK International
Fabrikstraße 17
70794 Filderstadt
Germany
Tel: ++49/711/7709422
Fax: ++49/711/7709433
Greece
YORK International
62 , Kifisias Ave
zip code: 115 26
Athens - Greece
Tel: ++301- 69 11 888
Fax:++301- 69 10 764
Hungary
YORK International
Wächtersbacher Straße 83
60386 Frankfurt
Germany
Tel: ++49/69/941402-0
Fax: ++49/69/94140244
YORK International
Sperberhorst 8
22459 Hamburg
Germany
Tel: ++49/40/5714410
Fax: ++49/40/57144133
YORK International
Alter Flughafen 18a
30179 Hannover
Germany
Tel: ++49/511/678040
Fax: ++49/511/6780433
YORK International
Leipziger Straße 35-37
34125 Kassel
Germany
Tel: ++49/561/507210
Fax: ++49/561/5072122
YORK Magyaroszag
YORK International Kft.
Váci út 206
H-1138 Budapest
Hungary
Tel: ++361/4657060
Fax: ++361/4657069
Ireland
YORK ACR Ltd
Unit 2004/3
City West Business Campus
Naas Road
Dublin 22
Ireland
Tel: ++ 353 1466 0177
Fax: ++ 353 1466 0198
York International
Unit 19
Sarsfield Road
University Hale Industrial Estate
Wilton
Cork
Ireland
Tel: ++353 2 134 6580
Europe
YORK
YORK INTERNATIONAL
Gardiners Lane South, Basildon, Essex SS14 3HE, England
Part No. 035L02203-100 Rev. 5 (10/03)
GB
Subject to change without notice. ALL RIGHTS RESERVED