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YAEP

HIGH AMBIENT
AIR COOLED LIQUID CHILLER

INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE

STYLE A
REFRIGERANT TYPE: R22, R407C
MODELS: 50 Hz

SOFTWARE:
2 Refrigerant Circuit Models - V4-2 REV 7 and V4C-2 REV 7 and Higher
4 Refrigerant Circuit Models - V4-4 REV 7 and V4C-4 REV 7 and Higher

EMEA 035L02537-100 Rev. 0

YORK
(02/04) GB
035L02537-100 Rev. 0 I-i

Table of Contents

1 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 1.2 4.4 Pipework Connection 4.2

1.5 About this Manual 1.2 4.5 Water Treatment 4.3

1.6 Misuse of Equipment 1.2 4.6 Pipework Arrangement 4.4

1.7 Emergency Shutdown 1.3 4.7 Connection Types & Sizes 4.4

1.8 Safety Labels 1.4 4.8 Refrigerant Relief Valve Piping 4.5

1.9 Material Safety Data 1.5 4.9 Ductwork Connection 4.5

4.10 Electrical Connection 4.6


2 PRODUCT DESCRIPTION
4.11 Power Wiring 4.6
2.1 Introduction 2.1
4.12 Control Section - Output Signals 4.7
2.2 Compressors 2.2
4.13 Control Section - Input Connections 4.8
2.3 Cooler(s) 2.2

2.4 Air Cooled Condensers 2.2 5 COMMISSIONING

2.5 Refrigerant Circuits 2.2 5.1 Preparation 5.1

2.6 Power and Control Panels 2.2 5.2 First Time Start-up 5.3

2.7 Options and Accessories 2.3 6 UNIT OPERATION


2.8 Functional Description 2.5
6.1 General Description 6.1
2.9 Nomenclature 2.6
6.2 Start-up 6.1
3 TRANSPORTATION, HANDLING 6.3 Normal Running and Cycling 6.1
AND STORAGE
6.4 Compressor Capacity Control 6.2
3.1 Delivery and Storage 3.1
6.5 Discharge Pressure Fan Control 6.2
3.2 Inspection on Arrival at Site 3.1
6.6 Shutdown 6.2
3.3 Moving the Chiller 3.1

3.4 Lifting Weights 3.2

3.5 Shipping Protection 3.2

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7 MAINTENANCE 10 SPARE PARTS

7.1 General Requirements 7.1 10.1 Recommended Spares 10.1

7.2 Daily Maintenance 7.1 10.2 Compressor Top Head Rebuild Kit 10.2

7.3 Scheduled Maintenance 7.2 10.3 Associated Drawings 10.2

7.4 Vessels In-Service Inspection 7.2


11 DE-COMMISSIONING, DISMANTLING
AND DISPOSAL
8 TROUBLE SHOOTING
11.1 General 11.1
8.1 Competent Persons Trouble
Shooting Guide 8.1

8.2 Compressor Components 8.3

8.3 Sensor Calibration Charts 8.4

9 TECHNICAL DATA

9.1 Flow Rate/Pressure Drop Charts 9.1

9.2 Operating Limitations 9.1

9.3 Physical Data - R22 Models 9.2

9.4 Physical Data - R407C Models 9.3

9.5 Electrical Data - R22 Models 9.4

9.6 Electrical Data - R407C Models 9.4

9.7 Control Circuit Electrical Data 9.5

9.8 Compressor Electrical Data -


R22 Models 9.5

9.9 Compressor Electrical Data -


R407C Models 9.5

9.10 Fan Data 9.5

9.11 Fuse Ratings and Lug Sizes 9.6

9.12 Clearances 9.7

9.13Dimensions9.8

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035L02537-100 Rev. 0 1- 1

1 SUPPLIER INFORMATION

1.1 Introduction

High ambient YAEP models will be built to good The unit warranty will be void if any modification to the
engineering practices and are completely assembled unit is carried out without prior written approval from
with all interconnecting refrigerant piping and internal York International.
wiring, ready for field installation. Four circuit units are
shipped in two sections and require the installation of a For warranty purposes, the following conditions must be
two wire communication link between control panels satisfied:
and a mixed leaving liquid temperature sensor.
The initial start of the unit must be carried out by trained
The YAEP range of chillers are designed for water personnel from an Authorised York Service Centre.
chilling. All units are designed to be located outside on
the roof of a building or at ground level and are not Only genuine York approved spare parts, oils and
suitable for purposes other than those specified in this refrigerants must be used. To obtain York spare parts
manual. contact your local York office. Details of York offices are
given on the rear cover of this manual
This manual and the Operating Instructions for the micro
based control system contain all the information All the scheduled maintenance operations detailed in
required for correct installation and commissioning of this manual must be performed at the specified times by
the unit, together with operating and maintenance suitably trained and qualified personnel.
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 1.3 Safety
must only be performed by suitably trained and qualified
personnel. Standards for Safety

The manufacturer will not be liable for any injury or YAEP units are designed and built within an EN ISO
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 , 9 0 0 1 a c c r e d i t e d d e s i g n a n d m a nu fa c t u r i n g
commissioning, operation or maintenance resulting organisation.
from a failure to follow the procedures and instructions
detailed in the manuals. All data in this manual is subject Units will conform to the applicable essential safety
to change without notice. requirements of Pressure Equipment Directive
97/23/EC and bear CE marking and are in conformity
1.2 Warranty with the essential health and safety requirements of the
following European Union Directives:
York International Limited warrants all equipment and
materials against defects in workmanship and materials Machinery Directive (89/392/EEC)
for a period of one year from initial start-up, or eighteen
Low Voltage Directive (73/23/EEC)
months from delivery (whichever occurs first) unless
extended warranty has been agreed as part of the EMC Directive (89/336/EEC)
contract.
unless otherwise stated for certain options.
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.

All warranty claims must specify the unit model, serial


number and order number. These details are printed on
the unit identification plate.

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1- 2 035L02537-100 Rev. 0

1.4 Responsibility for Safety 1.6 Misuse of Equipment

Every care has been taken in the design and Suitability for Application
manufacture of York Chillers to ensure that they meet
the safety requirements listed in the previous paragraph. The unit is intended for cooling water and is not suitable
However, the individual operating or working on any for purposes other than those specified in these
machinery is primarily responsible for: instructions. Any use of the equipment other than its
intended use, or operation of the equipment contrary to
Personal safety, safety of other personnel, and the the relevant procedures may result in injury to the
machinery operator, or damage to the equipment.

Correct utilisation of the machinery in accordance with The unit must not be operated outside the design
the procedures detailed in this manual. parameters specified in this manual.

1.5 About this Manual Structural Support

The following symbols are used in this document to alert Structural support of the unit must be provided as
the reader to areas of potential hazard. indicated in these instructions. Failure to provide proper
support may result in injury to the operator, or damage to
A Warning is given in this document to the equipment.
identify a hazard which could lead to
personal injury. Usually an instruction will Mechanical Strength
be given, together with a brief explanation
and the possible result of ignoring the The unit is not designed to withstand loads or stresses
instruction. from adjacent equipment, pipework or structures.
Additional components must not be mounted on the unit.
A Caution identifies a hazard which could Any such extraneous loads may cause structural failure
lead to damage to the machine, damage to and may result in injury to the operator, or damage to the
other equipment and/or environmental equipment. The unit should only be lifted in accordance
pollution. Usually an instruction will be given, with the instructions given in Section 3 of this manual.
together with a brief explanation and the
possible result of ignoring the instruction. General Access

A Note is used to highlight additional There are a number of areas and features which may be
information which may be helpful to you but a hazard and potentially cause injury when working with
where there are no safety implications. 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
The contents of this manual include suggested best operation and maintenance of equipment containing
working practices and procedures. These are issued for high and low temperatures, pressures and voltages.
guidance only, they do not take precedence over the
above stated individual responsibility and/or local safety Pressure Systems
regulations.
Each unit has two, three or four independent pressure
This manual and any other document supplied with the systems comprising the compressor, air cooled
unit, are the property of YORK which reserves all rights. condenser coils, cooler vessel and interconnecting
They may not be reproduced, in whole or in part, without copper pipework. Each system contains refrigerant
prior written authorisation from an authorised YORK vapour and liquid under pressure, release of which can
representative. 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.

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035L02537-100 Rev. 0 1- 3

Electrical 1.7 Emergency Shutdown

The unit must be ear thed. No installation or In case of emergency the control panel is fitted with an
maintenance work should be attempted on electrical emergency stop switch which, when operated, removes
equipment without first switching off, isolating and the electrical supply from the control system and the
locking-off the main power supply and any control microprocessor controller. A facility is available to
supplies. Work on live equipment must only be connect a remote emergency stop device for the same
carried-out by suitably trained and qualified personnel. purpose. The emergency stop switch can be pad-locked
No attempt should be made to gain access to internals in the off position.
of the control panel, wiring or other electrical enclosures
during normal operation of the unit.

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 PULL TO


PAD-LOCK
The finning on the air cooled condenser coils has sharp
metal edges. Reasonable care should be taken when Four circuit units have a main panel and a auxiliary
working in contact with the coils to avoid the risk of minor panel. In case of emergency each panel, main and
abrasions and lacerations. The use of gloves is auxiliary has its own emergency stop switch which can
recommended. be identified as red in colour and sited on a yellow
back-plate. Both emergency stop switches can be
Refrigerants and Oils pad-locked in the off position.

Refrigerants and oils used in the unit are generally The device on the main panel when operated, stops
non-toxic, non-flammable and non-corrosive, and pose systems 1 and 2 only.
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 A facility is available in the main panel to connect a
which may cause corrosion should also be avoided. remote emergency stop device to stop systems 1 and 2.

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The device on the auxiliary panel when operated, stops Black symbol on yellow
systems 3 and 4 only. 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
A facility is available in the auxiliary panel to connect a
remote emergency stop device to stop systems 3 and 4.

1.8 Safety Labels Black symbol on yellow


background
The following labels are fixed to each unit to give
instruction, or to indicate potential hazards which may General attention symbol
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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035L02537-100 Rev. 0 1- 5

1.9 Material Safety Data

Refrigerant Data:

Safety Data R22 R407C

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 R407C High atmospheric


initially produce stimulation and then concentrations may lead anaesthetic
depression of the central nervous effect, including loss of consciousness.
system causing headaches and Very high exposures may cause an
g i d d i n e s s a n d m a y le a d t o abnormal heart rhythm and prove
unconsciousness. Can prove suddenly suddenly fatal.
fatal if the exposure has been severe.

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 R407C A lifetime inhalation study in rats
and mice give a small excess in salivary has shown that exposure to 50,000 ppm
gland tumours in male rats only at resulted in benign tumours of the testis.
50,000 ppm. 10,000 ppm showed no This is not considered to be of relevance
effect. This information suggests that to humans exposed to concentrations at
R22 does not represent a carcinogenic or below the occupational exposure
hazard to humans. limit.

O c c u p a t i o n a l e x p o s u r e R22 Recommended limit : 1000 ppm R407C Recommended limit: 1000 ppm
limits v/v - 8 hr TWA 1250 ppm v/v - 12 hr v/v - 8 hr TWA.
TWA.

Stability R22 Unstable. R407C Not specified.

Conditions to avoid Use in presence of naked flames, red hot surfaces and high moisture levels.

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.

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Hazardous decomposition R22 Halogen acids formed by thermal R407C Halogen acids by thermal
products decomposition. decomposition and hydrolysis.

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 R407C Non-flammable at atmospheric


conditions.

Containers Fire exposed containers should be kept cool with water sprays. Containers may
burst if overheated.

Fire fighting protective Self contained breathing apparatus and protective clothing must be worn in fire
equipment 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 Flush eyes with eyewash solution or
plenty of eyewash solution or clean clean water for 15 minutes and consult a
water. physician.

Ingested Non-toxic. No first aid considered May cause nausea and diahorrhea.
necessary. Obtain immediate medical attention.

Inhalation If oil mist is inhaled, remove to fresh air and consult a physician.

O c c u p a t i o n a l e x p o s u r e Recommended limit : 5 mg/cubic metre Not determined.


limits of oil mist in air for 8 hr daily exposure.

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035L02537-100 Rev. 0 1- 7

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 Not fully. Analogous compounds evolve
ketones, combustion products of carbon monoxide, carbon dioxide and
nitrogen, sulphur. 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 Goggles or face shield should be worn.
shield recommended. 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 Flash point over 300°C. Use dry
spray, dry chemical, carbon dioxide or chemical, carbon dioxide or foam.
alcohol foam. Water or foam may cause Spraying water on hot or burning liquid,
frothing. may cause frothing or splashing.

If a leak or spill has not ignited use water spray to disperse the vapours and to
provide protection for persons attempting to stop the leak.

Containers Fire exposed containers should be kept cool with water sprays.

Fire fighting protective Self contained breathing apparatus should be worn in fire conditions.
equipment

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.

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Page Left Intentionally Blank

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035L02537-100 Rev. 0 2- 1

2 PRODUCT DESCRIPTION

2.1 Introduction All models are designed to be located outside on the


roof of a building or at ground level. All models are
York YAEP high ambient air cooled liquid chillers are delivered completely assembled with all interconnecting
designed for water cooling. Units are available with one, refrigerant piping and internal wiring, ready for field
two or four refrigerant circuits. installation.

One and two refrigerant circuit units have one and two Prior to delivery each unit is pressure tested, evacuated
compressors and a cooler mounted on a single base and fully charged with refrigerant, and includes an initial
with a single power and control panel mounted at the oil charge. After assembly a full run test is performed
end of the unit. with water flowing through the cooler to verify that each
refrigeration circuit operates correctly.
Four refrigerant circuit units are constructed in two
sections each having two compressors and a cooler. The unit base and framework are fabricated using
Four circuit units have a main power and control panel heavy-gauge galvanised steel which is zinc phosphate
mounted at one end of the unit and an auxiliary power pre-treated and powder coated to minimise corrosion.
and control panel mounted at the other end of the unit.

Four circuit units require the installation of a two wire


communication link between control panels and a mixed
leaving liquid temperature sensor.

Scrap view of unit


with optional Acoustic Enclosure
and optional Sun Shield kit fitted
6

3
4

KEY
1 Condenser Fan 5 Compressor
2 Condenser 6 Power and Control Panel
3 Cooler (with optional Sun Shield Kit fitted)
4 Filter Drier

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2- 2 035L02537-100 Rev. 0

2.2 Compressors 2.4 Air Cooled Condensers

Each unit is fitted with one, two or four semi-hermetic, Coils


reciprocating compressors. The compressor motors are
refrigerant gas cooled, with integral temperature The condenser coils are manufactured from seamless
sensing solid state overload protection in each phase. copper tubes arranged in staggered rows, mechanically
The motor terminal boxes are manufactured to prevent expanded into fins. Integral subcooling is included.
ingress of dust and water to IP54. Starting is by
part-winding. Fans

Compressor Housing The condenser fans are U.V. stable polypropylene, high
efficiency, airfoil-type fan blades directly driven by
The compressor housing is cast iron. It contains: independent motors, and positioned for vertical air
removable cylinder heads with internal muffling, discharge. The fan guards are constructed of
discharge service valve, optional suction service valve heavy-gauge wire hot dipped galvanized coated steel.
(when ordered), crankcase sight glass and heater, oil After construction the fan deck and cowl are hot dipped
and suction strainers, and internal relief valve galvanized prior to assembly. (Colour co-ordinated paint
conforming to ASHRAE/ANSI Standard 15 Safety finish is available as an extra). All blades are
Code. dynamically and statically balanced for vibration-free
operation.
Compressor Lubrication
The fan motors are fully enclosed. The motor bearings
The lubrication is force-fed by a reversible oil pump are double sealed and are permanently lubricated.
which supplies oil to all crankshaft and bearing surfaces
through a fine mesh stainless steel filter. 2.5 Refrigerant Circuits

Capacity Control Unit piping is ACR copper with brazed joints. The liquid
line includes: a shut off valve with charging port,
Capacity control is provided by solenoid-actuated sightglass with moisture-indicator, thermal expansion
capacity control valves, controlled by the Micro Based valve (direct acting, max-operating pressure), solenoid
Control System. valve, and filter drier. The entire suction line, the liquid
line between the expansion valve and the cooler, are
2.3 Cooler(s) insulated with flexible, closed-cell, foam insulation.

The single/multi-circuit cooler is the direct- expansion Compressor low, high and oil pressure transducers plus
type, with the refrigerant in the tubes and chilled liquid manual high pressure cut-outs are located on the
flowing through the baffled shell. compressor and system pipework. Transducers and
cut-outs have Econoseal all weather electrical
The design working pressure of the shell is 10.3 bar g, connections.
and 16.2 bar g for the tube side. The refrigerant side is
constructed and tested in accordance with CE/PED 2.6 Power and Control Panels
pressure vessel code requirements. ASME pressure
vessels are available on two and four refrigerant circuit All controls and motor starting equipment necessary for
models. full unit operation are factory wired and function tested.
Components are mounted on galvanised steel back
The water baffles are constructed of galvanised steel to plates, and enclosed in the relevant power, common
resist corrosion. The removable heads allow access to input or control sections of the galvanised steel
the internally enhanced, seamless, copper tubes. Vent enclosure. Separate doors are provided for each
and drain connections are included. Standard cooler section. All doors are hinged, lockable with door stays
connections are Victaulic nozzles. and are designed to IP55 weather protection. Enclosure
and doors are finished in zinc phosphate pre-treated
The cooler is covered with 19mm flexible, closed-cell, baked enamel coloured Desert Sand.
UV stable, colour co-ordinated foam insulation. Each
circuit is protected by a relief valve. Four circuit units have a main and auxiliary power and
control panel mounted at each end of the unit.

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035L02537-100 Rev. 0 2- 3

Each Power Section Contains: Partwind compressor 2.7 Options and Accessories
starting contactors, system fuses, fan contactors, fan
manual motor starters and control interface relays (CE Single Point Power Supply Option - Per Panel
Compliant). Customer single point power supply connection to
factory fitted terminal block. Internal wiring to fuses in
The Common Input Section Contains: Non-fused each power section (Not CE Compliant).
disconnect switch for customer single point power
supply connection. Transformer and wiring to allow Multi Point Power Supply Terminal Block Option -
control voltage to be internally derived (CE Compliant). Per Circuit
Customer supply connection to terminal block in power
The Control Section Contains: microprocessor board, section. A separate control supply is required to the
power supply board and relay board. The relay board control circuit switch disconnect (Not CE Compliant).
contains the control circuit serving compressor
solenoids, crankcase heaters and compressor and fan Multi Point Power Supply Fuse Block Option - Per
contactor coils. Circuit
Customer supply connection to terminal block in power
Controls section. A separate control supply is required to the
The microprocessor based control system is capable of control circuit switch disconnect (Not CE Compliant).
multi-circuit control to maintain chilled liquid
temperature. Cable Spreader Box
To separate cores of large multi-core cable before
Compressor starting/stopping and loading/ unloading connection to non-fused disconnect switch/terminal
decisions are performed by the microprocessor to block when Single Point Power Supply is specified.
maintain leaving water temperature.
Multi-unit Sequence Control
These decisions are a function of temperature deviation A separate sequencing control centre to manage
from setpoint and rate of change of temperature. sequencing control of up to eight chillers in parallel
based on mixed leaving liquid temperature (mounting
The 40 character display (2 lines of 20 characters) and interconnection/wiring by others). (Cannot be fitted
allows the operator to display system operating when a (BAS) Interface is fitted). See separate York
parameters as well as access programmed information documentation.
already in memory.
Building Automation System (BAS) / Energy
The keypad is provided for programming and accessing Management System (EMS) Interface
setpoints, pressures, temperatures, motor current, Provides a means to reset the leaving chilled liquid
cut-outs, daily schedule, options and fault information. temperature from a BAS/EMS.

Remote cycling, unloading and chilled water Consists of a factory mounted PCB to accept 4 to 20 mA,
temperature reset can be accomplished by voltage free 0 to 10 Vdc, or dry contact closure input from the
customer contacts. BAS/EMS. (Cannot be fitted when a Multi-unit
Sequence Control is fitted).

Micro Gateway
Interface to enable communication with building control
systems using BACnet and MODBUS protocols. See
separate York documentation.

York Talk Translator


Provides central communication with third party BMS for
monitoring and control of all chillers in the system. See
separate York documentation.

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Condenser Coil Fin Protection Flow Switch


Switch with 1 inch IPS thread suitable for 10 bar g DWP
Gold Epoxy Coated Aluminium Condenser Fins and having gold contacts for low voltage/ current, to
Offers corrosion resistance in mild coastal locations protect unit from loss of water flow. A flow switch must be
(ASTM 287* Test, after 1500 hours 7% weight loss). furnished with each unit for field installation by
contractor.
Copper Fin Condenser Coils
Condenser coils are constructed with copper fins Added Compressor Capacity Step
(ASTM 287* Test, after 1500 hours 17% weight loss). (Units with 6 and 8 cylinder compressors only)
The compressor control system is programmed with an
* ASTM 287 tests are based on Industrial / Coastal additional capacity step to improve par t load
locations. performance. This option includes compressor liquid
injection cooling.
Wire Panel Enclosure
Consists of welded-wire-mesh guards mounted on the Low Ambient Kit
exterior of the unit. Prevents unauthorized access, yet This accessory is factory fitted and includes all
provides free air flow. necessary components to allow chiller operation down
to -18°C condenser intake air.
Fan Deck Paint Finish
Paint finish for fan cowl and fan deck in Desert Sand Sun Shield Kit
(RAL1019). Sun shield kit to provide shade / air gap around the
power and control panels to prevent overheating due to
Cooler solar gain on applications above 38°C ambient.
Coolers constructed in accordance with ASME
pressure code requirements are available. This option Unit Aesthetic Panels
includes a single relief valve. Not available for single Non acoustically lined infill panels manufactured from
refrigerant circuit models. powder painted galvanised steel to cover the ends of the
condenser coil on the opposite end to the control panel.
Handed Evaporator
Simplifies unit layout and water connection enabling the Acoustic Enclosure
chillers to be placed in the best orientation to suite the A four sided acoustically treated enclosure fitted around
site compound. the compressors and refrigerant pipework below the
condenser coils to reduce sound emissions.
Double Thickness Insulation
The cooler is covered with 38 mm flexible, UV-stable Suction Service Valves
colour co-ordinated closed-cell, foam insulation for One ball valve per compressor in the low pressure
added frost protection. (suction) pipework.

Cooler Flange Kit Mechanical Gauge Kit


Factory fitted flanges on cooler water connections to Factory fitted mechanical dial gauges for discharge,
I.S.O. R2084-NP10. Available in Weld or Victaulic suction and oil pressure indication in addition to
Adaptor. transducer pressure display.

Companion Flange Kit Anti-Vibration Mounts


Weld/Victaulic Adaptor flanges to match cooler flange Open spring isolator mounts with levelling screws and
kit ISO 7005-1 PN10 supplied loose for field installation fixing down holes, supplied loose for field installation by
by contractor. Includes all necessary nuts, bolts, contractor.
gaskets, etc.
Lifting Lug Kit
One set of ISO Mk5 cam locs to enable safe and easy
unit handling.

(02/04)
035L02537-100 Rev. 0 2- 5

2.8 Functional Description

Condenser Coil
Refrigerant
Circuit No 2

Condenser Coil
Refrigerant
Circuit No 1

High Pressure
superheated vapour

Compressor
Fusible
Plug Optional
Suction
Service
High pressure Valve
sub-cooled liquid

Low pressure superheated vapour

Sight TEV
Glass

Filter
Low pressure
Drier Cooler
sub-cooled
liquid/vapour

Refrigerant Circuit No 2

Low pressure liquid/vapour refrigerant enters the cooler and is evaporated and superheated by the heat energy
absorbed from the chilled water passing through the cooler shell. Low pressure vapour enters the compressor
where pressure and superheat are increased. Heat is rejected via the air cooled condenser coil and fans. The fully
condensed and subcooled liquid refrigerant then enters the expansion valve where pressure reduction and further
cooling takes place before returning to the cooler.

(02/04)
2- 6 035L02537-100 Rev. 0

2.9 Nomenclature

1 2 3 4
YAEP99XD9B50PA 5 6 7 8 9 10 11 12 13
BASE PRODUCT TYPE COMPRESSOR SIZE COOLER CONDENSER FAN CODE REFRIGERANT POWER SUPPLY STARTING DESIGN LEVEL

Y : York 6 : Comp. 1/3 S C 1 B 50 P A : Engineering


A : Air Cooled 6 : Comp. 2/4 L, M, S, X A, B, C, D, F 7, 9 B : R407C 50 : 380/400/415 V P : Part Wind Change
E : Export Series 4, 5, C : R22 3 phase, 50 Hz C : Star Delta Closed or PIN Level
P : P Series 6, 7, O : Star Delta Open
Compressor 8, 9

Typical Unit Label

MODEL YAEP99XD7B50PA SERIAL No. ****** ORDER No. ******


UNIT DESIGN HIGH 450 Psi g LOW 235 Psi g REFRIGERANT R- 407C
WORKING PRESS.
31 Bar g 16.2 Bar g
VOLTS PHASE Hz WIRE
UNIT SUPPLY 380/400 3 50 3 VOLTAGE LIMIT AT TERMINALS MAX 440 MIN 342
VOLTS-PHASE-Hz AMPS MAX FUSE SIZE MAX OPERATING MAX
UNIT CONTROL SUPPLY - - - FUSE CHARGE SYSTEM
NOMINAL MAXIMUM SIZE kg AMPS
SYSTEM COMPRESSOR KW AMPS KW AMPS PW INRUSH @342v
1 PC84-T 113 200/196 135 235/227 689/725 355 65 kg 265
2 PC84-T 113 200/196 135 235/227 689/725 355 65 kg 265

EACH FAN MOTOR 2.2 5.7/5.8 24.1/25.4 LRA

TOTAL No. OF MOTORS 8


COMMON SUPPLY INPUT
576
MAX AMPS@342v
CAPACITY CONTROL 16 STEP

025L02600 000

(02/04)
035L02537-100 Rev. 0 3- 1

3 TRANSPORTATION, HANDLING
AND STORAGE

3.1 Delivery and Storage 3.3 Moving the Chiller

To ensure consistent quality and maximum reliability, Units are designed to be lifted using lifting lugs and
each YAEP is tested and inspected before leaving the cables. A spreader bar or frame 2.4 metres wide should
factory. Two and three refrigerant circuit units are be used in order to prevent damage to the unit from the
shipped as completely assembled units containing lifting chains:
refrigerant under pressure. Four refrigerant circuit units
are shipped in two parts.

If the chiller is to be put into storage, prior to installation,


the following precautions should be observed:

Ensure that all openings, such as water connections,


are securely capped.

D o n o t s t o r e w h e r e ex p o s e d t o a m b i e n t a i r
temperatures exceeding 52°C .

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 to ensure refrigerant pressures are
present and to identify any damage that may have
occurred and repair as necessary.

3.2 Inspection on Arrival at Site

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.

(02/04)
3- 2 035L02537-100 Rev. 0

CORRECT INCORRECT
3.4 Lifting Weights
LUG
LIFTING HOLE
LUG
IN BASE FRAME
For details of weights and weight distribution refer to
FLANGE
FLANGE section 9.

LOCKING PIN 3.5 Shipping Protection

LIFTING HOLE When commissioning the unit remove the wooden


LOCKING PIN IN BASE FRAME
condenser coil protection panels which are hung off the
top of the unit and secured by self-tapping bolts along
LUG the base. To prevent condenser coil damage York
recommend that the condenser coil protection panels
are refitted after commissioning until the unit is ready for
operation.
LOCKING
PIN Ensure the condenser coil protection panels
FLANGE are removed prior to operation.

The unit must only be lifted by the base frame


at the points provided.

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.

(02/04)
035L02537-100 Rev. 0 4- 1

4 INSTALLATION

4.1 Location Requirements On rooftop locations, choose a place with adequate


structural strength to safely support the entire operating
To achieve optimum performance and trouble-free weight of the unit and service personnel. The unit can be
service, it is essential that the proposed installation site mounted on a concrete slab, similar to ground floor
meets with the location and space requirements for the locations, or on steel channels of suitable strength. To
model being installed. For dimensions, weight and avoid noise and vibration transmission the unit should
space requirements, including service access details, not be secured to the building foundation. Channels
refer to Section 9. should be spaced at the same centres as the vibration
mounting holes in the unit base frame and must be at
It is important to ensure that the minimum service least 120 mm wide at the contact points. This will allow
access space is maintained for cleaning and vibration isolators to be fitted if required.
maintenance purposes.
Standard units are fitted with multi-blade cooling fans.
The unit should not be installed directly on Any ductwork or attenuators fitted to the unit must not
flammable materials, such as wooden have a total static pressure resistance, at full unit airflow,
structures or roof’s. exceeding the capability of the fans installed in the unit.
Refer to Section 9.

Indoor Installations
Outdoor Installations
The unit can be installed in an enclosed plant room
Units can be installed at ground level, or on a suitable providing the floor is level and of suitable strength to
rooftop location. In both cases an adequate supply of air support the full operating weight of the unit and service
is required. Avoid locations where the sound output and personnel. It is essential that there is adequate
air discharge from the unit may be objectionable. clearance for airflow to the unit. The discharge air from
the top of the unit must be ducted away to prevent
The location should be selected for minimum sun recirculation of air within the plant room. If common
exposure and away from boiler flues and other sources ducts are used for fans, non-return dampers must be
of airborne chemicals that could attack the condenser fitted to the outlet from each fan. Common ducts should
coils and steel parts of the unit. not be used on a four fan unit fitted with the optional low
ambient kit as these units use fans in the reverse
If located in an area which is accessible to unauthorised direction in some modes of operation.
persons, steps must be taken to prevent access to the
unit by means of a protective fence. This will help to The discharge ducting must be properly sized with a
prevent the possibility of vandalism, accidental damage, total static pressure loss, together with any intake static
or possible harm caused by unauthorised removal of pressure loss, less than the available static pressure
protective guards or opening panels to expose rotating capability for the type of fan fitted. For details refer to the
or high voltage components. details provided in “Outdoor Installations” and Section 9.
For ground locations, the unit must be installed on a The discharge air duct usually rejects outside the
suitable flat and level concrete base that extends to fully building through a louvre. The outlet must be positioned
support the two side channels of the unit base frame. A to prevent the air being drawn directly back into the air
one-piece concrete slab, with footings extending below intake for the condenser coils as such recirculation will
the frost line is recommended. affect unit performance.

(02/04)
4- 2 035L02537-100 Rev. 0

4.2 Location Clearances (refer to Section 9) 4.3 Vibration Isolator Installation & Dimensions

Clearances around the unit(s) are required for the When ordered, an optional set of spring type vibration
unrestricted access of airflow onto the air-cooled isolators will be supplied loose with each unit.
condenser coils and to prevent recirculation of warm
discharge air back onto the coils. If clearance n Using the Isolator tables (in Section 9), identify
dimensions are not maintained, airflow restriction or each mount and its correct location on the unit.
recirculation will cause a loss of unit performance, an
increase in power consumption and may cause the unit n Place each mount in its correct position and lower
to malfunction. Consideration should also be given to the unit carefully onto the mounts ensuring the
the possibility of down draughts, caused by adjacent locating pin on top of each mount engages in the
buildings, which may cause recirculation or uneven unit mounting holes in the unit base frame.
airflow.
n Transfer the unit weight evenly to the springs by
turning the mount adjusting nuts (located just
For locations where significant cross winds are
b e l o w t h e to p p l a t e o f th e m o u n t )
expected, such as exposed roof tops, an enclosure of
counter-clockwise to raise and clockwise to lower.
solid or louvre type is recommended to prevent wind
This should be done two turns at a time until the top
turbulence interfering with the unit airflow.
plates of all mounts are between 6 mm and 13 mm
clear of top of their housing and the unit base is
When units are installed in an enclosure, the enclosure
level.
height should not exceed the height of the unit. If the
enclosure is of louvred construction the same
4.4 Pipework Connection
requirement of static pressure loss applies as for ducts
and attenuators stated in Section 9.
General Requirements
Where accumulation of snow is likely, additional height
The following piping recommendations are intended to
must be provided under the unit to ensure normal airflow
ensure satisfactory operation of the unit(s). Failure to
to the unit.
follow these recommendations could cause damage to
the unit, or loss of performance, and may invalidate the
The clearance dimensions given are
warranty.
necessary to maintain good airflow and
ensure correct unit operation. It is also
The maximum flow rate and pressure drop for
necessary to consider access requirements
the cooler must not be exceeded at any time.
for safe operation and maintenance of the unit
Refer to Section 9 for details.
and control panel (600 mm wide doors). Local
health and safety regulations, or practical
considerations for service replacement of
large components, may require larger n The water must enter the heat exchanger(s) by the
clearances than those given below. inlet connection. The inlet connection for the cooler
is at the same end as the refrigerant pipework
Dimension to louvred wall assumes 60% connections.
minimum free area. For louvres of less free
area use dimensions for solid walls. n A flow switch must be installed in the customer
pipework at the outlet of the heat exchanger(s) as
Pressure drop through louvred walls must not shown in the arrangement diagrams, and wired
exceed available external static pressure back to the control panel using screened cable. For
capability for the type of fans fitted. details refer to “Electrical Connection”. This is to
prevent damage to the heat exchanger(s) caused
by the unit operating without adequate liquid flow.

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.

(02/04)
035L02537-100 Rev. 0 4- 3

n The liquid pump(s) installed in the pipework n Liquid systems at risk of freezing, due to low
system(s) should discharge directly into the unit ambient temperatures, should be protected using
heat exchanger section of the system. The insulation and heater tape and/or a suitable glycol
pump(s) may be controlled external to the unit - but solution. The liquid pump(s) must also be used to
an override must be wired to the control panel so ensure liquid is circulated when the ambient
that the unit can start the pump in the event that the temperature approaches freezing point. Insulation
liquid or ambient temperature falls below the should also be installed around the heat exchanger
minimum setting. This ensures that the optional nozzles.
heater mat and low temperature pump circulation is
enabled. When the unit is not operational, power Heater tape of 21 watts per metre under the
supplies should be maintained to the unit to allow insulation is recommended, supplied
the automatic frost protection to operate. In independently and controlled by an ambient
addition, the power is used to ensure the automatic temperature thermostat set to switch on at 3°C
pumpdown system is functioning. For details refer above the freezing temperature of the liquid.
to “Electrical Connection”.
n The chilled liquid circulation pump must be
n Pipework and fittings must be separately controlled to ensure that when the liquid
supported to prevent any loading on the heat temperature falls within 2 or 3°C of freezing the
exchanger(s). Flexible connections are pump will start.
recommended which will also minimise
transmission of vibrations to the building. Flexible Any debris left in the water pipework between
connections must be used if the unit is mounted on the strainer and heat exchanger could cause
anti-vibration mounts as some movement of the serious damage to the tubes in the heat
unit can be expected in normal operation. exchanger and must be avoided. The
installer/user must also ensure that the quality
n Pipework and fittings immediately adjacent to the
of the water in circulation is adequate, without
heat exchangers should be readily de-mountable
any dissolved gasses which can cause
to enable cleaning prior to operation, and to
oxidation of steel parts within the heat
facilitate visual inspection of the exchanger
exchanger(s).
nozzles.

n Each heat exchanger must be protected by a 4.5 Water Treatment


strainer, preferably of 30 mesh, fitted as close as
possible to the liquid inlet connection, and provided The unit performance given in the Design Guide is
with a means of local isolation. 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
n The heat exchanger(s) must not be exposed to water treatment will adversely affect the heat exchanger
flushing velocities or debris released during surfaces and therefore unit performance. Foreign matter
flushing. It is recommended that a suitably sized in the water system(s) can increase the heat exchanger
by-pass and valve arrangement is installed to allow pressure drop, reducing the flow rate and causing
flushing of the pipework system. The by-pass can potential damage to the heat exchanger tubes.
be used during maintenance to isolate the heat
exchanger without disrupting flow to other units. Aerated, brackish or salt water is not recommended for
use in the water system(s). York recommend that a
n Thermometer and pressure gauge connections water treatment specialist is consulted to determine that
should be provided on the inlet and outlet the proposed water composition will not affect the
connections of each heat exchanger. evaporator materials of carbon steel and copper. The pH
value of the water flowing through the heat exchangers
n Drain and air vent connections should be provided must be kept between 7 and 8.5.
at all low and high points in the pipework to permit
drainage of the system, and to vent any air in the
pipes.

(02/04)
4- 4 035L02537-100 Rev. 0

4.6 Pipework Arrangement 4.7 Connection Types & Sizes

The following are suggested pipework arrangements for For connection and nozzle sizes relevant to individual
single unit installations. For multiple unit installations, units, refer to the product drawings in Section 9.
each unit should be piped as shown.
Cooler Connections
Recommendations of the Building Services
Research Association Standard chilled liquid connections on all coolers are of
the Victaulic Groove type.
Chilled Water System - 2 Circuit Units
Standard Victaulic

Nom, Size OD T A B C
6" (150 mm) 168,3 7,1-8,0 16 9,5 164
8" (200 mm) 219,1 7,9-8,2 19 11 214

Chilled Water System - Four Circuit Units


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 R2084 NP10. Dimensions
are as follows:

Optional Flanges

WELD FLANGE VIC-ADAPTOR FLANGE

Nom. Size PCD T Bolts


6" (150 mm) 240 22 8 x M 20
8" (200 mm) 295 24 8 x M 20

(02/04)
035L02537-100 Rev. 0 4- 5

4.8 Refrigerant Relief Valve Piping n The unit is not designed to take structural loading.
No significant amount of weight should be allowed
Coolers are protected against internal refrigerant to rest on the fan outlet flange, deck assemblies or
overpressure and fire by refrigerant relief valves. The condenser coil module(s). No more than one metre
pressure relief valve is set at design pressure of the of light construction ductwork should be supported
system and has discharge capacity required by relevant by the unit. Where cross winds may occur, any
standard. For coolers, a pressure relief valve is mounted ductwork must be supported to prevent side
on each of the main refrigerant lines connecting the loading on the unit. Fan discharge ducts should be
cooler to the compressors. secured together with tie rods to prevent excessive
movement.
York fit a piece of pipe to each valve and direct it so that
when the valve is activated the release of high pressure n If the ducts from two or more fans are to be
gas and liquid cannot be a danger or cause injury. For combined into a common duct, back-flow dampers
indoor installations pressure relief valves should be should be fitted in the individual fan ducts. This will
piped to the exterior of the building. prevent recirculation of air when only one of the
fans is running. Common ducts should not be used
The size of any pipework attached to a relief valve must on a four fan unit fitted with the optional low ambient
be of sufficient diameter so as not to cause resistance to kit as these units use fans in the reverse direction in
the operation of the valve. Unless otherwise specified by some modes of operation.
local regulations, the minimum allowable internal
n Units are supplied with outlet side guards for safety
diameter depends on the length of pipe required and is
and to prevent damage to the fan blades. If these
given by the following formula:
guards are removed to fit ductwork, adequate
alternative precautions must be taken to ensure
D5 = 1.447 x L
persons cannot be harmed or put at risk from
rotating fan blades.
Where:
D = minimum pipe internal diameter in centimetres
Connection Details and Dimensions
L = length of pipe in metres
Fan Code 7
Precautions should be taken to ensure the exit of relief Top Flange Guard
valves/vent pipe remain clear of obstructions at all
times. 150 mm

4.9 Ductwork Connection


Mounting
Holes 8mm
General Requirements
Æ 970 mm

The following ductwork recommendations are intended


m

45°
m

to ensure satisfactory operation of the unit(s). Failure to


0

45°
90
Æ

follow these recommendations could cause damage to


the unit, or loss of performance, and may invalidate the
m

warranty.
m
50

n When ducting is to be fitted to the fan discharge it is Fan Code 9


recommended that the duct should be the same
Top Flange Guard
cross sectional area as the fan outlet and straight
for at least one metre in order to obtain static regain
175 mm
from the fan.

n Ductwork should be suspended with flexible


Mounting
hangers to prevent noise and vibration being Holes 10 mm
transmitted to the structure. A flexible joint is also
recommended between the duct attached to the
Æ 984 mm

fan and the next section for the same reason.


m

45°
m
0

Flexible connectors should not be allowed to 45°


92
Æ

concertina.
m
m
50

(02/04)
4- 6 035L02537-100 Rev. 0

4.10 Electrical Connection To ensure that no eddy currents are set up in the metal
gland plate the cables forming each 3 phase power
The following connection recommendations are supply must enter via the same hole in the gland plate. If
intended to ensure safe and satisfactory operation of the separate entries for each cable forming the 3 phase
unit(s). Failure to follow these recommendations could supplies are used, the metal gland plate must be
cause harm to persons, or damage to the unit, and may replaced by a non-metallic gland plate, with due regard
invalidate the warranty. given to sealing the panel to IP55.

No additional controls (relays, etc.) should All sources of supply to the unit must be
be mounted in any section of the control taken via a common point of isolation (not
panel. Power and control wiring not supplied by York).
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, Single Point Power Supply - Disconnect Switch (CE)
electrical noise could cause malfunctions, or Terminal Block Option (Non CE)
or damage the unit and its controls. (Refer to Power Supply Connection Diagram)

After connection do not switch on mains Each panel (master and auxiliary, if fitted) requires a 3
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 phase separately fused supply plus earth to be
components are live as soon as mains is connected to the common input section of the power
switched on, and this must only be done by and control panel.
authorised persons.
The cables should enter the common input section via
n The unit OFF/ON switch on the front of the control the site drilled gland plate on the bottom of the section.
panel has been sealed in the OFF position at the Connect each phase to the disconnect switch/terminal
factory. This seal must remain in place preventing block located in the common input section using the lug
running of the unit until commissioned by sizes detailed in Section 9.
authorised personnel. If the seal has been
removed before commissioning then it must be Connect the earth wire to the main protective earth
reported to the Basildon Factory Quality Manager terminal located in the common input section of the
otherwise warranty may be invalidated. control panel using an M10 lug.

4.11 Power Wiring Multi Point Power Supply Option (Non CE)
(Refer to Power Supply Connection Diagram)
YAEP units require an electrical power supply
of 380 V, 400 V or 415 V, 3Ø, 50 Hz Each refrigerant system requires a 3 phase separately
Minimum allowable voltage 342 V. fused supply plus earth to be connected to each power
Maximum allowable voltage 440 V. section of the power and control panel. A separate fused
2 phase control transformer supply plus earth is
required for the main and auxiliary (4 Circuit Units)
All electrical wiring should be carried out in accordance panels.
with local regulations. Route properly sized cables
(based on installation conditions and currents given in Each set of supply cables per system should enter via
electrical data tables) to site drilled holes in the Control the site drilled gland plate in the bottom of the applicable
Panel gland plate as specified below. power section. The supplies can then be routed to their
respective input terminals on the compressor
In accordance with EN 60204 it is the responsibility of contactors. Connect each phase to the compressor
the user to install overcurrent protection devices contactors using the lug sizes detailed in Section 9.
between the supply conductors and the customer input
supply terminals on the unit. Connect the earth wire to the main protective earth
terminal of the applicable power section, using an M4
lug.

Connect the two phase control transformer supply to the


input of the emergency stop/isolation device in the
applicable common input section with bare wire ends of
maximum cable size 4 mm. Also connect an earth wire
to the protective earth terminal using an M4 lug.

(02/04)
035L02537-100 Rev. 0 4- 7

Units with Optional Cable Spreader Box Run Contact


Under the common input section of the control panel is a
cable spreader box which should be used to separate Terminals 35 and 36 close to indicate that a system is
the cores of large multi-core cable prior to connection to running.
the terminal block/disconnect switch.
Alarm Contacts
Remote Emergency Stop Device
Each system has a voltage-free change over contact
If required, a remote emergency stop device can be which will operate to signal an alarm condition whenever
wired to terminals 3 and 4 in the main and auxiliary a system locks out, or there is a power failure. To obtain
control panels (located in the common input section). system alarm signal, connect alarm circuit to volt free
The existing link must first be removed. This device terminals as follows:
should be rated at 10 amps, 230V, AC-15. Terminals 3
and 4 are in a circuit protected by a 10 amp class gG 2 Circuit Units:
fuse.
System 1:
4.12 Control Section - Output Signals Terminals 31 and 32 (close on alarm) or 30 and 32 (open
(Refer to Control Connection Diagram) on alarm).

All wiring to the control section (relay board) output System 2:


contacts requires a supply, maximum 254 V, provided by Terminals 38 and 39 (close on alarm) or 37 and 39 (open
the customer. The customer must take particular care on alarm).
deriving the supplies for the output terminals with regard
to a common point of isolation. These circuits when used 4 Circuit Units:
must be fed via the common point of isolation so that the
voltage is removed when the common point of isolation Main Panel - System 1:
to the unit is opened. Terminals 31 and 32 (close on alarm) or 30 and 32 (open
on alarm).
In accordance with EN 60204 it is recommended that
the customer wiring to these terminals uses orange Main Panel - System 2:
wires. This will ensure that circuits not switched off by Terminals 38 and 39 (close on alarm) or 37 and 39(open
t h e YA E P 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 on alarm).
distinguished by colour, so that they can easily be
identified as live even when the YAEP disconnecting Auxiliary Panel - System 3:
device is off. Terminals 31 and 32 (close on alarm) or 30 and 32 (open
on alarm).
The YAEP output contacts are rated at 125 VA. All
inductive devices (relays) switched by the YAEP output Auxiliary Panel - System 4:
contacts must have their coil suppressed using Terminals 38 and 39 (close on alarm) or 37 and 39 (open
standard RC suppressors. on alarm).

Chilled Liquid Pump Starter

Terminals 33 and 34 in the main panel only 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 YAEP
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.

(02/04)
4- 8 035L02537-100 Rev. 0

4.13 Control Section - Input Connections Remote Lead/Lag


(Refer to Control Connection Diagram)
2 Circuit Units
All wiring to the input connections (relay board) is If manual lead/lag control is required, closure of suitable
nominal 30 Vdc and must be run in screened cable, with contacts connected to terminals 13 and 19 in the Main
the screen earthed at the panel end only. Run screened Panel will cause System 2 to operate as the lead system
cable separately from mains cable to avoid electrical of the main group. Open contacts will cause System 1 to
noise pick-up. be in lead.

The voltage free contacts must be suitable for 30 Vdc 4 Circuit Units
(gold contacts recommended). If the voltage free Closure of a suitable contact connected to terminals 13
contacts form part of a relay or contactor, the coil of the and 19 in the auxiliary panel will cause System 4 to
device must be suppressed using a standard RC operate as the lead system of the slave group. Open
suppressor. The above precautions must be taken to contact will cause System 3 to be in the lead.
avoid electrical noise which could cause a malfunction
or damage to the unit and its controls. Remote Set Point Offset

Flow Switch(es) Timed closure of suitable contacts connected to


terminals 13 and 17 (PWM contacts) will give remote
A chilled liquid flow switch (per cooler) of suitable type offset function of the chilled liquid set point if required
must be connected to terminals 10 and 13 to provide (terminals located in main control panel). This function
adequate protection against loss of liquid flow. cannot be used if “Remote Unload” function is required.

Remote Run/Stop Remote Unloading

Remove the link from main panel terminals 11 and 14 The Micro Based Control System is capable of remote
(system 1) and terminals 12 and 15 (system 2) and unloading (or pull-down demand limiting) in two steps.
connect remote switch(es) to provide system remote The first step of unloading is achieved by closing
run/stop control if required. suitable contacts connected to terminals 16 and 13
(terminals located in main control panel). The second
Auxiliary Panel (3 and 4 Circuit units): step of unloading is achieved by closing suitable
Remove the link from terminals 11 and 14 (System 3) contacts connected to terminals 17 and 13.
and terminals 12 and 15 (System 4) and connect remote
switch(es) to provide system remote run/stop control if The first step contacts must be closed before
required. the second step contacts are closed.

Remote Print

Closure of suitable contacts connected to terminals 18


and 13 will cause a hard copy printout of Operating For details of compressor load steps given by these
Data/Fault History to be made if an optional printer is contacts, refer to the Micro Based Control System
connected to the RS 232 port. Manual. This function cannot be used if “Remote Set
point Offset” is required.

(02/04)
035L02537-100 Rev. 0 4- 9

Power Supply Connection - (Main Panel and Auxiliary Panel when fitted)

YAEP 08L-09L Power Section Common Input


Section
Control Control Circuit Switch
Section
Disconnect / Emergency
Power Stop Device
Section 1

Common
Input
Section

YAEP 44M-77X & 5555S-7777X

Control
Section

Power Power
Section 1 Section 2

Common
Input
Section

YAEP 88X-99X & 8888X-9999X


Non-Fused
Disconnect Switch
Control or Terminal Block
Section Protective
Power Power Earth
Section 1 Section 2

Common
Input
Section

System Fuses, Protective


or Terminal Block Earth

Standard Single Point Power Supply (CE) DESIGNATION DESCRIPTION


One supply per panel to master non-fused disconnect switch AMB MICROPROCESSOR BOARD
(XCSISD) with internal power distribution to fuses, control supply APB POWER SUPPLY BOARD
to non-fused disconnect switch (QCSD/ESD) derived internally. ARB RELAY BOARD
CS CONTROL SECTION
CIS COMMON INPUT SECTION
F FUSE
1 PS 2 PS
CIS PE PROTECTIVE EARTH
F F F
PS POWER SECTION
F F F
QCSISD QCSD/ESD CONTROL CIRCUIT SWITCH DISCONNECT
U V W / EMERGENCY STOP DEVICE
PE 3 4 QCSISD COMMON SUPPLY INPUT SWITCH DISCONNECT
QCSITB COMMON SUPPLY INPUT TERMINAL BLOCK
QRESB REMOTE EMERGENCY STOP BUTTON

Multi Point Power Supply (Non CE) Options


One supply per refrigerant circuit to fuse/terminal block
PE
L1 L2 L3 QRESB with separate control supply to non-fused disconnect
3 50 Hz 380/400 V switch (QCSD/ESD).

Single Point Power Supply (Non CE) Option


APB

1 PS 2 PS
One supply per panel to a common terminal block (QCSITB) with
internal power distribution to fuses, control supply to non-fused AMB ARB
disconnect switch (QCSD/ESD) derived internally.
CS
Compressor CIS Compressor
3
1 PS 2 PS
Contactor 4 Contactor
CIS
U V W U V W
F F F F F F QCSD/ESD PE
QCSITB PE PE
U V W

PE 3 4

QRESB
PE
L1 L2 L3 QRESB
3 50 Hz 380/400 V

PE PE PE
L1 L2 L3 L1 L3 L1 L2 L3
3 50Hz 2 50Hz 3 50Hz
380/400V 380/400V 380/400V

(02/04)
4-10 035L02537-100 Rev. 0

Control Connections - (Main Panel and Auxiliary Panel when fitted)

YAEP 08L-09L YAEP 44M-77X & 5555S-7777X YAEP 88X-99X & 8888X-9999X

Control Control Control


Section Section Section
Power Power Power Power Power
Section 1 Section 1 Section 2 Section 1 Section 2

Common Common
Input Common Input
Section Input Section
Section

Control Section

Communication Link 34
(4 Circuit Units Only) APB
33
} Chilled Liquid Pump Start

}
36
Unit Run Signal
AMB 35

} Open on Alarm
}
ARB 37
MAIN System
PANEL 38
Close on Alarm No. 2 / 4
39 }
30
} Open on Alarm
}
BLACK
WHITE

31 System

32 } Close on Alarm No. 1 / 3

AUXILIARY
PANEL Mixed Water
Temperature
(4 Circuit Units Only)
DESIGNATION DESCRIPTION
Note 1 AMB MICROPROCESSOR BOARD
APB POWER SUPPLY BOARD
13 10 11 14 12 15 16 13 17 18 10 13 ARB RELAY BOARD
Communications Link Cable CS CONTROL SECTION
to be field run and CIS COMMON INPUT SECTION
connected to Main Panel TB7
PS POWER SECTION
during installation

Remote Lead/Lag

Remote Print (Main Panel only)

Remote Setpoint Reset (Main Panel only)


Remote Unload

System No. 2 / 4 Remote Start/Stop

System No. 1 / 3 Remote Start/Stop

Chilled Liquid Flow Switch

Note 1: Fit link between terminals 14 and 15 and connect a voltage free contact to terminals 11 and 14
for combined Remote Start/Stop of systems 1 / 2 (2 circuit units) and systems 3 / 4 (4 circuit units).

(02/04)
035L02537-100 Rev. 0 5- 1

5 COMMISSIONING

5.1 Preparation Valves: Open the compressor suction valves and the
liquid line service valves on both systems (CCW).
Commissioning of this unit should only be
carried out by York authorised personnel. Compressor oil: Compressor lubrication systems must
be primed prior to first time start-up. Only the YORK
Type H oil must be used as given by unit data
plate/labels and is as follows for YAEP standard units:
The Control System Manual must be read in conjunction
To prime each compressor - connect a York hand oil
with this section.
pump (part no. 470-10654-000) to the ¼" compressor oil
priming valve with a length of clean hose or copper line,
The unit switch on the front of the control panel has been
but do not tighten the flare nut. Using clean oil of the
sealed in the off position at the factory. This seal must
correct type, pump oil until all air has been purged from
remain in place preventing running of
the hose then tighten the nut. Stroke the oil pump 10
t h e u n i t u n t i l c o m m i s s i o n e d by
times (delivering approximately 1,5 litres) to prime the
authorised personnel. If the seal has
oil system. The oil level should be between the middle of
been removed before commissioning
the lower and middle of the upper sight glasses. If it is
then it must be reported to the Basildon
necessary to add oil, continue to stroke the pump until
Factory Quality Manager otherwise the
the correct level is achieved.
warranty may be invalidated.
Fans: Check that all fans are free to rotate and are not
Preparation - Power Off
damaged. Ensure blades are at the same height when
rotated. Ensure fan guard is securely fixed.
The following checks should be made
with the customer supply/supplies to the unit switched
Isolation/protection: Verify that all sources of electrical
off.
supply to the unit are taken from a single point of
isolation. For units not fitted with a switch disconnector
Inspection: Inspect unit for installation damage. If found
fuse check that the maximum recommended fuse sizes
take action and/or repair as appropriate.
given in the Technical Data section have not been
exceeded.
Refrigerant charge: Units are normally shipped as
standard with a full refrigerant operating charge. Check
Control panel: Check panel to see that it is free of
that refrigerant pressure is present in both systems and
foreign materials (wire, metal chips, etc.) and clean out if
that no leaks are apparent. If no pressure is present a
required.
leak test must be undertaken, the leak(s) located and
repaired. Repaired systems and units supplied with a
Power connections: Check the customer power cables
nitrogen holding charge must be evacuated with a
are connected to the unit incoming terminals. Ensure
suitable vacuum pump/recovery unit as appropriate to
that connections of power cables within the panel to
below 100 microns. Check the unit data plate or unit
contactors, terminal blocks or switch disconnector, and
labels for the type of refrigerant intended for use with the
external connection to compressors are tight.
unit and break vacuum from bottle connection for liquid
and raise system pressure to 4.6 barg.
Earthing: Verify that the units protective terminal(s) are
properly connected to a suitable earthing point. Ensure
Charging from the liquid connection on the
that all unit internal earth connections are tight.
cylinder is necessary on R407C to ensure the
correct refrigerant mix is maintained.
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.
Do not liquid charge with static water in any of the heat
exchangers. Care must also be taken to liquid charge Supply voltage: Verify that the site voltage supply
slowly to avoid excessive thermal stress at the charging corresponds to the unit requirement and is within the
point. Once the vacuum is broken, charge into the limits given on the unit data plate / Operating Limitations
condenser coils with the full operating charge as given section.
on the unit data plate and the Physical Data section of
this manual. Control Transformer: The 3-wire control transformer is
mounted on the unit framework below the control panel.

(02/04)
5- 2 035L02537-100 Rev. 0

It is important to check that the correct primary tapping Water system(s): Verify that the chilled water system
has been used: 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
n With the supply to the unit isolated remove the lid to through the cooler. Inlet should be at the refrigerant
the transformer box. Check that the tapping used pipework connection end of the cooler. Purge air from
conforms to the site supply voltage: the top of the cooler using the plugged air vent mounted
on the top of the cooler body.
50 Hertz Models
The two tappings are 342 - 424 V and 360 - 440 V. Flow switch(es): Verify a chilled water flow switch is
correctly fitted in the customer’s pipework on the cooler
60 Hertz Models outlet, and wired into the control panel logic section
The two tappings are 342 - 418 V and 414 - 506 V. Opto-isolator board terminals 10 and 13 using screened
cable.
Switch Settings: Ensure that the black handled unit
switch on the display door and the micro board system Temperature sensor(s): Ensure the leaving water
switches S2 and S3 in the logic section are set to "0" temperature sensor is coated with heat conductive
(OFF). Set the red handled control circuit switch compound (part no. 013-00890-000) and is inserted in
disconnector/emergency stop device on the lower the bottom of the water outlet sensor pocket of the
centre section door to "1" (ON). For units fitted with cooler. This sensor also acts as the freeze protection
switch disconnector fuse devices the two power section thermostat sensor and must always be in the water
doors must be closed and the devices set to "1" (ON). OUTLET sensor pocket.
The customers disconnection devices can now be set to
ON. Mixed leaving temperature sensor (4 Circuit Units)

The machine is now live! A pocket is provided for field mounting in the customers
mixed pipework. The pocket has a 0.5" NPT thread and
is 6" long. The mixed leaving sensor is connected to plug
J17 on the main micro board and the 10m lead is coiled
up waiting field running to the location of the field
mounted pocket provided.
Crankcase heaters: Verify the compressor crankcase
heaters are energised. If the ambient temperature is A communication link cable is wired into the auxiliary
above 30oC the compressor crankcase heaters must be panel micro board TB7 to be field run and connected to
on for at least 24 HOURS prior to start-up to ensure all the main panel micro board TB7 (refer to Control
refrigerant liquid is driven out of the oil. If the ambient Connections in Section 4). Run cable away from other
temperature is below 30oC then allow 8 hours. power cables.

Control supply: Verify the control centre display is


illuminated.

HP cut-outs (on units with hand reset): Check that the


hand reset mechanical high pressure cut-outs mounted
on the unit are reset.

(02/04)
035L02537-100 Rev. 0 5- 3

Programmed options: Verify that the options factory 5.2 First Time Start-up
programmed into the Microprocessor Control Centre
are in accordance with the customers order When reading the following text remember
requirements by pressing the `Options’ key on the that for systems 3 and 4 a communication
keypad and reading the settings from the display. Refer d e l a y e x i s t s w i t h t h e ma i n p a n e l ,
also to the Micro Based Control System Manual for communications taking place at
notes and explanation of messages. approximately 10 second intervals. Thus the
values displayed for systems 3 and 4 are not
Programmed settings: Ensure the system cut-out and in real time and may be up to 10 seconds old.
operational settings are in accordance with the
instructions given in the Microprocessor Control Centre During the commissioning period there should
Manual and with operational requirements by pressing be sufficient heat load to run the YAEP unit
the ‘Program’ key. The chilled liquid temperature control under stable full load operation to enable the
settings need to be set according to the unit model and unit controls, and system operation to be set
required operating conditions. The following table gives up correctly and a commissioning log taken.
suggested settings. Read the following section in conjunction with
the Micro Based Control System Manual, then
Unit Capacity Steps 4 6 8 proceed step by step as follows:
∆t through cooler at full
4 7 4 7 4 7
load / °C
Interlocks: Verify that water is flowing through the
Rate Control temp. /°C
Rate Sensitivity °C / min
cooler and that heat load is present (if heat recovery
Control Range / °C condenser(s) are fitted, do not allow water flow through
Anti-Recycle timer / sec 600 the condensers at this stage). Ensure that any remote
run interlocks are in the run position and that the run
Unit Capacity Steps 10, 11, 12 16 schedule requires the unit to run or is overridden.
∆t through cooler at full
4 7 4 7
load / °C System switches: Place the ‘Sys 1’and ‘Sys 2’switches
Rate Control temp. /°C
on the microprocessor board to the ON position - see
Rate Sensitivity °C / min
Control Range / °C
operating sequence in the Microprocessor Control
Anti-Recycle timer / sec 600 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).

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).

(02/04)
5- 4 035L02537-100 Rev. 0

Start-up: Remove the locking device from the unit Superheat: Check the compressor suction superheat
switch which prevents unauthorised starting of the unit value only when pull down is complete and steady full
before commissioning. Press the ‘Status’ key, then turn load operation has been established. It is also important
the unit switch to the "1" position to start the unit (there that there are no bubbles showing in the liquid line sight
may be a few seconds delay before the first compressor glass. Suction line temperature should be measured on
starts because of the anti-recycle timer). Be ready when the copper line about 150 mm before the compressor
each compressor star ts to switch the unit off service valve. Suction pressure should be measured at
immediately if any unusual noises or other adverse the compressor service valve with a suitably calibrated
conditions develop. Also refer to the Micro Based gauge. Suction superheat at the compressor should be
Control System Manual for the normal operating between 5oC and 6oC for R22 and between 4oC and 5oC
sequence of the YAEP from start-up. relative to the `dew’ temperature for R407C.

Oil pressure: When a compressor starts, press the Thermal expansion valve adjustment: Thermal
relevant ‘System Pressures’ key and verify that oil expansion valves are factory set and should not need
differential pressure is developed immediately. If oil adjustment. If the superheat is out of range, however, the
pressure does not develop the automatic controls will expansion valve adjusting screw should be adjusted no
shut down the compressor (see the Micro Based Control more than 1 turn at a time (`in’ to increase superheat,
System Manual for the flow chart of the automatic oil `out’ to decrease superheat), allowing at least 10
pressure safety system). Under no circumstances minutes for the valve to stabilise before rechecking the
should a restart attempt be made on a compressor value of superheat.
which does not develop oil pressure immediately. Switch
the unit switch to the "0" position. Subcooling: Check the amount of subcooling leaving
the condenser coils only when pull down is complete
Refrigerant flow: When a compressor starts a flow of and steady full load operation has been established. It is
liquid refrigerant will be seen in the liquid line sight glass. also important that all fans are running, giving full airflow
After several minutes operation, and providing a full across the condenser coils. Liquid line temperature
charge of refrigerant is in the system, the bubbles will should be measured on the copper line between the
disappear and be replaced by a solid column of liquid. liquid line service valve and the filter/drier. Liquid
pressure should be measured at the liquid line service
Fan rotation: As the discharge pressure rises the valve with a suitably calibrated gauge. Liquid subcooling
o o
condenser fans will start as required. Verify that the fan should be between 7 C and 10 C for R22 and between
o o
rotation is correct and that airflow is in the upward 6 C and 8 C relative to the ‘bubble’ temperature for
direction. R407C. If necessary, add or remove refrigerant to obtain
the correct level of subcooling. Do not overcharge the
If fan operation is not in the correct direction, stop the unit.
unit, switch off the main customer disconnecting device
to the unit, and reverse (or arrange to have reversed) two Acoustic compressor enclosure option: To prevent
of the three main supply phases. damage to panels and to ease commissioning the two
side and front acoustically lined panels are shipped
General operation: Check the system operating strapped to the condenser frame.
parameters are normal by selecting the various
readouts of pressure, temperature, etc. After commissioning, the panels require mounting in
position by fixing the top of the side panels into locating
tangs and securing the bottom of the side panels with
the self-tapping bolts provided. The front panel is
secured with the self-tapping bolts provided.

(02/04)
035L02537-100 Rev. 0 6- 1

6 UNIT OPERATION

6.1 General Description The display will show the anti-coincidence timer status
for the lag compressor, followed by `NO COOL LOAD’
YAEP packaged chillers are designed to work until it is called to operate by the control system.
independently, or in conjunction with other equipment
via a York ISN building management system or other 6.3 Normal Running and Cycling
automated control system. When operating, the unit
controls monitor the chilled liquid system temperature at Once the unit has been started, all operations are fully
the unit and takes appropriate action to maintain this automatic. After an initial period at minimum capacity
temperature within desired limits. This action will involve step on the lead compressor, the control system will
running one or both compressors at a suitable load step adjust the unit load step depending on the chilled liquid
to match the cooling effect of the refrigerating systems temperature and rate of temperature change. If high
to the heat load on the liquid system. The heat removed heat load is present, the controller will increase the
from the chilled liquid is then rejected from the air cooled number of active cylinders on the lead compressor
condenser coils, or can optionally be recovered into a and/or star t-up the lag compressor (`START
hot water system. SEQUENCE’ will be displayed for the lag compressor,
followed by the same sequence as for the lead
The following sections give an overview of the operation compressor).
of a YAEP unit. For detailed information, reference
should be made to the Microprocessor Control System If very little heat load is present, however, the lead
Manual for this product. compressor will continue at minimum step, or may
simply stop again to avoid overcooling the liquid. If the
6.2 Start-up latter is the case, one compressor will restar t
automatically should the liquid temperature rise again.
Ensure the mains power to the unit and controls is ON,
the microprocessor 'Sys 1', 'Sys 2', 'Sys 3' and 'Sys 4' When a compressor is running, discharge pressure
circuit board switches are in the 'ON' position, all rises as refrigerant is pumped into the air cooled
r e f r i g e ra n t s e r v i c e s t o p va l ve s a r e o p e n condenser coils. This pressure is controlled by stages of
(anti-clockwise), and the chilled liquid flow has been fans to ensure maximum unit efficiency whilst
established (unless the unit chilled liquid pump start maintaining sufficient pressure for correct operation of
control is being used, in which case just ensure the the condensers and expansion valves.
pump supply is on)
As soon as a compressor is running the controller
Press the ‘STATUS’ key on the keypad and then switch monitors oil pressure, motor current, and various other
the unit switch on the control section door to the '1' (ON) system parameters such as discharge pressure, chilled
position. liquid temperature, etc. Should any problems occur the
control system will immediately take appropriate action
The controller will perform a pre-check to ensure that the and display the nature of the fault (see Microprocessor
daily/holiday schedule and any remote interlocks will Control System Manual for full details).
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.

(02/04)
6- 2 035L02537-100 Rev. 0

6.4 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 YAEP 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 Discharge Pressure Fan Control

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. For pressure setting values of
each stage of fan control for individual models - refer to
the Micro Base Control System Manual.

6.6 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.

(02/04)
035L02537-100 Rev. 0 7- 1

7 MAINTENANCE

7.1 General Requirements Operating conditions: read the operating pressures


and temperatures at the control panel using the display
The York YAEP range of liquid chillers have been keys and check that these are within the limitations
designed to operate continuously provided they are given this manual.
regularly maintained and operated within the limitations
given in this manual. Each unit should be included in a Compressor oil level: Check the compressor oil level
routine schedule of daily maintenance checks by the after the compressor has been operating on "FULL
operator/customer, backed up by regular service LOAD" for approximately 15 minutes. The maximum
inspection and maintenance visits by a suitably qualified acceptable operating oil level is the middle of the top
Service Engineer. sight glass and the minimum acceptable operating oil
level is the middle of the bottom sight glass. When the
It is entirely the responsibility of the owner to provide for compressor is operating for long periods at "PART
these regular maintenance requirements and/or enter LOAD" the level may fall as far as the middle of the
into a maintenance agreement with York International bottom sight glass but should not fall below this level.
service organisation to protect the operation of the unit.
If damage or a system failure occurs due to improper Do not overfill the PC style compressor with oil
maintenance during the warranty period, York shall not as this could cause damage to the
be liable for costs incurred to return the unit to compressor.
satisfactory condition.

This maintenance section applies only to the


basic YAEP chiller unit and may, on individual For units fitted with acoustic enclosures it is
contracts, be supplemented by additional recommended to access the compressors by
requirements to cover any modifications or removing the side panels and using a torch
ancillary equipment as applicable. and mirror to view the oil levels.

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 Maximum Acceptable Operating Oil Level
note, however, that YAEP 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 Minimum Acceptable Operating Oil Level
of action).
Refrigerant charge: when a system starts up, or
Refrigerant leaks: visually check the heat exchangers, sometimes after a change of capacity step, a flow of
compressors and pipework for damage and gas leaks. bubbles will be seen in the liquid line sight glass. After a
few minutes of stable operation the bubbles should clear
Airflow obstructions: check the air cooled condenser leaving just liquid refrigerant showing in the sight glass.
coil intakes and adjacent areas are clear of foreign
materials or obstructions, e.g., paper, leaves, etc.

(02/04)
7- 2 035L02537-100 Rev. 0

7.3 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

MAJOR SERVICE
SERVICE SCHEDULE MINOR SERVICE
All items under Minor Service plus:
Unit general: Check thermal insulation Check main structure
Check vibration isolators Check paint-work
Refrigerant systems general: 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: 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
Microprocessor controls: 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

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.

(02/04)
035L02537-100 Rev. 0 8- 1

8 TROUBLE SHOOTING

8.1 Competent Persons Trouble Shooting Guide

PROBLEM POSSIBLE CAUSE ACTION


No display on panel - unit will not Mains supply to control system off. Switch on mains supply if safe to do so.
operate
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 RUN PERM displayed 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.

Note: on some systems the pump starter may be wired to


the unit and controlled to start with the unit.

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 TEMP INHIBIT displayed Oil temperature has not reached Use the oil temperature display key to confirm that the oil
working temperature following temperature is slowly rising. The warning message should
power-up. clear when the oil temperature has reached the correct
working temperature.

Compressor crankcase heater not Check the operation of the heater. Measure the current
working. 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.


CHILLER FAULT: LOW AMBIENT Ambient air temperature is lower than Use the ‘ambient temp.’ key to display the temperature and
TEMP displayed the programmed operating limit. 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.

Measured temperature is incorrect. Check sensor calibration, location and wiring.


CHILLER FAULT: HIGH AMBIENT Ambient air temperature is higher Use the ‘ambient temp.’ key to display the temperature and
TEMP displayed than the programmed operating limit. 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.

Measured temperature is incorrect. Check sensor calibration, location and wiring.

(02/04)
8- 2 035L02537-100 Rev. 0

PROBLEM POSSIBLE CAUSE ACTION


CHILLER FAULT: LOW WATER Leaving liquid drops below the Check for restrictions in the liquid flow line.
TEMP displayed programmed low limit faster than the Check the liquid flow is stable.
unit can unload.

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 LWT sensor out of range. Check sensor calibration. Check sensor wiring for
FAULT displayed open/short circuit.
CHILLER FAULT: POW E R Incorrect mains supply voltage. Check mains supply voltage is stable and within
FAILURE MANUAL RESET permissible limits. Check voltage drop on compressor
displayed start.
SYS # HIGH DSCH displayed Discharge high pressure trip due to Check for airflow restrictions caused by blockages on
poor airflow through the condenser intake faces of air coils.
coils. Check for damaged fins/return bends.
Check for correct fan operation and direction of rotation.

Excessive refrigerant charge. Check for signs of air in the refrigerant system(s).
Check sub-cooling is correct.

Measured pressure is incorrect. Check discharge transducer calibration and wiring.


SYS # DSCH LIMITING displayed Discharge pressure unloading due to Check chilled liquid temperature is within range. Check if
unit operating above load limit. See ambient air temperature is above design conditions.
also SYS # HIGH DSCH.
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.
SYS # LOW SUCTION displayed 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.

Badly adjusted or faulty expansion Check superheat.


valve.

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 Compressor current too high or too Check compressor mains supply, fuses, contactors and
displayed low. 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 Check motor protector and wiring.


failure (no MP light on opto board). Check compressor motor.

Mechanical high pressure cut-out trip Check compressor discharge valve is open.
(standard and heat recovery Check cut-out setting and wiring.
systems). Check for restricted liquid flow in heat recovery system.
Check discharge line solenoid valve operation (including
pressure regulator setting).
SYS # PUMPDOWN FAIL displayed Liquid line solenoid valve not closed. Check operation of valve.
(Failure to pump down) Check wiring to valve.

Leak on low pressure side of system. Check low pressure side for air/liquid leaks.
Measured pressure incorrect. Check suction pressure transducer calibration and wiring.

(02/04)
035L02537-100 Rev. 0 8- 3

PROBLEM POSSIBLE CAUSE ACTION


SYS # CURR LIMITING displayed High compressor motor current has Check liquid temperature is within operating limits. Check if
activated unloading. ambient air temperature is above operating limits.
See also SYS # CURRENT/MP/HPX

8.2 Compressor Components Optional Compressor Liquid Injection Cooling


System
PC Compressors Unloading Valves
(oil pressure actuated) 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.

The liquid feed to the compressor is directly from the


main liquid line.

The operation of the solenoid valve 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.
Oil Pump-end Components

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

(02/04)
8- 4 035L02537-100 Rev. 0

8.3 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)


Temperature °C Resistance Ω Voltage Vdc
-10 16598 1,45
-8 14896 1,57
-6 13388 1,69
-4 12047 1,80
-2 10856 1,93
0 9795 2,05
2 8849 2,17
4 8005 2,30
6 7251 2,42
8 6575 2,54
10 5970 2,66
20 3748 3,22
30 2417 3,69
40 1598 4,05
Microboard test points: -BCLT Leaving Water: J11-7/1
-BMLT Mixed Leaving Water J17-11/1 YDAJ

Ambient Temperature Sensor


and 10 k Oil Temperature Sensor
Temperature °C Resistance Ω Voltage Vdc
-10 55330 0,97
-5 42227 1,20
0 32650 1,45
5 25390 1,72
10 19900 2,00
15 15710 2,29
20 12490 2,58
25 10000 2,85
30 8057 3,11
35 6530 3,35
40 5327 3,57
Microboard test point: - BAMB Ambient Air: J11-9/3
1-BOT Sys.1 Oil Temp: J11-8/2
2-BOT Sys.2 Oil Temp: J16-6/3

(02/04)
035L02537-100 Rev. 0 9- 1

9 TECHNICAL DATA

9.1 Flow Rate/Pressure Drop Charts

Cooler Water Pressure Drops


140
120

100
44M
80

77X
60 88X
99X
50

40
Pressure Drop (kPa)

30

Model Pressure Drop Calculation


20 08L,
Pressure Drop [kPa] = 0.2133 x (Flow Rate [l/s]1.7018)
09L

44M Pressure Drop [kPa] = 0.2920 x (Flow Rate [l/s]1.6730)

10 55S,
55S Pressure Drop [kPa] = 0.2101 x (Flow Rate [l/s]1.6914)
66S 66S
8
77X,
Pressure Drop [kPa] = 0.1103 x (Flow Rate [l/s]1.7282)
6 88X, 99X
08L
5 09L Pressure drop applies to each cooler on 4 Circuit Models
4 (i.e. the total unit flow should be divided by 2 to obtain the
5 6 8 10 20 30 40 50 60
Flow Rate (l/S)
flow rate through each cooler).

9.2 Operating Limitations

All YAEP Models Min. °C (°F) Max. °C (°F)


Leaving Chilled Liquid Temperature - R22 Units 4 (39) 12 (54)
Leaving Chilled Liquid Temperature - R407C Units 6 (43) 12 (54)
Chilled Liquid Temperature Difference 3.3 (6) 8 (15)
Air Entering Standard Units -4 (25) 52 (125)
Condenser Units with Low Ambient Kit -18*(0) 52 (125)
Electrical Power Supply 380/400/415 V, 3Ø, 50 Hz V 342 440

1 Circuit Units 2 Circuit Units


Model YAEP 08L 09L 44M 55S 66S 77X 88X 99X
Minimum Cooler Flow l/s (gpm) 6.0 (95) 6.0 (95) 7.5 (120) 9.4 (150) 9.4 (150) 15.8 (250) 15.8 (250) 15.8 (250)
Maximum Cooler Flow l/s (gpm) 19 (300) 19 (300) 36.5 (580) 40.5 (640) 40.5 (640) 50.7 (805) 50.7 (805) 50.7 (805)
Minimum System Volume l (Usg) 1310 (375) 1600 (455) 1330 (380) 1620 (460) 1870 (530) 2170 (615) 2570 (730) 3130 (890)

4 Circuit Units
Model YAEP 5555S 6666S 7777X 8888X 8899X 9999X
Minimum Cooler Flow l/s (gpm) 9.4 (150) 9.4 (150) 15.8 (250) 15.8 (250) 15.8 (250) 15.8 (250)
Maximum Cooler Flow l/s (gpm) 40.5 (640) 40.5 (640) 50.7 (805) 50.7 (805) 50.7 (805) 50.7 (805)
Minimum Unit Flow l/s (gpm) 18.8 (300) 18.8 (300) 31.6 (500) 31.6 (500) 31.6 (500) 31.6 (500)
Maximum Unit Flow l/s (gpm) 81 (1280) 81 (1280) 101.4 (1610) 101.4 (1610) 101.4 (1610) 101.4 (1610)
Minimum System Volume l (Usg) 3235 (920) 3735 (1065) 4335 (1235) 5140 (1465) 5910 (1680) 6265 (1785)
4 circuit units are fitted with 2 coolers. The table details flow rate for each cooler and total flow rate for the unit.

(02/04)
9- 2 035L02537-100 Rev. 0

9.3 Physical Data - R22 Models

1 Circuit Units 2 Circuit Units


YAEP 08LA7C 09LC9C 44MA7C 55SC7C 66SC9C 77XC9C 88XB7C 99XB7C 99XD9C
Unit Number of Capacity Steps 4 4 4 4 4 4 6 6 6
Cylinders per Compressor 8 8 4 4 6 6 8 8 8
Compressor
Oil Capacity per Compressor l 11 11 11 11 11 11 11 11 11
Coolers per Unit 1 1 1 1 1 1 1 1 1
Cooler Refrigerant Circuits per Cooler 1 1 2 2 2 2 2 2 2
Water Capacity per Cooler l 90 90 135 150 150 205 205 205 205
Condenser Face Area m2 11.9 11.9 11.9 11.9 11.9 11.9 23.8 23.8 23.8
Quantity 4 4 4 4 4 4 8 8 8
Fans Power (each) kW 2.2 3.8 2.2 2.2 3.8 3.8 2.2 2.2 3.8
Total Airflow m3/s 30.4 34.8 30.4 30.4 34.8 34.8 60.8 60.8 69.6
Systems 1 kg 39.0 42.0 42.0 49.0 49.0 49.0 57.0 57.0 64.0
Refrigerant Charge
Systems 2 kg 42.0 49.0 49.0 49.0 57.0 57.0 64.0
Shipping kg 3550 3665 4000 4200 4350 4495 5222 5222 5422
Aluminium Fins
Operating kg 3640 3640 4135 4350 4500 4700 5427 5427 5627
Weight
Shipping kg 3740 3955 4190 4490 4640 4785 5797 5797 5997
Copper Fins
Operating kg 3830 4045 4325 4640 4790 4990 6002 6002 6202
Length mm 2969 2969 2969 2969 2969 2969 5703 5703 5703
Dimensions Width mm 2241 2241 2241 2241 2241 2241 2241 2241 2241
Height mm 2466 2466 2466 2466 2466 2466 2466 2466 2466

4 Circuit Units
YAEP 5555SC7C 6666SC9C 7777XC9C 8888XB7C 8899XB7C 9999XD9C
Unit Number of Capacity Steps 8 8 8 12 12 12
Cylinders per Compressor 4 6 6 8 8 8
Compressor
Oil Capacity per Compressor l 11 11 11 11 11 11
Coolers per Unit 2 2 2 2 2 2
Cooler Refrigerant Circuits per Cooler 2 2 2 2 2 2
Water Capacity per Cooler l 150 150 205 205 205 205
Condenser Face Area m2 23.8 23.8 23.8 47.6 47.6 47.6
Quantity 8 8 8 16 16 16
Fans Power (each) kW 2.2 3.8 3.8 2.2 2.2 3.8
Total Airflow m3/s 60.8 69.6 69.6 121.6 121.6 139.2
Systems 1/2 kg 49.0 49.0 49.0 57.0 57.0 64.0
Refrigerant Charge
Systems 3/4 kg 49.0 49.0 49.0 57.0 57.0 64.0
Shipping kg 8400 8700 8990 10444 10444 10844
Aluminium Fins
Operating kg 8700 9000 9400 10854 10854 10844
Weight
Shipping kg 8980 9280 9570 11594 11594 10844
Copper Fins
Operating kg 9280 9580 9980 12004 12004 10844
Length mm 6128 6128 6128 11705 11705 11705
Dimensions Width mm 2241 2241 2241 2241 2241 2241
Height mm 2466 2466 2466 2466 2466 2466

(02/04)
035L02537-100 Rev. 0 9- 3

9.4 Physical Data - R407C Models

1 Circuit Units 2 Circuit Units


YAEP 08LA7B 09LC9B 44MC7B 55SC9B 66SC9B 77XC9B 77XF7B 88XD7B 99XD9B
Unit Number of Capacity Steps 4 4 4 4 4 4 4 6 6
Cylinders per Compressor 8 8 4 4 6 6 6 8 8
Compressor
Oil Capacity per Compressor l 11 11 11 11 11 11 11 11 11
Coolers per Unit 1 1 1 1 1 1 1 1 1
Cooler Refrigerant Circuits per Cooler 1 1 2 2 2 2 2 2 2
Water Capacity per Cooler l 90 90 135 150 150 205 205 205 205
Condenser Face Area m2 11.9 11.9 11.9 11.9 11.9 11.9 17.8 23.8 23.8
Quantity 4 4 4 4 4 4 6 8 8
Fans Power (each) kW 2.2 3.8 2.2 3.8 3.8 3.8 2.2 2.2 3.8
Total Airflow m3/s 30.4 34.8 30.4 34.8 34.8 34.8 44.7 60.8 69.6
Systems 1 kg 39.0 42.0 42.0 49.0 49.0 49.0 53.0 57.0 64.0
Refrigerant Charge
Systems 2 kg 42.0 49.0 49.0 49.0 53.0 57.0 64.0
Shipping kg 3550 3665 4000 4200 4350 4495 4985 5222 5422
Aluminium Fins
Operating kg 3640 3640 4135 4350 4500 4700 5190 5427 5627
Weight
Shipping kg 3740 3955 4190 4490 4640 4785 5400 5797 5997
Copper Fins
Operating kg 3830 4045 4325 4640 4790 4990 5605 6002 6202
Length mm 2969 2969 2969 2969 2969 2969 4193 5703 5703
Dimensions Width mm 2241 2241 2241 2241 2241 2241 2241 2241 2241
Height mm 2466 2466 2466 2466 2466 2466 2466 2466 2466

4 Circuit Units
YAEP 5555SC9B 6666SC9B 7777XC9B 7777XF7B 8888XD7B 8899XD7B 9999XD9B
Unit Number of Capacity Steps 8 8 8 8 12 12 12
Cylinders per Compressor 4 6 6 6 8 8 8
Compressor
Oil Capacity per Compressor l 11 11 11 11 11 11 11
Coolers per Unit 2 2 2 2 2 2 2
Cooler Refrigerant Circuits per Cooler 2 2 2 2 2 2 2
Water Capacity per Cooler l 150 150 205 205 205 205 205
Condenser Face Area m2 23.8 23.8 23.8 35.6 47.6 47.6 47.6
Quantity 8 8 8 12 16 16 16
Fans Power (each) kW 3.8 3.8 3.8 2.2 2.2 2.2 3.8
Total Airflow m3/s 69.6 69.6 69.6 89.4 121.6 121.6 139.2
Systems 1/2 kg 49.0 49.0 49.0 53.0 57.0 57.0 64
Refrigerant Charge
Systems 3/4 kg 49.0 49.0 49.0 53.0 57.0 57.0 64
Shipping kg 8400 8700 8990 9970 9970 9970 9970
Aluminium Fins
Operating kg 8700 9000 9400 9970 9970 9970 9970
Weight
Shipping kg 8980 9280 9570 9970 9970 9970 9970
Copper Fins
Operating kg 9280 9580 9980 9970 9970 9970 9970
Length mm 6128 6128 6128 8586 11705 11705 11705
Dimensions Width mm 2241 2241 2241 2241 2241 2241 2241
Height mm 2466 2466 2466 2466 2466 2466 2466

(02/04)
9- 4 035L02537-100 Rev. 0

9.5 Electrical Data - R22 Models


Power Requirement per Panel - 1, 2 and 4 Refrigerant Circuit Units with Single Point Power Supply - Disconnect Switch (CE) or Terminal Block Option (Non CE)
(Data includes one/both compressors and associated fans)
Note: To obtain the total unit power requirements on four circuit models 5555SC7C / 6666SC9C / 7777XC9C / 8888XB7C / 9999XD9C multiply the panel values by 2.
Note: To obtain the total unit power requirements on four circuit model 8899XB7C the panel values should be added together.

YAEP Model 35°C/7°C Nominal. Amps Maximum. Amp Part Wind Inrush
Circuits
Nom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V
08LA7C 1 101 144 195 194 193 293 268 266 264 689 725 752
09LC9C 1 122 150 228 226 224 293 268 266 264 689 725 752
44MC7C 2 107 125 197 195 193 275 231 225 221 398 409 420
(55)55SC7C 2/4 137 163 239 237 235 315 289 285 279 500 518 532
(66)66SC9C 2/4 149 185 278 276 274 356 336 332 328 626 648 674
(77)77XC9C 2/4 189 227 348 344 342 422 408 404 400 753 780 802
(88)88XB7C 2/4 228 300 410 408 406 580 530 526 522 954 988 1015
99XB7C 2 270 300 480 470 466 580 530 526 522 954 988 1015
228 300 410 408 406 580 530 526 522 954 988 1015
8899XB7C 2+2
270 300 480 470 466 580 530 526 522 954 988 1015
(99)99XD9C 2/4 250 300 469 463 461 595 545 541 537 961 995 1020

Power Requirement per Refrigeration Circuit - 2 and 4 Refrigerant Circuit Units with Multi Point Power Supply Option (Non CE)
(Data includes each circuit compressor and associated fans)

YAEP Model 35°C/7°C Nominal. Amps Maximum. Amp Part Wind Inrush
Circuits
Nom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V
44MC7C 2 53 62 98 97 96 137 115 112 110 283 297 308
55SC7C 2 69 82 119 118 117 157 144 142 139 356 376 390
66SC9C 2 75 93 139 138 137 178 168 166 164 458 482 508
77XC9C 2 95 114 174 172 171 211 204 202 200 549 578 600
88XB7C 2 114 150 205 204 203 290 265 263 261 689 725 752
99XB7C 2 135 150 240 235 233 290 265 263 261 689 725 752
99XD9C 2 125 150 234 231 230 297 272 270 268 689 725 752
5555SC7C 4 65 82 119 118 117 157 144 142 139 356 376 390
6666SC9C 4 71 93 139 138 137 178 168 166 164 458 482 508
7777XC9C 4 91 114 174 172 171 211 204 202 200 549 578 600
8888XB7C 4 114 150 205 204 203 290 265 263 261 689 725 752
8899XB7C Main 2 114 150 205 204 203 290 265 263 261 689 725 752
8899XB7C Aux 2 135 150 240 235 233 290 265 263 261 689 725 752
9999XD9C 4 125 150 234 227 230 297 272 270 268 689 725 752

9.6 Electrical Data - R407C Models

Power Requirement per Panel - 1, 2 and 4 Refrigerant Circuit Units with Single Point Power Supply - Disconnect Switch (CE) or Terminal Block Option (Non CE)
(Data includes one/both compressors and associated fans)
Note: To obtain the total unit power requirements on four circuit models 5555SC9B / 6666SC9B / 7777XC9B / 7777XF7B / 8888XB7B / 9999XD9B multiply the panel values by 2.
Note: To obtain the total unit power requirements on four circuit model 8899XB7B the panel values should be added together.

YAEP Model 35°C/7°C Nominal. Amps Maximum. Amp Part Wind Inrush
Circuits
Nom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V
08LC7B 1 97 144 190 189 188 293 268 266 264 689 725 752
09LC9B 1 123 150 228 226 224 293 268 266 264 689 725 752
44MC7B 2 105 125 197 195 193 275 231 225 221 398 409 418
(55)55SC9B 2/4 137 163 246 244 242 322 296 292 286 504 522 533
(66)66SC9B 2/4 149 185 280 278 276 356 336 332 328 626 648 672
(77)77XC9B 2/4 187 227 348 346 342 422 412 406 400 755 781 800
(77)77XF7B 2/4 177 225 331 329 327 427 417 411 405 758 784 803
(88)88XB7B 2/4 200 288 386 380 374 580 530 526 522 954 988 1013
200 288 386 380 446 580 530 526 522 954 988 1013
(88)99XB7B 2+2
244 288 450 448 446 580 530 526 522 954 988 1013
(99)99XD9B 2/4 250 300 457 455 453 595 545 541 537 961 995 1020

Power Requirement per Refrigeration Circuit - 2 and 4 Refrigerant Circuit Units with Multi Point Power Supply Option (Non CE)
(Data includes each circuit compressor and associated fans)

YAEP Model 35°C/7°C Nominal. Amps Maximum. Amp Part Wind Inrush
Circuits
Nom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V
44MC7B 2 52 62 98 97 96 137 115 112 110 283 297 308
55SC9B 2 69 82 123 122 121 161 148 146 143 356 376 390
66SC9B 2 75 93 140 139 138 178 168 166 164 458 482 508
77XC9B 2 94 114 174 173 171 211 206 203 200 549 578 600
77XF7B 2 89 113 166 165 164 214 209 206 203 549 578 600
88XB7B 2 100 144 193 190 187 290 265 263 261 689 725 752
99XD9B 2 125 150 228 227 226 297 272 270 268 689 725 752
5555SC9B 4 65 82 123 122 121 161 148 146 143 356 376 390
6666SC9B 4 71 93 140 139 138 178 168 166 164 458 482 508
7777XC9B 4 90 114 174 173 171 211 206 203 200 549 578 600
7777XF7B 4 91 113 166 165 164 214 209 206 203 549 578 600
8888XB7B 4 100 144 193 190 187 290 265 263 261 689 725 752
8899XB7B Main 2 100 144 193 190 187 290 265 263 261 689 725 752
8899XB7B Aux 2 122 144 225 224 223 290 265 263 261 689 725 752
9999XD9B 4 125 150 228 227 226 297 272 270 268 689 725 752

(02/04)
035L02537-100 Rev. 0 9- 5

9.7 Control Circuit Electrical Data


Units with Multi Point Power Supply Option (Non CE)
Control Supply Load at 400 V (A) 3.5
Internal Fuse Rating Class aM 10
Maximum Customer Fuse Rating 16

9.8 Compressor Electrical Data - R22 Models (All values are per compressor)

Comp. 35°C/7°C 380 V 400 V 415 V 342 V 380 V 400 V 415 V Part Wind
Size Nom kw Max kw Nom. Amps Nom. Amps Nom. Amps Max. Amp Max. Amps Max. Amps Max. Amps Inrush
4 49 58 86 85 84 125 103 98 98 283
5 61 74 107 106 105 145 132 128 127 356
6 67 85 123 122 122 162 152 148 148 482
7 87 106 158 154 155 195 190 184 184 578
8 99 135 180 178 180 265 240 238 236 725
9 110 135 196 195 194 265 240 238 236 725

Note on 99XB7 models the nominal power (kW) and norminal current (A) is 2% higher.

9.9 Compressor Electrical Data - R407C Models (All values are per compressor)

Comp. 35°C/7°C 380 V 400 V 415 V 342 V 380 V 400 V 415 V Part Wind
Size Nom kw Max kw Nom. Amps Nom. Amps Nom. Amps Max. Amp Max. Amps Max. Amps Max. Amps Inrush
4 48 58 86 85 84 125 103 98 98 283
5 61 74 107 106 105 145 132 128 127 356
6 67 85 123 122 122 162 152 148 148 482
7 82 106 149 145 146 195 190 184 184 578
8 91 135 168 164 162 265 240 238 236 725
9 110 135 196 195 194 265 240 238 236 725

9.10 Fan Data - (All values per fan)

R22 Units R407C Units


YAEP Model Fans per Power (kW) Current (A) Power (kW) Current (A)
Circuit
R22 R407C Circuit per Fan per Fan per Fan per Fan
08MA7C 08MC7B 1 4 2.2 6.2 2.2 6.2
09MC9C 09MC9B 1 4 3.8 8.2 3.8 8.2
44MA7C 44MC7B 1 and 2 2 2.2 6.2 2.2 6.2
55SC7C 55SC9B 1 and 2 2 2.2 6.2 3.8 8.2
66SC9C 66SC9B 1 and 2 2 3.8 8.2 3.8 8.2
77XC9C 77XC9B 1 and 2 2 3.8 8.2 3.8 8.2
77XF7B 1 and 2 3 2.2 6.2
88XB7C 88XB7B 1 and 2 4 2.2 6.2 2.2 6.2
99XB7C 1 and 2 4 2.2 6.2
99XD9C 99XD9B 1 and 2 4 3.8 8.2 3.8 8.2
5555SC7C 5555SC9B 1, 2, 3 and 4 2 2.2 6.2 3.8 8.2
6666SC9C 6666SC9B 1, 2, 3 and 4 2 3.8 8.2 3.8 8.2
7777XC9C 7777XC9B 1, 2, 3 and 4 2 3.8 8.2 3.8 8.2
7777XF9B 1, 2, 3 and 4 3 3.8 8.2
8888XB7C 8888XD7B 1, 2, 3 and 4 4 2.2 6.2 2.2 6.2
8899XB7C 8899XD7B 1, 2, 3 and 4 4 2.2 6.2 2.2 6.2
9999XD9C 9999XD9B 1, 2, 3 and 4 4 3.8 8.2 3.8 8.2

(02/04)
9- 6 035L02537-100 Rev. 0

9.11 Fuse Ratings and Lug Sizes

Units with Single Point Power Supply Multi Point


Disconnect Switch Terminal Block System Fuses Power Supply
(CE) (Non CE) Max IEC 269-2-1 gG fuse Size (Non CE)
YAEP Model Input Rating Input Rating Din NH Max. 5 S Contactor
R22 R407C Lug Size Ie (A) Lug Size (A) Size Interrupt (A) Lug Size
08MA7C 08MC7B M12 630 M12 355 2 2200 M10
09MC9C 09MC9B M12 630 M12 355 2 2200 M10
44MA7C 44MC7B M10 500 M12 160 1 810 M10
55SC7C 55SC9B M10 500 M12 200 1 1000 M10
66SC9C 66SC9B M10 500 M12 250 1 1300 M10
77XC9C 77XC9B M10 500 M12 250 1 1300 M10
77XF7B M10 500 M12 250 1 1300 M10
88XB7C 88XB7B M12 630 M12 355 2 2200 M10
99XB7C M12 630 M12 355 2 2200 M10
99XD9C 99XD9B M12 630 M12 355 2 2200 M10
5555SC7C 5555SC9B M10 500 M12 200 1 1000 M10
6666SC9C 6666SC9B M10 500 M12 250 1 1300 M10
7777XC9C 7777XC9B M10 500 M12 250 1 1300 M10
7777XF9B M10 500 M12 250 1 1300 M10
8888XB7C 8888XD7B M12 630 M12 355 2 2200 M10
8899XB7C 8899XD7B M12 630 M12 355 2 2200 M10
8899XB7C 8899XD7B M12 630 M12 355 2 2200 M10
9999XD9C 9999XD9B M12 630 M12 355 2 2200 M10

(02/04)
035L02537-100 Rev. 0 9- 7

9.12 Clearances

The recommended clearances and dimensions are the distances between the edge of the units and the
architectural enclosure surrounding them. It is important that adequate space is available to ensure that air
discharged via the fans is not recirculated into the condenser coil intake, which would reduce the unit capacity.

The dimensions at the front and rear of the units allow for access to the control panel and for component removal.

The enclosure height should not exceed the height of the units except that only one adjacent wall may be higher than
the unit. Horizontal obstructions or overhangs should not be closer than 15 metres above the top of any unit and no
obstructions are allowed directly above the unit

1.3 m
2m

2m 2m

1.3 m 2m
2m

2m
1.3 m

2m 3m 2m

2m
2m

(02/04)
9- 8 035L02537-100 Rev. 0

9.13 Dimensions

Models - YAEP 08L - 09L

520

446

2172 AVM POSITIONS


2241
148
840
1990

L
1911 AVM C

2897
1778
2969

500
493 AVM

335

2466
946

(02/04)
(02/04)
Models - YAEP 44M - 77XC

2969

2466.4
407
(382 on 44M and 446 on 77XC)

2241 493 1911 702


035L02537-100 Rev. 0

340 2108 (2160 on 44M) 449 2172 AVM POSITIONS


(314 on 44M) 2897
9- 9
9-10

Model - YAEP 77XF


035L02537-100 Rev. 0

4250

2241

2467
446

312 1676 AVM POSNS. 1707 AVM POSNS. 493 702


1631 2108 2166 AVM POSNS.
4187

(02/04)
(02/04)
Models - YAEP 88X - 99X

1800
5700
221

40
1153

2426
124
838

446
634 2108 702
2166 AVM POSITIONS
COMPRESSOR
199 AVM 2438 AVM POSITIONS 1220 AVM 1257 AVM 292 AVM
2241 SYSTEM 2
5407
035L02537-100 Rev. 0

SYSTEM 1 COMPRESSOR
REMOVED FOR DRAWING CLARITY
9-11
9-12 035L02537-100 Rev. 0

Models - YAEP 5555S - 7777XC


WITH ALUMINIUM / PHENOLIC COATED
CONDENSER COILS
MODEL
MOUNT POSITION
A B C D E F G H TOTAL
77SB7 POINT LOAD 775 788 795 916 715 766 773 832 6360
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
88XB7 POINT LOAD 828 846 853 978 820 904 919 952 7100
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
99XB7 POINT LOAD 828 846 853 978 820 904 919 952 7100
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
99XD9 POINT LOAD 847 865 872 998 838 922 938 970 7250
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

WITH COPPER FINNED CONDENSER COILS


MODEL MOUNT POSITION
A B C D E F G H TOTAL
77SB7 POINT LOAD 892 905 912 1033 832 883 890 949 7296
MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-31 CP-2-28 CP-2-28 CP-2-31 CP-2-31
88XB7 POINT LOAD 894 905 913 1035 833 883 896 954 7313
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
99XB7 POINT LOAD 945 963 970 1095 937 1021 1036 1069 8036
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
99XD9 POINT LOAD 996 1014 1021 1147 987 1071 1087 1119 8442
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

1150 840

2172 AVM POSITIONS


2241

(446 on 7777XC)
406

1911 AVM POS.


2108
2897
493
340
6232

300
340
493
1911 AVM POS.
2108
2897

2466

(02/04)
(02/04)
Model - YAEP 7777XF

8812
300 2241

2467
446
2108 1631 1631 2108 702
493 1707 1676 312 312 1676 1707 2172
4187 4187
8675
035L02537-100 Rev. 0
9-13
9-14

MULTI POINT
MULTI POINT CABLE ENTRY
CABLE ENTRY SYSTEM 2
SYSTEM 3

SINGL POINT
SINGL POINT CABLE ENTRY
CABLE ENTRY SYSTEMS 1 & 2

1800
SYSTEMS 3 & 4
Models - YAEP 8888X - 9999X

MULTI POINT
CABLE ENTRY
MULTI POINT SYSTEM 1
CABLE ENTRY
035L02537-100 Rev. 0

SYSTEM 4

11700

221

40
1153

2426
838

446
2166 AVM POSITIONS
292 1257 AVM 1220 AVM 2438 AVM POSITIONS 699 1257 AVM 292
702
COMPRESSOR
292 2664 2108 1568 REF. 292 SYSTEM 2,3
2241
5407 5407
SYSTEM 1 and 4 COMPRESSORS
300 REMOVED FOR DRAWING CLARITY

Note: DIMENSIONS AND AVM POSITIONS


ARE IDENTICAL FOR BOTH SECTIONS
- REFER TO OTHER SECTION FOR DETAILS

(02/04)
035L02537-100 Rev. 0 10-1

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.

For further details on unit spare parts refer to Renewal


Parts List 035L02601-100 Rev. 0. For details of
compressor spare parts refer to Illustrated Parts
Catalogue 035L02426-000.
DESCRIPTION PART NUMBER
Transducer, Pressure, Discharge 025-29139-001

Transducer, Pressure, Oil 025-29583-000

Sensor, Temperature, Oil 025-34177-000

Heater, Crankcase (350W) 025L02296-000


Valve, Solenoid, Unloading 025L02488-000
Oil See Section 2
Heater, Crankcase (450W) (Optional part) 025L02297-000

Switch, Pressure, High (Internal Manual Reset) (Optional part) 025-34119-990

Switch, Pressure, High (External Manual Reset) (Optional part) 025-34120-990

Switch, Pressure, High (Automatic) (Optional part) 025-28985-002

Sensor, Temperature, Water 025L02168-000

Core, Drier 026-37540-000


Coil, Solenoid, Replacement 025L02027-DAN
Powerhead, Valve, Expansion, Replacement 025-32902-000

Transducer, Pressure, Suction 025-29583-000

Coil, Solenoid, Replacement (Optional part) 025-29139-001


Fuse 025L02645-000
Fuse 025L02431-000
Fuse 025L02434-000
Fuse 025L02428-000

Key, Door 021L00724-000

Key, Door 021L00736-000


Sensor, Temperature, Water, Mix (Duplex Units only) 025L02168-000
Sensor, Temperature, Air, Outside 025L01963-000
Compound, Conductive, Heat 013-00898-000
Switch, Flow, Water (Optional part) 024-26116-000

(02/04)
10-2 035L02537-100 Rev. 0

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

10.3 Associated Drawings


Model YAEP 08L - 09L 44M - 77XC 77XF 88X - 99X
Product Drawing 035L02594-000 035L02593-000 035L02622-000 035L02532-000

Model YAEP 5555S - 7777XC 7777XF 8888X - 9999X


Product Drawing 035L02621-000 035L02623-000 035L02539-000

System 1 & 2 System 3 & 4


Schematic 035L02534-000 035L02574-000
Wiring
Connection 035l02535-000 035L02575-000
Diagrams
Legend/Notes 035L02384-GB1
Process & Instrumentation Diagram 035L02533-000

(02/04)
035L02537-100 Rev. 0 11-1

11 DE-COMMISSIONING, DISMANTLING
AND DISPOSAL

Never release refrigerant to the If glycol or similar solutions have been


atmosphere when emptying the used in the water system(s), or chemical
refrigerating circuits. Suitable retrieval additives are contained, the solution
equipment must be used. If reclaimed MUST be disposed of in a suitable and safe
refrigerant cannot be re-used. It must be manner. Under NO circumstances should
returned to the manufacturer through any system containing glycol or similar
authorised agencies. solutions be drained directly into domestic
waste or natural water systems.
Never discard used compressor oil, as it
contains refrigerant in solution. Return After draining, the water pipework can be disconnected
used oil to the oil manufacturer through and removed.
authorised agencies.
Packaged units can generally be removed in one piece
after disconnection as above. Any fixing down bolts
Unless otherwise indicated, the operations described should be removed and then the unit should be lifted
below can be performed by any properly trained from position using the points provided and equipment
maintenance technician. of adequate lifting capacity.
11.1 General Reference should be made to Section 4 for unit
installation instructions, Section 9 for unit weights and
Isolate all sources of electrical supply to the unit Section 3 for handling.
including any control system supplies switched by the
unit. Ensure that all points of isolation are secured in the Units which cannot be removed in one piece after
‘OFF’ position. The supply cables may then be disconnection as above must be dismantled in position.
disconnected and removed. For connection points refer Special care should be taken regarding the weight and
to Section 4. handling of each component. Where possible units
should be dismantled in the reverse order of installation.
Remove all refrigerant from each system of the unit into
a suitable container using a refrigerant reclaim or Residual refrigerant oil and glycol or
recovery unit. This refrigerant may then be re-used, if similar solutions may remain in some
appropriate, or returned to the manufacturer for parts of the system. These should be
disposal. Under NO circumstances should refrigerant mopped up and disposed of as described
be vented to atmosphere. Drain the refrigerant oil from above.
each system into a suitable container and dispose of
according to local laws and regulations governing the It is important to ensure that whilst components are
disposal of oily wastes. Any spilt oil should be mopped being removed the remaining parts are supported in a
up and similarly disposed of. safe manner.
Isolate the unit heat exchanger(s) from all external water Only use lifting equipment of adequate
systems and drain the heat exchanger section(s) of the capacity.
system. If no isolation valves are installed it may be
necessary to drain the complete system(s).

After removal from position the unit parts may be


disposed of according to local laws and regulations.

(02/04)
EMEA
YORK
YORK INTERNATIONAL
Part No. 035L02537-100 Rev. 0 (02/04) GB
Gardiners Lane South, Basildon, Essex SS14 3HE, England Subject to change without notice. ALL RIGHTS RESERVED