LCHM/LCHHM

LIQUID CHILLERS

INSTALLATION, COMMISSIONING,
OPERATION AND MAINTENANCE

STYLE E
REFRIGERANT TYPE: R22, R407C, R134A

035L02374-GB2 (05/02)

GB
 035L02374-GB2 (05/02) 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 Foundation and Mounting 4.1

1.3 Safety 1.1 4.3 Vibration Isolator Installation

& Dimensions 4.1
1.4 Responsibility for Safety 1.1
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 4.3
1.7 Emergency Shutdown 1.4
4.7 Connection Types & Sizes 4.5
1.8 Safety Labels 1.4
4.8 Refrigerant Relief Valve Piping 4.6
1.9 Material Safety Data 1.6
4.9 Condenser Cooling Water Systems 4.6
2 PRODUCT DESCRIPTION
4.10 Remote Refrigerant Condenser
2.1 Introduction 2.1 Systems 4.7

2.2 Compressors 2.1 4.11 Electrical Connection 4.9

2.3 Cooler 2.1 4.12 Power Wiring 4.10

2.4 Condensers 2.1 4.13 Power Section Volt Free Contacts 4.11

2.5 Refrigerant Circuits 2.2 4.14 Logic Section Connections 4.12

2.6 Power and Control Panels 2.2 4.15 Connection Schematics 4.13

2.7 Options and Accessories 2.2 5 COMMISSIONING

2.8 Nomenclature 2.4 5.1 Preparation 5.1

3 TRANSPORTATION, HANDLING 5.2 First Time Start-up 5.4

AND STORAGE
6 UNIT OPERATION
3.1 Delivery and Storage 3.1
6.1 General Description 6.1
3.2 Inspection 3.1
6.2 Start-up 6.1
3.3 Moving the Chiller 3.1
6.3 Normal Running and Cycling 6.1
3.4 Lifting Weights 3.2
6.4 Compressor Capacity Control 6.2

6.5 Heat Recovery Operation 6.2

6.6 Shutdown 6.2

 I-ii 035L02374-GB2 (05/02)

7 MAINTENANCE 9 TECHNICAL DATA

7.1 General Requirements 7.1 9.1 Flow Rate/Pressure Drop Charts 9.1

7.2 Daily Maintenance 7.1 9.2 Operating Limitations 9.3

7.3 Scheduled Maintenance 7.2 9.3 Physical Data 9.6

7.4 Vessels In-Service Inspection 7.2 9.4 Electrical Data 9.10

8 TROUBLE SHOOTING 9.5 Dimensions and Layout 9.14

8.1 Competent Persons Trouble 9.6 Lifting Weights 9.23

Shooting Guide 8.1
9.7 Weight Distribution 9.23
8.2 Compressor Components 8.3
9.8 Isolator Positions 9.24
8.3 Sensor Calibration Charts 8.4
9.9 Process and Instrumentation
8.4 Electronic Expansion Valve Diagrams (per circuit) 9.26
Calibration 8.5
10 SPARE PARTS
8.5 Electronic Expansion Valve Trouble
Shooting 8.6 10.1 Recommended Spares 10.1

10.2 Compressor Top Head Rebuild Kit 10.1

11 DE-COMMISSIONING, DISMANTLING
AND DISPOSAL

11.1 General 11.1


1 SUPPLIER INFORMATION
1.1 Introduction
Y or k LC HM /L CHHM Se ri e s Ch i l l ers are
manufactured to the highest design and
c ons t r uc t ion sta n d a rd s t o e n su re high
performance, reliability and adaptability to all types
of air conditioning installations.
The unit is intended for cooling (and heating) water
or glycol solutions and is not suitable for purposes
other than those specified in this manual.
This manual and the Operating Instructions for the
Micro Based Control System contain all the
information required for correct installation and
commissioning of the unit, together with operating
and maintenance instructions. The manuals
should be read thoroughly before attempting to
operate or service the unit.
All procedures detailed in the manuals, including
installation, commissioning and maintenance
tasks must only be performed by suitably trained
and qualified personnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation,
commissioning, operation or maintenance
resulting from a failure to follow the procedures and
instructions detailed in the manuals.
1.2 Warranty
York International Limited warrants all equipment
and materials against defects in workmanship and
materials for one year from initial start-up, or
eighteen months from delivery (whichever occurs
first) unless extended warranty has been agreed
as part of the contract.
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 design parameters specified.
All warranty claims must specify the unit model,
serial number and order number. These details are
printed on the unit identification plate.
035L02374-GB2 (05/02) 1- 1
The unit warranty will be void if any modification to
the unit is carried out without prior written approval
from York International.
For warranty purposes, the following conditions
must be satisfied:
The initial start of the unit must be carried out by
trained personnel from an Authorised York Service
Centre.
Only genuine York approved spare parts, oils and
refrigerants must be used.
All the scheduled maintenance operations detailed
in this manual must be performed at the specified
times by suitably trained and qualified personnel.
Failure to satisfy any of these conditions will
automatically void the warranty.
1.3 Safety
Standards for Safety
LCHM/LCHHM Series Chillers are designed and
built within an EN ISO 9001 accredited design and
manufacturing organisation and, within the limits
specified in this manual, are in conformity with the
essential health and safety requirements of the
following European Union Directives:
Machinery Directive (89/392/EEC)
Low Voltage Directive (73/23/EEC)
EMC Directive (89/336/EEC)
Refrigeration equipment built at York Basildon
conforms to the applicable essential safety
requirements of Pressure Equipment Directive
97/23/EC and bear CE marking.
1.4 Responsibility for Safety
Every care has been taken in the design and
manufacture of York Chillers to ensure that they
meet the safety requirements listed in the previous
paragraph. However, the individual operating or
working on any machinery is primarily responsible
for:
Personal safety, safety of other personnel, and the
machinery
 1- 2 035L02374-GB2 (05/02)

Correct utilisation of the machinery in accordance

with the procedures detailed in this manual.

1.5 About this Manual

The following symbols are used in this document to

alert the reader to areas of potential hazard.

A Warning is given in this document to

identify a hazard which could lead to
personal injury. Usually an instruction
will be given, together with a brief
explanation and the possible result of
ignoring the instruction.

A Caution identifies a hazard which could

lead to damage to the machine, damage
to other equipment and/or environmental
pollution. Usually an instruction will be
given, together with a brief explanation
and the possible result of ignoring the
instruction.

A Note is used to highlight additional

information which may be helpful to you
but where there are no special safety
implications.

The contents of this manual include suggested

best working practices and procedures. These are
issued for guidance only, they do not take
precedence over the above stated individual
responsibility and/or local safety regulations.

This manual and any other document supplied with

the unit, are the property of YORK which reserves
all rights. They may not be reproduced, in whole or
in part, without prior written authorisation from an
authorised YORK representative.

1.6 Misuse of Equipment

Suitability for Application

The unit is intended for cooling (and heating) water

or glycol solutions and is not suitable for purposes
other than those specified in these instructions.
Any use of the equipment other than its intended
use, or operation of the equipment contrary to the
relevant procedures may result in injury to the
operator, or damage to the equipment.

The unit must not be operated outside the design

parameters specified in this manual.

Structural Support
Structural support of the unit must be provided as
indicated in these instructions. Failure to provide
proper support may result in injury to the operator,
or damage to the equipment.
Mechanical Strength
The unit is not designed to withstand loads or
stresses from adjacent equipment, pipework or
structures. Additional components must not be
mounted on the unit. Any such extraneous loads
may cause structural failure and may result in injury
to the operator, or damage to the equipment.
General Access
There are a number of areas and features which
may be a hazard and potentially cause injury when
working with the unit unless suitable safety
precautions are taken. It is important to ensure
access to the unit is restricted to suitably qualified
persons who are familiar with the potential hazards
and precautions necessary for safe operation and
maintenance of equipment containing high
temperatures, pressures and voltages.
Pressure Systems
Each unit has one or two independent pressure
systems each comprising a compressor, water
cooled condenser (WL units) or receiver tank
(AL-R units), cooler vessel and interconnecting
copper pipework. Each system contains refrigerant
vapour and liquid under pressure, release of which
can be a danger and cause injury. The user should
ensure that care is taken during installation,
operation and maintenance to avoid damage to the
pressure system. No attempt should be made to
gain access to the component parts of the pressure
system other than by suitably trained and qualified
personnel.
035L02374-GB2 (05/02) 1- 3
Electrical
The unit must be earthed. No installation or
maintenance work should be attempted on
electrical equipment without first switching off,
isolating and locking-off the main power supply
and any control supplies. Work on live equipment
must only be carried-out by suitably trained and
qualified personnel. No attempt should be made to
gain access to internals of the control panel, wiring
or other electrical enclosures during normal
operation of the unit.
LCHM LCHHM
Sharp Edges
Reasonable care should be taken when working in
contact with the unit to avoid the risk of minor
abrasions and lacerations from sharp edges. The
use of gloves is recommended.
Refrigerants and Oils
Refrigerants and oils used in the unit are generally
non-toxic, non-flammable and non-corrosive, and
pose no special safety hazards. Use of gloves and
safety glasses are, however, recommended when
working on the unit. Build up of refrigerant vapour,
from a leak for example, does pose a risk of
asphyxiation in confined or enclosed spaces and
attention should be given to good ventilation. For
more comprehensive information on safety
precautions for use of refrigerants and oils, refer to
the Materials Safety Data tables provided.
High Temperature and Pressure Cleaning
High temperature and pressure cleaning methods
(e.g. steam cleaning) should not be used on any
part of the pressure system as this may cause
operation of the pressure relief device(s).
Detergents and solvents which may cause
corrosion should also be avoided.
 1- 4 035L02374-GB2 (05/02)

1.7 Emergency Shutdown 1.8 Safety Labels

In case of emergency the control panel is fitted with The following labels are fixed to each unit to give
an emergency stop button (LCHM) or stop switch instruction, or to indicate potential hazards which
(LCHHM) which, when operated, removes the may exist.
electrical supply from the control system and the
microprocessor controller. On LCHM units the White symbol on b lu e
button, once pressed, requires key release. On background
LCHHM units the switch can be pad-locked in the
off position. A facility is available to connect a For safe operation - read the
remote emergency stop device for the same Instructions first
purpose. The unit emergency stop button or switch
is red on a yellow back plate.

Black symbol on yellow

background

Warning: This machine may

start automatically without
prior warning

Black symbol on yellow

background

Warning: Hot surface

Black symbol on yellow

background

Warning: Safety relief valve

may discharge gas or liquid
without prior warning
 035L02374-GB2 (05/02) 1- 5

Black symbol on yellow

background

W a rn i n g : Iso l ate all

electrical sources of supply
before opening or removing
the cover, as lethal voltages
may exist

Black symbol on yellow

background

General attention symbol

 1- 6 035L02374-GB2 (05/02)

1.9 Material Safety Data

Refrigerant Data:

Safety Data R22, R407C, R134a

Toxicity Low.

In contact with skin
Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous
by skin absorption. R22 may be slightly irritant and liquid has a degreasing
effect. Thaw affected areas with water. Remove contaminated clothing
carefully - may adhere to skin in case of freeze burns. Wash affected areas
with plenty of warm water. If symptoms occur (irritation or blistering) obtain
medical attention.

In contact with eyes Vapour has no effect. Liquid splashes or spray may cause freeze burns.
Immediately irrigate with eyewash solution or clean water for at least 10
minutes. Obtain immediate medical attention.

Ingested Highly unlikely to occur -but should this occur freeze burn will occur. Do not
induce vomiting. Provided patient is conscious, wash mouth with water and
give about 250 ml (0.5 pint) to drink. Obtain immediate medical attention.

Inhalation R22 Hig h l evel s of vapour R407C, R134a High atmospheric

concentration initially produce
stimulation and then depression of
the central nervous system causing
headaches and giddiness and may
lead to unconsciousness. Can
prove suddenly fatal if the exposure
has been severe.
concent r at i ons may le a d
anaesthetic effect, including loss of
consci ousness. Ver y h ig h
exposures may cause an abnormal
heart rhythm and prove suddenly
fatal.

At higher concentration there is a danger from asphyxiation due to reduced

oxygen content of atmosphere. Remove patient to fresh air, keep warm and
at rest. Administer oxygen if necessary. Apply artificial respiration if
breathing has ceased or shows signs of failing. In event of cardiac arrest
apply external cardiac massage. Obtain immediate medical attention.

Further medical advice Symptomatic and supportive therapy is indicated. Cardiac sensitisation
has been described which may, in the presence of circulating
catecholamines such as adrenalin, give rise to cardiac arrhythmias and
subsequent arrest following exposure to high concentrations.

Long term exposure
R22 A lifetime inhalation study in
rats and mice give a small excess in
salivary gland tumours in male rats
only at 50,000 ppm. 10,000 ppm
showed no effect. This information
suggests t hat R 22 does not
represent a carcinogenic hazard to
humans.
R407C, R134a A lifetime inhalation
study in rats has shown that
exposure to 50,000 ppm resulted in
benign tumours of the testis. This is
not considered to be of relevance to
humans exposed to concentrations
at or below the occupational
exposure limit.

Occupational exposure limits R22 Recommended limit: 1000 ppm R407C, R134a Recommended
v/v - 8 hr TWA 1250 ppm v/v - 12 hr limit: 1000 ppm v/v - 8 hr TWA.
TWA.

Stability R22 Unstable. R407C, R134a Not specified.

Conditions to avoid Use in presence of naked flames, red hot surfaces and high moisture
levels.

Hazardous reactions
Hazardous decomposition products
General precautions
Respiratory protection
Storage
Protective clothing
Spill/leak procedure
Disposal
Fire extinguishing data
Containers
Fire fighting protective equipment
Refrigerant Oil Data
Safety Data
Classification
In contact with skin
In contact with eyes
Ingested
035L02374-GB2 (05/02) 1- 7
May react violently with sodium, potassium, barium and other alkali and
alkaline earth metals. Incompatible materials: Magnesium and alloys
containing more then 2% magnesium.
R22 Halogen acids formed by R407C, R134a Halogen acids by
thermal decomposition. t her mal decomposi t i on a n d
hydrolysis.
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.
Where doubt exists on atmospheric concentration, HSE approved
breathing apparatus should be worn. This should be self contained or of the
long breather type.
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.
Wear overalls, impervious gloves and goggles/face protection.
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.
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.
R22 Non-flammable R407C. R134a Non-flammable at
atmospheric conditions.
Fire exposed containers should be kept cool with water sprays. Containers
may burst if overheated.
Self contained breathing apparatus and protective clothing must be worn in
fire conditions.
York “C” Oil York “H” Oil
Non-hazardous
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.
As with most foreign materials flush Flush eyes with eyewash solution or
with plenty of eyewash solution or clean water for 15 minutes and
clean water. consult a physician.
Non-toxic. No first aid considered May cause nausea and diahorrhea.
necessary. Obtain immediate medical attention.
 1- 8 035L02374-GB2 (05/02)
Inhalation
Occupational exposure limits
Stability
Conditions to avoid
Hazardous decomposition
Respiratory protection
Protective clothing
Spill / Leak procedure
Disposal
Fire extinguishing data
Containers
Fire fighting protective equipment
If oil mist is inhaled, remove to fresh air and consult a physician.
Recommended limit: 5 mg/cubic Not determined.
metre of oil mist in air for 8 hr daily
exposure.
Stable. Stable but hygroscopic -store in
sealed containers.
None Specified. Strong oxidisers, caustic or acid
solutions, excessive heat. May
degrade some paints and rubber
materials.
Oxides of carbon, aldehydes and Not fully. Analogous compounds
ketones, combustion products of evolve carbon monoxide, carbon
nitrogen, sulphur. dioxide and other unidentified
fragments when burned. Burning
fluid may evolve irritating/noxious
fumes.
Use in well ventilated areas. Use in well ventilated areas -
ventilate locally.
Not necessary but goggles or face Goggles or face shield should be
shield recommended. worn. Gloves not necessary, but
recommended, especially for
prolonged exposure.
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).
Incinerate the oil and all associated wastes in an approved facility in
accordance with local laws and regulations governing oily wastes.
Flash point over 180°C. Use water Flash point over 300°C. Use dry
spray, dry chemical, carbon dioxide chemical, carbon dioxide or foam.
or alcohol foam. Water or foam may Spraying water on hot or burning
cause frothing. liquid, may cause frothing or
splashing.
If a leak or spill has not ignited use water spray to disperse the vapours and
to provided protection for persons attempting to stop the leak.
Fire exposed containers should be kept cool with water sprays.
Self contained breathing apparatus should be worn in fire conditions.
 035L02374-GB2 (05/02) 1- 9

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.
1-10 035L02374-GB2 (05/02)

Page Left Intentionally Blank


2 PRODUCT DESCRIPTION
2.1 Introduction
York LCHM/LCHHM Liquid Cooled and Remote
Air Cooled Chillers are delivered completely
assembled with all interconnecting refrigerant
piping and internal wiring, ready for field
installation.
Prior to delivery each unit is pressure tested,
evacuated and charged with a refrigerant (WL,
WL-HP and WL-HR units) or nitrogen (AL and ALR
units) holding charge, and includes an initial oil
charge. After assembly an electrical function test is
performed to ensure correct operation.
The unit structure is heavy-gauge steel plate
primed and finished in Caribbean blue.
2.2 Compressors
Each unit is fitted with one or two semi-hermetic,
reciprocating compressors. The compressor
motors are refrigerant gas cooled, with integral
temperature sensing solid state overload
protection in each phase. The motor terminal
boxes are manufactured to prevent ingress of dust
and water to IP33. Starting is by part-winding or on
some models star/delta is an option.
Compressor Housing
The compressor housing is cast iron. It contains:
removable cylinder heads with internal muffling,
suction and discharge service valves, crankcase
sight glass and heater, oil and suction strainers,
an d int er nal re l i e f va l ve co n fo rming to
ASHRAE/ANSI Standard 15 Safety Code.
Crankshaft
The crankshaft is ductile (nodular) iron, drilled for
po s it iv e oil d i stri b u t i o n , wi th integral
counterweights for balancing. The main bearings
are insert type, steel backed babbit. The thrust
bearing is bronze.
035L02374-GB2 (05/02) 2- 1
Cylinder Assemblies
Suction and discharge valves are high quality,
non-flexing, stainless steel. The pistons are
aluminium alloy with two piston rings. The
connecting rods are aluminium alloy with integral
bearing surfaces on both ends. Cylinder liners are
removable.
Compressor Lubrication
The lubrication is force-fed by a reversible oil pump
which supplies oil to all crankshaft and bearing
surfaces through a fine mesh stainless steel filter.
Capacity Control
Capacity control is provided by solenoid-actuated
capacity control valves, controlled by the Micro
Based Control System. This method efficiently and
effectively matches unit capacity to low load
conditions as required. Gas flow is sufficient at all
times to ensure motor cooling.
2.3 Cooler
The single circuit (LCHM) or dual-circuit (LCHHM)
shell-and-tube cooler is of the direct expansion
type, with refrigerant in the tubes and chilled liquid
flowing through the baffled shell.
The water baffles are constructed from galvanised
steel to minimise corrosion. The removable heads
allow access to the internally enhanced, seamless
copper tubes. Vent and drain connections are
included.
The cooler is insulated with 19 mm closed cell type
insulation.
2.4 Condensers
A 3-pass single circuit (LCHM) or 2-pass
dual-circuit (LCHHM) shell-and-tube liquid cooled
condenser operates with refrigerant in the shell
and cooling liquid flowing within the tubes. A
refrigerant subcooler is integral.
The removable heads allow access to the finned
seamless copper tubes. Vent and d r a in
connections are included.
 2- 2 035L02374-GB2 (05/02)
2.5 Refrigerant Circuits
Two complete, independent, refrigerant circuits
are supplied on each LCHM/LCHHM unit. All unit
piping is manufactured from ACR copper with
brazed joints. Each liquid line includes: a shut-off
valve with charging port, sight glass with moisture
indicator, thermal expansion valve (direct acting,
maximum operating pressure), solenoid valve and
filter. Each suction line and liquid line from
expansion valve to the cooler are insulated with
flexible, closed cell, foam insulation.
2.6 Power and Control Panels
All control and motor starting equipment necessary
for the unit operation are located in galvanised
steel enclosures manufactured to IP33 protection.
The power and logic sections are fully factory wired
and function tested during manufacture.
Components are mounted on galvanised steel
back plates in separate power or control
compartments, each having a separate galvanised
steel access door. All doors are hinged and
lockable.
Control Panel - Power Sections
Each power section contains a 380/400V power
group formed by the compressor contactors and
incoming terminals or switch disconnector fuse
(option), overloads and fuses. A 220/230V control
group is formed by control fuses, residual current
device, compressor timer, compressor current
transformer and relay boards.
Control Panel - Logic Section
The logic section door has mounted on it the Micro
Based Control System keypad and display. The
l og ic c ont r ol co mp a rt me n t co n t a i n s the
microprocessor board, power supply board, optical
isolation board and, if fitted, electronic expansion
valve controllers. For details refer to the Operating
Instructions for the Micro Based Control System
supplied with the chiller.
2.7 Options and Accessories
3-Wire Kit (Mandatory on CE units)
A 3-wire kit comprising a control transformer and
associated wiring can be supplied to allow the
control voltage to be internally derived on sites
where there is no neutral connection available.
Mains Isolation (Mandatory on CE units)
Factory fitted door interlocked isolat o r s
(switch-disconnector-fuse type), one per power
section. Available with B.S. or D.I.N. fuses.
Common Input Supply + Mains Isolation
(LCHHM only)
Factory fitted fused door interlocked isolators
(switch-disconnector-fuse type), one per power
section, plus interconnecting wiring and terminals
to allow connection at a single point. Available with
B.S. or D.I.N. fuses. A gland plate extension box is
included with this option to allow additional space
for cable spreading.
Heat Recovery (WL units only)
One (LCHM) or two (LCHHM) single refrigerant
circuit/dual 2-pass or 3-pass coolant circuit
condenser(s), fitted instead of the standard
condenser(s), to allow heat rejection or recovery
via two separate liquid systems. Design is
generally as per the standard unit condensers
except for a higher design pressure on the
refrigerant side.
Liquid Receiver (AL units only)
Remote Air Cooled units can be fitted with a single
section (LCHM) or dual section (LCHHM) liquid
refrigerant receiver complete with relief valve(s)
built to pressure vessel code.
High Pressure Condenser (LCHHM - WL only)
A high pressure condenser can be supplied for
units, using R22 or R407C; to allow operation with
condenser leaving water temperatures above the
normal maximum of 40°C for R22 or 35°C for
R407C. This option includes oversized motor(s)
and electrical starters.

Compresser Oversized Motor(s)
(LCHM/LCHHM - WL only)
To replace standard compressors where
maximum design operating conditions give
compressor power consumption values close to or
exceeding the rate output of the standard
compressor. This option also includes increased
rating contactors where applicable.
Condenser Water Temperature Sensor
Temperature sensor with 1/2" NPT thread and 6"
pocket for mounting in the external condenser
outlet pipework. Supplied loose with 4 metres of
cable for field installation.
Pressure Vessel Code Approval
Cooler and co n d e n se r ve sse l (s) can be
manufactuered/tested and certified to the following
Pressure Vessel Codes: T.Ue.V. (Germany and
Austria); I.S.P.E.S.L. (Italy); D.R.I.R.E. (France);
S.A.Q. (Sweden) and T.T.K. (Finland). For other
Approval Authorities contact York.
Full Operating Refrigerant Charge
A full operating charge of the relevant refrigerant
can be supplied within the unit. (WL, WL-HP,
WL-HR units only).
Loadminder (LCHM only)
A hot gas bypass system to allow continuous
stable operation of the unit at cooling loads below
the minimum capacity step of the compressor.
Electronic Expansion Valve(s)
(WL units only)
Electronic expansion valves and controls instead
of thermally operated valves for improved
efficiency.
Mechanical Gauge Kit
Factory fitted mechanical dial gauges for
discharge, suction and oil pressure (one set per
compressor) in addition to electronic pressure
display.
035L02374-GB2 (05/02) 2- 3
Star/Delta Compressor Starting
Compressors using larger sizes of drive motor can
be fitted with star/delta wound motors and open
transition contactors for reduced current starting
(not available for M and N code drive motors).
Microprocessor Contact Isolator Kit
Additional printed circuit board which allows
customer volt-free contacts to be located more
than 7.5 m from panel connections.
EMS Offset Card
Additional printed circuit board which allows
alternative signals to be used from the customers
Energy Management System (EMS) to perform
remote temperature set-point offset function.
Sequence Commander
A Sequence Commander allows control of
common liquid leaving temperature from up to four
units operating in parallel (each unit requires an
additional printed circuit board fitted to interface
with the Sequence Commander).
VBG 20 Compliance Kit
Factory fitted T.Ue.V. approved mechanical high
pressure cut-out switches (two per system) as
required to comply with some pressure vessel
safety codes.
Flange Kits
Units can be supplied with all liquid connections
fitted with flanges to BS 4504 (ISO 7005 - NP 10).
Companion flanges can also be supplied to the
same standard.
Flow Switch
Switch suitable for up to 10 barg pressure and
having gold plated contacts suitable for low
voltage/current for protection of the unit against
loss of water flow. This, or an equivalent switch,
must be fitted in the liquid outlet pipe of the
evaporator.
 2- 4 035L02374-GB2 (05/02)

Anti-vibration Mounts Printer

Set of level adjustable spring vibration isolator Hand held printer for obtaining print-outs of the unit
mounts with mounting holes for fixing to operating and history data from the Micro Based
foundations. Control System.

2.8 Nomenclature
LC H M 115 W L xx 50 E
York Liquid Chiller Design Level (Style)
H = Single Compressor
50 = 380/400/415-3-50
HH = Dual Compressor
Option Code
Microprocessor Controlled
HR = Heat Recovery
HP = High Pressurre
Model Size
Condenser
W = Liquid Cooled
York UK Manufactured
A = Remote Air Cooled

Range of Models

R22/R407C Models R134a Models

Single Circuit Dual Circuit Single Circuit Dual Circuit
LCHM 60 LCHHM 140 LCHM 55 LCHHM 90
LCHM 70 LCHHM 170 LCHM 65 LCHHM 110
LCHM 85 LCHHM 200 LCHM 75 LCHHM 130
LCHM 100 LCHHM 230 LCHHM 150
LCHM 115

Related Drawings

R22 / R407c R134a

Single Circuit Models LCHM
LCHM 60-115 LCHM 55-75
Product Water Cooled Units (WL & WL-HP) 035L01577-000 035L01677-000
Drawings With 2 Pass Heat Recovery Condensers (WL-HR) 035L01591-000 035L01678-000
With 3 Pass Heat Recovery Condensers (WL-HR) 035L01592-000 035L01679-000
Remote Air Cooled Units (AL) 035L01576-000 035L01680-000
Remote Air Cooled Units with Receiver (ALR) 035L01578-000 Refer Basildon
Wiring Schematic 035L02305-001
Diagrams Connection 035L02306-001
Customer Wiring 035L02307-001
Legend 035L02110-001

R22 / R407c R134a R134a

Dual Circuit Models LCHHM
LCHHM 140-230 LCHHM 90-110 LCHHM 130-150
Product Water Cooled Units (WL & WL-HP) 035L01583-000 035L01671-000 035L01670-000
Drawings With 2 Pass Heat Recovery Condensers (WL-HR) 035L01634-000 - 035L01673-000
With 3 Pass Heat Recovery Condensers (WL-HR) 035L01635-000 - 035L01674-000
Remote Air Cooled Units (AL) 035L01582-000 035L01676-000 035L01676-000
Remote Air Cooled Units with Receiver (ALR) 035L01584-000 Refer to York Refer to York
Wiring Schematic 035L02308-001
Diagrams Connection 035L02309-001
Customer Wiring 035L02310-001
Legend 035L02110-001
 035L02374-GB2 (05/02) 3- 1

3 TRANSPORTATION, HANDLING
AND STORAGE

3.1 Delivery and Storage 3.3 Moving the Chiller

To ensure consistent quality and maximum LCHM/LCHHM-Series Chillers are designed to be

reliability, each LCHM/LCHHM Chiller is tested
and inspected before leaving the factory.
LCHM/LCHHM-Series Chillers are shipped as
completely assembled units containing a holding
charge of refrigerant or nitrogen under pressure.
Units are shipped without export crating unless this
has been specified on the Sales Order.
lifted using lifting chains. A spreader frame should
be used in order to prevent damage to the unit from
the lifting chains. Lifting points are 50 mm diameter
holes in the unit main frame.
The unit must only be lifted by the main
frame at the points provided.

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

installation, the following precautions should be
observed: Never move the unit on rollers, or lift the
unit using a fork-lift truck.
Ensure that all openings, such as water
connections, are securely capped.

Do not store where exposed to ambient air

temperatures exceeding 45°C (R22 and R134a
models) or 42°C (R407C models).

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.

3.2 Inspection

Remove any transit packing and inspect the unit to
ensure that all components have been delivered
and that no damage has occurred during transit. If
any damage is evident, it should be noted on the
carrier’s freight bill and a claim entered in
accordance with the instructions given on the
advice note.
LCHM - Single Compressor Units
Prior to moving the unit 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.

Major damage must immediately be reported to

your local York representative.
 3- 2 035L02374-GB2 (05/02)

LCHHM - Twin Compressor Units

On LCHHM WL-HR units (water cooled

with heat recovery) a second condenser
is fitted above the compressors on a
mounting frame. This frame must not be
used to lift the unit.

3.4 Lifting Weights

For details of weights and weight distribution refer

to Section 9.
 035L02374-GB2 (05/02) 4- 1

4 INSTALLATION For basement locations, remove a portion of the

4.1 Location Requirements
The unit should not be installed
directly on flammable materials, such
as wooden structures or roof’s.
basement floor so that a flat and level concrete
base can be poured resting on the ground. The
base should extend 15-20 cm above the basement
floor with cork-board around the sides and a
waterproof sealing compound. Do not tie the slab
to the building foundations to avoid noise and
vibration transmission.

To achieve optimum performance and trouble-free

service, it is essential that the proposed installation
s it e m eet s wi th t h e l o ca ti o n a n d space
requirements for the model being installed. For
dimensions, weight and space requirements,
including service access details, refer to Section 9.
When installing the unit on upper floors, both the
LCHM and LCHHM units are designed for indoor unit and pipework should be isolated from the walls
installation and are not suitable for wet corrosive or and ceiling.
explosive atmospheres. The installation area
should have sufficient ventilation and drainage to 4.3 Vibration Isolator Installation &
prevent the possible build up of refrigerant or water Dimensions
if there is a leak.
When ordered, an optional set of spring type
It is important to ensure that the minimum service vibration isolators will be supplied loose with each
access space is maintained for cleaning and unit. LCHM units have one isolator at each of the
maintenance purposes including pulling tubes four mounting points. LCHHM units have two
from the heat exchanges (tube withdrawal space of isolators at each of the four mounting points.
3 m to one end of the heat exchanger(s)).

For installation in equipment rooms near

noise-critical areas, common walls should be of
adequate sound attenuating construction. All
doors should be tightly sealed with gaskets. If
located in an area accessible to unauthorised
persons, steps must be taken to prevent access to
the unit This will prevent the possibility of
vandalism, accidental damage, or possible harm
caused by opening guards or panels and exposing
moving or live parts.

4.2 Foundation and Mounting

Base foundations must be capable of supporting

150% of the operating weight of the unit. For
DIM. W&X Y&Z
ground locations on an earth floor, the unit should
Isolators Isolators
be installed on a suitable flat and level concrete
A 95 mm 102 mm
base extending 15-20 cm above the level of the
B 127 mm 127 mm
floor:
C 76 mm 76 mm
Dia. D 11 mm 11 mm

■ Using the Isolator tables (in Section 9), identify

each mount and its correct location on the unit.
 4- 2 035L02374-GB2 (05/02)
■ The isolators should be loosely attached to the
holes provided in the unit feet using the lock
screw in the top of the mount main levelling
bolt. Levelling of the unit is accomplished by
turning the levelling bolt and then tightening
the lock screw.
■ To maintain isolator efficiency, no mechanical
ties should be made to the building and flexible
connectors should be used for all piping.
On LCHHM units two mounts are located
side by side at each mounting foot of the
unit. The centre line distance between
each mount is 80 mm.
4.4 Pipework Connection
General Requirements
The following piping recommendations are
intended to ensure satisfactory operation of the
unit(s). Failure to follow these recommendations
could cause damage to the unit, or loss of
performance, and may invalidate the warranty.
The maximum flow rate and pressure
drop for the cooler and condenser must
not be exceeded at any time. Refer to
Section 9 for details.
■ The water must enter the heat exchanger(s)
by the inlet connection. The inlet connection
for the cooler is at the same end as the
refrigerant pipework connections. The inlet
connection for a heat recovery condenser is
the bottom liquid connection.
■ A flow switch must be installed in the customer
pipework at the outlet of the cooler as shown in
the arrangement diagrams, and wired back to
the control panel using screened cable. For
details refer to “Electrical Connection”. This is
to prevent damage to the cooler 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.
■ The liquid pump(s) installed in the pipework
system(s) should discharge directly into the
unit heat exchanger section of the system. The
pump(s) require an auto-starter (by others) to
be wired to the control panel. For details refer
to “Electrical Connection”.
■ Pipework and fittings must be separately
supported to prevent any loading on the heat
exchanger(s). Flexible connections are
recommended which will also minimise
transmission of vibrations to the building.
Flexible connections must be used if the unit is
mounted on anti-vibration mounts as some
movement of the unit can be expected in
normal operation.
■ Pipework and fittings immediately next to the
heat exchangers should be rea d ily
de-mountable to enable cleaning prior to
operation, and to facilitate visual inspection of
the exchanger nozzles.
■ Each heat exchanger must be protected by a
strainer, preferably of 40 mesh, fitted as close
as possible to the liquid inlet connection, and
provided with a means of local isolation.
■ The heat exchanger(s) must not be exposed to
flushing velocities or debris released during
flushing. It is recommended that a suitably
sized by-pass and valve arrangement is
installed to allow flushing of the pipework
system. The by-pass can be used during
maintenance to isolate the heat exchanger
without disrupting flow to other units.
■ Thermometer and pressure ga u g e
connections should be provided on the inlet
and outlet connections of each heat
exchanger.

■ Drain and air vent connections should be
provided at all low and high points in the
pipework to permit drainage of the system,
and to vent any air in the pipes.
■ Liquid systems at risk of freezing, due to low
ambient temperatures, should be protected
using insulation and heater tape and/or a
suitable glycol solution. The liquid pump(s)
must also be used to ensure liquid is circulated
when the ambient temperature approaches
freezing point. Insulation should also be
installed around the heat exchanger nozzles.
Heater tape of 21 watts per metre under the
insulation is recommended, supplied
independently and controlled by an ambient
temperature thermostat set to switch on at 3°C
above the freezing temperature of the liquid.
Any debris left in the water pipework
between the strainer and heat exchanger
could cause serious damage to the tubes
in the heat exchanger and must be
avoided. The installer/user must also
ensure that the quality of the water in
circulation is adequate, without any
dissolved gasses which can cause
oxidation of steel parts within the heat
exchanger(s).
4.5 Water Treatment
The unit performance given in the Design Guide is
based on a fouling factor of 0.044 m² °C/kW
(0.00025 ft²hr °F/Btu). Dirt, scale, grease and
certain types of water treatment will adversely
affect the heat exchanger surfaces and therefore
unit performance. Foreign matter in the water
system(s) can increase the heat exchanger
pressure drop, reducing the flow rate and causing
potential damage to the heat exchanger tubes.
Aer at ed, br a cki sh o r sa l t wa t e r is not
recommended for use in the water system(s). York
recommend that a water treatment specialist is
consulted to determine that the proposed water
composition will not affect the evaporator materials
of carbon steel and copper. The pH value of the
water flowing through the heat exchangers must be
kept between 7 and 8.5.
035L02374-GB2 (05/02) 4- 3
Glycol Solutions
For unit operation with chilled liquid temperatures
leaving the cooler at below 4°C (below 6°C for
R407C units), glycol solutions can be used to help
prevent freezing. Section 9, gives recommended
solution strength with water, as a percentage by
weight, for the most common types of glycol. It is
important to check glycol concentration regularly to
ensure adequate concentration and avoid possible
freeze-up in the cooler.
When using glycol solutions, pressure
drops are higher than with water. Special
care must be taken not to exceed the
maximum pressure drop allowed.
4.6 Pipework Arrangement
The follow ing are suggested pip e wo r k
arrangements for single unit installations. For
multiple unit installations, each unit should be
piped as shown.
Recommendations of the Building Services
Research Association
Chilled Water/Glycol System
Key
Isolating Valve - Normally Open
Isolating Valve - Normally Closed
Flow Regulating Valve
Flow Measurement Device
Strainer
Pressure Tapping
Flow Switch
Flanged Connection
 4- 4 035L02374-GB2 (05/02)

Condenser Water/Glycol System (WL units) Condenser Water/Glycol System (WL-HR 3

Pass Condenser units)

Condenser Water/Glycol System (WL-HR 2

Pass Condenser units)

LCHHM WL-HR units are provided with

two double water circuit condensers, one
per refrigerant system. For parallel water
flow it is important that the main cooling
system flow and the heat recovery system
flow are both divided equally between the
two condensers EXCEPT for the LCHHM
WL-HR 200 on which the flows should be
divided 57.5% to the LOWER condenser
and 42.5% to the UPPER condenser.

Key

Isolating Valve - Normally Open

Isolating Valve - Normally Closed

Flow Regulating Valve

Flow Measurement Device

Strainer

Pressure Tapping

Flow Switch

Flanged Connection
 035L02374-GB2 (05/02) 4- 5

4.7 Connection Types & Sizes Standard Flange

For connection sizes relevant to individual models

refer to Section 9.

Standard Connections

Standard chilled liquid connections on all coolers

are of the Victaulic Groove type. Condenser
cooling water connections can be of the Victaulic Nom. Size PCD Bolts
Groove type, female threaded to BSPT, or drilled 4" (100mm) 180 8 x M 16
and tapped as flange connections to ISO 7005 - All dimensions in millimetres
NP10 (BS4504 - NP10). Dimensions are as
follows:
Optional Connections
Standard Victaulic
Optionally all connections may be supplied flanged
depending on the customer or local Pressure
Vessel Code requirements. These are Vic-Adapter
flanges, normally supplied loose, weld flanges
which may be supplied loose or ready fitted, or a
set of threaded flanges and pipe nipples normally
supplied loose. All flange dimensions are to ISO
7005 - NP10 (BS 4504 - NP10) as follows:

Nom. Size OD T A B C WELD FLANGE VIC-ADAPTOR FLANGE

2.5" (63mm) 76.1 7.1 16 9.5 72.3
3" ( 75 mm) 88.9 11.0 16 9.5 84.9
4" (100mm) 114.3 5.6 16 9.5 110.1
6" (150mm) 168.3 8.0 16 9.5 164.0
8" (200mm) 219.1 8.0 19 11.0 214.4
All dimensions in millimetres

Standard Threaded

Nom. Size PCD T Bolts

2.5" (63mm) 145 18 4 x M 16
3" ( 75 mm) 160 20 8 x M 16
4" (100mm) 180 20 8 x M 16
Nom. Size Thread Type 6" (150mm) 240 22 8 x M 20
2 1/2 " (65mm) 2 1/2 “ BSP Female Taper 8" (200mm) 295 24 8 x M 20
3 " (80mm) 3 “ BSP Female Taper All dimensions in millimetres
 4- 6 035L02374-GB2 (05/02)

Threaded Flange Relief Outlet

Application Pressure Connection " C "
Setting Size
Coolers / WL Condensers 300 psi 1/2" Flare 1.447
WL-HP & -HR Condensers* 400 psi 1/2" Flare 0.689
WL-HP & -HR Condensers* 400 psi 5/8" Flare 3.347
Note * See unit dimensional drawings for valve connection sizes
on individual models

Nom. Size PCD T Bolts

Precautions should be taken to ensure the exit of
2 1/2 " (65mm) 145 18 4 x M 16
relief valves/vent pipe remain clear of obstructions
at all times.
3 " (80mm) 160 20 8 x M 16
All dimensions in millimetres
4.9 Condenser Cooling Water Systems

4.8 Refrigerant Relief Valve Piping Main Cooling System

Coolers, condensers and liquid receiver vessels
are each protected against internal refrigerant side
over-pressure and fire by refrigerant relief valves.
The pressure relief valve is set at design pressure
of the system and has discharge capacity required
by relevant standard. On coolers the relief valve(s)
are mounted on the end of the vessel, one per
refrigerant circuit. On condensers and receiver
tanks the relief valve(s) are mounted on top of
vessel body.
For primary cooling of WL units, condensers are
usually piped in conjunction with a cooling tower,
although in some cases they can be cooled by well
water.
For LCHM and LCHHM units it is necessary to
control coolant flow and/or temperature into the
condenser to maintain refrigerant pressure as
constant as possible to ensure satisfactory
operation of the refrigerant expansion valve(s).

It is recommended that each valve is piped to the

exterior of the building. The outlet of the pipe
should be directed so that if circumstances occur to
cause operation of the valve, the relief of high
pressure gas and liquid cannot be a danger or
cause injury.

The size of any pipe attached to a relief valve must

be of sufficient diameter so as not to cause
resistance to the operation of the valve. Unless
otherwise specified by local regulations, the
minimum allowable internal diameter depends on
the length of pipe required and is given by the
following formula:

D5 = C x L

Where:
D = minimum pipe internal diameter in centimetres
L = length of pipe in metres
C = constant given in table below

Direct Pressure Control
With LCHM units it is possible, if desired, to control
the condenser water inlet temperature / flow
directly from the unit refrigerant pressure.
The refrigerant pressure can either be used to
control cooling tower effectiveness by controlling
fans or dampers on the tower, or to control
condenser flow using a three way bypass valve as
shown below.
The aim is to maintain a stable discharge pressure
as low as possible, but at least 5.2 bar above
suction pressure on R22 and R407C units and at
least 4.0 bar above suction pressure on R134a
units. This can be done at a fixed value above the
highest expected suction pressure or by also
measuring suction pressure and using differential
control. In either case water flow and temperature
limits must also be observed.
035L02374-GB2 (05/02) 4- 7
Inlet Temperature Control
For a cooling tower system the simplest forms of
control are to use fan cycling fan speed control, or
air damper control, with the tower having a
thermostat in its sump. This will ensure stable
condenser water temperature sensing at design
conditions and should be adjusted to ensure a
condenser water entering temperature of not lower
than 21°C to 24°C at later ambient conditions.
If these methods are not available or a cooling
tower is not the source of cooling water, then a
three way valve recirculation system can be used
with control based on condenser inlet water
temperature as shown below. In this case the
objective is to maintain the inlet cooling water
temperature as low as possible although still
observing the minimum limit of 21°C to 24°C.
4.10 Remote Refrigerant Condenser Systems
General
For cooling of AL units, condensers are usually of
the remote air-cooled type either roof or ground
level mounted. Refrigerant systems should be
designed and installed by suitably qualified
persons in compliance with relevant national
codes and standards. The complete pipework
system and condenser MUST have a Design
Working Pressure of at least 27.6 barg.
Suitable controls (e.g. fan cycling) should be
included to keep discharge pressure within the unit
operational limits and at least 5.2 bar above
suction pressure on R22 and R407C units or 4.0
bar above suction pressure on R134a units.
 4- 8 035L02374-GB2 (05/02)

The condenser should be designed to provide
sufficient subcooling at its outlet to ensure that no
'flashing' will occur in the liquid line to the unit, or in
the filter/drier and liquid valves on the unit itself.
Liquid subcooling should be 4°C to 10°C on arrival
at the unit.
■ To avoid the risk of discharge gas pulsation's
causing undesired noise within the building, a
suitably sized discharge gas muffler may be
fitted in the discharge line near the unit. A
slight loss of performance may, however,
result at full load.

LCHM and LCHHM units perform a 'pump-down'
cycle whenever a compressor starts. If the optional
liquid receiver tank has not been ordered with the
unit, it is important to ensure that for each system
the remote condenser and liquid line volume is at
least 1.65 times the liquid volume of the operating
refrigerant charge.
When the unit has been located in its final position,
the refrigerant system pipework can be connected.
Pipework and fittings MUST be separately
supported and not cause any loading on the unit.
Flexible connections are recommended and will
also minimise transmission of vibrations to the
building. Flexible connections MUST be used if the
unit is mounted on anti-vibration mounts as some
movement of the unit can be expected in operation.
Pipework Design
The following notes give guidance but should not
be considered exhaustive:
Incorrectly or badly designed and/or
installed pipew ork systems m a y
invalidate unit warranty.
Refrigerant Connections
Units are supplied with a nitrogen holding charge.
This should be relieved carefully via the
compressor suction service valve connections and
the liquid line stop valve service connection.
Discharge Line
Remove the clamp bolts on the compressor
discharge service valve and slide the flange over
the discharge line pipe. Remove the brazing collar
careful from the gasket and braze to the discharge
line. Oil the gasket with appropriate refrigerant oil
and reassemble the joint.

■ Discharge lines but MUST be sized for

guaranteed oil transfer at minimum load step
on the compressor (2 cylinders only
operating). P-traps and double risers may be
required when the condenser is sighted above
the unit. Horizontal runs should be inclined
slightly towards the condenser to aid oil
transfer. On units fitted with a Starting Bypass Line
or Loadminder Hot Gas Injection Line, a
■ Where the condenser is above or level with the short length of discharge line may already
unit, the discharge line should rise to at least be fitted to the valve. In this case simply
the top edge of the condenser at some point. cut the blank from the end of the line and
This will prevent liquid draining back to the make an appropriate swage joint.
compressor during the off cycle.

■ Elbows, bends and valves should be

minimised to reduce pressure drop and
prevent loss of performance. The liquid line in
particular should be designed for minimum
pressure drop to avoid 'flashing' in the liquid
line which will cause loss of performance and
fault conditions to occur. Particular care
should be taken where the condenser is below
or level with the unit.
 035L02374-GB2 (05/02) 4- 9

Liquid Lines 4.11 Electrical Connection

On AL units the liquid line connection is made at the The following connection recommendations are
liquid line service valve. Pipework can be brazed intended to ensure safe and satisfactory operation
directly onto the valve taking care to protect the of the unit(s). Failure to follow t h e se
valve from excess heat which may cause recommendations could cause harm to persons, or
distortion. damage to the unit, and may invalidate the
warranty.
On AL-R units the liquid connection is made to the
liquid receiver vessel at the brazing stub on top of No additional controls (relays, etc.)
the vessel. Care should be taken to avoid debris should be mounted in any section of
falling into the vessel when making this connection the control panel. Power and control
wiring not connected to the Control
Connection Sizes Panel should not be run through the
System 1 System 2 Control Panel. If these precautions are
Model Disch. Liquid Disch. Liquid not followed it could lead to a risk of
All units AL units AL-Runits All units AL units AL-Runits
LCHM electrocution. In addition, electrical
60 2 5/8" 1 3/8" 2 1/8" - - - noise could cause malfunctions, or
R22 / 70 2 5/8" 1 3/8" 2 5/8" - - -
R407C 85 2 5/8" 1 5/8" 2 5/8" - -
damage the unit and its controls.
100 3 1/8" 1 5/8" 3 1/8" - - -
115 3 1/8" 1 5/8" 3 1/8" - - -
After connection do not switch on
55 2 5/8" 1 3/8" 2 1/8" - - -
R134a 65 3 1/8" 1 5/8" 2 5/8" - - - mains power to the unit. Some internal
75 3 1/8" 1 5/8" 2 5/8" - - - components are live as soon as mains
LCHHM
140 2 5/8" 1 3/8" 2 5/8" 2 5/8" 1 3/8" 2 5/8" is switched on, and this must only be
R22 / 170 2 5/8" 1 3/8" 2 5/8" 2 5/8" 1 3/8" 2 5/8" done by authorised persons.
R407C 200 3 1/8" 1 5/8" 3 1/8" 2 5/8" 1 3/8" 3 1/8"
230 3 1/8" 1 5/8" 3 1/8" 3 1/8" 1 5/8" 3 1/8"
90 2 5/8" 1 3/8" * 2 5/8" 1 3/8" * ■ The main Off/Auto unit selector switch on the
R134a 110 2 5/8" 1 3/8" * 2 5/8" 1 3/8" *
130 3 1/8" 1 5/8" 2 5/8" 3 1/8" 1 5/8" 2 5/8"
front of the control panel has been sealed in
150 3 1/8" 1 5/8" 2 5/8" 3 1/8" 1 5/8" 2 5/8" the off position at the factory.
All connections are Female for brazing to the given O.D. size of copper pipe. This seal must remain in place
* Refer to York Basildon for these connection sizes.
preventing running of the unit
until commissioned by
System Testing authorised personnel. If the
seal has been removed before
All newly installed pipework must be pressure/leak commissioning then it must be
tested to national code requirements (normally reported to the Basildon
1.1 x Design Working Pressure) then fully Factory Quality Manager
evacuated before charging. Refer to the Section 5 otherwise warranty may be
for correct charging methods. invalidated.
 4-10 035L02374-GB2 (05/02)

4.12 Power Wiring LCHHM Standard Units and Units with Switch
Disconnector Fuse*
LCHM and LCHHM units are suitable for
380/400 volt, 3 phase, 50 Hz nominal Standard units and units fitted with optional switch
supplies only. disconnector fuse require two-off 3 phase
Minimum allowable voltage 342 V. separately fused 3 wire supplies plus earth, with
Maximum allowable voltage 440 V. one supply to be connected to each of the two
system power sections of the control panel. Also
All electrical wiring should be carried out in required is a separate control supply connected to
accordance with local regulations. Route properly customer terminals in the centre common power
sized cables (based on installation conditions and section of the panel.
currents given in electrical data tables) to site
drilled holes in the Control Panel gland plate as All three supply cables should enter via site drilled
specified below. gland plate in the bottom of the centre common
power section. The 3 phase supplies can then be
In accordance with EN 60204 it is the responsibility routed to their respective input terminals in each of
of the user to install overcurrent protection devices the power sections, number 1 to the left and
between the supply conductors and the customer number 2 to the right.
input supply terminals on the unit.
Connect each of the two main 3 phase supplies to
To ensure that no eddy currents are set up in the
the customer terminal blocks, or optional switch
metal gland plate the cables forming each 3 phase
disconnector fuse, located in the two separate
power supply must enter via the same hole in the
power sections of the control panel using lug sizes
gland plate. If separate entries for each cable
detailed in the Technical Specification Section.
forming the 3 phase supplies are used, the metal
gland plate must be replaced by a non-metallic
Connect earth wires to the main protective earth
gland plate, with due regard given to sealing the
terminals, using M10 lugs, in each power section.
panel to IP33.
On standard units connect a 220/230 V single
All sources of supply to the unit must
phase control supply to the control switch
be taken via a common point of
disconnector in the centre main common power
isolation (not supplied by York).
section with bare wire ends of maximum cable size
4 mm. For details refer to the Technical
Specification Section (customer control circuit
LCHM Standard Units and Units with Switch supply data). Also connect an earth wire to the
Disconnector Fuse* protective earth terminal using an M4 lug.
Standard units and units fitted with an optional
On units fitted with a 3 wire supply option* connect
switch disconnector fuse require a 3 phase 4 wire
two phases (380/400 V) to the control switch
supply plus earth. One phase and the neutral are
disconnector in the centre main common power
used internally to derive the 220/230 V control
section with bare wire ends of maximum cable size
supply. On units fitted with a 3 wire supply option*
4 mm². For details refer to Technical Specification
an internal transformer is used to create the
Section (customer control circuit supply data). Also
220/230 V control circuit supply and therefore no
connect an earth wire to the protective earth
neutral connection is required.
terminal using an M4 lug.
All cables should enter via the site drilled gland
plate on the right side of the control panel and be *Fitted as standard on CE units
connected to the 3 phase supply customer terminal
block or the optional switch disconnector fuse
terminals. For details of lug sizes, refer to section 9.
Connect the earth wire to the main protective earth
terminal, using an M10 lug.

*Fitted as standard on CE units


Units with Common Input Supply and
Isolators
Units fitted with the common input supply option
require one 3 phase and neutral supply plus earth
only. If a 3 wire mains supply option is fitted**, no
neutral is required. Under the centre power section
of the control panel is a cable spreader box which
should be used to separate the cores of large
multi-core cable prior to connection to the
customer main terminal block. The cable should
enter the spreader box through a site drilled gland
plate on the left hand side of the box.
**Fitted as standard with common input supply
option on CE units
Connect the 3 phases to the main customer
terminal block located in the centre power section
of the control panel using M16 lugs. If no 3 wire
supply option is fitted, also connect neutral to the
main neutral terminal block using an M12 lug.
Connect an earth wire to the main protective earth
terminal located in the centre power section of the
control panel using an M10 lug.
Control Transformer Primary Voltage
Tappings
The 3-wire control transformer is mounted behind
the control panel. It is important to check that the
correct primary tapping has been used:
■ With the supply to the unit isolated remove the
lid to the transformer box.
■ Check that the tapping used conforms to the
site supply voltage. The two tappings are
342-424 V and 360-440 V.
Remote Emergency Stop Device
If required, a remote emergency stop device can
be wired to terminals 3 and 4 in the control panel.
The existing link must first be removed. This device
should be rated at 4 amps (LCHM) or 6 amps
(LCHHM), 230V, AC-15. Terminals 3 and 4 are in a
circuit protected by a 4 amp (LCHM) or 6 amp
(LCHHM) class gG fuse.
035L02374-GB2 (05/02) 4-11
4.13 Power Section Volt Free Contacts
All wiring to the power section volt free contacts
requires a supply, maximum 254 V, provided by
the customer. The customer must take particular
care deriving the supplies for the volt free terminals
with regard to a common point of isolation. These
circuits when used must be fed via the common
point of isolation so that the voltage is removed
when the common point of isolation to the unit is
opened.
In accordance with EN 60204 it is recommended
that the customer wiring to these terminals uses
orange wires. This will ensure that circuits not
switched off by the unit supply disconnecting
device are distinguished by colour, so that they can
easily be identified as live even when the unit
disconnecting device is off.
The unit volt-free contacts are rated at 125 VA. All
inductive devices (relays) switched by the unit
volt-free contacts must have their coil suppressed
using standard R/C suppressors.
Chilled Liquid Pump Starter
Terminals 33 and 34 close to start chilled liquid
pump. This contact can be used as a master
start/stop for the pump in conjunction with the daily
start/stop schedule. If no schedule is set, and the
customer has master control of the pump, the unit
contact must be used to override the customer
master start/stop so that the York contact can start
the pump in the event of a low temperature liquid
condition.
Run Contact
Terminals 35 and 36 close to indicate that a system
is running. This contact may be used to start the
condenser waterpump(s) or condenser fans as
required.
 4-12 035L02374-GB2 (05/02)
Alarm Contacts
Each system has a voltage-free change over
contact which will operate to signal an alarm
condition whenever a system locks out, or there is
a power failure. To obtain system alarm signal,
connect alarm circuit to volt free terminals 31 and
32 (close on alarm) or 30 and 32 (open on alarm)
for LCHM and LCHHM No. 1 system. For LCHHM
No. 2 system terminals 38 and 39 (close on alarm)
or 37 and 39 (open on alarm).
4.14 Logic Section Connections
All wiring to the logic section terminal block is
nominal 30 Vdc and must be run in screened cable,
with the screen earthed at the panel end only. Run
screened cable separately from mains cable to
avoid electrical noise pick-up. Use the gland plate
on the back of the control panel, to connect directly
into the logic section to avoid mains cable.
The voltage free contacts must be suitable for
30 Vdc (gold contacts recommended). If the
voltage free contacts form part of a relay or
contactor, the coil of the device must be
suppressed using a standard R/C suppressor. The
above precautions must be taken to avoid
electrical noise which could cause a malfunction or
damage to the unit and its controls.
The length of cable to these terminals
must not exceed 7.5 m unless an optional
input isolator kit is fitted.
The optional input isolator kit uses 15 Vdc
(not 30 Vdc).
Flow Switch
A chilled liquid flow switch of suitable type must be
connected to terminals 10 and 13 to provide
adequate protection against loss of liquid flow.
Remote Run/Stop
Remove the link from terminals 11 and 14 LCHM
and LCHHM No. 1 system and terminals 12 and 15
LCHHM No. 2 system and connect remote
switch(es) to provide remote run/stop control if
required.
Remote Print
Closure of suitable contacts connected to
terminals 18 and 13 will cause a hard copy printout
of Operating Data/Fault History to be made if an
optional printer is connected to the RS 232 port.
Remote Lead/Lag (LCHHM)
If manual lead/lag control is required, closure of
suitable contacts connected to terminals 13 and 19
will cause system 2 to operate in lead. Open
contacts will cause system 1 to be in lead.
Remote Set Point Offset
Timed closure of suitable contacts connected to
terminals 13 and 17 (PWM contacts) will give
remote offset function of the chilled liquid set point
if required. This function cannot be used if “Remote
Unload” function is required.
Remote Unloading
The Micro Based Control System is capable of
remote unloading (or pull-down demand limiting) in
two steps. The first step of unloading is achieved
by closing suitable contacts connected to terminals
16 and 13. The second step of unloading is
achieved by closing suitable contacts connected to
terminals 17 and 13. Note: the first step contacts
must be closed before the second step contacts
are closed. For details of compressor load steps
given by these contacts, refer to the Micro Based
Control System Manual. This function cannot be
used if “Remote Set point Offset” is required.
 035L02374-GB2 (05/02) 4-13

4.15 Connection Schematics

LCHM Units
+5V
GND

RS232
RXD LOGIC POWER
TXD SECTION SECTION
DSR
DTR

INPUT
SECTION

3 4

PE
N
30 31 32 33 34 35 36
13 10 11 14 12 15 16 13 13 17 18 13 13 19 20 13
REMOTE 3-PHASE + NEUTRAL
EMERGENCY 50 Hz 380/400 V
STOP DEVICE

OPEN CHILLED
ON LIQUID
ALARM PUMP
STARTER
CHILLED LIQUID
FLOW SWITCH
REMOTE REMOTE TEMP REMOTE
RUN UNLOAD RESET PRINT
INTERLOCK OR CLOSE RUN CONTACT
(REMOVE LINK REMOTE
3 WIRE CONTROL SUPPLY
ON (CONDENSER
IF CONTACT FITTED) UNLOAD OPTION ALARM PUMP/FAN
STARTER)

U W 3 4

PE
REMOTE
EMERGENCY
2-PHASE 50 Hz STOP DEVICE
˜
380/400V
 4-14 035L02374-GB2 (05/02)

LCHHM Units
CONTROL PANEL
No.1 POWER LOGIC SECTION No.2 POWER
+5V SECTION SECTION
GND
RS232

RXD
TXD
DSR
DTR

THIS PORT CAN BE

USED FOR A PRINTER COMMON
SEE CONTROL SYSTEM POWER
OPERATING INSTRUCTIONS SECTION
FOR WARNINGS AND
LIMITATIONS ON USE
OF THIS PORT

U V W N U 3 4 U V W

PE PE N L PE
REMOTE
EMERGENCY
3˜ 50Hz 1˜ 50Hz STOP 3˜ 50Hz
380/400V 220/230V DEVICE 380/400V

POWER SECTION LOGIC SECTION

VOLT FREE CONTACTS LINK LINK CONNECTIONS
30 31 32 33 34 35 36 37 38 39 13 10 11 14 12 15 16 13 13 17 18 13 13 19 20 13

SCR
No.1 CHILLED COMMON No.2
SYSTEM LIQUID RUN SYSTEM
CLOSE PUMP SIGNAL CLOSE
ON STARTER ON
ALARM ALARM

CHILLED Sys.1 Sys.2 Step 1 Step 2 REMOTE REMOTE

WATER REMOTE RUN REMOTE PRINT LEAD/LAG
No.1 No.2 FLOW SELECT
SYSTEM SYSTEM INTERLOCKS UNLOAD
SWITCH (REMOVE LINK OR
OPEN OPEN
ON ON IF CONTACT OPEN PWM
ALARM ALARM FITTED)

COMMON SUPPLY INPUT OPTION FITTED 3 WIRE CONTROL SUPPLY

(in the common power section) OPTION FITTED

3 4 N U V W U W 3 4
INPUT SECTION
N U V W

CABLE
SPREADER
BOX
PE N PE
REMOTE REMOTE
EMERGENCY 3N~50Hz OMIT NEUTRAL EMERGENCY
STOP DEVICE 380/400V IF 3 WIRE OPTION 2˜ 50Hz STOP DEVICE
ALSO FITTED 380/400V

5 COMMISSIONING
5.1 Preparation
Commissioning of this unit should
only be carried out by York authorised
personnel.
The Micro Based Control System Manual must be
read in conjunction with this section.
The unit switch on the front of the control panel has
been sealed in the off position at the factory. This
seal must remain in place preventing running of the
un it unt il c o mmi ssi o n e d b y
authorised personnel. If the seal
ha s been re mo ve d b e fo re
commissioning then it must be
reported to the Basildon Factory
Quality Manager otherwise the
warranty may be invalidated.
Preparation - Power Off
The following checks should be made with the
customer supply/supplies to the unit switched off.
Inspection: Inspect unit for installation damage. If
found take action and/or repair as appropriate.
Remote Condenser Systems
All units require a suitable remote refrigerant
condenser system. Verify that the system has been
installed correctly and that the condenser has
discharge pressure control capable of maintaining
a reasonably stable working pressure.
035L02374-GB2 (05/02) 5- 1
Refrigerant charge: WL units are normally
shipped as standard with a refrigerant holding
charge or optionally with a full operating charge. AL
units are shipped with a nitrogen holding charge.
Check that pressure is present in both systems and
that no leaks are apparent. If no pressure is
present a leak test must be undertaken, the leak(s)
located and repaired. Repaired systems and units
supplied with a nitrogen holding charge must be
evacuated with a suitable vacuum pump / recovery
unit as appropriate to below 100 microns. Check
the unit data plate or unit labels for the type of
refrigerant intended for use with the unit and break
the vacuum with refrigerant as follows:
Break vacuum from Raise system pressure
Refrigerant
bottle connection for: to approximately:
R22 Vapour 4.0 barg (60 psig)
R407c Liquid 4.6 barg (70 psig)
R134a Vapour 2.0 barg (30 psig)
Charging from the liquid connection on
the cylinder is necessary on R407C to
ensure the correct refrigerant mix is
maintained.
Do not liquid charge with static water in any of the
heat exchangers. Care must also be taken to liquid
charge slowly to avoid excessive thermal stress at
the charging point. Once the vacuum is broken,
charge into the condenser coils with the full
operating charge as given on the unit data plate
and the Section 9 of this manual, (including
additional condenser charge for AL units).
Valves: Open the compressor suction and
discharge, and the liquid line service valves on
both systems (CCW).
Condenser Water Temperature Sensor: Ensure
the condenser water temperature sensor is coated
with heat conductive compound (part no.
013-00890-000) and inserted in the sensor pocket.
The pocket should be installed in the external
condenser outlet pipework within 4 metres of the
control panel. Connect the temperature sensor to
the control panel in accordance with the
connection diagram in section 4.
 5- 2 035L02374-GB2 (05/02)
Compressor oil: Compressor lubrication systems
must be primed prior to first time start-up. Only the
correct type of oil must be used as given by unit
d ata plat e/ label s a n d i s a s fo l l o ws for
LCHM/LCHHM standard units:
Refrigerant Compressor Oil
R22 York grade C
R407c York grade H
R134a York grade H
To prime each compressor - connect a York hand
oil pump (part no. 470-10654-000) to the 1/4"
compressor oil priming valve with a length of clean
hose or copper line, but do not tighten the flare nut.
Using clean oil of the correct type, pump oil until all
air has been purged from the hose then tighten the
nut. Stroke the oil pump 10 times (delivering
approximately 1,5 litres) to prime the oil system.
The oil level should be between the middle of the
lower and middle of the upper sight glasses. If it is
necessary to add oil, continue to stroke the pump
until the correct level is achieved.
Isolation/protection: Verify that all sources of
electrical supply to the unit are taken from a single
point of isolation. For units not fitted with a switch
disconnector fuse check that the maximum
recommended fuse sizes given in the Technical
Data section have not been exceeded.
Control panel: Check panel to see that it is free of
foreign materials (wire, metal chips, etc.) and clean
out if required.
Power connections: Check the customer power
cables are connected to the unit incoming
terminals. Ensure that connections of power
cables within the panel to contactors, terminal
blocks or switch disconnector fuse, and external
connection to compressors are tight.
Earthing: Verify that the units protective
terminal(s) are properly connected to a suitable
earthing point. Ensure that all unit internal earth
connections are tight.
Supply voltage: Verify that the site voltage supply
corresponds to the unit requirement and is within
the limits given on the unit data plate / Operating
Limitations section.
Control Transformer: The 3-wire control
transformer is mounted behind the control panel. It
is important to check that the correct primary
tapping has been used:
■ With the supply to the unit isolated remove the
lid to the transformer box.
■ Check that the tapping used conforms to the
site supply voltage. The two tappings are 342 -
424 V and 360 - 440 V.
Switch Settings: Ensure that the black handled
unit switch on the display door and the micro board
system switches S2 and S3 in the logic section are
set to "0" (OFF). For LCHM units ensure the
emergency stop button is reset. For LCHHM units
set the red handled control circuit switch
disconnector/emergency stop device on the lower
centre section door to "1" (ON). For units fitted with
switch disconnector fuse devices the power
section doors must be closed and the devices set
to "1" (ON). The customers disconnection devices
can now be set to ON.
The machine is now live!
The unit is fitted with an under voltage
relay and it may take between 5 to 10
seconds for its contacts to close and
energise the units electronics, including
the display.
Crankcase heaters: Verify the compressor
crankcase heaters are energised. The compressor
crankcase heaters must be on for at least 24
HOURS prior to start-up to ensure all refrigerant
liquid is driven out of the oil.

Water/Glycol system(s): Verify that the chilled
water system has been installed correctly, and has
been commissioned with the correct direction of
water flow through the cooler. Inlet should be at the
refrigerant pipework connection end of the cooler.
With water flowing, (it may be necessary to bypass
the unit pump control if this is connected) purge air
from the top of the cooler using the ¼" angle valve
mounted on the top of the cooler body.
On WL units, verify that the hot water system has
be en ins t all e d co rre ct l y, a n d h as been
commissioned with the correct direction of water
flaw through the condenser(s). Inlet should be at
the condenser connection nearest the bottom of
the vessel. With water flowing, (it may again be
necessary to bypass the unit pump control if this is
connected) purge air from the condenser(s) using
the ¼" angle valve mounted on the top of water
head.
Flow rates and pressure drops must be
within the limits given in Section 9 of this
manual. Operation outside of these limits
is undesirable and could cause damage.
Pressure drop should not be used to
determine flow rate.
Flow switch: Verify a chilled water flow switch is
correctly fitted in the customer’s pipework on the
cooler outlet, and wired into the control panel logic
section Opto-isolator board terminals 10 and 13
using screened cable.
Temperature sensor(s): Ensure the leaving water
temperature sensor is coated with heat conductive
compound (part no. 013-00890-000) and is
inserted in the bottom of the water outlet sensor
pocket of the cooler. This sensor also acts as the
freeze protection thermostat sensor and must
always be in the water OUTLET sensor pocket.
035L02374-GB2 (05/02) 5- 3
Control supply: Verify the control centre display is
illuminated. If an electronic expansion valve option
is fitted, the `power to expansion valve’ on the
valve controllers (in the logic section) should pulse
to indicate the 24 volt supply is on to these items.
HP cut-out reset: Check that the hand reset
mechanical high pressure cut-outs mounted on the
unit are reset.
EEV controller settings (if fitted): Loosen the four
screws holding the Danfoss controller to its base
and remove by pulling the handle. Check that the
refrigerant setting is correct for the refrigerant used
in the unit and that the MOP value is set for 5,8 barg
for R22 or 3,8 barg for R134a as applicable. Set the
(-BS2 (-) -BS1) temperature differential on the
controllers to 9°C and check that the Tn (time
integration) value is set to 200 seconds and the Kp
(amplification factor) value is set to 1,0. The `TQ
Power’ light will be pulsing indicating that the valve
actuator is ready for operation and the `beyond
neutral zone’ (∆∇) light will be on.
EEV sensors (if fitted): Check that the electronic
expansion valve sensor -BS1 is coated with heat
conductive compound (013-00890-000) and is
firmly to the bottom of the sensor pocket. Sensor
-BS2, located on the suction line, should also be
coated in the heat conductive compound and
should be securely strapped to the suction pipe.
Programmed options: Verify that the options
factory programmed into the Microprocessor
Control Centre are in accordance with the
customers order requirements by pressing the
`Options’ key on the keypad and reading the
settings from the display. Refer also to the
Microprocessor Based Control System Manual for
notes and explanation of messages.
 5- 4 035L02374-GB2 (05/02)

Programmed settings: Ensure the system cut-out 5.2 First Time Start-up
and operational settings are in accordance with the
instructions given in the Microprocessor Based During the commissioning period there
Control System Manual and with operational should be sufficient heat load to run the
requirements by pressing the ‘Program’ key. The unit under stable full load operation to
chilled liquid temperature control settings need to enable the unit controls, and system
be set according to the unit model and required operation to be set up correctly and a
operating conditions. The following tables give commissioning log taken. Read the
suggested settings: following section in conjunction with the
Microprocessor Based Control System
LCHM Units LCHHM Units Manual, then proceed step by step as
Water / Glycol Range follows:
4 6 8 4 6 8
through Cooler / °C
Rate Sensitivity / °C/min 3 4 4 2 3 4
Interlocks: Verify that water is flowing through the
Control Range / °C 2.5 3.7 4.4 1.3 1.9 2.5
cooler and on WL units through the condenser(s)
Rate Control Temperature / °C 5 5
(unless the unit chilled liquid pump and condenser
Anti-recycle Timer / s 300 300
liquid pump start control is being used, in which
case just ensure the pump supplies are on).
Additional settings for units operating on glycol with Ensure that any remote run interlocks are in the run
a cooler leaving temperature below 4.5°C: position and that the run schedule requires the unit
to run or is overridden.
Glycol leaving
-10 -7.5 -5 -2.5 0 2.5
temperature / °C System switches: Place the ‘Sys 1’ and ‘Sys 2’
Leaving liquid
-14 -11.5 -9 -6.5 -4 -1.5 switches on the microprocessor board to the ON
temp. cut-out / °C
position - see operating sequence in the
Suction pressure cut-out / barg
R22 1.52 1.79 2.07 2.34 2.62 2.97
Microprocessor Control Centre Manual.
R407C 1.56 1.84 2.14 2.43 2.73 3.09
R134a 0.42 0.58 0.73 0.9 1.1 1.32 Start-up: Remove the locking device from the unit
switch which prevents unauthorised starting of the
unit before commissioning. Press the ‘Status’ key,
Date & time: Programme the date and time by first then turn the unit switch to the "1" position to start
ensuring that the CLK jumper J18 on the the unit (there may be a few seconds delay before
microprocessor board is in the ON position (top two the first compressor starts because of the
pins). Then press the ‘Clock Set Time’ key and set anti-recycle timer). Be ready when each
the date and time (see Microprocessor Based compressor starts to switch the unit off
Control System Manual). immediately if any unusual noises or other adverse
conditions develop. Also refer to the Micro Based
Start/Stop schedule: Programme the daily and Control System Manual for the normal operating
h ol id ay s t ar t / sto p b y p re ssi n g th e ‘Set sequence of the unit from start-up.
Schedule/Holiday’ key (see Microprocessor Based
Control System Manual). Oil pressure: When a compressor starts, press
the relevant ‘System Pressures’ key and verify that
Set-point and Remote offset: Set the required oil differential pressure is developed immediately.
leaving chilled liquid temperature set-point and If oil pressure does not develop the automatic
control range (see table above for recommended controls will shut down the compressor (see the
control ranges). If remote temperature reset Micro Based Control System Manual for the flow
(offset) is to be used, the maximum reset must be chart of the automatic oil pressure safety system).
programmed by pressing the ‘Remote Reset Under no circumstances should a restart attempt
Temp’. key (see Microprocessor Based Control be made on a compressor which does not develop
System Manual). oil pressure immediately. Switch the unit switch to
the "0" position (OFF).

Refrigerant flow: When a compressor starts a
flow of liquid refrigerant will be seen in the liquid line
sight glass. After several minutes operation, and
providing a full charge of refrigerant is in the
system, the bubbles will disappear and be replaced
by a solid column of liquid.
General operation: Check the system operating
parameters are normal by selecting the various
readouts of pressure, temperature, etc.
Superheat: Check the compressor suction
superheat value only when pull down is complete
and steady full load operation has been
established. It is also important that there are no
bubbles showing in the liquid line sight glass.
Suction line temperature should be measured on
the copper line about 150 mm before the
compressor service valve. Suction pressure
should be measured at the compressor service
valve with a suitably calibrated gauge. Suction
superheat at the compressor should be between
5°C and 6°C for R22 and R134a, and between 4°C
and 5°C relative to the `dew’ temperature for
R407C. Discharge line temperature should not
exceed 80°C during normal operation.
Thermal expansion valve adjustment: Thermal
expansion valves are factory set and should not
need adjustment. If the superheat is out of range,
however, the expansion valve adjusting screw
should be adjusted no more than 1 turn at a time
(`in’ to increase superheat, `out’ to decrease
superheat), allowing at least 10 minutes for the
valve to stabilise before rechecking the value of
superheat.
035L02374-GB2 (05/02) 5- 5
Electronic expansion valve adjustment (if
fitted): Electronic expansion valves, when fitted,
are set for 9°C difference between the -BS2 and
-BS1 sensors during preparatio n f o r
commissioning and should be adjusted to their
running setting only when steady operation has
been established. During pull down the `TQ Power’
light will pulse rapidly and the `beyond neutral
zone’ (∆∇) light will be on. When steady operation
is reached the ∆∇ light will go out and the `within
neutral zone’ (SP) light will illuminate indicating
that the difference between -BS2 and -BS1 is
within 1°C of the setting.
The actual superheat value at the compressor will
still be quite high and the expansion valve
controller setting should be reduced 1°C at a time,
normally to a value of 6°C, until the correct value of
measured superheat is achieved. The valve
should be allowed to stabilise for at least 5 minutes
between adjustments before rechecking the value
of superheat.
Subcooling: Check the amount of subcooling
leaving the condenser coils only when pull down is
complete and steady full load operation has been
established. It is also important that all fans are
running, giving full airflow across the condenser
coils. Liquid line temperature should be measured
on the copper line between the liquid line service
valve and the filter/drier. Liquid pressure should be
measured at the liquid line service valve with a
suitably calibrated gauge. Liquid subcooling
should be between 4°C and 10°C for R22 and
R134a, and between 4°C and 8°C relative to the
‘bubble’ temperature for R407C. If necessary, add
or remove refrigerant to obtain the correct level of
subcooling. Do not overcharge the unit.
 5- 6 035L02374-GB2 (05/02)

Loadminder adjustment (if fitted): The

Loadminder hot gas bypass system consists of a
line running from the compressor discharge to the
cooler refrigerant inlet via a pressure regulator
valve with integral solenoid actuator. On falling
load the control system will (reduce the
compressor to minimum capacity step then actuate
the regulator solenoid to open the bypass line (see
Microprocessor Based Control System Manual).
The regulator, valve will then inject hot discharge
gas into the cooler to modulate the refrigerant
pressure and prevent a further drop in chilled liquid
temperature. This occurs until the injection
capacity of the valve is reached (the valve is fully
Loadminder Hot Gas Injection Regulator
open), when the chilled liquid temperature will
begin to fall again and the control system will stop
the compressor.

The valve should only be set during low load

operation with the correct chilled liquid leaving
temperature and the compressor running on
minimum capacity step.

The Loadminder system only operates on

falling load, not on compressor start-up.

As the chilled liquid temperature falls towards the

set-point check the cooler refrigerant pressure.
When the set-point is reached and the valve opens
sufficient hot gas should be injected to raise the
cooler refrigerant pressure slightly so that the
chilled liquid leaving temperature settles near the
middle of the thermostat control zone.

If the regulator valve control pressure does not give

the correct leaving liquid temperature, the pressure
can be adjusted using the screw on top of the valve.
Loosen the lock-nut and turn the screw clockwise
to raise the pressure.

6 UNIT OPERATION
6.1 General Description
LCHM and LCHHM packaged chillers are
designed to work independently, or in conjunction
with other equipment via a York ISN building
management system or other automated control
system. When operating, the unit controls monitor
the chilled liquid system temperature at the unit
and take appropriate action to maintain this
temperature within desired limits. This action will
involve running one or (on LCHHM units) both
compressors at a suitable load step to match the
cooling effect of the refrigerating systems to the
heat load on the liquid system.
On WL units the heat removed from the chilled
liquid is transferred to a hot water system to then
either be rejected via a cooling tower of coils, or
recovered for use elsewhere via an optional heat
recovery system.
On AL units the heat removed from the chilled
liquid is usually rejected directly to atmosphere
from remote air cooled condenser coils.
The following sections give an overview of the
operation of a unit. For detailed information,
reference should be made to the Microprocessor
Based Control System Manual for the unit.
6.2 Start-up
Ensure the mains power to the unit and controls is
on, the microprocessor ‘Sys 1’ (LCHM and
LCHHM) and ‘Sys 2’ (LCHHM) circuit board
switches are in the `on’ position, all refrigerant
service stop valves are open (anti-clockwise), and
the chilled liquid flow has been established (unless
the unit chilled liquid pump and condenser liquid
pump start control is being used, in which case just
ensure the pump supplies are on).
Press the ‘STATUS’ key on the keypad and then
switch the unit switch below the keypad to the ‘1’
(on) position.
035L02374-GB2 (05/02) 6- 1
The controller will perform a pre-check to ensure
that the daily/holiday schedule and any remote
interlocks will allow the unit to run, that all safety
cut-outs are satisfied and that cooling load is
required (i.e. that the chilled liquid temperature is
outside the set limits). Any problems encountered
by the pre-check will be displayed if present. If no
problems are present and cooling duty is required
`START SEQUENCE’ will be displayed and after a
short delay the compressor will start on its first
capacity step (on LCHHM units the lead
compressor will start).
On LCHHM units the display will show the
anti-coincidence timer status for the lag
compressor, followed by `NO COOL LOAD’ until it
is called to operate by the control system.
6.3 Normal Running and Cycling
Once the unit has been started, all operations are
fully automatic. After an initial period at minimum
capacity step the control system will adjust the unit
load step depending on the chilled liquid
temperature and rate of temperature change. If
high heat load is present, the controller will
increase the number of active cylinders on the
compressor and on LCHHM units start-up the lag
compressor (`START SEQUENCE’ will be
displayed for the lag compressor, followed by the
same sequence as for the lead compressor).
If very little heat load is present, however, the
compressor will continue at minimum step, or may
simply stop again to avoid overcooling the liquid. If
the latter is the case, a compressor will restart
automatically should the liquid temperature rise
again.
On LCHM units with the Loadminder option fitted,
the compressor once started will continue to run at
minimum step even down to very small cooling
loads. Overcooling is avoided and stable operation
maintained by the Loadminder hot gas injection
system.
As soon as a compressor is running the controller
monitors oil pressure, motor current, and various
other system parameters such as discharge
pressure, chilled liquid temperature, etc. Should
any problems occur the control system will
immediately take appropriate action and display
the nature of the fault (see Microprocessor Based
Control System Manual for full details).
 6- 2 035L02374-GB2 (05/02)

6.4 Compressor Capacity Control

York 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 unit 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 to the unloader mechanisms in the
compressor.

6.5 Heat Recovery Operation

Whenever a compressor is running due to cooling

demand, the optional dual water circuit heat
recovery condenser(s) allow recovery of the heat
into a hot water system as well as rejection of the
heat to a cooling tower or similar system. The
Microprocessor Based Control System does not
have hot water controls, these will need to be fitted
separately.

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.
 035L02374-GB2 (05/02) 7- 1

7 MAINTENANCE Refrigerant leaks: visually check the heat

exchangers, compressors and pipework for
7.1 General Requirements damage and gas leaks.

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

This maintenance section applies only to

the basic LCHM/LCHHM unit and may, on
individual contracts, be supplemented by
additional requirements to cover any
modifications or ancillary equipment as
applicable.

The Safety Section of this manual Maximum Acceptable Operating Oil Level
should be read carefully before
at t em p ti n g any m a i n tenance
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

c ar r ied out o n a d a i l y b a si s by the Minimum Acceptable Operating Oil Level
operator/customer. Please note, however, that
units are not generally user serviceable and no Refrigerant charge: when a system starts up, or
attempt should be made to rectify faults or sometimes after a change of capacity step, a flow
problems found during daily checks unless of bubbles will be seen in the liquid line sight glass.
competent and equipped to do so. If in any doubt, After a few minutes of stable operation the bubbles
contact your local York Service Agent. should clear leaving just liquid refrigerant showing
in the sight glass.
Unit status: press the ‘STATUS’ key on the
keypad and ensure no fault messages are
displayed (refer to the Micro Based Control System
Manual for explanation of messages and the
Trouble Shooting section for courses of action).
 7- 2 035L02374-GB2 (05/02)

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

SERVICE SCHEDULE
Unit general:
Refrigerant systems general:
Compressors:
Evaporator:
AL air cooled condensers:
Power & Control system general:
Microprocessor controls:
MINOR SERVICE
Check thermal insulation
Check vibration isolators
Check relief valves
Check fusible plugs
Check for pipework damage
Check for leaks
Check moisture indicator
Check suction superheat
Check liquid subcooling
Check oil level
Check oil pressure
Check unloader operation
Check crankcase heater
Check condition of oil
Check water flow
Check water pressure drop
Check for airflow obstructions
Check fins
Check fans and fan guards
Check panel condition
Check mains and control wiring
Check sensor locations
Check mechanical HP cut-outs
Check emergency stop
Check residual current devices
Check fault history
Check program settings
Check HP / LP cut-out functions
Check pump-down function
Check load / unload function
MAJOR SERVICE
All items under Minor Service plus:
Check main structure
Check paint-work
Change filter/drier cores
Check solenoid valves
Check big ends
Check sump for white metal
Check suction valves and springs
Check discharge valves and springs
Check cylinder sleeves
Check suction strainer
Check oil filter
Check pistons and rings
Change compressor oil
Check water pH / glycol strength
Brush fins
Check fan motor bearings
Check all connections
Check compressor contactors
Check sensor / transducer calibration
Check motor protectors
Check contactor contacts
Check ambient cut-out function
Check LTL cut-out function
Check low oil pressure 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 mmcorrosion 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.

8 TROUBLE SHOOTING
8.1 Competent Persons Trouble Shooting Guide
PROBLEM
No display on panel - unit will not
operate
NO RUN PERM displayed
OIL TEMP INHIBIT displayed
CHILLER FAULT: LOW AMBIENT
TEMP displayed
CHILLER FAULT: HIGH AMBIENT
TEMP displayed
POSSIBLE CAUSE
Mains supply to control system off.
Emergency stop device off.
Undervoltage relay tripped.
No supply to -T3.
No 24 V ac supply to power board.
No +12 V output from power board.
No liquid flow through the cooler.
Flow switch contacts are not made.
Remote cycling device open.
Oil temperature has not reached
working temperature following
power-up.
Compressor crankcase heater not
working.
Liquid flooding.
Measured temperature incorrect.
Ambient air temperature is lower than
the programmed operating limit.
Measured temperature is incorrect.
Ambient air temperature is higher
than the programmed operating limit.
Measured temperature is incorrect.
035L02374-GB2 (05/02) 8- 1
ACTION
Switch on mains supply if safe to do so.
Check if control panel emergency stop device and any
remote emergency stop devices are in the ‘OFF’ position.
Turn to ‘ON’ position (1) if safe to do so.
Check mains supply.
Check emergency stop switch fuses -F1 and -F4 (when
fitted), -F13 (LCHM), -F1 (LCHHM) and -F4.
Check wiring from -T3 to power board and fuse -F3.
Replace power board or isolate excessive load on the
board.
Ensure that liquid pumps are running, valves are correctly
set and flow is established.
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.
Check cycling devices connected to terminals 11 & 14
(SYS 1) and 12 & 15 (SYS 2) on the opto interface board
are closed.
Use the oil temperature display key to confirm that the oil
temperature is slowly rising. The warning message should
clear when the oil temperature has reached the correct
working temperature.
Check the operation of the heater. Measure the current
drawn by the heater (should be 1A).
Check expansion valve operation, especially during
unloading steps.
Check sensor calibration, location and wiring.
Use the ‘ambient temp.’ key to display the temperature and
confirm that the displayed value is approximately correct.
The warning message should clear when the ambient air
temperature reaches the programmed operating limit.
Check the programmed settings are correct for the options
fitted to the unit.
Check sensor calibration, location and wiring.
Use the ‘ambient temp.’ key to display the temperature and
confirm that the displayed value is approximately correct.
The warning message should clear when the ambient air
temperature falls below the programmed operating limit.
Check the programmed settings are correct for the options
fitted to the unit.
Check sensor calibration, location and wiring.
 8- 2 035L02374-GB2 (05/02)
PROBLEM POSSIBLE CAUSE
CHILLER FAULT: LOW WATER Leaving liquid drops below the
TEMP displayed programmed low limit faster than the
unit can unload.
Unit is not unloading.
Measured temperature is incorrect.
CHILLER FAULT: LWT SENS LWT sensor out of range.
FAULT displayed
CHI L L ER FAULT: POWER Incorrect mains supply voltage.
FAIL U R E M AN U A L R E S E T
displayed
SYS # HIGH DSCH displayed Poor flow through the condenser
Excessive refrigerant charge.
Measured pressure is incorrect.
SYS # DSCH LIMITING displayed Discharge pressure unloading due to
unit operating above load limit. See
also SYS # HIGH DSCH.
SYS # OIL PRESS displayed Oil loss. Oil pump wear or failure.
Too much refrigerant in the oil.
Measured pressure incorrect.
SYS # LOW SUCTION displayed Insufficient liquid flow through chiller.
Badly adjusted or faulty expansion
valve.
Reduced evaporator performance.
Low refrigerant charge.
Measured pressure incorrect.
SYS # C U R R EN T/ M P / H P X Compressor current too high or too
displayed low.
Measured current is incorrect.
Compressor motor protector signal
failure (no MP light on opto board).
Mechanical high pressure cut-out
trip.
ACTION
Check for restrictions in the liquid flow line.
Check the liquid flow is stable.
Check the electrical supply to the unloader valve
solenoids.
Check the compressor unloads correctly.
Check sensor calibration, location and wiring.
Check sensor calibration. Check sensor wiring for
open/short circuit.
Check mains supply voltage is stable and within
permissible limits. Check voltage drop on compressor
start.
On WL units, check liquid pump(s) are running correctly
and the valves are correctly set.
On AL units, check the liquid filter for blockages and check
for airflow restrictions caused by blockages on intake faces
of air coils.
Check for signs of air in the refrigerant system(s).
Check sub-cooling is correct.
Check discharge transducer calibration and wiring.
Check chilled liquid temperature is within range. Check if
ambient air temperature is above design conditions.
Check oil level, particularly at minimum load step.
Replace oil pump.
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).
Check suction/oil pressure transducer calibration and
wiring.
Check operation of liquid pumps.
Check valves are correctly set.
Check liquid filter for blockages.
Check liquid line suction valve is operating correctly.
Check superheat.
Check for fouled tube surfaces.
Check refrigerant charge level.
Check for leaks.
Check suction pressure transducer calibration and wiring.
Check compressor mains supply, fuses, contactors and
wiring. Check mains supply voltage is within tolerance.
Check for defective current transformer (resistance should
be between 55 and 60 Ohms).
Check calibration resistor is correctly fitted.
Check motor protector and wiring.
Check compressor motor.
Check compressor discharge valve is open.
Check cut-out setting and wiring.
Check discharge line solenoid valve operation (including
pressure regulator setting).
 035L02374-GB2 (05/02) 8- 3

PROBLEM POSSIBLE CAUSE ACTION

SYS # PUMPDOWN FAIL displayed Liquid line solenoid valve not closed. Check operation of valve.
(Failure to pump down on start up) Check wiring to valve.

SYS # CURR LIMITING displayed
Leak on low pressure side of system.
Measured pressure incorrect.
High compressor motor current has
activated unloading.
See also SYS # CURRENT/MP/HPX
Check low pressure side for air/liquid leaks.
Check suction pressure transducer calibration and wiring.
Check liquid temperature is within operating limits. Check if
ambient air temperature is above operating limits.

8.2 Compressor Components

PC Compressors Unloading Valves Logic Section Components

(oil pressure actuated)

Oil Pump-end Components

AE4BC Expansion Board (When Fitted)

APB Power Board
AMB Microprocessor Board
AOIB Opto Interface Board
YEEVC Electronic Expansion Valve Controller
F# Fuses

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
 8- 4 035L02374-GB2 (05/02)

Compressor liquid injection cooling system 8.3 Sensor Calibration Charts

Pressure Transducers
On PC 6 and 8 cylinder compressors that unload to
two operational cylinders the compressor is fitted 0 - 200 psig Transducer 0 - 400 psig Transducer
with a liquid injection system. This consists of Pressure psig Voltage V dc Pressure psig Voltage V dc
0 0,5 0 0,5
solenoid valve, filter and ball valve mounted on the 25 1,0 50 1,0
side of the compressor which controls the feed of 50 1,5 100 1,5
liquid refrigerant into the compressor’s unloaded 75 2,0 150 2,0
100 2,5 200 2,5
suction plenums through an orifice in each plenum. 125 3,0 250 3,0
In some early compressors the liquid feed was into 150 3,5 300 3,5
the crankcase through a capillary tube. 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
The liquid feed to the compressor is directly from
the main liquid line, on heat recovery units there Leaving Water Temperature Sensor (LWT)
are two liquid feeds one from the main liquid line and 3 k Oil Temperature Sensor*
and the other from the heat recovery liquid line. The Temperature °C Resistance Ω Voltage Vdc
two solenoid valves control the liquid feed into the -10 16598 1,45
compressor depending on the mode of operation. -8 14896 1,57
-6 13388 1,69
The operation of the solenoid valve(s) is controlled -4 12047 1,80
by the compressor crankcase oil temperature as -2 10856 1,93
0 9795 2,05
sensed by the micro panel. If the oil temperature is
2 8849 2,17
above 60 °C and the compressor is operating then 4 8005 2,30
the liquid injection solenoid valve is energised. 6 7251 2,42
When the oil temperature is below 55 °C the liquid 8 6575 2,54
injection solenoid valve is de-energised, it is also 10 5970 2,66
de-energised when the compressor is not 20 3748 3,22
operating. 30 2417 3,69
40 1598 4,05
Microboard test points: Leaving water: J11-7/1
Sys.1 oil temp: J11-8/2
Sys.2 oil temp: J16-6/3

Ambient Temperature Sensor

and 10 k Oil Temperature Sensor*
Temperature °C 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: Ambient Air: J11-9/3
Sys.1 oil temp: J11-8/2
Sys.2 oil temp: J16-6/3

* Two types of oil temperature sensors

can be found on the compressors, 3 kΩ or
10 kΩ. The 3 kΩ sensor is 3 kΩ at 25 °C,
the 10 kΩ is 10 kΩ at 25 °C.
 035L02374-GB2 (05/02) 8- 5

8.4 Electronic Expansion Valve Calibration Calibration Checks

(See Section 5 for Valve Adjustment)
Electronic Expansion Valve and Controller
base connections
Measurements should be made on controller base
with the controller removed:
■ Supply voltage should measure 24 Vac + 10%
across terminals 1 and 2.

■ Actuator power circuit should measure 8 - 20

ohms across terminals 77 and 78.

■ Actuator temperature feedback circuit should

measure 100Ω - 100 kΩ across terminals 35
and 36.

-BS1 and -BS2 resistance should correspond the

table below measured across terminals 26 and 27
Orifice assembly and 24 and 25 respectively.

The spring in the orifice assembly is factory set and

is critical to the correct operation of the valve. The
length of the spring should be as follows:
Temperature °C Resistance Ω Temperature °C Resistance Ω
-30 882,2 0 1000
-29 886,2 1 1003,9
-28 890,1 2 1007,8
-27 894,0 3 1011,7
-26 898,0 4 1015,6
-25 901,9 5 1019,5
-24 905,9 6 1023,4
VALVE TYPE SPRING LENGTH `Y’
-23 909,8 7 1027,3
TQ 55 - 2 31,0 mm ± 0,3 mm -22 913,7 8 1031,2
-21 917,7 9 1035,1
PHTQ 85 - 3, PHTQ 85 - 4 26,5 mm ± 0,3 mm
-20 921,6 10 1039
-19 925,5 11 1042,9
-18 929,5 12 1046,8
-17 933,4 13 1050,7
-16 937,3 14 1054,6
-15 941,2 15 1058,5
-14 945,2 16 1062,4
-13 949,1 17 1066,3
-12 953,0 18 1070,2
-11 956,9 19 1074
-10 960,9 20 1077,9
-9 964,8 21 1081,8
-8 968,7 22 1085,7
-7 972,6 23 1089,6
-6 976,5 24 1093,5
-5 980,4 25 1097,3
-4 984,4 26 1101,2
-3 988,3 27 1105,1
-2 992,2 28 1109
-1 996,1 29 1112,8
0 1000 30 1116,7
Controller base test points: -BS1 = terminals 26 & 27
-BS2 = terminals 24 & 25
 8- 6 035L02374-GB2 (05/02)

8.5 Electronic Expansion Valve Trouble Shooting

PROBLEM POSSIBLE CAUSES ACTION

Valve capacity Insufficient liquid subcooling. Check liquid subcooling.

low - actuator Check for blocked filter drier.
hot
Insufficient pressure drop across valve. Check discharge pressure fan control settings.
Check for blocked filter drier.

Voltage supply too low. Temporarily set S2-S1 knob on controller to 18°C,
check TQ power lamp lights up constantly, then
check supply at terminals 77 & 78 on actuator is 24
Vac +/- 10%.

Valve capacity Sensors swapped over. Check sensors are wired correctly.
low - actuator
cold Broken or short circuited sensor cable or Check sensors are located correctly: -BS1 firmly in
sensor out of calibration / out of position. bottom of cooler pocket and -BS2 strapped on
suction line.

Broken or short circuited wiring from Test wiring.

controller base to valve actuator.

Defective NTC resistor in valve actuator. Check NTC resistance from controller base.

Defective actuator heater element. Check heater resistance from controller base.

V a lve does Defective NTC resistor circuit. Check NTC resistance from controller base.
not close
Defective controller / incorrect set-up. Remove controller from base and check if valve
now closes.

Obstruction in valve orifice. Check orifice is clean and O-ring is in place.

Broken or short circuited sensor cable or Check sensor resistance at controller base.
sensor out of calibration / out of position. Check sensors are located correctly: -BS1 firmly in
bottom of cooler pocket and -BS2 strapped on
suction line.
 035L02374-GB2 (05/02) 9- 1

9 TECHNICAL DATA

9.1 Flow Rate/Pressure Drop Charts

Cooler Water Pressure Drops (A) Cooler Water Pressure Drops (B)

COOLER WATER PRESSURE DROP kPa

COOLER WATER PRESSURE DROP kPa

COOLER WATER FLOW RATE l/s

COOLER WATER FLOW RATE l/s

Condenser Water Pressure Drops (A) Condenser Water Pressure Drops (B)
CONDENSER WATER PRESSURE DROP kPa

CONDENSER WATER PRESSURE DROP kPa

CONDENSER WATER FLOW RATE l/s

CONDENSER WATER FLOW RATE l/s

Models Coolers WL Condensers Models Coolers WL Condensers

60 LINE (A) 1 LINE (A) 1 55 LINE (A) 1 LINE (A) 1
70 LINE (A) 1 LINE (A) 2 65 LINE (A) 1 LINE (A) 2
85 LINE (A) 2 LINE (A) 3 R134a 75 LINE (A) 1 LINE (A) 3
R22 / 100 LINE (A) 2 LINE (A) 4 Models 90 LINE (A) 2 LINE (A) 5
R407C 115 LINE (A) 2 LINE (A) 5 110 LINE (A) 2 LINE (A) 5
Models 140 LINE (B) 2 LINE (B) 1 130 LINE (B) 2 LINE (B) 1
170 LINE (B) 1 LINE (B) 2 150 LINE (B) 1 LINE (B) 2
200 LINE (B) 2 LINE (B) 3
230 LINE (B) 3 LINE (B) 3
Notes
When using glycol solutions, pressure drops are higher than with water. Special care must be taken not to exceed the maximum allowed.
Pressure drops quoted are nominal values. Manufacturing variations may cause up to 15% increase.
 9- 2 035L02374-GB2 (05/02)

Heat Recovery Condenser (HR) 2-Pass Heat Recovery Condenser (HR) 3-Pass
Water Pressure Drops Water Pressure Drops
CONDENSER WATER PRESSURE DROP kPa

CONDENSER WATER FLOW RATE l/s CONDENSER WATER PRESSURE kPa CONDENSER WATER FLOW RATE l/s

WL-HR 2 & 3 PASS Condensers WL-HR 2 & 3 PASS Condensers

Models Models
Upper Condenser Lower Condenser Upper Condenser Lower Condenser
60 - LINE 1 55 - LINE 1
70 - LINE 2 R134a 65 - LINE 2
85 - LINE 3 Models 75 - LINE 3
R22 / 100 - LINE 4 90 - -
R407C 115 - LINE 5 110 - -
Models 140 LINE 2 LINE 2 130 LINE 2 LINE 2
170 LINE 3 LINE 3 150 LINE 3 LINE 3
200 LINE 3 LINE 5
230 LINE 5 LINE 5
Notes
When using glycol solutions, pressure drops are higher than with water. Special care must be taken not to exceed the maximum allowed.
Pressure drops quoted are nominal values. Manufacturing variations may cause up to 15% increase.

Pressure Drop Corrections Recommended Glycol Solution Strengths

Leaving Liquid Temperature Ethylene Glycol Propylene Glycol

R22 / R134a R407C Concentration Concentration
°C °C % w/w % w/w
4 6 5 5
2 4 12 13
0 2 18 20
-2 0 23 25
-4 -2 28 30
-6 -4 32 34
-8 -6 35 38

A Correction Factor
B Mean Glycol Temperature through Cooler
C Concentration W/W
 035L02374-GB2 (05/02) 9- 3

9.2 Operating Limitations

General Limitations
Minimum Maximum
ELECTRICAL Mains ( 380 / 400 / 415 V - 3ph - 50 Hz Nominal ) : 342 V 440 V
SUPPLY Controls ( 220 / 230 / 240 V - 1ph - 50 Hz Nominal ) : 198 V 254 V
Chilled Water Leaving Temperature : R22 & R134a models : 4.0 °C 10 °C
R 407C models : 6.0 °C 10 °C
Chilled Glycol Leaving Temperature : R22 & R134a models : - 6 °C 10 °C
R 407C models : - 2 °C 10 °C
WATER / Chilled Liquid Temperature Range through Cooler : 3.3 °C 8 °C
GLYCOL Standard Condenser R22 models : 30 °C 41 °C
SYSTEMS Liquid Leaving Temperaure : R134a models : 30 °C 55 °C
R407C models : 30 °C 35 °C
High Pressure Condenser and Heat Recovery R22 models : 30 °C 52 °C*
Condenser Liquid Leaving Temperature : R134a models : 30 °C 55 °C*
R407C models : 30 °C 49 °C*
Evaporator & Condenser Water / Glycol Pressure at Unit : - 10 barg
High Pressure Side Design Pressure : WL Units : - 20.7 barg
WL-HR,WL-HP,AL,ALR Units : - 27.6 barg
REFRIGERANT Operating Discharge Pressure (AL Units): R22 models : 13.0 barg 24.1 barg
SYSTEM(S) R134a models : 8.0 barg 17.9 barg
R407C models : 13.0 barg 24.1 barg
Low Pressure Side Design Pressure : All models : - 20.7 barg
AIR TEMPERATURE SURROUNDING UNIT 4.4 °C 46 °C
* In excess of 49 °C for R22 units, 52 °C for R134a units and 46 °C for R407C units the flow rate must be guaranteed
steady within +/-10% at 5.5 °C range to avoid nuisance HP cutout trips.

Compressor Limitations

Minimum Maximum
Compression Ratio : - 9.5 : 1
Discharge Pressure : - 27.9 barg
Suction Pressure (operating) : - 8.5 barg
Differential Pressure : - 22.5 barg
Oil Pressure (above suction pressure) : 1.4 bar ** -
Oil Temperature (at oil pump suction) : - 70 °C
Suction Gas Superheat : 2.8 °C -
Discharge Gas Temperature : - 135 °C
** 1.4 bar provides bearing protection but is insufficient to operate oil pressure actuated unloading
system on PC compressors which may require up to 4.2 bar.
 9- 4 035L02374-GB2 (05/02)

Individual Unit Limitations

Liquid Flow Rate, System Water Content and Pressure Drop Limitations Compressor

COOLER CONDENSER(S) Motor Max.

Standard WL-HR Units WL-HR Units Input Power
Flow Rate Pressure Minimum WL Units 2 Pass 3 Pass (kW per motor)
MODEL ( l/s ) Drop Recommended Flow Rate Flow Rate Flow Rate WL-HP
( kPa ) System ( l/s ) ( l/s ) ( l/s ) WL WL-HR
Min. Max. Max. Content (l) Min. Max. Min. Max. Min. Max. AL
60 3.8 18.0 97 1300 3.5 13.0 4.8 17.4 3.2 11.6 58.3 (M) 67.7 (N)
70 3.8 18.0 97 970 4.0 15.6 5.8 21.0 3.8 14.0 67.7 (N) 78.8 (P)
85 5.2 22.0 54 1170 5.0 19.0 7.0 25.5 4.7 17.0 78.8 (P) 112 (S)
R22 / 100 5.2 22.0 54 970 6.0 22.2 8.2 30.0 5.5 20.0 112 (S) 112 (S)
R407c 115 5.2 22.0 54 1090 6.4 24.5 9.0 33.0 6.0 22.0 112 (S) 134 (T)
140 9.1 34.9 80 950 11.5 42.0 11.5 42.0 7.6 28.0 67.7 (N) 78.8 (P)
170 10.6 34.1 90 1120 14.0 51.0 14.0 51.0 9.4 34.0 78.8 (P) 112 (S)
200 11.4 37.9 90 1160 18.0 66.0 16.0 58.5 10.7 39.0 112(S)/78.8(P) 134(T)/112(S)
230 15.2 42.0 90 1240 18.0 66.0 18.0 66.0 12.0 44.0 112 (S) 134 (T)
55 3.8 18.0 97 780 3.5 13.0 4.8 17.4 3.2 11.6 67.7 (N) 67.7 (N)
65 3.8 18.0 97 680 4.0 15.6 5.8 21.0 3.8 14.0 78.8 (P) 78.8 (P)
R134a 75 3.8 18.0 97 770 5.0 19.0 7.0 25.5 4.7 17.0 90.9 (Q) 90.9 (Q)
90 5.2 22.0 54 620 6.4 24.5 - - - - 58.3 (M) 58.3 (M)
110 5.2 22.0 54 740 6.4 24.5 - - - - 67.7 (N) 67.7 (N)
130 9.1 34.9 80 750 11.5 42.0 11.5 42.0 7.6 28.0 78.8 (P) 78.8 (P)
150 10.6 34.1 90 860 14.0 51.0 14.0 51.0 9.4 34.0 90.9 (Q) 90.9 (Q)
Notes.
1. The maximum cooler flow rates shown are for water operation.
On glycol operation maximum flow value must be reduced in order to observe the maximum pressure drop limit
2. For LCHHM units flow limits given are for the TOTAL flow through both condensers.
3. Condenser flow rates should also be limited between 3.6 l/s and 7.2 l/s per 100 kW heat rejection.
4. Maximum Motor Input Power for R22 WL-HP & WL-HR units above 41 °C hot water leaving temperature.
4. Maximum Motor Input Power for R407C WL-HP & WL-HR units above 31 °C hot water leaving temperature.

Recommended concentrations for Factors at otherconcentrations for

Ethylene glycol solutions Ethylene glycol solutions

0.28
GLYCOL FACTOR (l/s) °C / kW AT
RECOMMENDED CONCENTRATION

0.27
CONCENTRATION BY WEIGHT %

CONCENTRATION BY WEIGHT %

GLYCOL FACTOR AT 0.26

GLYCOL FACTOR (l/s) °C / kW

RECOMMENDED
CONCENTRATION
0.25
RECOMMENDED
CONCENTRATION 0.24

0.23

FREEZING
TEMPERATURE

LEAVING LIQUID TEMPERATURE °C

LEAVING LIQUID TEMPERATURE °C
 035L02374-GB2 (05/02) 9- 5

Recommended concentrations for Factors at other concentrations for

Propylene glycol solutions Propylene glycol solutions

0.26

GLYCOL FACTOR (l/s) °C / kW AT

RECOMMENDED CONCENTRATION
GLYCOL FACTOR AT
RECOMMENDED 0.25

CONCENTRATION BY WEIGHT %
CONCENTRATION
CONCENTRATION BY WEIGHT %

GLYCOL FACTOR (l/s) °C / kW

0.24

0.23
RECOMMENDED
CONCENTRATION

FREEZING
TEMPERATURE

LEAVING LIQUID TEMPERATURE °C LEAVING LIQUID TEMPERATURE °C

Pressure drop correction factors for Pressure drop correction factors for
Ethylene glycol solutions Propylene glycol solutions

1.50
CORRECTION FACTOR

% CONCENTRATION
CORRECTION FACTOR

% CONCENTRATION

MEAN LIQUID TEMPERATURE °C MEAN LIQUID TEMPERATURE °C

Correction Factors
Ethylene Glycol Propylene Glycol
% By Weight
Capacity Factor Comp. Input Factor Capacity Factor Comp. Input Factor
10 1.045 1.020 1.070 1.025
20 1.020 1.010 1.040 1.015
30 1.000 1.000 1.000 1.000
40 0.970 0.990 0.950 0.985
50 0.940 0.980 0.900 0.970

To adjust 30% Ethylene Glycol Ratings

 9- 6 035L02374-GB2 (05/02)

9.3 Physical Data

LCHM R22/R407C Models

MODEL 60 70 85 100 115
NUMBER OF REFRIGERANT CIRCUITS 1 1 1 1 1
MODEL - WL Standard Units System 1 PC441-M PC632-N PC642-P PC833-Q PC843-S
MODEL - WL-HP, WL-HR & AL Units System 1 PC441-N PC632-P PC642-S PC833-S PC843-T
NOMINAL SPEED rpm 1450 1450 1450 1450 1450
OIL CHARGE (per compressor) ltr. 11.4 11.4 11.4 11.4 11.4
No. Unit Capacity Steps 2 3 3 4 4
COMPRESSORS 59-100 37-73 37-73 27-60 27-60
Cooling capacity % -100 -100 -81-100 -81-100

51-100 32-68 37-73 24-51 24-51

Power Input % -100 -100 -75-100 -75-100

COOLER Model 1007H 1007H 1207H 1207H 1207H

Water Capacity ltr. 61 61 90 90 90
STANDARD WL Model PC51 PC60 PC73 PC87 PC98
CONDENSER Water Capacity ltr. 39 51 59 72 77
WL-HR SYSTEM 1 Model PC102 PC120 PC146 PC174 PC196
CONDENSER(S) Water Capacity ltr. 79 101 117 143 155
NOMINAL WL UNITS kg 1460 1610 1830 1990 2040
OPERATING WL-HR UNITS kg 1920 2070 2320 2520 2590
WEIGHTS AL UNITS kg 1280 1360 1560 1640 1670
AL-R UNITS kg 1390 1485 1680 1795 1820
REFERENCE SOUND LEVEL to EN292 1991 SPL at 1m (SWL) dBA 91 (105) 91 (105) 91 (105) 92 (106) 92 (106)
WL/WL-HP UNITS System 1 kg 36 42 50 59 65
OPERATING WL-HR UNITS System 1 kg 43 50 60 71 81
REFRIGERANT AL UNITS (Unit only) System 1 kg 18 21 26 31 34
CHARGE AL-R UNITS (Unit only) System 1 kg 27 34 39 47 50
Receiver Pump Down Capacity Per System kg 92 132 132 162 162

Sound levels are for fully loaded unit. SPL values are adjacent to compressors
(SWL values are based on measurements to ISO 3744 or ISO 3746)
AL-R operating weight & charge are based on receiver tank filled to 10% of pump down capacity.
Pump down capacity is based on 80% of receiver volume.
 035L02374-GB2 (05/02) 9- 7

LCHHM R22/R407C Models

MODEL 140 170 200 230
NUMBER OF REFRIGERANT CIRCUITS 2 2 2 2
MODEL - WL Standard Units System 1 PC632-N PC642-P PC843-S PC843-S
System 2 PC632-N PC642-P PC642-P PC843-S
MODEL - WL-HP, WL-HR & AL Units System 1 PC632-P PC642-S PC843-T PC843-T
System 2 PC632-P PC642-S PC642-S PC843-T
NOMINAL SPEED rpm 1450 1450 1450 1450
OIL CHARGE (per compressor) ltr. 11.4 11.4 11.4 11.4
COMPRESSORS No. Unit Capacity Steps 3+3 3+3 4+3 4+4
18-37 18-37 16-31-46 15-27-40
Cooling capacity % -59-72 -59-72 -66-77-89 -60-72-81
-86-100 -86-100 -100 -90-100
18-32 18-32 15-28 14-24-34
Power Input % -51-66 -51-66 -39-59 -51-64-76
-82-100 -82-100 -72-85-100 -86-100
COOLER Model 1507H 17069H 170711H 17083H
Water Capacity ltr. 116 145 155 176
STANDARD WL Model PC120 PC146 PC196 PC196
CONDENSER Water Capacity ltr. 101 117 155 155
HEAT SYSTEM 1 Model PC120 PC146 PC196 PC196
RECOVERY Water Capacity ltr. 101 117 155 155
WL-HR SYSTEM 2 Model PC120 PC146 PC146 PC196
CONDENSER(S) Water Capacity ltr. 101 117 117 155
NOMINAL WL UNITS kg 3330 3580 3990 4120
OPERATING WL-HR UNITS kg 4230 4540 4960 5270
WEIGHTS AL UNITS kg 2750 2920 3180 3320
AL-R UNITS kg 2910 3090 3365 3510
REFERENCE SOUND LEVEL to EN292 1991 SPL at 1m (SWL) dBA 92 (108) 92 (108) 93 (109) 93 (109)
WL/WL-HP UNITS System 1 kg 42 50 64 64
System 2 kg 42 50 50 64
WL-HR UNITS System 1 kg 68 78 100 100
OPERATING System 2 kg 68 78 78 100
REFRIGERANT AL UNITS System 1 kg 21 26 34 34
CHARGE (Unit only) System 2 kg 21 26 26 34
AL-R UNITS System 1 kg 33 38 50 50
(Unit only) System 2 kg 33 38 42 50
Receiver Pump Down Capacity Per System kg 124 124 158 158

Sound levels are for fully loaded unit. SPL values are adjacent to compressors
(SWL values are based on measurements to ISO 3744 or ISO 3746)
AL-R operating weight & charge are based on receiver tank filled to 10% of pump down capacity.
Pump down capacity is based on 80% of receiver volume.
 9- 8 035L02374-GB2 (05/02)

LCHM R134a Models

MODEL 55 65 75
NUMBER OF REFRIGERANT CIRCUITS 1 1 1
MODEL - All Units System 1 PC642-N PC833-P PC84Q
NOMINAL SPEED rpm 1450 1450 1450
OIL CHARGE (per compressor) ltr. 11.4 11.4 11.4
No. Unit Capacity Steps 3 4 4
37-73 27-60 27-60
COMPRESSORS
Cooling capacity % -100 -81-100 -81-100

37-73 24-51 24-51

Power Input % -100 -75-100 -75-100

COOLER Model 1007H 1007H 1007H

Water Capacity ltr. 61 61 61
STANDARD WL Model PC51 PC60 PC73
CONDENSER Water Capacity ltr. 39 51 59
WL-HR SYSTEM 1 Model PC102 PC120 PC146
CONDENSER(S) Water Capacity ltr. 79 101 117
NOMINAL WL UNITS kg 1570 1680 1780
OPERATING WL-HR UNITS kg 2030 2140 2270
WEIGHTS AL UNITS kg 1390 1430 1510
AL-R UNITS kg 1500 1545 1630
REFERENCE SOUND LEVEL to EN292 1991 SPL at 1m (SWL) dBA 89 (103) 90 (104) 90 (104)
WL UNITS System 1 kg 37 43 52
OPERATING WL-HR UNITS System 1 kg 44 51 62
REFRIGERANT AL UNITS System 1 kg 19 22 27
CHARGE AL-R UNITS (Unit only) System 1 kg 28 35 40
Receiver Pump Down Capacity Per System kg 92 132 132

Sound levels are for fully loaded unit. SPL values are adjacent to compressors
(SWL values are based on measurements to ISO 3744 or ISO 3746)
AL-R operating weight & charge are based on receiver tank filled to 10% of pump down capacity.
Pump down capacity is based on 80% of receiver volume.
 035L02374-GB2 (05/02) 9- 9

LCHHM R134a Models

MODEL 90 110 130 150
NUMBER OF REFRIGERANT CIRCUITS 2 2 2 2
MODEL - All Units System 1 PC632-M PC642-N PC833-P PC843-Q
System 2 PC632-M PC642-N PC833-P PC843-Q
NOMINAL SPEED rpm 1450 1450 1450 1450
OIL CHARGE (per compressor) ltr. 11.4 11.4 11.4 11.4
No. Unit Capacity Steps 3+3 3+3 4+4 4+4
COMPRESSORS 18-37 18-37 15-27-40 15-27-40
Cooling capacity % -59-72 -59-72 -60-72-81 -60-72-81
-86-100 -86-100 -90-100 -90-100
18-32 18-32 14-24-34 14-24-34
Power Input % -51-66 -51-66 -51-64-76 -51-64-76
-82-100 -82-100 -86-100 -86-100
COOLER Model 1207H 1207H 1507H 17069H
Water Capacity ltr. 90 90 116 145
STANDARD WL Model PC110 PC110 PC120 PC146
CONDENSER Water Capacity ltr. 77 77 101 117
HEAT SYSTEM 1 Model PC120 PC146
RECOVERY Water Capacity ltr. 101 117
WL-HR SYSTEM 2 Model PC120 PC146
CONDENSER(S) Water Capacity ltr. 101 117
NOMINAL WL UNITS kg 2760 2860 3480 3720
OPERATING WL-HR UNITS kg - - 4380 4680
WEIGHTS AL UNITS kg 2390 2490 2900 3060
AL-R UNITS kg 2510 2640 3115 3285
REFERENCE SOUND LEVEL to EN292 1991 SPL at 1m (SWL) dBA 90 (106) 90 (106) 91 (107) 91 (107)
WL UNITS System 1 kg 32 34 44 52
System 2 kg 32 34 44 52
WL-HR UNITS System 1 kg 70 80
OPERATING System 2 kg 70 80
REFRIGERANT AL UNITS System 1 kg 16 18 22 27
CHARGE (Unit section only) System 2 kg 16 18 22 27
AL-R UNITS System 1 kg 24 26 34 39
(Unit section only) System 2 kg 24 26 34 39
Receiver Pump Down Capacity Per System kg 81 81 124 124

Sound levels are for fully loaded unit. SPL values are adjacent to compressors
(SWL values are based on measurements to ISO 3744 or ISO 3746)
AL-R operating weight & charge are based on receiver tank filled to 10% of pump down capacity.
Pump down capacity is based on 80% of receiver volume.
 9-10 035L02374-GB2 (05/02)

9.4 Electrical Data

R22 Models Compressor Data (all values are per compressor)
RUNNING CONDITIONS
UNIT COMPRESSOR MOTOR NOMINAL MAXIMUM
MODELS MODEL CODE Power Current Amps Power Current Amps
kW @380V @400V kW @342V @380V @400V
R22 - LCHM/LCHHM WL STANDARD UNITS
60 PC441-M 5M 50.7 90 87 56.5 111 101 97
70 & 140 PC632-N 1N 54.9 98 97 60.8 118 108 105
70 & 140 PC632-P 1P 54.9 100 98 60.8 119 109 107
85, 170, 200 sys2 only PC642-P 6P 71.2 126 122 78.8 160 142 136
100 PC833-Q 1Q 74.1 132 132 82.1 160 146 144
115, 200 sys1 only, 230 PC843-S 1S 93.7 167 163 104.0 203 183 178
R22 - LCHM/LCHHM WL-HP & WL-HR UNITS
60 PC441-N 2N 58.1 103 101 66.3 130 117 114
70 & 140 PC632-P 2P 62.5 112 110 71.4 144 128 123
85, 170, 200 sys2 only PC642-S 4S 80.7 146 142 91.5 177 163 160
100 PC833-S 2S 84.8 153 150 96.7 187 171 167
115, 200 sys1 only, 230 PC843-T 2T 107.1 194 191 121.7 235 218 214
R22 - LCHM/LCHHM AL UNITS
60 PC441-N 2N 58.5 103 102 67.7 135 121 116
70 & 140 PC632-P 5P 63.0 112 110 74.4 149 132 128
85, 170, 200 sys2 only PC642-S 4S 81.4 146 145 95.5 180 170 166
100 PC833-S 5S 86.0 154 152 101.0 195 179 175
115, 200 sys1 only, 230 PC843-T 3T 108.4 196 192 127.5 249 227 222

Maximum Fuse SWITCH LOCKED ROTOR CONDITIONS

UNIT COMPRESSOR Size (BS/DIN gG) DISCONNECTOR STAR / DELTA PART-WIND FULL-WIND
MODELS MODEL Per Comp. Fuse (Ie) Rating Current Amps Current Amps Current Amps
Amps BS DIN @380V @400V @380V @400V @380V @400V
R22 - LCHM/LCHHM WL STANDARD UNITS
60 PC441-M 125 160 160 - - 282 297 382 402
70 & 140 PC632-N 160 160 160 - - 329 346 447 471
70 & 140 PC632-P 160 200 250 161 169 - - 483 508
85, 170, 200 sys2 only PC642-P 200 250 250 161 169 357 376 483 508
100 PC833-Q 200 250 250 207 218 458 482 628 657
115, 200 sys1 only, 230 PC843-S 250 315 400 247 260 549 578 742 781
R22 - LCHM/LCHHM WL-HP & WL-HR UNITS
60 PC441-N 160 200 250 - - 329 346 447 471
70 & 140 PC632-P 200 200 250 161 169 357 376 483 508
85, 170, 200 sys2 only PC642-S 250 250 250 247 260 549 578 742 781
100 PC833-S 250 315 400 247 260 549 578 742 781
115, 200 sys1 only, 230 PC843-T 315 315 400 304 320 689 725 912 960
R22 - LCHM/LCHHM AL UNITS
60 PC441-N 160 200 250 - - 329 346 447 471
70 & 140 PC632-P 200 250 250 161 169 357 376 483 508
85, 170, 200 sys2 only PC642-S 250 250 250 247 260 549 578 742 781
100 PC833-S 250 315 400 247 260 549 578 742 781
115, 200 sys1 only, 230 PC843-T 315 400 400 304 320 689 725 912 960

Notes:
1 Fuse sizes given are for the maximum rating permitted. Lower rated fuses can be used based on load and
inrush values under actual installation and operational conditions.
2 Compressor models are named as follows:
PC (compressor type) X (No. of cylinders) X (4=long stroke, 3=short stroke) X (No. of unloading pairs of cylinders) -X (motor size code)
3 Nominal rating conditions are:
WL units 6.7°C chilled water leaving temperature, 35°C condenser water leaving temperature
WL-HR units 6.7°C chilled water leaving temperature, 45°C condenser water leaving temperature
AL and AL-R units 6.7°C chilled water leaving temperature, 50°C saturation temperature at compressor discharge
4 Maximum rating conditions are:
R22: WL units 10°C chilled water leavig temperature, 40°C condenser water leaving temperature
WL-HP and WL-HR units 10°C chilled water leavig temperature, 52°C condenser water leaving temperature
AL model 60 8°C chilled water leavig temperature, 60°C saturation temperature at compressor discharge
Other AL and AL-R units 10°C chilled water leavig temperature, 60°C saturation temperature at compressor discharge
5 When selecting cable sizes for LCHHM units fitted with the common input supply option, the sum of the current values
for both compressors should be considered.
 035L02374-GB2 (05/02) 9-11

R134a Models Compressor Data (all values are per compressor)

RUNNING CONDITIONS
UNIT COMPRESSOR MOTOR NOMINAL MAXIMUM
MODELS MODEL CODE Power Current Amps Power Current Amps
kW @380V @400V kW @342V @380V @400V
R134a - LCHM/LCHHM WL STANDARD UNITS
90 PC632-M 4M 36.3 66 67 46.5 91 83 81
55 & 110 PC642-N 1N 48.1 87 87 61.0 118 108 105
65 & 130 PC833-P 3P 51.7 96 93 66.5 136 120 116
75 & 150 PC843-Q 1Q 62.8 116 115 82.0 160 146 144
R134a - LCHM/LCHHM WL-HR UNITS
55 PC642-N 1N 53.3 95 94 61.0 118 108 105
65 & 130 PC833-P 3P 57.9 104 103 66.5 136 120 116
75 & 150 PC843-Q 1Q 70.6 126 125 82.0 160 146 144
R134a - LCHM/LCHHM AL UNITS
90 PC632-M 4M 40.9 74 73 46.9 91 83 81
55 & 110 PC642-N 1N 53.7 96 95 61.3 118 108 105
65 & 130 PC833-P 3P 58.9 106 105 67.3 136 120 118
75 & 150 PC843-Q 1Q 71.6 129 128 83.0 163 148 145

Maximum Fuse SWITCH LOCKED ROTOR CONDITIONS

UNIT COMPRESSOR Size (BS/DIN gG) DISCONNECTOR STAR / DELTA PART-WIND FULL-WIND
MODELS MODEL Per Comp. Fuse (Ie) Rating Current Amps Current Amps Current Amps
Amps BS DIN @380V @400V @380V @400V @380V @400V
R134a - LCHM/LCHHM WL STANDARD UNITS
90 PC632-M 125 160 160 - - 282 297 382 402
55 & 110 PC642-N 160 160 160 - - 329 346 447 471
65 & 130 PC833-P 160 200 250 161 169 357 376 483 508
75 & 150 PC843-Q 200 250 250 207 218 458 482 628 657
R134a - LCHM/LCHHM WL-HR UNITS
55 PC642-N 160 160 160 - - 329 346 447 471
65 & 130 PC833-P 160 200 250 161 169 357 376 483 508
75 & 150 PC843-Q 200 250 250 207 218 458 482 628 657
R134a - LCHM/LCHHM AL UNITS
90 PC632-M 125 160 160 - - 282 297 382 402
55 & 110 PC642-N 160 160 160 - - 329 346 447 471
65 & 130 PC833-P 160 200 250 161 169 357 376 483 508
75 & 150 PC843-Q 200 250 250 207 218 458 482 628 657

Notes:
1 Fuse sizes given are for the maximum rating permitted. Lower rated fuses can be used based on load and
inrush values under actual installation and operational conditions.
2 Compressor models are named as follows:
PC (compressor type) X (No. of cylinders) X (4=long stroke, 3=short stroke) X (No. of unloading pairs of cylinders) -X (motor size code)
3 Nominal rating conditions are:
WL units 6.7°C chilled water leaving temperature, 35°C condenser water leaving temperature
WL-HR units 6.7°C chilled water leaving temperature, 45°C condenser water leaving temperature
AL and AL-R units 6.7°C chilled water leaving temperature, 50°C saturation temperature at compressor discharge
4 Maximum rating conditions are:
R134a: WL and WL-HR units 10°C chilled water leavig temperature, 55°C condenser water leaving temperature
AL and AL-R units 10°C chilled water leavig temperature, 60°C saturation temperature at compressor discharge
5 When selecting cable sizes for LCHHM units fitted with the common input supply option, the sum of the current values
for both compressors should be considered.
 9-12 035L02374-GB2 (05/02)

R407C Models Compressor Data (all values are per compressor)

RUNNING CONDITIONS
UNIT COMPRESSOR MOTOR NOMINAL MAXIMUM
MODELS MODEL CODE Power Current Amps Power Current Amps
kW @380V @400V kW @342V @380V @400V
R407C - LCHM/LCHHM WL STANDARD UNITS
60 PC441-M 5M 52.7 94 91 54.4 107 96 93
70 & 140 PC632-N 3N 57.1 101 100 58.6 109 103 102
85, 170, 200 sys2 only PC642-P 5P 74.0 132 128 76.4 153 136 131
100 PC833-Q 3Q 76.1 136 134 79.1 154 142 139
115, 200 sys1 only, 230 PC843-S 5S 97.4 173 168 100.9 195 179 175
R407C - LCHM/LCHHM WL-HP & WL-HR UNITS
60 PC441-N 2N 60.4 107 105 66.4 130 117 114
70 & 140 PC632-P 2P 65.0 117 113 71.6 143 127 124
85, 170, 200 sys2 only PC642-S 4S 83.9 152 149 91.6 177 163 160
100 PC833-S 2S 88.2 157 155 96.7 187 171 167
115, 200 sys1 only, 230 PC843-T 2T 111.4 202 198 122.1 235 218 214
R407C - LCHM/LCHHM AL UNITS
60 PC441-N 2N 60.8 108 105 67.6 133 121 116
70 & 140 PC632-P 2P 65.5 116 114 72.8 146 130 125
85, 170, 200 sys2 only PC642-S 4S 84.7 153 150 93.4 179 167 163
100 PC833-S 5S 89.4 159 156 98.9 192 175 171
115, 200 sys1 only, 230 PC843-T 3T 112.7 203 199 124.8 242 223 215

Maximum Fuse SWITCH LOCKED ROTOR CONDITIONS

UNIT COMPRESSOR Size (BS/DIN gG) DISCONNECTOR STAR / DELTA PART-WIND FULL-WIND
MODELS MODEL Per Comp. Fuse (Ie) Rating Current Amps Current Amps Current Amps
Amps BS DIN @380V @400V @380V @400V @380V @400V
R407C - LCHM/LCHHM WL STANDARD UNITS
60 PC441-M 125 160 160 - - 282 297 382 402
70 & 140 PC632-N 125 160 160 - - 329 346 447 471
85, 170, 200 sys2 only PC642-P 200 250 250 161 169 357 376 483 508
100 PC833-Q 200 250 250 207 218 458 482 628 657
115, 200 sys1 only, 230 PC843-S 250 315 400 247 260 549 578 742 781
R407C - LCHM/LCHHM WL-HP & WL-HR UNITS
60 PC441-N 160 200 250 - - 329 346 447 471
70 & 140 PC632-P 200 200 250 161 169 357 376 483 508
85, 170, 200 sys2 only PC642-S 250 250 250 247 260 549 578 742 781
100 PC833-S 250 315 400 247 260 549 578 742 781
115, 200 sys1 only, 230 PC843-T 315 315 400 304 320 689 725 912 960
R407C - LCHM/LCHHM AL UNITS
60 PC441-N 160 200 250 - - 329 346 447 471
70 & 140 PC632-P 200 200 250 161 169 357 376 483 508
85, 170, 200 sys2 only PC642-S 250 250 250 247 260 549 578 742 781
100 PC833-S 250 315 400 247 260 549 578 742 781
115, 200 sys1 only, 230 PC843-T 315 400 400 304 320 689 725 912 960

Notes:
1 Fuse sizes given are for the maximum rating permitted. Lower rated fuses can be used based on load and
inrush values under actual installation and operational conditions.
2 Compressor models are named as follows:
PC (compressor type) X (No. of cylinders) X (4=long stroke, 3=short stroke) X (No. of unloading pairs of cylinders) -X (motor size code)
3 Nominal rating conditions are:
WL units 6.7°C chilled water leaving temperature, 35°C condenser water leaving temperature
WL-HR units 6.7°C chilled water leaving temperature, 45°C condenser water leaving temperature
AL and AL-R units 6.7°C chilled water leaving temperature, 50°C saturation temperature at compressor discharge
4 Maximum rating conditions are:
R407C: WL units 10°C chilled water leavig temperature, 35°C condenser water leaving temperature
WL-HP and WL-HR units 10°C chilled water leavig temperature, 49°C condenser water leaving temperature
AL and AL-R units 10°C chilled water leavig temperature, 55°C saturation temperature at compressor discharge
5 When selecting cable sizes for LCHHM units fitted with the common input supply option, the sum of the current values
for both compressors should be considered.
 035L02374-GB2 (05/02) 9-13

Customer Control Circuit Supply Data

4-Wire Units 230V Customer Supply 3-Wire Units 380/400V Customer Supply
Control Supply Internal Fuse Max. Customer Control Supply Internal Fuse Max. Customer
Load at 230V Rating Class gG Fuse Rating Load at Rating Class aM Fuse Rating
380/400V
LCHHM 4.5 6 10 2.5 8 16

Control Panel Power Wiring Connections - Lug Sizes

CE UNITS WITH BS CE UNITS WITH DIN
NON CE UNITS WITH
LCHM SWITCH FUSE SWITCH FUSE
TERMINAL BLOCK
DISCONNECT DISCONNECT
R22/R407C WL
60, 70, 140 M8 M8 M8 *
85, 100, 170, 200 SYS 2 M8 M10 M10
115, 200 SYS 1, 230 M10 M10 M10
R22 /R407C WL-HP & WL-HR
60, 70, 140 M8 M8 M10
85, 100, 115, 170, 200 ,230 M10 M10 M10
R22/R407C AL
60 M8 M8 M10
70, 140 M8 M10 M10
85, 100,170, 200 SYS 2 M10 M10 M10
115, 200 SYS 1, 230 M12 M10 M10
R134a WL
90 M6 M8 M8
55, 110 M8 M8 M8,
65, 130 M8 M8 M10
75, 150 M8 M10 M10
R134a WL-HR
55 M8 M8 M8
65, 130 M8 M8 M10
75, 150 M8 M10 M10
R134a AL
90 M6 M8 M8
55, 110 M8 M8 M8
65, 130 M8 M8 M10
75, 150 M8 M10 M10

1* M10 ON R22 LCHM70WL & LCHHM140WL STAR DELTA UNITS

 9-14 035L02374-GB2 (05/02)

9.5 Dimensions and Layout

LCHM 55 - 115 WL and LCHM 55 - 115 WL-HP

DSV
PS
RV 1/2” FL. ZCMTB
RV 1/2” FL. CP

SSV

COMP IS LSV
LIQUID RCF
CONDENSER
YLLSV WATER
INLET Y
CLR CDR
CDR

LIQUID

TEV/YEEV

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

WL A B C D E F G G1 H J K L1 L2 X Y
55 2725 860 1740 320 32 195 720 720 940 508 275 315 235 4" N.B.¹ 2½" N.B.²
60 2600 860 1740 320 32 195 720 720 940 508 275 315 235 4" N.B.¹ 2½" N.B.²
65 2725 885 1740 320 32 195 720 720 940 508 275 315 235 4" N.B.¹ 3" N.B.²
70 2610 860 1740 320 32 195 720 720 940 508 275 315 235 6" N.B.¹ 3" N.B.²
75 2725 885 1740 320 32 195 725 725 940 508 275 315 235 4" N.B.¹ 3" N.B.²
85 2640 875 1785 375 32 200 605 710 890 470 300 340 260 6" N.B.¹ 3" N.B.²
100 2640 875 1785 375 32 200 605 710 890 470 300 300 300 6" N.B.¹ 4" N.B.³
115 2640 875 1785 375 32 200 605 710 890 470 300 300 300 6" N.B.¹ 4" N.B.³
Connections: ¹ Victaulic, ² Threaded female taper to BSPT / ISO R7 / DIN 2999, ³ Flanged with face dimensions to BS 4504 PN10 / ISO 7005 / DIN 2502
 035L02374-GB2 (05/02) 9-15

LCHM 55 - 115 WL-HR (with 2-Pass Heat Recovery Condenser)

DSV

RV 5/8” FL. ZCMTB

PS
CP
RV 1/2” FL. SSV

LSV
RCF
COMP IS HEAT
YLLSV RECOVERY
OR MAIN
CONDENSER
WATER
CLR CDR CONNECTION
Y

TEV/YEEV

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

WL-HR A B C D E F G G1 H J K L M N X Y
55 2995 920 1825 340 32 170 720 720 940 530 350 275 205 75 4" N.B.¹ 2½" N.B.²
60 2995 910 1845 340 32 195 720 720 940 560 375 275 205 75 4" N.B.¹ 2½" N.B.²
65 3045 1000 1850 370 32 170 720 720 940 560 375 265 220 75 4" N.B.¹ 3" N.B.²
70 3045 986 1845 370 32 195 720 720 940 560 375 265 220 75 6" N.B.¹ 3" N.B.²
75 3045 1000 1850 370 32 170 725 725 940 560 375 265 220 75 4" N.B.¹ 3" N.B.²
85 3045 990 1855 410 32 195 605 710 890 545 375 265 220 75 6" N.B.¹ 3" N.B.²
100 3065 1020 1880 375 32 195 605 710 890 545 375 260 230 75 6" N.B.¹ 4" N.B.³
115 3065 1020 1880 375 32 195 605 710 890 545 375 260 230 75 6" N.B.¹ 4" N.B.³
Connections: ¹ Victaulic, ² Threaded female taper to BSPT / ISO R7 / DIN 2999, ³ Flanged with face dimensions to BS 4504 PN10 / ISO 7005 / DIN 2502

3-Pass Heat Recovery Condenser

WL-HR P R S T Y2
55 102 102 275 64 2½" N.B.¹
60 102 102 256 64 2½" N.B.¹
65 114 114 262 64 3" N.B.¹
70 114 114 262 64 3" N.B.¹
75 114 114 262 64 3" N.B.¹
85 114 114 262 64 3" N.B.¹
100 127 137 239 70 3" N.B.¹
115 127 137 239 70 3" N.B.¹
Connections: ¹ Victaulic
 9-16 035L02374-GB2 (05/02)

LCHM 55 - 115 AL

DSV
DSV PS
ZCMTB
CP
RV 1/2” FL. SSV

LSV
RCF
COMP IS YLLSV

CLR

TEV/YEEV

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

AL A B C D E F G G1 H J K L1 L2 X
55 2700 860 1740 320 32 190 720 720 940 510 275 2 5/8" OD ² 1 3/8 OD ² 4" N.B.¹
60 2600 860 1740 320 32 190 720 720 940 510 275 2 5/8" OD ² 1 3/8 OD ² 4" N.B.¹
65 2700 885 1740 320 32 190 720 720 940 510 275 3 1/8" OD ² 1 5/8 OD ² 4" N.B.¹
70 2600 860 1740 320 32 190 720 720 940 510 275 2 5/8" OD ² 1 3/8 OD ² 4" N.B.¹
75 2700 885 1740 320 32 190 590 725 940 510 275 3 1/8" OD ² 1 5/8 OD ² 4" N.B.¹
85 2640 875 1785 375 32 200 605 710 890 470 300 2 5/8" OD ² 1 5/8 OD ² 6" N.B.¹
100 2640 875 1785 375 32 200 605 710 890 470 3003 3 1/8" OD ² 1 5/8 OD ² 6" N.B.¹
115 2640 875 1785 375 32 200 605 710 890 470 3003 3 1/8" OD ² 1 5/8 OD ² 6" N.B.¹
Connections: ¹ Victaulic, ² Female for Brazing
 035L02374-GB2 (05/02) 9-17

LCHM 60 - 115 AL-R

DSV DSV

PS
RV 1/2” FL.
ZCMTB CP
RV 1/2” FL. SSV

LSV
COMP IS RCF
LR YLLSV

LR
CLR

TEV/YEEV

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

Pump Down
AL-R A B C D E F G G1 H J K L1 L2 X Capacity

60 2700 860 1740 320 32 190 720 720 940 460 275 2 5/8" OD ² 2 1/8" OD ² 4" N.B.¹ 92 kg
70 2700 860 1740 320 32 190 720 720 940 460 275 2 5/8" OD ² 2 5/8" OD ² 4" N.B.¹ 132 kg
85 2715 880 1785 375 32 200 605 720 890 470 300 2 5/8" OD ² 2 5/8" OD ² 6" N.B.¹ 132 kg
100 2715 880 1785 375 32 200 605 710 890 470 300 3 1/8" OD ² 3 1/8" OD ² 6" N.B.¹ 162 kg
115 2715 880 1785 375 32 200 605 710 890 470 300 3 1/8" OD ² 3 1/8" OD ² 6" N.B.¹ 162 kg
Connections: ¹ Victaulic, ² Female for Brazing
 9-18 035L02374-GB2 (05/02)

LCHHM 90 and 110 WL

1-DSV

1-ZCMTB
Ps1 Ps2
CP
2-ZCMTB
RV 1/2” FL. 1-YLLSV
2-SSV
1-SSV
COMP1 IS
1-LSV RCF
COMP2
1-RCF
LSV

CDR 2-YLLSV
CLR

WATER
INLET R

S GPCS 120 DIA.

T GP 240x90

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

WL A B C D E J K L P R
90 2890 1265 855 925 1500 8 1215 1860 6" N.B.¹ 4" N.B.²
110 2890 1265 855 925 1500 8 1215 1860 6" N.B.¹ 4" N.B.²
Connections: ¹ Victaulic, ² Flanged with face dimensions to BS 4504 PN10 / ISO 7005 / DIN 2502
When Door Interlocked Isolator Option fitted, Add 30 mm to dimension B
 035L02374-GB2 (05/02) 9-19

LCHHM 130 - 230 WL and LCHHM 130 - 230 WL-HP

1-DSV

1-ZCMTB
Ps1 Ps2
CP
2-ZCMTB
1-YLLSV
1-SSV 2-SSV
1-LSV COMP1 IS
RV 1/2” FL. 1-RCF COMP2 2-YLLSV

WATER 2-LSV
OUTLET 2-RCF
R
CLR CDR RV 1/2” FL.
(R22/407c WL-HP 5/8” FL.)

YEEV

S GPCS 120 DIA.

T GP 240x90

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

WL A B C D E E1 F J K L M N P R
130 2905 1275 855 925 1525 1380 65 1380 1950 260 230 6" N.B.¹ 4" N.B.¹
140 2905 1195 855 925 1525 1380 95 1380 1950 260 230 6" N.B.¹ 4" N.B.¹
150 2905 1275 825 815 1525 1380 90 1380 1950 260 230 8" N.B.¹ 4" N.B.¹
170 2905 1240 825 815 1525 1380 120 1380 1950 260 230 8" N.B.¹ 4" N.B.¹
200 3135 1240 825 1170 1630 1390 120 1390 1950 255 240 8" N.B.¹ 6" N.B.¹
230 3240 1240 825 1270 1630 1390 120 1390 1950 255 240 8" N.B.¹ 6" N.B.¹
Connections: ¹ Victaulic
When Door Interlocked Isolator Option fitted, Add 30 mm to dimension B
 9-20 035L02374-GB2 (05/02)

LCHHM 130 - 230 WL-HR

RV 5/8” FL.

1-DSV
1-SSV
Ps1 Ps2
1-ZCMTB 2-ZCMTB
1-YLLSV CP
1-SSV
RV 1/2” FL. 1-LSV
COMP1 IS COMP2
2-SSV
1-RCF 2-LSV
2-RCF
2-YLLSV

CLR HRCDR1 RV 1/2” FL.

HRCDR1.

TEV/YEEV

S GPCS 120 DIA.

T GP 240x90

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section
WL-HR A B C D E F G J K L M N P Q R Z
130 3175 1275 855 925 1650 1180 2285 65 1520 220 265 220 6" N.B.¹ 1525 3" N.B.¹ 1310
140 3175 1195 855 925 1560 1220 2285 65 1520 220 265 220 6" N.B.¹ 1525 3" N.B.¹ 1310
150 3115 1275 825 815 1595 1100 2285 90 1520 220 265 220 8" N.B.¹ 1525 3" N.B.¹ 1310
170 3120 1240 825 815 1525 1150 2285 90 1520 220 265 220 8" N.B.¹ 1525 3" N.B.¹ 1310
200 3175 1240 825 1170 1670 1495 2285 90 1520 220 260 230 8" N.B.¹ 1525 4" N.B.¹ 1300
230 3250 1240 825 1270 1670 1600 2325 90 1520 230 260 230 8" N.B.¹ 1530 4" N.B.¹ 1315
Connections: ¹ Victaulic
When Door Interlocked Isolator Option fitted, Add 30 mm to dimension B

3-Pass Heat Recovery Condenser

WL-HR P R S T Y2
130 115 115 265 65 3" N.B.¹
140 115 115 265 65 3" N.B.¹
150 115 115 265 65 3" N.B.¹
170 115 155 265 65 3" N.B.¹
200 260 115 115 114 260 65 70 3" N.B.¹
230 130 135 260 70 3" N.B.¹
Connections: ¹ Victaulic
 035L02374-GB2 (05/02) 9-21

LCHHM 90 - 230 AL

1-DSV
1-DSV 2-DSV

1-ZCMTB
1-YLLSV Ps1 CP Ps2 2-ZCMTB

1-SSV
RV 1/2” FL. 1-LSV
COMP1 IS 2-SSV
1-RCF COMP2
2-LSV
2-RCF

2-YLLSV
CLR 1-LSV

TEV/
YEEV

S GPCS 120 DIA.

T GP 240x90

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

AL A B C D E F J M P R U V1 V2 W X Y
90 2890 1265 855 925 1500 1185 95 1 3/8 OD ² 6" N.B.¹ 1 3/8 OD ² 1410 160 160 670 2 5/8" OD ² 2 5/8" OD ²
110 2890 1265 855 925 1500 1185 1185 1 3/8 OD ² 6" N.B.¹ 1 3/8 OD ² 1410 160 160 670 2 5/8" OD ² 2 5/8" OD ²
130 2740 1275 855 925 1500 1180 180 1 5/8 OD ² 6" N.B.¹ 1 5/8 OD ² 1430 155 155 675 3 1/8" OD ² 3 1/8" OD ²
140 2940 1195 855 925 1430 1255 1255 1 3/8 OD ² 6" N.B.¹ 1 3/8 OD ² 1410 190 120 675 2 5/8" OD ² 2 5/8" OD ²
150 2890 1275 825 815 1500 1100 1100 1 5/8 OD ² 8" N.B.¹ 1 5/8 OD ² 1430 155 155 675 3 1/8" OD ² 3 1/8" OD ²
170 2680 1240 825 815 1525 1155 1155 1 3/8 OD ² 8" N.B.¹ 1 3/8 OD ² 1410 155 165 675 2 5/8" OD ² 2 5/8" OD ²
200 3135 1240 825 1170 1670 1495 1495 1 5/8 OD ² 8" N.B.¹ 1 3/8 OD ² 1430/1410 150 160 675 3 1/8" OD ² 3 1/8" OD ²
230 3240 1240 825 1270 1670 1600 1600 1 5/8 OD ² 8" N.B.¹ 1 5/8 OD ² 1430 150 150 675 3 1/8" OD ² 3 1/8" OD ²
Connections: ¹ Victaulic, ² Female for Brazing
When Door Interlocked Isolator Option fitted, Add 30 mm to dimension B
 9-22 035L02374-GB2 (05/02)

LCHHM 140 - 230 AL-R

1-DSV 1-YLLSV
1-DSV 2-DSV
RV 1/2” FL.
(130,150,200 & 23)
1-ZCMTB 2-ZCMTB
COMP1 CP
Ps1 Ps2 2
RV 1/2” FL.
(130,150,200
RV 1/2” FL. & 23) 2-SSV
IS
1-SSV 2-LSV
1-LSV 2-RCF
1-RCF
LR 2-YLLSV
CLR 1-LSV
2-PV
1-PV
3/8” FL.

TEV/
YEEV

S GPCS 120 DIA.

T GP 240x90

CDR Condenser SKP Key Pad

-ECH Crankcase Heater -YLLSV Liquid Line Solenoid Valve
CLR Cooler -LSV Liquid Service Valve
-ZCMTB Compressor Motor Terminal Box (Liquid connection - AL units)
COMP Compressor LR Liquid Receiver
CP Control Panel PV X”FL Purge Valve - X inch SAE Flare connection
-DSV Discharge Service Valve -RCF Replaceable Core Filter/Drier
(Discharge gas connection - AL/ALR units) -RV X”FL Relief Valve - X inch SAE Flare connection
-YEEV Electronic Expansion Valve -SSV Service Stop Valve
GP Gland Plate -TEV Thermostatic Expansion Valve
GPCS Gland Plate if Common Input Option fitted 1 System 1
HRCDR-*P Heat Recovery Condenser - 2 System 2
*number of water side passes - each circuit IS Input Section
PS Power Section

Pump Down
AL-R A B C D E F J M N P K U V1 V2 X Y
Capacity

140 2955 1120 855 925 1430 1255 95 1/2" 2 5/8" OD ² 6" N.B.¹ 275 1410 195 120 2 5/8" OD ² 2 5/8" OD ² 2 x 124 kg
170 2955 1120 825 814 1525 1155 120 1/2" 2 5/8" OD ² 8" N.B.¹ 275 1410 155 165 2 5/8" OD ² 2 5/8" OD ² 2 x 124 kg
200 3135 1120 825 1170 1670 1495 120 5/8" 3 1/8" OD ² 8" N.B.¹ 300 1430/1410 150 160 3 1/8" OD ² 2 5/8" OD ² 2 x 158 kg
230 3240 1120 825 1270 1670 1600 120 5/8" 3 1/8" OD ² 8" N.B.¹ 300 1430 150 150 3 1/8" OD ² 3 1/8" OD ² 2 x 158 kg
Connections: ¹ Victaulic, ² Female for Brazing
When Door Interlocked Isolator Option fitted, Add 30 mm to dimension B
Contact York for R134a Details
 035L02374-GB2 (05/02) 9-23

9.6 Lifting Weights

MODEL UNIT TYPE MODEL UNIT TYPE

LCHM WL WL-HR AL AL-R LCHHM WL WL-HR AL AL-R
60 1360 1780 1200 1300 140 3115 3910 2590 2725
R22 / 70 1500 1910 1280 1390 R22 / 170 3320 4160 2725 2870
R407C 85 1680 2115 1445 1550 R407C 200 3680 4535 2965 3115
100 1830 2285 1520 1660 230 3790 4785 3075 3235
115 1875 2345 1545 1680 90 2595 - 2270 2370
55 1470 1890 1310 1410 R134a 110 2695 - 2365 2500
R134a 65 1570 1980 1345 1450 130 3265 4060 2740 2930
75 1660 2090 1420 1530 150 3460 4300 2860 3060

9.7 Weight Distribution

LCHM WL and LCHM WL-HR

WL UNITS WL-HR UNITS

LCHM MOUNT POSITION MOUNT POSITION
A B C D TOTAL A B C D TOTAL
60 459 260 453 288 1460 550 366 557 447 1920
R22 / 70 493 314 474 329 1610 595 382 602 491 2070
R407C 85 562 377 515 376 1830 639 432 683 566 2320
100 601 395 577 417 1990 697 486 747 590 2520
115 611 405 592 432 2040 702 492 776 620 2590
55 514 295 472 289 1570 597 358 620 455 2030
R134a 65 530 311 512 327 1680 637 379 635 489 2140
75 563 319 554 344 1780 676 391 685 518 2270

LCHM AL and LCHM AL-R

AL UNITS AL-R UNITS

LCHM MOUNT POSITION MOUNT POSITION
A B C D TOTAL A B C D TOTAL
60 442 278 345 215 1280 461 297 421 291 1470
R22 / 70 470 290 372 228 1360 495 314 470 326 1605
R407C 85 532 347 410 271 1560 559 374 500 362 1795
100 562 356 441 281 1640 597 391 558 399 1945
115 570 363 449 288 1670 603 397 563 402 1965
55 497 278 399 216 1390 516 297 475 292 1580
R134a 65 507 288 410 225 1430 531 311 504 319 1665
75 537 293 445 235 1510 561 316 541 332 1750
AL-R loads based on the receiver tank full to capacity with refrigerant
 9-24 035L02374-GB2 (05/02)

LCHHM WL and LCHHM WL-HR

WL UNITS WL-HR UNITS

LCHHM MOUNT POSITION MOUNT POSITION
A B C D TOTAL A B C D TOTAL
140 901 901 764 764 3330 1141 1141 974 974 4230
R22 / 170 969 969 821 821 3580 1225 1225 1045 1045 4540
R407C 200 1087 1038 944 921 3990 1346 1297 1170 1147 4960
230 1107 1107 953 953 4120 1375 1375 1260 1260 5270
90 791 791 589 589 2760 - - - - -
R134a 110 825 825 605 605 2860 - - - - -
130 963 963 777 777 3480 1203 1203 987 987 4380
150 1045 1045 815 815 3720 1301 1301 1039 1039 4680

LCHHM AL and LCHHM AL-R

AL UNITS AL-R UNITS

LCHHM MOUNT POSITION MOUNT POSITION
A B C D TOTAL A B C D TOTAL
140 845 845 530 530 2750 890 890 675 675 3130
R22 / 170 901 901 559 559 2920 947 947 708 708 3310
R407C 200 1002 953 624 601 3180 1056 1008 802 779 3645
230 1026 1026 634 634 3320 1081 1082 816 816 3795
90 749 749 446 446 2390 779 780 548 548 2655
R134a 110 782 782 463 463 2490 818 818 577 577 2790
130 907 907 543 543 2900 960 960 710 710 3340
150 976 976 554 554 3060 1030 1030 725 725 3510
AL-R loads based on the receiver tank full to capacity with refrigerant

9.8 Isolator Positions

LCHM WL and LCHM WL-HR

WL UNITS WL-HR UNITS

LCHM MOUNT POSITION MOUNT POSITION
A B C D A B C D
60 Y W Y W Y W Z Y Identification
R22 / 70 Y W Y W Y W Z Y Mount Main Main Inner Stripe Nominal
R407C 85 Y W Y W Y W Z Y Type Spring Spring Spring Colour Deflection
100 Y W Y W Y W Z Y Colour Diameter Colour
115 Y W Y W Y W Z Y W Grey 64 mm - White 25 mm
55 Y W Y W Z X Z X X Blue 64 mm - Black 23 mm
R134a 65 Y X Y X Z X Z Y Y Blue 76 mm - Yellow 25 mm
75 Y X Y X Z X Z Y Z Blue 76 mm White Red 25 mm
 035L02374-GB2 (05/02) 9-25

LCHM AL and LCHM AL-R

AL UNITS AL-R UNITS

LCHM MOUNT POSITION MOUNT POSITION
A B C D A B C D
60 Y W Y W Y W Y W Identification
R22 / 70 Y W X W Y W X W Mount Main Main Inner Stripe Nominal
R407C 85 Y W X W Y W X W Type Spring Spring Spring Colour Deflection
100 Y W Y W Y W Y W Colour Diameter Colour
115 Y W Y W Y W Y W W Grey 64 mm - White 25 mm
55 Y W X W Y W X W X Blue 64 mm - Black 23 mm
R134a 65 Y W X W Y W X W Y Blue 76 mm - Yellow 25 mm
75 Y W X W Y W X W Z Blue 76 mm White Red 25 mm

LCHHM WL and LCHHM WL-HR

WL UNITS WL-HR UNITS

LCHHM MOUNT POSITION MOUNT POSITION
A B C D A B C D
140 X+X X+X W+W W+W Y+Y Y+Y Y+Y Y+Y Identification
R22 / 170 Y+Y Y+Y X+X X+X Y+Y Y+Y Y+Y Y+Y Mount Main Main Inner Stripe Nominal
R407C 200 Y+Y Y+Y X+X X+X Y+Y Y+Y Y+Y Y+Y Type Spring Spring Spring Colour Deflection
230 Y+Y Y+Y X+X X+X Y+Y Y+Y Y+Y Y+Y Colour Diameter Colour
90 X+X X+X W+W W+W - - - - W Grey 64 mm - White 25 mm
R134a 110 X+X X+X W+W W+W - - - - X Blue 64 mm - Black 23 mm
130 X+X X+X X+X X+X Z+Z Z+Z Y+Y Y+Y Y Blue 76 mm - Yellow 25 mm
150 Y+Y Y+Y X+X X+X Z+Z Z+Z Y+Y Y+Y Z Blue 76 mm White Red 25 mm

LCHHM AL and LCHHM AL-R

AL UNITS AL-R UNITS

LCHHM MOUNT POSITION MOUNT POSITION
A B C D A B C D
140 X+X X+X W+W W+W X+X X+X W+W W+W Identification
R22 / 170 X+X X+X W+W W+W Y+Y Y+Y X+X X+X Mount Main Main Inner Stripe Nominal
R407C 200 X+X X+X W+W W+W Y+Y Y+Y X+X X+X Type Spring Spring Spring Colour Deflection
230 X+X X+X W+W W+W Y+Y Y+Y X+X X+X Colour Diameter Colour
90 Y+Y Y+Y W+W W+W X+X X+X W+W W+W W Grey 64 mm - White 25 mm
R134a 110 Y+Y Y+Y W+W W+W X+X X+X W+W W+W X Blue 64 mm - Black 23 mm
130 Y+Y Y+Y W+W W+W X+X X+X X+X X+X Y Blue 76 mm - Yellow 25 mm
150 Y+Y Y+Y W+W W+W Y+Y Y+Y X+X X+X Z Blue 76 mm White Red 25 mm
 9-26 035L02374-GB2 (05/02)

9.9 Process and Instrumentation Diagrams (per circuit)

WL Units
MICROPROCESSOR
CONTROL FUNCTIONS

DV DISPLAY VALVE
CHT CHILLED LIQUID
THEROMOSTAT
HPC HIGH PRESSUR CUTOUT
HPL HIGH PRESSURE LOAD
LIMITING
LPC LOW PRESSURE CUTOUT
DIF DIFFERENTIAL PRESSURE
CUTOUT
HTC HIGH TEMPERATURE CUTOUT
LTC LOW TEMPERATURE CUTOUT
LTI LOW DIFFERENTIAL
TEMPERATURE START INHIBIT
HCC HIGH CURRENT CUTOUT
LCC LOW CURRENT CUTOUT
-YLLSV LIQUID LINE SV
-YLISV LIQUID INJECTION SV

ECH

SYSTEM COMPONENTS

COMPRESSOR ANGLE VALVE WITH BACK ELECTRONIC EXPANSION

COOLER (EVAPORATOR) SEAT CONNECTION VALVE
CONDENSER VALVE WITH FLANGE PRESSURE RELIEF VALVE
CONNECTIONS SELF-SEALING ACCESS VALVE
HEAT RECOVERY
CONDENSER SOLENOID VALVE
PLANT ROOM THERMMOSTATIC MANUAL CHANGE-OVER
LIQUID RECEIVER EXPANSION VALVE VALVE
 035L02374-GB2 (05/02) 9-27

AL Units
MICROPROCESSOR
CONTROL FUNCTIONS

DV DISPLAY VALVE
CHT CHILLED LIQUID THEROMOSTAT
HPC HIGH PRESSUR CUTOUT
HPL HIGH PRESSURE LOAD LIMITING
LPC LOW PRESSURE CUTOUT
DIF DIFFERENTIAL PRESSURE CUTOUT
HTC HIGH TEMPERATURE CUTOUT
LTC LOW TEMPERATURE CUTOUT
LTI LOW DIFFERENTIAL
TEMPERATURE START INHIBIT
HCC HIGH CURRENT CUTOUT
LCC LOW CURRENT CUTOUT
-YLLSV LIQUID LINE SV
-YLISV LIQUID INJECTION SV

ECH

SYSTEM COMPONENTS (continued)

BALL VALVE COMPRESSOR MECHANICAL HIGH PRESSURE

-SHP
SIGHT GLASS DRIVE MOTOR CUTOUT - TOOL RESET
OIL PUMP -SF FLOW SWITCH
BURSTING DISC WITH
MOTOR OVER-TEMPERATURE
TELL-TALE CONNECTION PRESSURE SENSOR -BMP
PROTECTOR
REPLACEABLE CORE TEMPERATURE SENSOR -TC CURRENT TRANSFORMER
FILTER / DRIER
-SHP MECHANICAL HIGH PRESSURE -ECH CRANKCASE HEATER
FILTER / STRAINER
CUTOUT - HAND RESET ALTERNATIVE / OPTIONAL
COMPONENT
9-28 035L02374-GB2 (05/02)

Page Left Intentionally Blank

 035L02374-GB2 (05/02) 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. Contact your local York Service
Centre for information and please quote the Chiller
model number and serial number.
Item Quantity Per Panel
Description Part Number
Designation LCHM LCHHM
Pressure Transducer 200 psi BSP, BOP 025-29583-000 2 4
Pressure Transducer 400 psi BDP 025L01916-000 1 2
Fuse 6 AMP Gg, 38 x 10mm F1 025L02430-000 1
Fuse 1 AMP F, 20 x 5mm F2 025L02438-000 1 1
Fuse 2.5 AMP T, 20 x 5mm F3 025L02439-000 1 1
Fuse 0.5 AMP aM 38 x 5mm F4 025L02434-000 1 1
Fuse 4 AMP T, 20 x 10mm F5 025L02670-000 1 1
Fuse 4 AMP T, 20 x 10mm F6 025L02670-000 1
Fuse 4 AMP Gg 38 x 10mm F13 025L02431-000 1 2
Fuse 4 AMP aM 38 x 10mm F14 025L02724-000 1
Fuse 8 AMP aM 38 x 10mm 025L02804-000 1
Fuse 4 AMP aM 38 x 10mm F15 025L02724-000 1
Fuse 8 AMP aM 38 x 10mm 025L02804-000 1
Fuse 2 AMP aM 38 x 10mm F16 025L02432-000 1 1
Sensor, Oil Temperature 3 kΩ BOT 025L01952-000 1 2
Sensor, Oil Temperature 10 kΩ* BOT 025-32966-000* 1 2
Sensor, Water Temperature BLCT 025L02168-000 1 1

* The 10 KΩ sensor listed, screws directly into

the compressor. For the 10 kΩ sensor that fits
into a pocket in the compressor contact use
Part Number 025-34176C-000.

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 398L00654-001
6 Cylinder 398L00654-002
8 Cylinder 398L00654-003
10-2 035L02374-GB2 (05/02)

Page Left Intentionally Blank


11 DE-COMMISSIONING,
DISMANTLING AND DISPOSAL
Never release refrigerant to the
atmosphere when emptying the
refrigerating circuits. Suitable retrieval
equipment must be used. If reclaimed
refrigerant cannot be re-used. It must
be returned to the manufacturer.
Never discard used compressor oil, as
it contains refrigerant in solution.
Return used oil to the oil manufacturer.
Unless otherwise indicated, the operations
described below can be performed by any properly
trained maintenance technician.
11.1 General
Isolate all sources of electrical supply to the unit
including any control system supplies switched by
the unit. Ensure that all points of isolation are
secured in the ‘OFF’ position. The supply cables
may then be disconnected and removed. For
connection points refer to Section 4.
Remove all refrigerant from each system of the unit
into a suitable container using a refrigerant reclaim
or recovery unit. This refrigerant may then be
re-used, if appropriate, or returned to the
m anuf ac t ur er f o r d i sp o sa l . Un der N O
circumstances should refrigerant be vented to
atmosphere. Drain the refrigerant oil from each
system into a suitable container and dispose of
according to local laws and regulations governing
the disposal of oily wastes. Any spilt oil should be
mopped up and similarly disposed of.
Isolate the unit heat exchanger(s) from all external
water systems and drain the heat exchanger
section(s) of the system. If no isolation valves are
installed it may be necessary to drain the complete
system(s).
035L02374-GB2 (05/02) 11-1
If glycol or similar solutions have been
used in the water system(s), or
chemical additives are contained, the
solution MUST be disposed of in a
suitable and safe manner. Under NO
circumstances should any system
containing glycol or similar solutions
be drained directly into domestic
waste or natural water systems.
After draining, the water pipework can be
disconnected and removed.
Packaged units can generally be removed in one
piece after disconnection as above. Any fixing
down bolts should be removed and then the unit
should be lifted from position using the points
provided and equipment of adequate lifting
capacity.
Reference should be made to Section 4 for unit
installation instructions, Section 9 for unit weights
and Section 3 for handling.
Units which cannot be removed in one piece after
disconnection as above must be dismantled in
position. Special care should be taken regarding
the weight and handling of each component.
Where possible units should be dismantled in the
reverse order of installation.
Residual refrigerant oil and glycol or
similar solutions may remain in some
parts of the system. These should be
mopped up and disposed of as
described above.
It is important to ensure that whilst components are
being removed the remaining parts are supported
in a safe manner.
Only use lifting equipment of adequate
capacity.
After removal from position the unit parts may be
disposed of according to local laws and
regulations.
11-2 035L02374-GB2 (05/02)

Page Left Intentionally Blank

Italy
YORK International
20051 Limbiate (Milan)
Via Manara 2
Italia
Tel: ++39/0299450.1
Fax: ++39/0299450.860
Kazakhstan
YORK International
Representation Office
92 Maulenov Str. office 329,327
KZ-480012 Almaty
Kazakhstan
Tel: ++732 72/ 62 97 77
Fax: ++732 72/ 63 37 19
Latvia
YORK Latvia
YORK International S.I.A.
Krustpils iela 1
LV-1073 Riga
Latvia
Tel: ++371/7113068
Fax: ++371/7113067
Lithuania
YORK International GmbH
Representation Office
Fabijoniskiu 96
2029 Vilnius/Lithuania
Tel: ++3702 - 388337,
388339
Fax: ++3702 388112
Nederland
YORK International
Tinstraat 15
Postbus 3453
4800 DL Breda
Nederland
Tel: ++31 765486800
Fax: ++31 765421800
Poland
YORK Polska
YORK INT. Sp.z.o.o.
Al. Slowianska 10
PL-01-695 Warszawa
Poland
Tel: ++4822/83 22 220
Fax: ++4822/8330303
Portugal
Roca/YORK
Estrada Outeiro de Polima
Lote 9 3 A/D
Abübada Cascais
2785 518,
S. Domingos de Rana
Portugal
Tel: ++351 21 445 0601
Fax: ++351 21 445 0598
Romania
YORK Romania
YORK International S.R.L.
6 Londra St.
1 District
RO-712171 Bucharest
Romania
Tel: ++401/2304516/2315319
2315320/2315321
Fax: ++401/2304406
Russia
YORK International ZAO
Poklonnaya, 14a
CIS-121170 Moscow
Russia
Tel: ++7095/232-2075
Fax: ++7095/232-6661
YORK International ZAO
28 Zagorodny prospect
CIS-191002
St. Petersburg
Russia
Tel: ++7812/325 4700
Fax: ++7812/325 4701
YORK International ZAO
Alexeevskaya St. 26, Office
208
N. Novgorod,
CIS
Tel/Fax: ++7 8312/35 19 03
Serbia
YORK International
YU Business Center
Bulevar Lenjina 10/D/I/127
YU-11070 Belgrade
Serbia
Tel: ++381 11 311 41 43
++381 11 311 91 19
Fax: ++381 11 137 694
Slovak Republic
YORK Slovensko
YORK International spol.sr.o.
Pekna cesta 6b
SK-83105 Bratislava
Slovak Republic
Tel/Fax: ++421/7/44880952,
0953, 0954, 0955
South Africa
YORK International
Johannesburg Head Office.
60 B Electron Ave.
Isando. 1600
Johannesburg
Tel: +27 11 921 7100
Fax: +27 11 921 7200
Supremeair (YORK Service)
th
'43 11 Rd.
Kew
Johannesburg
Tel: +27 11 786 0868
Fax: +27 11 786 0876
YORK International
35 Haulage Rd.
Carletonville 2500
Tel: +27 18 786 1062/3
Fax: +27 18 787 3213
YORK International
2 Cassiafield Grove
Springfield Park 4091
Durban
Tel: +27 31 579 4646
Fax: +27 31 579 1030
YORK International
5 Stepmar Building
27 Stells Rd.
Montague Gardens 7441
Cape Town
Tel: +27 21 551 3012
Fax: +27 21 551 4176
Supremair (YORK Service)
9 Henri van Rooijen St.
Eastend 9300
Bloemfontein
Tel: +27 51 432 7828
Fax: +27 51 432 2450
YORK International
118D Constantia St.
Welkom 9459
Tel: +27 57 352 3240
Fax: +27 57 352 8982
Spain
Roca/YORK
Industria 94-96
08908 Hospitalet de Llobregat
Barcelona
Spain
Tel: ++34 93 422 90 90
Fax: ++34 93 332 16 14
Roca/YORK
Hurtado de Amézaga 20, 4°
48008 Bilbao
Spain
Tel: ++34 944 162 833
Fax: ++34 94 415 49 69
Roca/YORK York International
Av. Valdelaparra 47 Unit 4
28100 Alcobendas Zealley Estate
Madrid Greenhill Way
Spain Kingsteignton
Tel: ++34 916 624 101 Newton Abbott
Fax: ++34 91 662 41 57 Devon
TQ12 3TD
Roca/YORK England
Juventud 8 Tel: ++44 1626 333734
Parque Ind. PISA Fax: ++44 1626 335220
41927 Mairena de Aljarafe
Seville York International
Spain Gardiners Lane South
Tel: ++34 954 183 012 Basildon
Fax: ++34 95 418 30 68 Essex
SS14 3HE
Roca/YORK England
Senyera s/n Tel: ++44 1268 246000
Pol. Ind. Mediterráneo Parc 28 Nave 3 Fax: ++44 1268 246001
46560 Massalfassar
Valencia York International
Spain Unit 10
Tel: ++34 961 400 711 Hadrians Court
Fax: ++34 96 140 22 53 Seventh Avenue
Team Valley Trading Estate
Switzerland Gateshead
YORK International Tyne & Wear NE11 0XW
Grindelstrasse 19 England
CH-8303 Bassersdorf Tel: ++44 (0) 191 491 0598
Switzerland Fax: ++44 (0) 191 482 6167
Tel: ++41/1/83844-11
Fax: ++41/1/8369780 York International
1 Donaldson Crescent,
YORK International Southbank Business Park
4, Chemin des I'Esparcette Kirkintillock
CH-1023 Crissier Glasgow
Switzerland G66 1XF
Tel: ++41/21/6328011 Scotland
Fax: ++41/21/6328013 Tel: ++44 (0) 141 776 7576
Fax: ++44 (0) 141 777 7425
Ukraine
YORK Ukraine York International
YORK International GmbH Unit 1
36, Degterevskaya street Western Access
floor 7, room 723-725 Guinness Road
Kiev/Ukraine Trafford Park
Tel: ++38044/219 32 89, Manchester M17 1SY
461 91 77, 211 09 91 England
Fax: ++38044/213 36 95 Tel: ++44 (0) 161 848 0202
Fax: ++44 (0) 161 848 7196
United Kingdom
York International
York International
Unit 25
72 Buckingham Avenue
Portsmouth Enterprise Centre
Slough
Quartremaine Road
Berkshire
The Airport
SL1 4PN
Portsmouth
England
PO3 5QT
Tel: ++44 1753 693919
England
Fax: ++44 1753 692405
Tel: ++44 2392 650149
Fax: ++44 2392 650225
York International
14-16 St Martins Avenue
York International
Fieldhead Business Centre
Arden House
Bradford
Marsh Lane
BD7 1LG
Hampton-In-Arden
England
Solihull
Tel: ++44 1274 765300
West Midlands
Fax: ++44 1274 765301
B92 0AJ
England
York International
Tel: ++44 1675 443341
Unit 17
Fax: ++44 1675 442402
Garanor Way
Royal Portbury
Bristol Uzbekistan
BS920 7XE YORK International
England Representation Office
C4, Place 35
Tel: ++44 1275 375713
Fax: ++44 1275 375714 UZ - 700017 Tashkent
Uzbekistan
York International Tel: ++998 71 137 5770
Unit 5 ++998 71 137 5062
Swift Business Centre Fax: ++998 71 137 5055
Keen Road
Cardiff European Parts Centre
CF1 5JR Unit 1, Capitol Industrial Centre
Wales Fulmar Way, Wickford
Tel: ++44 292 0470619 Essex
Fax: ++44 292 0470624 SS11 8YW
England
Tel: ++44 1268 577000
Fax: ++44 1268 577100
YORK Service and Parts Contact
Addresses
Austria YORK International YORK International YORK International
YORK Austria 114-126 Avenue d'Alfortville 6 Bis rue Chalutier-La-Tanche Widdersdorfer Straße 215
Central & Eastern Europe Headquarters 94607 Choisy-le-Roi Cedex 56100 Lorient 50825 Köln
Zetschegasse 3 France France Germany
A 1232 Wien Tel: ++33 1.45.12.10.30 Tel: ++33 3.20.87.61.62 Tel: ++49/221/498750
Austria Fax: ++33 1.48.52.59.34 Fax: ++33 2.97.83.83.80 Fax: ++49/221/4987539
Tel: ++43 1 66 136 195 YORK International
Fax: ++43 1 66 136 86 YORK International Rue de la Longuerais YORK International
31 rue Wilson ZA des Landelles Fuggerstraße 1
Azerbaijan 69150 Decines- Charpieu 35520 Melesse 04158 Leipzig - Wiederitzsch
YORK International AO France France Germany
90 M. Mansurov Str. Tel: ++33 4.72.02.62.50 Tel: ++33 2.99.66.01.87 Tel: ++49/341/566630
AZ-370004 Baku Fax: ++33 4.72.05.30.01 Fax: ++33 2.99.66.92.73 Fax: ++49/341/5666333
Republic of Azerbaijan
Tel.: ++99 412/ 97 10 35 YORK International YORK International YORK International
Fax: ++99 412/ 97 10 36 15 rue des Combattants d'Extrême Orient 78 Avenue de Laon Gottlieb-Daimler-Strasse 6
13700 Marignane 02200 Soissons 68165 Mannheim
Belarus France France Germany
YORK International AO Tel: ++33 4.42.77.04.60 Tel: ++33 3.23.59.65.55 Tel: ++49/621/468-532
Leningradskaya str, 18 Fax: ++33 4.42.15.08.99 Fax: ++33 3.23.59.65.56 Fax: ++49/621/468-680
Minsk
Belarus YORK International YORK International YORK International
Tel/Fax: ++375/172/06 63 80 Rue A.Fruchard - Z.I. Jean Prouvé 8 rue de l'Artisanat Geisenhausener Straße 6
Tel/Fax: ++375/172/10 43 35 54320 Maxeville 67120 Dupigheim 81379 München
France France Germany
Tel: ++33 3.83.32.49.83 Tel: ++33 3.88.48.22.50 Tel: ++49/89/78048
Belgium Fax: ++33 3.83.32.43.16 Fax: ++33 3.88.48.22.51 Fax: ++49/89/7804844
YORK International
Prins Boudewijnlaan 1 YORK International YORK International
YORK International
2550 Kontich 14 rue de Constantine Edisonstraße 60
Z.A. du Prieuré
Belgium 62200 Boulogne Sur-Mer 90431 Nürnberg
37530 Poce Sur Cisse
Tel: ++32 34510600 France Germany
France
Fax:++32 34582444 Tel: ++33 3.21.83.17.70 Tel: ++49/911/961750
Tel: ++33 2.47.23.29.23
Fax: ++33 3.21.83.11.02 Fax: ++33 2.47.23.25.50 Fax: ++49/911/9617544
Bulgaria
YORK Bulgaria YORK International YORK International YORK International
YORK International EOOD 102 Bd de Strasbourg Avenue Lavoisier Mainzer Straße 29
10, Marko Balabanov Str. 49300 Cholet Z.I. de Villemilan 66111 Saarbrücken
BG-1303 Sofia France 91320 Wissous Germany
Bulgaria Tel: ++33 2.41.29.13.73 France Tel: ++49/681/67494
Tel: ++3592/9803040, Fax: ++33 2.41.29.13.80 Tel: ++33 1.60.11.88.76 Fax: ++49/681/66243
9815780, 9817578 Fax: ++33 1.60.11.90.16
Fax: ++3592/9818386 YORK International YORK International
3 rue du Moros Germany Fabrikstraße 17
Croatia 29900 Concarneau YORK International 70794 Filderstadt
YORK International France Paradiesstraße 210 Germany
Vrlicka 24 Tel: ++33 2.98.60.52.10 12526 Berlin Tel: ++49/711/7709422
HR-10000 Zagreb Fax: ++33 2.98.60.52.11 Germany Fax: ++49/711/7709433
Croatia Tel: ++49/30/6797190
Tel.: ++385/1/3843 444 YORK International Fax: ++49/30/67971944 Greece
++385/1/3843 851 Parc du Talou - 7 rue A.Legras YORK International
++385/1/3840 352 76200 Dieppe YORK International 62 , Kifisias Ave
Fax: ++385/1/3840 398 France Hafenstraße 100 zip code: 115 26
Tel: ++33 2.32.14.41.50 45356 Essen Athens - Greece
Czech Republic Fax: ++33 2.32.14.41.51 Germany Tel: ++301- 69 11 888
YORK Ceska Republika Tel: ++49/201/364000 Fax:++301- 69 10 764
YORK International spol. sr.o. YORK International Fax: ++49/201/3640041
Edisonova 27 44 rue Gambetta Hungary
CZ-10900 Praha 10 -Petrovice 17260 Gemozac YORK International YORK Magyaroszag
Tel: ++420/2/721 21 111 France Wächtersbacher Straße 83 YORK International Kft.
Fax: ++420/2/721 21 100 Tel: ++33 5.46.95.87.80 60386 Frankfurt Váci út 206
Fax: ++33 5.46.94.56.41 Germany H-1138 Budapest
France Tel: ++49/69/941402-0 Hungary
YORK International YORK International Fax: ++49/69/94140244 Tel: ++361/4657060
Innolac n°7 Z.I. du Vern Fax: ++361/4657069
Rue du Professeur G.Jeanneney 29230 Landivisiau YORK International
33300 Bordeaux France Sperberhorst 8
Tel: ++33 2.98.68.21.52
Ireland
France 22459 Hamburg YORK ACR Ltd
Tel: ++33 5.57.19.06.30 Fax: ++33 2.98.68.90.91 Germany Unit 2004/3
Fax: ++33 5.56.69.04.96 Tel: ++49/40/5714410 City West Business Campus
YORK International Fax: ++49/40/57144133 Naas Road
YORK International 4 rue du Grand Fief
Dublin 22
14 rue de Bel Air 85150 Vaire YORK International Ireland
B.P.309 France Alter Flughafen 18a Tel: ++ 353 1466 0177
44473 Carquefou Cedex Tel: ++33 2.51.33.70.83 30179 Hannover Fax: ++ 353 1466 0198
France Fax: ++33 2.51.33.70.85 Germany
Tel: ++33 2.40.30.62.93 Tel: ++49/511/678040 York International
Fax: ++33 2.40.30.22.66 Fax: ++49/511/6780433 Unit 19
Sarsfield Road
YORK International University Hale Industrial Estate
Leipziger Straße 35-37 Wilton
34125 Kassel Cork
Germany Ireland
Tel: ++49/561/507210 Tel: ++353 2 134 6580

Europe Fax: ++49/561/5072122

YORK Part No. 035L02374-GB2 (05/02)

YORK INTERNATIONAL
Subject to change without notice
Gardiners Lane South, Basildon, Essex SS14 3HE, England
ALL RIGHTS RESERVED