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