High Ambient Air Cooled Liquid Chiller

YAEP

YORK

EMEA

HIGH AMBIENTAIR COOLED LIQUID CHILLER

INSTALLATION, COMMISSIONING,OPERATION AND MAINTENANCE

STYLE A

REFRIGERANT TYPE:MODELS:

SOFTWARE:

Refrigerant Circuit Models -

R22, R407C50 Hz

2 V4-2 REV 7 V4C-2 REV 74

and and HigherRefrigerant Circuit Models - V4-4 REV 7 V4C-4 REV 7and and Higher

035L -100 Rev. 002537

(02/04) GB

Table of Contents

1 SUPPLIER INFORMATION

1.1 Introduction 1.1

1.2 Warranty 1.1

1.3 Safety 1.1

1.4 Responsibility for Safety 1.2

1.5 About this Manual 1.2

1.6 Misuse of Equipment 1.2

1.7 Emergency Shutdown 1.3

1.8 Safety Labels 1.4

1.9 Material Safety Data 1.5

2 PRODUCT DESCRIPTION

2.1 Introduction 2.1

2.2 Compressors 2.2

2.3 Cooler(s) 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 Functional Description 2.5

2.9 Nomenclature 2.6

3 TRANSPORTATION, HANDLINGAND STORAGE

3.1 Delivery and Storage 3.1

3.2 Inspection on Arrival at Site 3.1

3.3 Moving the Chiller 3.1

3.4 Lifting Weights 3.2

3.5 Shipping Protection 3.2

4 INSTALLATION

4.1 Location Requirements 4.1

4.2 Location Clearances 4.2

4.3 Vibration Isolator Installation & Dimensions 4.2

4.4 Pipework Connection 4.2

4.5 Water Treatment 4.3

4.6 Pipework Arrangement 4.4

4.7 Connection Types & Sizes 4.4

4.8 Refrigerant Relief Valve Piping 4.5

4.9 Ductwork Connection 4.5

4.10 Electrical Connection 4.6

4.11 Power Wiring 4.6

4.12 Control Section - Output Signals 4.7

4.13 Control Section - Input Connections 4.8

5 COMMISSIONING

5.1 Preparation 5.1

5.2 First Time Start-up 5.3

6 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 Shutdown 6.2

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7 MAINTENANCE

7.1 General Requirements 7.1

7.2 Daily Maintenance 7.1

7.3 Scheduled Maintenance 7.2

7.4 Vessels In-Service Inspection 7.2

8 TROUBLE SHOOTING

8.1 Competent Persons TroubleShooting Guide 8.1

8.2 Compressor Components 8.3

8.3 Sensor Calibration Charts 8.4

9 TECHNICAL DATA

9.1 Flow Rate/Pressure Drop Charts 9.1

9.2 Operating Limitations 9.1

9.3 Physical Data - R22 Models 9.2

9.4 Physical Data - R407C Models 9.3

9.5 Electrical Data - R22 Models 9.4

9.6 Electrical Data - R407C Models 9.4

9.7 Control Circuit Electrical Data 9.5

9.8 Compressor Electrical Data -R22 Models 9.5

9.9 Compressor Electrical Data -R407C Models 9.5

9.10 Fan Data 9.5

9.11 Fuse Ratings and Lug Sizes 9.6

9.12 Clearances 9.7

9.13Dimensions9.8

10 SPARE PARTS

10.1 Recommended Spares 10.1

10.2 Compressor Top Head Rebuild Kit 10.2

10.3 Associated Drawings 10.2

11 DE-COMMISSIONING, DISMANTLINGAND DISPOSAL

11.1 General 11.1

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1 SUPPLIER INFORMATION

1.1 Introduction

High ambient YAEP models will be built to goodengineering practices and are completely assembledwith all interconnecting refrigerant piping and internalwiring, ready for field installation. Four circuit units areshipped in two sections and require the installation of atwo wire communication link between control panelsand a mixed leaving liquid temperature sensor.

The YAEP range of chillers are designed for waterchilling. All units are designed to be located outside onthe roof of a building or at ground level and are notsuitable for purposes other than those specified in thismanual.

This manual and the Operating Instructions for the microbased control system contain all the informationrequired for correct installation and commissioning ofthe unit, together with operating and maintenanceinstructions. The manuals should be read thoroughlybefore attempting to operate or service the unit.

All procedures detailed in the manuals, includinginstallation, commissioning and maintenance tasksmust only be performed by suitably trained and qualifiedpersonnel.

The manufacturer will not be liable for any injury ordamage caused by incorrect instal lat ion,commissioning, operation or maintenance resultingfrom a failure to follow the procedures and instructionsdetailed in the manuals.All data in this manual is subjectto change without notice.

1.2 Warranty

York International Limited warrants all equipment andmaterials against defects in workmanship and materialsfor a period of one year from initial start-up, or eighteenmonths from delivery (whichever occurs first) unlessextended warranty has been agreed as part of thecontract.

The warranty is limited to free replacement and shippingof any faulty part, or sub-assembly which has failed dueto poor quality or manufacturing errors. All claims mustbe supported by evidence that the failure has occurredwithin the warranty period, and that the unit has beenoperated within the designed parameters specified.

All warranty claims must specify the unit model, serialnumber and order number. These details are printed onthe unit identification plate.

The unit warranty will be void if any modification to theunit is carried out without prior written approval fromYork International.

For warranty purposes, the following conditions must besatisfied:

The initial start of the unit must be carried out by trainedpersonnel from an Authorised York Service Centre.

Only genuine York approved spare parts, oils andrefrigerants must be used. To obtain York spare partscontact your local York office. Details of York offices aregiven on the rear cover of this manual

All the scheduled maintenance operations detailed inthis manual must be performed at the specified times bysuitably trained and qualified personnel.

Failure to satisfy any of these conditions willautomatically void the warranty.

1.3 Safety

Standards for Safety

YAEP units are designed and built within an EN ISO9001 accredi ted design and manufactur ingorganisation.

Units will conform to the applicable essential safetyrequirements of Pressure Equipment Directive97/23/EC and bear CE marking and are in conformitywith the essential health and safety requirements of thefollowing European Union Directives:

Machinery Directive (89/392/EEC)

Low Voltage Directive (73/23/EEC)

EMC Directive (89/336/EEC)

unless otherwise stated for certain options.

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1.4 Responsibility for Safety

Every care has been taken in the design andmanufacture of York Chillers to ensure that they meetthe safety requirements listed in the previous paragraph.However, the individual operating or working on anymachinery is primarily responsible for:

Personal safety, safety of other personnel, and themachinery

Correct utilisation of the machinery in accordance withthe procedures detailed in this manual.

1.5 About this Manual

The following symbols are used in this document to alertthe reader to areas of potential hazard.

A Warning is given in this document toidentify a hazard which could lead topersonal injury. Usually an instruction willbe given, together with a brief explanationand the possible result of ignoring theinstruction.

A Caution identifies a hazard which couldlead to damage to the machine, damage toother equipment and/or environmentalpollution. Usually an instruction will be given,together with a brief explanation and thepossible result of ignoring the instruction.

A Note is used to highlight additionalinformation which may be helpful to you butwhere there are no safety implications.

The contents of this manual include suggested bestworking practices and procedures. These are issued forguidance only, they do not take precedence over theabove stated individual responsibility and/or local safetyregulations.

This manual and any other document supplied with theunit, are the property of YORK which reserves all rights.They may not be reproduced, in whole or in part, withoutprior written authorisation from an authorised YORKrepresentative.

1.6 Misuse of Equipment

Suitability for Application

The unit is intended for cooling water and is not suitablefor purposes other than those specified in theseinstructions. Any use of the equipment other than itsintended use, or operation of the equipment contrary tothe relevant procedures may result in injury to theoperator, or damage to the equipment.

The unit must not be operated outside the designparameters specified in this manual.

Structural Support

Structural support of the unit must be provided asindicated in these instructions. Failure to provide propersupport may result in injury to the operator, or damage tothe equipment.

Mechanical Strength

The unit is not designed to withstand loads or stressesfrom adjacent equipment, pipework or structures.Additional components must not be mounted on the unit.Any such extraneous loads may cause structural failureand may result in injury to the operator, or damage to theequipment. The unit should only be lifted in accordancewith the instructions given in Section 3 of this manual.

General Access

There are a number of areas and features which may bea hazard and potentially cause injury when working withthe unit unless suitable safety precautions are taken. It isimportant to ensure access to the unit is restricted tosuitably qualified persons who are familiar with thepotential hazards and precautions necessary for safeoperation and maintenance of equipment containinghigh and low temperatures, pressures and voltages.

Pressure Systems

Each unit has two, three or four independent pressuresystems comprising the compressor, air cooledcondenser coils, cooler vessel and interconnectingcopper pipework. Each system contains refrigerantvapour and liquid under pressure, release of which canbe a danger and cause injury. The user should ensurethat care is taken during installation, operation andmaintenance to avoid damage to the pressure system.No attempt should be made to gain access to thecomponent parts of the pressure system other than bysuitably trained and qualified personnel.

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Electrical

The unit must be ear thed. No instal lat ion ormaintenance work should be attempted on electricalequipment without first switching off, isolating andlocking-off the main power supply and any controlsupplies. Work on live equipment must only becarried-out by suitably trained and qualified personnel.No attempt should be made to gain access to internalsof the control panel, wiring or other electrical enclosuresduring normal operation of the unit.

Rotating Parts

Fan guards must be fitted at all times and not removedunless the main power supply has been isolated. Ifductwork is to be fitted, requiring the wire fan guards tobe removed, alternative safety measures must be takento protect against the risk of injury from rotating fans.

Sharp Edges

The finning on the air cooled condenser coils has sharpmetal edges. Reasonable care should be taken whenworking in contact with the coils to avoid the risk of minorabrasions and lacerations. The use of gloves isrecommended.

Refrigerants and Oils

Refrigerants and oils used in the unit are generallynon-toxic, non-flammable and non-corrosive, and poseno special safety hazards. Use of gloves and safetyglasses are, however, recommended when working onthe unit. Build up of refrigerant vapour, from a leak forexample, does pose a risk of asphyxiation in confined orenclosed spaces and attention should be given to goodventilation. For more comprehensive information onsafety precautions for use of refrigerants and oils, referto 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 thepressure system as this may cause operation of thepressure relief device(s). Detergents and solventswhich may cause corrosion should also be avoided.

1.7 Emergency Shutdown

In case of emergency the control panel is fitted with anemergency stop switch which, when operated, removesthe electrical supply from the control system and themicroprocessor controller. A facility is available toconnect a remote emergency stop device for the samepurpose.The emergency stop switch can be pad-lockedin the off position.

Four circuit units have a main panel and a auxiliarypanel. In case of emergency each panel, main andauxiliary has its own emergency stop switch which canbe identified as red in colour and sited on a yellowback-plate. Both emergency stop switches can bepad-locked in the off position.

The device on the main panel when operated, stopssystems 1 and 2 only.

A facility is available in the main panel to connect aremote emergency stop device to stop systems 1 and 2.

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PULL TOPAD-LOCK

The device on the auxiliary panel when operated, stopssystems 3 and 4 only.

A facility is available in the auxiliary panel to connect aremote emergency stop device to stop systems 3 and 4.

1.8 Safety Labels

The following labels are fixed to each unit to giveinstruction, or to indicate potential hazards which mayexist.

White symbol on bluebackground

For safe operation - read theInstructions first

Black symbol on yel lowbackground

Warning: This machine maystart automatically without priorwarning

Black symbol on yel lowbackground

Warning: Hot surface

Black symbol on yel lowbackground

Warning: Safety relief valvemay discharge gas or liquidwithout prior warning

Black symbol on yel lowbackground

Warning: Isolate all electricalsources of supply beforeopening or removing the cover,as lethal voltages may exist

Black symbol on yel lowbackground

General attention symbol

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1.9 Material Safety Data

Refrigerant Data:

Safety Data R22 R407C

Toxicity Low.

In contact with skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skinabsorption. R22 may be slightly irritant and liquid has a degreasing effect. Thawaffected areas with water. Remove contaminated clothing carefully - may adhereto skin in case of freeze burns. Wash affected areas with plenty of warm water. Ifsymptoms 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 inducevomiting. Provided patient is conscious, wash mouth with water and give about250 ml (0.5 pint) to drink. Obtain immediate medical attention.

Inhalation R22 High levels of vapour concentrationinitially produce stimulation and thendepression of the central nervoussystem causing headaches andgiddiness and may lead tounconsciousness. Can prove suddenlyfatal if the exposure has been severe.

R407C High atmospher icconcentrations may lead anaestheticeffect, including loss of consciousness.Very high exposures may cause anabnormal heart rhythm and provesuddenly fatal.

At higher concentration there is a danger from asphyxiation due to reduced oxygencontent of atmosphere. Remove patient to fresh air, keep warm and at rest.Administer oxygen if necessary. Apply artificial respiration if breathing has ceasedor 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 beendescribed which may, in the presence of circulating catecholamines such asadrenalin, give rise to cardiac arrhythmias and subsequent arrest followingexposure to high concentrations.

Long term exposure R22 A lifetime inhalation study in ratsand mice give a small excess in salivarygland tumours in male rats only at50,000 ppm. 10,000 ppm showed noeffect. This information suggests thatR22 does not represent a carcinogenichazard to humans.

R407C A lifetime inhalation study in ratshas shown that exposure to 50,000 ppmresulted in benign tumours of the testis.This is not considered to be of relevanceto humans exposed to concentrations ator below the occupational exposurelimit.

Occupat ional exposurelimits

R22 Recommended limit : 1000 ppmv/v - 8 hr TWA 1250 ppm v/v - 12 hrTWA.

R407C Recommended limit: 1000 ppmv/v - 8 hr TWA.

Stability R22 Unstable. R407C Not specified.

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

Hazardous reactions May react violently with sodium, potassium, barium and other alkali and alkalineearth metals. Incompatible materials : Magnesium and alloys containing more then2% magnesium.

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Hazardous decompositionproducts

R22 Halogen acids formed by thermaldecomposition.

R407C Halogen acids by thermaldecomposition and hydrolysis.

General precautions Avoid inhalation of high concentrations of vapours. Atmospheric concentrationsshould be minimised and kept as low as reasonably practicable below theoccupational exposure limit. The vapour is heavier than air and collects at low leveland in confined areas. Ventilate by extraction at lowest levels.

Respiratory protection Where doubt exists on atmospheric concentration, HSE approved breathingapparatus should be worn. This should be self contained or of the long breathertype.

Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and allsources 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 toevaporate provided there is suitable ventilation.Large spillages : Ventilate area. Contain spillages with sand, earth or any suitableabsorbent material. Prevent liquid from entering drains, sewers, basements andwork pits since vapour may create a suffocating atmosphere.

Disposal Best to recover and recycle. If this is not possible, destruction is to be in anapproved facility which is equipped to absorb and neutralise acids and other toxicprocessing products.

Fire extinguishing data R22 Non-flammable R407C Non-flammable at atmosphericconditions.

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

Fire f ight ing protect iveequipment

Self contained breathing apparatus and protective clothing must be worn in fireconditions.

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 personalcleanliness including cleansing exposed skin areas several times daily with soapand water. Launder soiled work clothes at least weekly.

In contact with eyes As with most foreign materials flush withplenty of eyewash solution or cleanwater.

Flush eyes with eyewash solution orclean water for 15 minutes and consult aphysician.

Ingested Non-toxic. No first aid considerednecessary.

May cause nausea and diahorrhea.Obtain immediate medical attention.

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

Occupat ional exposurelimits

Recommended limit : 5 mg/cubic metreof oil mist in air for 8 hr daily exposure.

Not determined.

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Stability Stable. Stable but hygroscopic -store in sealedcontainers.

Conditions to avoid None Specified. Strong oxidisers, caustic or acidsolutions, excessive heat. May degradesome paints and rubber materials.

Hazardous decomposition Oxides of carbon, aldehydes andketones, combustion products ofnitrogen, sulphur.

Not fully. Analogous compounds evolvecarbon monoxide, carbon dioxide andother unidentified fragments whenburned. Burning fluid may evolveirritating/noxious fumes.

Respiratory protection Use in well ventilated areas. Use in well ventilated areas - ventilatelocally.

Protective clothing Not necessary but goggles or faceshield recommended.

Goggles or face shield should be worn.Gloves not necessary, butrecommended, especially for prolongedexposure.

Spill / Leak procedure Wear suitable protective equipment, especially goggles. Stop source of spill. Useabsorbent materials to soak up fluid (i.e. sand, sawdust, and commerciallyavailable materials).

Disposal Incinerate the oil and all associated wastes in an approved facility in accordancewith local laws and regulations governing oily wastes.

Fire extinguishing data Flash point over 180°C. Use waterspray, dry chemical, carbon dioxide oralcohol foam. Water or foam may causefrothing.

Flash point over 300°C. Use drychemical, 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 toprovide protection for persons attempting to stop the leak.

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

Fire f ight ing protect iveequipment

Self contained breathing apparatus should be worn in fire conditions.

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 locallaws and regulations governing non-biodegradable non-hazardous solidwastes.

Fire & Explosion Flammability rating Class 1 to BS 476 pt 7 : Non-flammable. If forced toburn, combustion products are typically over 95% carbon dioxide andcarbon monoxide.

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2 PRODUCT DESCRIPTION

2.1 Introduction

York YAEP high ambient air cooled liquid chillers aredesigned for water cooling. Units are available with one,two or four refrigerant circuits.

One and two refrigerant circuit units have one and twocompressors and a cooler mounted on a single basewith a single power and control panel mounted at theend of the unit.

Four refrigerant circuit units are constructed in twosections each having two compressors and a cooler.Four circuit units have a main power and control panelmounted at one end of the unit and an auxiliary powerand control panel mounted at the other end of the unit.

Four circuit units require the installation of a two wirecommunication link between control panels and a mixedleaving liquid temperature sensor.

All models are designed to be located outside on theroof of a building or at ground level. All models aredelivered completely assembled with all interconnectingrefrigerant piping and internal wiring, ready for fieldinstallation.

Prior to delivery each unit is pressure tested, evacuatedand fully charged with refrigerant, and includes an initialoil charge. After assembly a full run test is performedwith water flowing through the cooler to verify that eachrefrigeration circuit operates correctly.

The unit base and framework are fabricated usingheavy-gauge galvanised steel which is zinc phosphatepre-treated and powder coated to minimise corrosion.

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1

2

3

6

5

4

Scrap view of unitwith optional Acoustic Enclosureand optional Sun Shield kit fitted

KEY1 Condenser Fan 5 Compressor2 Condenser 6 Power and Control Panel3 Cooler (with optional Sun Shield Kit fitted)4 Filter Drier

2.2 Compressors

Each unit is fitted with one, two or four semi-hermetic,reciprocating compressors.The compressor motors arerefrigerant gas cooled, with integral temperaturesensing solid state overload protection in each phase.The motor terminal boxes are manufactured to preventingress of dust and water to IP54. Starting is bypart-winding.

Compressor Housing

The compressor housing is cast iron. It contains:removable cylinder heads with internal muffling,discharge service valve, optional suction service valve(when ordered), crankcase sight glass and heater, oiland suction strainers, and internal relief valveconforming to ASHRAE/ANSI Standard 15 SafetyCode.

Compressor Lubrication

The lubrication is force-fed by a reversible oil pumpwhich supplies oil to all crankshaft and bearing surfacesthrough a fine mesh stainless steel filter.

Capacity Control

Capacity control is provided by solenoid-actuatedcapacity control valves, controlled by the Micro BasedControl System.

2.3 Cooler(s)

The single/multi-circuit cooler is the direct- expansiontype, with the refrigerant in the tubes and chilled liquidflowing through the baffled shell.

The design working pressure of the shell is 10.3 bar g,and 16.2 bar g for the tube side. The refrigerant side isconstructed and tested in accordance with CE/PEDpressure vessel code requirements. ASME pressurevessels are available on two and four refrigerant circuitmodels.

The water baffles are constructed of galvanised steel toresist corrosion. The removable heads allow access tothe internally enhanced, seamless, copper tubes. Ventand drain connections are included. Standard coolerconnections are Victaulic nozzles.

The cooler is covered with 19mm flexible, closed-cell,UV stable, colour co-ordinated foam insulation. Eachcircuit is protected by a relief valve.

2.4 Air Cooled Condensers

Coils

The condenser coils are manufactured from seamlesscopper tubes arranged in staggered rows, mechanicallyexpanded into fins. Integral subcooling is included.

Fans

The condenser fans are U.V. stable polypropylene, highefficiency, airfoil-type fan blades directly driven byindependent motors, and positioned for vertical airdischarge. The fan guards are constructed ofheavy-gauge wire hot dipped galvanized coated steel.After construction the fan deck and cowl are hot dippedgalvanized prior to assembly. (Colour co-ordinated paintfinish is available as an extra). All blades aredynamically and statically balanced for vibration-freeoperation.

The fan motors are fully enclosed. The motor bearingsare double sealed and are permanently lubricated.

2.5 Refrigerant Circuits

Unit piping is ACR copper with brazed joints. The liquidline includes: a shut off valve with charging port,sightglass with moisture-indicator, thermal expansionvalve (direct acting, max-operating pressure), solenoidvalve, and filter drier. The entire suction line, the liquidline between the expansion valve and the cooler, areinsulated with flexible, closed-cell, foam insulation.

Compressor low, high and oil pressure transducers plusmanual high pressure cut-outs are located on thecompressor and system pipework. Transducers andcut-outs have Econoseal all weather electricalconnections.

2.6 Power and Control Panels

All controls and motor starting equipment necessary forfull unit operation are factory wired and function tested.Components are mounted on galvanised steel backplates, and enclosed in the relevant power, commoninput or control sections of the galvanised steelenclosure. Separate doors are provided for eachsection. All doors are hinged, lockable with door staysand are designed to IP55 weather protection. Enclosureand doors are finished in zinc phosphate pre-treatedbaked enamel coloured Desert Sand.

Four circuit units have a main and auxiliary power andcontrol panel mounted at each end of the unit.

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Each Power Section Contains: Partwind compressorstarting contactors, system fuses, fan contactors, fanmanual motor starters and control interface relays (CECompliant).

The Common Input Section Contains: Non-fuseddisconnect switch for customer single point powersupply connection. Transformer and wiring to allowcontrol voltage to be internally derived (CE Compliant).

The Control Section Contains: microprocessor board,power supply board and relay board. The relay boardcontains the control circuit serving compressorsolenoids, crankcase heaters and compressor and fancontactor coils.

ControlsThe microprocessor based control system is capable ofmulti-circuit control to maintain chil led liquidtemperature.

Compressor starting/stopping and loading/ unloadingdecisions are performed by the microprocessor tomaintain leaving water temperature.

These decisions are a function of temperature deviationfrom setpoint and rate of change of temperature.

The 40 character display (2 lines of 20 characters)allows the operator to display system operatingparameters as well as access programmed informationalready in memory.

The keypad is provided for programming and accessingsetpoints, pressures, temperatures, motor current,cut-outs, daily schedule, options and fault information.

Remote cycling, unloading and chil led watertemperature reset can be accomplished by voltage freecustomer contacts.

2.7 Options and Accessories

Single Point Power Supply Option - Per PanelCustomer single point power supply connection tofactory fitted terminal block. Internal wiring to fuses ineach power section (Not CE Compliant).

Multi Point Power Supply Terminal Block Option -Per CircuitCustomer supply connection to terminal block in powersection. A separate control supply is required to thecontrol circuit switch disconnect (Not CE Compliant).

Multi Point Power Supply Fuse Block Option - PerCircuitCustomer supply connection to terminal block in powersection. A separate control supply is required to thecontrol circuit switch disconnect (Not CE Compliant).

Cable Spreader BoxTo separate cores of large multi-core cable beforeconnection to non-fused disconnect switch/terminalblock when Single Point Power Supply is specified.

Multi-unit Sequence ControlA separate sequencing control centre to managesequencing control of up to eight chillers in parallelbased on mixed leaving liquid temperature (mountingand interconnection/wiring by others). (Cannot be fittedwhen a (BAS) Interface is fitted). See separate Yorkdocumentation.

Building Automation System (BAS) / EnergyManagement System (EMS) InterfaceProvides a means to reset the leaving chilled liquidtemperature from a BAS/EMS.

Consists of a factory mounted PCB to accept 4 to 20 mA,0 to 10 Vdc, or dry contact closure input from theBAS/EMS. (Cannot be fitted when a Multi-unitSequence Control is fitted).

Micro GatewayInterface to enable communication with building controlsystems using BACnet and MODBUS protocols. Seeseparate York documentation.

York Talk TranslatorProvides central communication with third party BMS formonitoring and control of all chillers in the system. Seeseparate York documentation.

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Condenser Coil Fin Protection

Gold Epoxy Coated Aluminium Condenser FinsOffers corrosion resistance in mild coastal locations(ASTM 287* Test, after 1500 hours 7% weight loss).

Copper Fin Condenser CoilsCondenser coils are constructed with copper fins(ASTM 287* Test, after 1500 hours 17% weight loss).

* ASTM 287 tests are based on Industrial / Coastallocations.

Wire Panel EnclosureConsists of welded-wire-mesh guards mounted on theexterior of the unit. Prevents unauthorized access, yetprovides free air flow.

Fan Deck Paint FinishPaint finish for fan cowl and fan deck in Desert Sand(RAL1019).

CoolerCoolers constructed in accordance with ASMEpressure code requirements are available. This optionincludes a single relief valve. Not available for singlerefrigerant circuit models.

Handed EvaporatorSimplifies unit layout and water connection enabling thechillers to be placed in the best orientation to suite thesite compound.

Double Thickness InsulationThe cooler is covered with 38 mm flexible, UV-stablecolour co-ordinated closed-cell, foam insulation foradded frost protection.

Cooler Flange KitFactory fitted flanges on cooler water connections toI.S.O. R2084-NP10. Available in Weld or VictaulicAdaptor.

Companion Flange KitWeld/Victaulic Adaptor flanges to match cooler flangekit ISO 7005-1 PN10 supplied loose for field installationby contractor. Includes all necessary nuts, bolts,gaskets, etc.

Flow SwitchSwitch with 1 inch IPS thread suitable for 10 bar g DWPand having gold contacts for low voltage/ current, toprotect unit from loss of water flow.A flow switch must befurnished with each unit for field installation bycontractor.

Added Compressor Capacity Step(Units with 6 and 8 cylinder compressors only)The compressor control system is programmed with anadditional capacity step to improve par t loadperformance. This option includes compressor liquidinjection cooling.

Low Ambient KitThis accessory is factory fitted and includes allnecessary components to allow chiller operation downto -18°C condenser intake air.

Sun Shield KitSun shield kit to provide shade / air gap around thepower and control panels to prevent overheating due tosolar gain on applications above 38°C ambient.

Unit Aesthetic PanelsNon acoustically lined infill panels manufactured frompowder painted galvanised steel to cover the ends of thecondenser coil on the opposite end to the control panel.

Acoustic EnclosureA four sided acoustically treated enclosure fitted aroundthe compressors and refrigerant pipework below thecondenser coils to reduce sound emissions.

Suction Service ValvesOne ball valve per compressor in the low pressure(suction) pipework.

Mechanical Gauge KitFactory fitted mechanical dial gauges for discharge,suction and oil pressure indication in addition totransducer pressure display.

Anti-Vibration MountsOpen spring isolator mounts with levelling screws andfixing down holes, supplied loose for field installation bycontractor.

Lifting Lug KitOne set of ISO Mk5 cam locs to enable safe and easyunit handling.

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2-4 035L02537-100 Rev. 0

2.8 Functional Description

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

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035L02537-100 Rev. 0 2-5

Condenser CoilRefrigerantCircuit No 2

Refrigerant Circuit No 2

TEV

Cooler

Compressor

Low pressure superheated vapour

High Pressuresuperheated vapour

High pressuresub-cooled liquid

Low pressuresub-cooledliquid/vapour

OptionalSuctionServiceValve

FilterDrier

SightGlass

FusiblePlug

Condenser CoilRefrigerantCircuit No 1

2.9 Nomenclature

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2-6 035L02537-100 Rev. 0

YAEP99XD9B50PA1 2 3 4 5 6 7 8 9 10 11 12 13

BASE PRODUCT TYPE COMPRESSOR SIZE COOLER CONDENSER FAN CODE REFRIGERANT POWER SUPPLY STARTING DESIGN LEVEL

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

A : Air Cooled 6 : Comp. 2/4 L, M, S, X A, B, C, D, F 7, 9 B : R407C 50 : 380/400/415 V P : Part Wind Change

E : Export Series 4, 5, C : R22 3 phase, 50 Hz C : Star Delta Closed or PIN Level

P : P Series 6, 7, O : Star Delta Open

Compressor 8, 9

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

HIGH LOW REFRIGERANT R-450 235 407CPsi g Psi g

Bar g Bar g31

380/400

-

503 3 342

265

265

355

355

135

135

113

113

2.2

8

16576

025L02600 000

STEP

1

2

689/725

689/725

24.1/25.4 LRA

235/227

235/227

200/196

200/196

5.7/5.8

PC84-T

PC84-T

AMPSAMPS KWKWMAXIMUMNOMINAL PW INRUSH

65 kg

65 kg

440

- -

VOLTS

VOLTS-PHASE-Hz

HzPHASE WIRE

MINMAX

MAXFUSESIZE

OPERATINGCHARGE

kg

MAXSYSTEM

AMPS@342v

AMPS MAX FUSE SIZE

VOLTAGE LIMIT AT TERMINALS

16.2

UNIT SUPPLY

UNIT CONTROL SUPPLY

SYSTEM COMPRESSOR

EACH FAN MOTOR

TOTAL No. OF MOTORS

CAPACITY CONTROL

COMMON SUPPLY INPUTMAX AMPS@342v

UNIT DESIGNWORKING PRESS.

Typical Unit Label

3 TRANSPORTATION, HANDLINGAND STORAGE

3.1 Delivery and Storage

To ensure consistent quality and maximum reliability,each YAEP is tested and inspected before leaving thefactory. Two and three refrigerant circuit units areshipped as completely assembled units containingrefrigerant under pressure. Four refrigerant circuit unitsare shipped in two parts.

If the chiller is to be put into storage, prior to installation,the following precautions should be observed:

Ensure that all openings, such as water connections,are securely capped.

Do not store where exposed to ambient airtemperatures exceeding 52°C .

The finned heat exchangers should be covered toprotect the fins from potential damage and corrosion,particularly where building work is in progress.

The unit should be stored in a location where there isminimal activity in order to limit the risk of accidentalphysical damage.

To prevent inadvertent operation of the pressure reliefdevices the unit must not be steam cleaned.

It is recommended that the control panel keys areremoved and deposited with a responsible personon-site.

It is recommended that the unit is periodically inspectedduring storage to ensure refrigerant pressures arepresent and to identify any damage that may haveoccurred and repair as necessary.

3.2 Inspection on Arrival at Site

Inspect the unit to ensure that all components have beendelivered and that no damage has occurred duringtransit. If any damage is evident, it should be noted onthe carrier’s freight bill and a claim entered inaccordance with the instructions given on the advicenote.

Major damage must immediately be reported to yourlocal York representative.

3.3 Moving the Chiller

Units are designed to be lifted using lifting lugs andcables. A spreader bar or frame 2.4 metres wide shouldbe used in order to prevent damage to the unit from thelifting chains:

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035L02537-100 Rev. 0 3-1

The unit must only be lifted by the base frameat the points provided.

Never move the unit on rollers, or lift the unitusing a fork-lift truck.

Care should be taken to avoid damaging thecondenser cooling fins when moving the unit.

Prior to moving the chiller ensure that the installation siteis suitable for installing the unit, and is capable ofsupporting the weight of the unit and all associatedservices.

3.4 Lifting Weights

For details of weights and weight distribution refer tosection 9.

3.5 Shipping Protection

When commissioning the unit remove the woodencondenser coil protection panels which are hung off thetop of the unit and secured by self-tapping bolts alongthe base. To prevent condenser coil damage Yorkrecommend that the condenser coil protection panelsare refitted after commissioning until the unit is ready foroperation.

Ensure the condenser coil protection panelsare removed prior to operation.

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3-2 035L02537-100 Rev. 0

LOCKING PIN

LUG

FLANGE

LIFTING HOLEIN BASE FRAME

CORRECT

LOCKING PIN

LUG

LIFTING HOLEIN BASE FRAME

FLANGE

INCORRECT

LOCKINGPIN

FLANGE

LUG

4 INSTALLATION

4.1 Location Requirements

To achieve optimum performance and trouble-freeservice, it is essential that the proposed installation sitemeets with the location and space requirements for themodel being installed. For dimensions, weight andspace requirements, including service access details,refer to Section 9.

It is important to ensure that the minimum serviceaccess space is maintained for cleaning andmaintenance purposes.

The unit should not be installed directly onflammable materials, such as woodenstructures or roof’s.

Outdoor Installations

Units can be installed at ground level, or on a suitablerooftop location. In both cases an adequate supply of airis required. Avoid locations where the sound output andair discharge from the unit may be objectionable.

The location should be selected for minimum sunexposure and away from boiler flues and other sourcesof airborne chemicals that could attack the condensercoils and steel parts of the unit.

If located in an area which is accessible to unauthorisedpersons, steps must be taken to prevent access to theunit by means of a protective fence. This will help toprevent the possibility of vandalism, accidental damage,or possible harm caused by unauthorised removal ofprotective guards or opening panels to expose rotatingor high voltage components.

For ground locations, the unit must be installed on asuitable flat and level concrete base that extends to fullysupport the two side channels of the unit base frame. Aone-piece concrete slab, with footings extending belowthe frost line is recommended.

On rooftop locations, choose a place with adequatestructural strength to safely support the entire operatingweight of the unit and service personnel.The unit can bemounted on a concrete slab, similar to ground floorlocations, or on steel channels of suitable strength. Toavoid noise and vibration transmission the unit shouldnot be secured to the building foundation. Channelsshould be spaced at the same centres as the vibrationmounting holes in the unit base frame and must be atleast 120 mm wide at the contact points. This will allowvibration isolators to be fitted if required.

Standard units are fitted with multi-blade cooling fans.Any ductwork or attenuators fitted to the unit must nothave a total static pressure resistance, at full unit airflow,exceeding the capability of the fans installed in the unit.Refer to Section 9.

Indoor Installations

The unit can be installed in an enclosed plant roomproviding the floor is level and of suitable strength tosupport the full operating weight of the unit and servicepersonnel. It is essential that there is adequateclearance for airflow to the unit. The discharge air fromthe top of the unit must be ducted away to preventrecirculation of air within the plant room. If commonducts are used for fans, non-return dampers must befitted to the outlet from each fan. Common ducts shouldnot be used on a four fan unit fitted with the optional lowambient kit as these units use fans in the reversedirection in some modes of operation.

The discharge ducting must be properly sized with atotal static pressure loss, together with any intake staticpressure loss, less than the available static pressurecapability for the type of fan fitted. For details refer to thedetails provided in “Outdoor Installations”and Section 9.

The discharge air duct usually rejects outside thebuilding through a louvre. The outlet must be positionedto prevent the air being drawn directly back into the airintake for the condenser coils as such recirculation willaffect unit performance.

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035L02537-100 Rev. 0 4-1

4.2 Location Clearances (refer to Section 9)

Clearances around the unit(s) are required for theunrestricted access of airflow onto the air-cooledcondenser coils and to prevent recirculation of warmdischarge air back onto the coils. If clearancedimensions are not maintained, airflow restriction orrecirculation will cause a loss of unit performance, anincrease in power consumption and may cause the unitto malfunction. Consideration should also be given tothe possibility of down draughts, caused by adjacentbuildings, which may cause recirculation or uneven unitairflow.

For locations where significant cross winds areexpected, such as exposed roof tops, an enclosure ofsolid or louvre type is recommended to prevent windturbulence interfering with the unit airflow.

When units are installed in an enclosure, the enclosureheight should not exceed the height of the unit. If theenclosure is of louvred construction the samerequirement of static pressure loss applies as for ductsand attenuators stated in Section 9.

Where accumulation of snow is likely, additional heightmust be provided under the unit to ensure normal airflowto the unit.

The clearance dimensions given arenecessary to maintain good airflow andensure correct unit operation. It is alsonecessary to consider access requirementsfor safe operation and maintenance of the unitand control panel (600 mm wide doors). Localhealth and safety regulations, or practicalconsiderations for service replacement oflarge components, may require largerclearances than those given below.

Dimension to louvred wall assumes 60%minimum free area. For louvres of less freearea use dimensions for solid walls.

Pressure drop through louvred walls must notexceed available external static pressurecapability for the type of fans fitted.

4.3 Vibration Isolator Installation & Dimensions

When ordered, an optional set of spring type vibrationisolators will be supplied loose with each unit.

Using the Isolator tables (in Section 9), identifyeach mount and its correct location on the unit.

Place each mount in its correct position and lowerthe unit carefully onto the mounts ensuring thelocating pin on top of each mount engages in themounting holes in the unit base frame.

Transfer the unit weight evenly to the springs byturning the mount adjusting nuts (located justbelow the top plate of the mount)counter-clockwise to raise and clockwise to lower.This should be done two turns at a time until the topplates of all mounts are between 6 mm and 13 mmclear of top of their housing and the unit base islevel.

4.4 Pipework Connection

General Requirements

The following piping recommendations are intended toensure satisfactory operation of the unit(s). Failure tofollow these recommendations could cause damage tothe unit, or loss of performance, and may invalidate thewarranty.

The maximum flow rate and pressure drop forthe cooler must not be exceeded at any time.Refer to Section 9 for details.

The water must enter the heat exchanger(s) by theinlet connection. The inlet connection for the cooleris at the same end as the refrigerant pipeworkconnections.

A flow switch must be installed in the customerpipework at the outlet of the heat exchanger(s) asshown in the arrangement diagrams, and wiredback to the control panel using screened cable. Fordetails refer to “Electrical Connection”. This is toprevent damage to the heat exchanger(s) causedby the unit operating without adequate liquid flow.

The flow switch used must have gold platedcontacts for low voltage/current operation. Paddletype flow switches suitable for 10 barg workingpressure and having a 1" N.P.T. connection can beobtained from York as an accessory for the unit.Alternatively a differential pressure switch sitedacross an orifice plate may be used, preferably ofthe high/low limit type.

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4-2 035L02537-100 Rev. 0

The liquid pump(s) installed in the pipeworksystem(s) should discharge directly into the unitheat exchanger section of the system. Thepump(s) may be controlled external to the unit - butan override must be wired to the control panel sothat the unit can start the pump in the event that theliquid or ambient temperature falls below theminimum setting. This ensures that the optionalheater mat and low temperature pump circulation isenabled. When the unit is not operational, powersupplies should be maintained to the unit to allowthe automatic frost protection to operate. Inaddition, the power is used to ensure the automaticpumpdown system is functioning. For details referto “Electrical Connection”.

Pipework and fitt ings must be separatelysupported to prevent any loading on the heatexchanger(s) . Flexible connect ions arerecommended which wi l l a lso minimisetransmission of vibrations to the building. Flexibleconnections must be used if the unit is mounted onanti-vibration mounts as some movement of theunit can be expected in normal operation.

Pipework and fittings immediately adjacent to theheat exchangers should be readily de-mountableto enable cleaning prior to operation, and tofacilitate visual inspection of the exchangernozzles.

Each heat exchanger must be protected by astrainer, preferably of 30 mesh, fitted as close aspossible to the liquid inlet connection, and providedwith a means of local isolation.

The heat exchanger(s) must not be exposed toflushing velocities or debris released duringflushing. It is recommended that a suitably sizedby-pass and valve arrangement is installed to allowflushing of the pipework system. The by-pass canbe used during maintenance to isolate the heatexchanger without disrupting flow to other units.

Thermometer and pressure gauge connectionsshould be provided on the inlet and outletconnections of each heat exchanger.

Drain and air vent connections should be providedat all low and high points in the pipework to permitdrainage of the system, and to vent any air in thepipes.

Liquid systems at risk of freezing, due to lowambient temperatures, should be protected usinginsulation and heater tape and/or a suitable glycolsolution. The liquid pump(s) must also be used toensure liquid is circulated when the ambienttemperature approaches freezing point. Insulationshould also be installed around the heat exchangernozzles.

Heater tape of 21 watts per metre under theinsulat ion is recommended, suppl iedindependently and controlled by an ambienttemperature thermostat set to switch on at 3°Cabove the freezing temperature of the liquid.

The chilled liquid circulation pump must becontrolled to ensure that when the liquidtemperature falls within 2 or 3°C of freezing thepump will start.

Any debris left in the water pipework betweenthe strainer and heat exchanger could causeserious damage to the tubes in the heatexchanger and must be avoided. Theinstaller/user must also ensure that the qualityof the water in circulation is adequate, withoutany dissolved gasses which can causeoxidation of steel parts within the heatexchanger(s).

4.5 Water Treatment

The unit performance given in the Design Guide isbased on a fouling factor of 0.044 m2 °C/kW (0.00025ft2hr°F/Btu). Dirt, scale, grease and certain types ofwater treatment will adversely affect the heat exchangersurfaces and therefore unit performance.Foreign matterin the water system(s) can increase the heat exchangerpressure drop, reducing the flow rate and causingpotential damage to the heat exchanger tubes.

Aerated, brackish or salt water is not recommended foruse in the water system(s). York recommend that awater treatment specialist is consulted to determine thatthe proposed water composition will not affect theevaporator materials of carbon steel and copper.The pHvalue of the water flowing through the heat exchangersmust be kept between 7 and 8.5.

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035L02537-100 Rev. 0 4-3

4.6 Pipework Arrangement

The following are suggested pipework arrangements forsingle unit installations. For multiple unit installations,each unit should be piped as shown.

Recommendations of the Building ServicesResearch Association

Chilled Water System - 2 Circuit Units

4.7 Connection Types & Sizes

For connection and nozzle sizes relevant to individualunits, refer to the product drawings in Section 9.

Cooler Connections

Standard chilled liquid connections on all coolers are ofthe Victaulic Groove type.

Standard Victaulic

Optionally, one of two types of flanges may be fitteddepending on the customer or local Pressure VesselCode requirements. These are Vic-Adapter flanges,normally supplied loose, or weld flanges which may besupplied loose or ready fitted. Vic-Adapter and weldflange dimensions are to ISO R2084 NP10. Dimensionsare as follows:

Optional Flanges

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4-4 035L02537-100 Rev. 0

Chilled Water System - Four Circuit Units

Nom, Size OD T A B C

6" (150 mm) 168,3 7,1-8,0 16 9,5 164

8" (200 mm) 219,1 7,9-8,2 19 11 214

Nom. Size PCD T Bolts

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

8" (200 mm) 295 24 8 x M 20

WELD FLANGE VIC-ADAPTOR FLANGE

4.8 Refrigerant Relief Valve Piping

Coolers are protected against internal refrigerantoverpressure and fire by refrigerant relief valves. Thepressure relief valve is set at design pressure of thesystem and has discharge capacity required by relevantstandard.For coolers, a pressure relief valve is mountedon each of the main refrigerant lines connecting thecooler to the compressors.

York fit a piece of pipe to each valve and direct it so thatwhen the valve is activated the release of high pressuregas and liquid cannot be a danger or cause injury. Forindoor installations pressure relief valves should bepiped to the exterior of the building.

The size of any pipework attached to a relief valve mustbe of sufficient diameter so as not to cause resistance tothe operation of the valve.Unless otherwise specified bylocal regulations, the minimum allowable internaldiameter depends on the length of pipe required and isgiven by the following formula:

D5 = 1.447 x L

Where:D = minimum pipe internal diameter in centimetresL = length of pipe in metres

Precautions should be taken to ensure the exit of reliefvalves/vent pipe remain clear of obstructions at alltimes.

4.9 Ductwork Connection

General Requirements

The following ductwork recommendations are intendedto ensure satisfactory operation of the unit(s). Failure tofollow these recommendations could cause damage tothe unit, or loss of performance, and may invalidate thewarranty.

When ducting is to be fitted to the fan discharge it isrecommended that the duct should be the samecross sectional area as the fan outlet and straightfor at least one metre in order to obtain static regainfrom the fan.

Ductwork should be suspended with flexiblehangers to prevent noise and vibration beingtransmitted to the structure. A flexible joint is alsorecommended between the duct attached to thefan and the next section for the same reason.Flexible connectors should not be allowed toconcertina.

The unit is not designed to take structural loading.No significant amount of weight should be allowedto rest on the fan outlet flange, deck assemblies orcondenser coil module(s). No more than one metreof light construction ductwork should be supportedby the unit. Where cross winds may occur, anyductwork must be supported to prevent sideloading on the unit. Fan discharge ducts should besecured together with tie rods to prevent excessivemovement.

If the ducts from two or more fans are to becombined into a common duct, back-flow dampersshould be fitted in the individual fan ducts. This willprevent recirculation of air when only one of thefans is running. Common ducts should not be usedon a four fan unit fitted with the optional low ambientkit as these units use fans in the reverse direction insome modes of operation.

Units are supplied with outlet side guards for safetyand to prevent damage to the fan blades. If theseguards are removed to fit ductwork, adequatealternative precautions must be taken to ensurepersons cannot be harmed or put at risk fromrotating fan blades.

Connection Details and Dimensions

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035L02537-100 Rev. 0 4-5

45°

45°

MountingHoles 8mm

Top Flange Guard

150 mm

97

0m

m

50m

m

Fan Code 7

45°

45°

MountingHoles 10 mm

Top Flange Guard

175 mm

98

4m

m

50m

m

Fan Code 9

90

0m

m

92

0m

m

4.10 Electrical Connection

The following connection recommendations areintended to ensure safe and satisfactory operation of theunit(s). Failure to follow these recommendations couldcause harm to persons, or damage to the unit, and mayinvalidate the warranty.

No additional controls (relays, etc.) shouldbe mounted in any section of the controlpanel. Power and control wiring notconnected to the Control Panel should notbe run through the Control Panel. If theseprecautions are not followed it could leadto a risk of electrocution. In addition,electrical noise could cause malfunctions,or damage the unit and its controls.

After connection do not switch on mainspower to the unit . Some internalcomponents are live as soon as mains isswitched on, and this must only be done byauthorised persons.

The unit OFF/ON switch on the front of the controlpanel has been sealed in the OFF position at thefactory. This seal must remain in place preventingrunning of the unit until commissioned byauthorised personnel. If the seal has beenremoved before commissioning then it must bereported to the Basildon Factory Quality Managerotherwise warranty may be invalidated.

4.11 Power Wiring

YAEP units require an electrical power supplyof 380 V, 400 V or 415 V, 3Ø, 50 HzMinimum allowable voltage 342 V.Maximum allowable voltage 440 V.

All electrical wiring should be carried out in accordancewith local regulations. Route properly sized cables(based on installation conditions and currents given inelectrical data tables) to site drilled holes in the ControlPanel gland plate as specified below.

In accordance with EN 60204 it is the responsibility ofthe user to install overcurrent protection devicesbetween the supply conductors and the customer inputsupply terminals on the unit.

To ensure that no eddy currents are set up in the metalgland plate the cables forming each 3 phase powersupply must enter via the same hole in the gland plate. Ifseparate entries for each cable forming the 3 phasesupplies are used, the metal gland plate must bereplaced by a non-metallic gland plate, with due regardgiven to sealing the panel to IP55.

All sources of supply to the unit must betaken via a common point of isolation (notsupplied by York).

Single Point Power Supply - Disconnect Switch (CE)or Terminal Block Option (Non CE)(Refer to Power Supply Connection Diagram)

Each panel (master and auxiliary, if fitted) requires a 3phase separately fused supply plus earth to beconnected to the common input section of the powerand control panel.

The cables should enter the common input section viathe site drilled gland plate on the bottom of the section.Connect each phase to the disconnect switch/terminalblock located in the common input section using the lugsizes detailed in Section 9.

Connect the earth wire to the main protective earthterminal located in the common input section of thecontrol panel using an M10 lug.

Multi Point Power Supply Option (Non CE)(Refer to Power Supply Connection Diagram)

Each refrigerant system requires a 3 phase separatelyfused supply plus earth to be connected to each powersection of the power and control panel. A separate fused2 phase control transformer supply plus earth isrequired for the main and auxiliary (4 Circuit Units)panels.

Each set of supply cables per system should enter viathe site drilled gland plate in the bottom of the applicablepower section. The supplies can then be routed to theirrespective input terminals on the compressorcontactors. Connect each phase to the compressorcontactors using the lug sizes detailed in Section 9.

Connect the earth wire to the main protective earthterminal of the applicable power section, using an M4lug.

Connect the two phase control transformer supply to theinput of the emergency stop/isolation device in theapplicable common input section with bare wire ends ofmaximum cable size 4 mm. Also connect an earth wireto the protective earth terminal using an M4 lug.

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4-6 035L02537-100 Rev. 0

Units with Optional Cable Spreader BoxUnder the common input section of the control panel is acable spreader box which should be used to separatethe cores of large multi-core cable prior to connection tothe terminal block/disconnect switch.

Remote Emergency Stop Device

If required, a remote emergency stop device can bewired to terminals 3 and 4 in the main and auxiliarycontrol panels (located in the common input section).The existing link must first be removed. This deviceshould be rated at 10 amps, 230V, AC-15. Terminals 3and 4 are in a circuit protected by a 10 amp class gGfuse.

4.12 Control Section - Output Signals(Refer to Control Connection Diagram)

All wiring to the control section (relay board) outputcontacts requires a supply, maximum 254 V, provided bythe customer. The customer must take particular carederiving the supplies for the output terminals with regardto a common point of isolation.These circuits when usedmust be fed via the common point of isolation so that thevoltage is removed when the common point of isolationto the unit is opened.

In accordance with EN 60204 it is recommended thatthe customer wiring to these terminals uses orangewires. This will ensure that circuits not switched off bythe YAEP supply disconnect ing device aredistinguished by colour, so that they can easily beidentified as live even when the YAEP disconnectingdevice is off.

The YAEP output contacts are rated at 125 VA. Allinductive devices (relays) switched by the YAEP outputcontacts must have their coil suppressed usingstandard RC suppressors.

Chilled Liquid Pump Starter

Terminals 33 and 34 in the main panel only close to startchilled liquid pump. This contact can be used as amaster start/stop for the pump in conjunction with thedaily start/stop schedule. If no schedule is set, and thecustomer has master control of the pump, the YAEPcontact must be used to override the customer masterstart/stop so that the York contact can start the pump inthe event of a low temperature liquid condition.

Run Contact

Terminals 35 and 36 close to indicate that a system isrunning.

Alarm Contacts

Each system has a voltage-free change over contactwhich will operate to signal an alarm condition whenevera system locks out, or there is a power failure. To obtainsystem alarm signal, connect alarm circuit to volt freeterminals as follows:

2 Circuit Units:

System 1:Terminals 31 and 32 (close on alarm) or 30 and 32 (openon alarm).

System 2:Terminals 38 and 39 (close on alarm) or 37 and 39 (openon alarm).

4 Circuit Units:

Main Panel - System 1:Terminals 31 and 32 (close on alarm) or 30 and 32 (openon alarm).

Main Panel - System 2:Terminals 38 and 39 (close on alarm) or 37 and 39(openon alarm).

Auxiliary Panel - System 3:Terminals 31 and 32 (close on alarm) or 30 and 32 (openon alarm).

Auxiliary Panel - System 4:Terminals 38 and 39 (close on alarm) or 37 and 39 (openon alarm).

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035L02537-100 Rev. 0 4-7

4.13 Control Section - Input Connections(Refer to Control Connection Diagram)

All wiring to the input connections (relay board) isnominal 30 Vdc and must be run in screened cable, withthe screen earthed at the panel end only. Run screenedcable separately from mains cable to avoid electricalnoise pick-up.

The voltage free contacts must be suitable for 30 Vdc(gold contacts recommended). If the voltage freecontacts form part of a relay or contactor, the coil of thedevice must be suppressed using a standard RCsuppressor. The above precautions must be taken toavoid electrical noise which could cause a malfunctionor damage to the unit and its controls.

Flow Switch(es)

A chilled liquid flow switch (per cooler) of suitable typemust be connected to terminals 10 and 13 to provideadequate protection against loss of liquid flow.

Remote Run/Stop

Remove the link from main panel terminals 11 and 14(system 1) and terminals 12 and 15 (system 2) andconnect remote switch(es) to provide system remoterun/stop control if required.

Auxiliary Panel (3 and 4 Circuit units):Remove the link from terminals 11 and 14 (System 3)and terminals 12 and 15 (System 4) and connect remoteswitch(es) to provide system remote run/stop control ifrequired.

Remote Print

Closure of suitable contacts connected to terminals 18and 13 will cause a hard copy printout of OperatingData/Fault History to be made if an optional printer isconnected to the RS 232 port.

Remote Lead/Lag

2 Circuit UnitsIf manual lead/lag control is required, closure of suitablecontacts connected to terminals 13 and 19 in the MainPanel will cause System 2 to operate as the lead systemof the main group.Open contacts will cause System 1 tobe in lead.

4 Circuit UnitsClosure of a suitable contact connected to terminals 13and 19 in the auxiliary panel will cause System 4 tooperate as the lead system of the slave group. Opencontact will cause System 3 to be in the lead.

Remote Set Point Offset

Timed closure of suitable contacts connected toterminals 13 and 17 (PWM contacts) will give remoteoffset function of the chilled liquid set point if required(terminals located in main control panel). This functioncannot be used if “Remote Unload” function is required.

Remote Unloading

The Micro Based Control System is capable of remoteunloading (or pull-down demand limiting) in two steps.The first step of unloading is achieved by closingsuitable contacts connected to terminals 16 and 13(terminals located in main control panel). The secondstep of unloading is achieved by closing suitablecontacts connected to terminals 17 and 13.

The first step contacts must be closed beforethe second step contacts are closed.

For details of compressor load steps given by thesecontacts, refer to the Micro Based Control SystemManual. This function cannot be used if “Remote Setpoint Offset” is required.

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4-8 035L02537-100 Rev. 0

(02/04)

035L02537-100 Rev. 0 4-9

1 PS 2 PS

QCSITB

3 50 Hz 380/400 V

PE

PE

U V W

L1 L2 L3

3 4

QRESB

Single Point Power Supply (Non CE) Optionommon terminal block (QCSITB) with

internal power distribution to fuses,One supply per panel to a c

control supply to non-fuseddisconnect switch (QCSD/ESD) derived internally.

CIS

1 PS 2 PS

QCSISD

3 50 Hz 380/400 V

PE

PE

U V W

L1 L2 L3

3 4

QRESB

Standard Single Point Power Supply (CE)

fuses,One supply per panel to master non-fused disconnect switch(XCSISD) with internal power distribution to control supplyto non-fused disconnect switch (QCSD/ESD) derived internally.

CIS COMMON INPUT SECTION

PE PROTECTIVE EARTHF FUSE

PS POWER SECTIONQCSD/ESD CONTROL CIRCUIT SWITCH DISCONNECT

/ EMERGENCY STOP DEVICEQCSISD COMMON SUPPLY INPUT SWITCH DISCONNECTQCSITB COMMON SUPPLY INPUT TERMINAL BLOCKQRESB REMOTE EMERGENCY STOP BUTTON

ARB RELAY BOARD

CIS

AMB MICROPROCESSOR BOARD

CS CONTROL SECTION

1 PS 2 PS

3 50Hz380/400V

PE

PE

U V W

L1 L2 L3

3 50Hz380/400V

U

PE

PE

V W

L3L2L1

CompressorContactor

PE

380/400V2 50Hz

PEL3L1

QCSD/ESD

34

QRESB

Multi Point Power Supply (Non CE) OptionsOne supply per refrigerant circuit to fuse/terminal blockwith separate control supply to non-fused disconnectswitch (QCSD/ESD).

CIS

CS

AMB ARB

AP

B

APB POWER SUPPLY BOARD

CompressorContactor

F F F F F F

F F F F F F

Common InputSection

Non-FusedDisconnect Switchor Terminal Block

ProtectiveEarth

Control Circuit SwitchDisconnect / Emergency

Stop Device

DESIGNATION DESCRIPTION

System Fuses,or Terminal Block

Power Section

ProtectiveEarth

ControlSection

PowerSection 2

CommonInput

Section

PowerSection 1

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

PowerSection 2

ControlSection

CommonInput

Section

PowerSection 1

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

YAEP 08L-09L

PowerSection 1

ControlSection

CommonInput

Section

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

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AMB

APB

ARB

13 10 11 14 12 15 16 13 17 18 1310

Unit Run Signal

32

31

30

39

37

35

38

Chilled Liquid Pump Start

Close on Alarm

SystemNo. 1 / 3

Open on Alarm

36

33

34

Close on Alarm

SystemNo. 2 / 4

Open on Alarm

Note 1

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

System No. 1 / 3 Remote Start/Stop

System No. 2 / 4 Remote Start/Stop

Remote Setpoint Reset (Main Panel only)

Remote Unload

Chilled Liquid Flow Switch

Remote Print (Main Panel only)

Remote Lead/Lag

Mixed WaterTemperature

(4 Circuit Units Only)

BLA

CK

WH

ITE

MAINPANEL

AUXILIARYPANEL

Communication Link(4 Circuit Units Only)

Communications Link Cableto be field run andconnected to Main Panel TB7during installation

CIS COMMON INPUT SECTIONPS POWER SECTION

ARB RELAY BOARD

AMB MICROPROCESSOR BOARD

CS CONTROL SECTION

APB POWER SUPPLY BOARD

DESIGNATION DESCRIPTION

Control Section

ControlSection

PowerSection 2

CommonInput

Section

PowerSection 1

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

PowerSection 2

ControlSection

CommonInput

Section

PowerSection 1

YAEP 88X-99X & 8888X-9999XYAEP 08L-09L

PowerSection 1

ControlSection

CommonInput

Section

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

5 COMMISSIONING

5.1 Preparation

Commissioning of this unit should only becarried out by York authorised personnel.

The Control System Manual must be read in conjunctionwith this section.

The unit switch on the front of the control panel has beensealed in the off position at the factory. This seal mustremain in place preventing running ofthe uni t unt i l commissioned byauthorised personnel. If the seal hasbeen removed before commissioningthen it must be reported to the BasildonFactory Quality Manager otherwise thewarranty may be invalidated.

Preparation - Power Off

The following checks should be madewith the customer supply/supplies to the unit switchedoff.

Inspection: Inspect unit for installation damage. If foundtake action and/or repair as appropriate.

Refrigerant charge: Units are normally shipped asstandard with a full refrigerant operating charge. Checkthat refrigerant pressure is present in both systems andthat no leaks are apparent. If no pressure is present aleak test must be undertaken, the leak(s) located andrepaired. Repaired systems and units supplied with anitrogen holding charge must be evacuated with asuitable vacuum pump/recovery unit as appropriate tobelow 100 microns. Check the unit data plate or unitlabels for the type of refrigerant intended for use with theunit and break vacuum from bottle connection for liquidand raise system pressure to 4.6 barg.

Charging from the liquid connection on thecylinder is necessary on R407C to ensure thecorrect refrigerant mix is maintained.

Do not liquid charge with static water in any of the heatexchangers. Care must also be taken to liquid chargeslowly to avoid excessive thermal stress at the chargingpoint. Once the vacuum is broken, charge into thecondenser coils with the full operating charge as givenon the unit data plate and the Physical Data section ofthis manual.

Valves: Open the compressor suction valves and theliquid line service valves on both systems (CCW).

Compressor oil:Compressor lubrication systems mustbe primed prior to first time start-up. Only the YORKType H oil must be used as given by unit dataplate/labels and is as follows for YAEP standard units:

To prime each compressor - connect a York hand oilpump (part no.470-10654-000) to the ¼" compressor oilpriming valve with a length of clean hose or copper line,but do not tighten the flare nut. Using clean oil of thecorrect type, pump oil until all air has been purged fromthe hose then tighten the nut. Stroke the oil pump 10times (delivering approximately 1,5 litres) to prime theoil system. The oil level should be between the middle ofthe lower and middle of the upper sight glasses. If it isnecessary to add oil, continue to stroke the pump untilthe correct level is achieved.

Fans: Check that all fans are free to rotate and are notdamaged. Ensure blades are at the same height whenrotated. Ensure fan guard is securely fixed.

Isolation/protection:Verify that all sources of electricalsupply to the unit are taken from a single point ofisolation. For units not fitted with a switch disconnectorfuse check that the maximum recommended fuse sizesgiven in the Technical Data section have not beenexceeded.

Control panel: Check panel to see that it is free offoreign materials (wire, metal chips, etc.) and clean out ifrequired.

Power connections:Check the customer power cablesare connected to the unit incoming terminals. Ensurethat connections of power cables within the panel tocontactors, terminal blocks or switch disconnector, andexternal connection to compressors are tight.

Earthing: Verify that the units protective terminal(s) areproperly connected to a suitable earthing point. Ensurethat all unit internal earth connections are tight.

Overloads: Ensure that the fan overloads settingcorrespond to the current drawn value shown on the unitdata plate for the type of fan fitted.

Supply voltage: Verify that the site voltage supplycorresponds to the unit requirement and is within thelimits given on the unit data plate / Operating Limitationssection.

Control Transformer: The 3-wire control transformer ismounted on the unit framework below the control panel.

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It is important to check that the correct primary tappinghas been used:

With the supply to the unit isolated remove the lid tothe transformer box. Check that the tapping usedconforms to the site supply voltage:

50 Hertz ModelsThe two tappings are 342 - 424 V and 360 - 440 V.

60 Hertz ModelsThe two tappings are 342 - 418 V and 414 - 506 V.

Switch Settings: Ensure that the black handled unitswitch on the display door and the micro board systemswitches S2 and S3 in the logic section are set to "0"(OFF). Set the red handled control circuit switchdisconnector/emergency stop device on the lowercentre section door to "1" (ON). For units fitted withswitch disconnector fuse devices the two power sectiondoors must be closed and the devices set to "1" (ON).The customers disconnection devices can now be set toON.

The machine is now live!

Crankcase heaters: Verify the compressor crankcaseheaters are energised. If the ambient temperature isabove 30oC the compressor crankcase heaters must beon for at least 24 HOURS prior to start-up to ensure allrefrigerant liquid is driven out of the oil. If the ambienttemperature is below 30oC then allow 8 hours.

Water system(s): Verify that the chilled water systemhas been instal led correct ly, and has beencommissioned with the correct direction of water flowthrough the cooler. Inlet should be at the refrigerantpipework connection end of the cooler. Purge air fromthe top of the cooler using the plugged air vent mountedon the top of the cooler body.

Flow switch(es): Verify a chilled water flow switch iscorrectly fitted in the customer’s pipework on the cooleroutlet, and wired into the control panel logic sectionOpto-isolator board terminals 10 and 13 using screenedcable.

Temperature sensor(s): Ensure the leaving watertemperature sensor is coated with heat conductivecompound (part no. 013-00890-000) and is inserted inthe bottom of the water outlet sensor pocket of thecooler. This sensor also acts as the freeze protectionthermostat sensor and must always be in the waterOUTLET sensor pocket.

Mixed leaving temperature sensor (4 Circuit Units)

A pocket is provided for field mounting in the customersmixed pipework. The pocket has a 0.5" NPT thread andis 6" long.The mixed leaving sensor is connected to plugJ17 on the main micro board and the 10m lead is coiledup waiting field running to the location of the fieldmounted pocket provided.

A communication link cable is wired into the auxiliarypanel micro board TB7 to be field run and connected tothe main panel micro board TB7 (refer to ControlConnections in Section 4). Run cable away from otherpower cables.

Control supply: Verify the control centre display isilluminated.

HP cut-outs (on units with hand reset):Check that thehand reset mechanical high pressure cut-outs mountedon the unit are reset.

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Programmed options: Verify that the options factoryprogrammed into the Microprocessor Control Centreare in accordance with the customers orderrequirements by pressing the `Options’ key on thekeypad and reading the settings from the display. Referalso to the Micro Based Control System Manual fornotes and explanation of messages.

Programmed settings: Ensure the system cut-out andoperational settings are in accordance with theinstructions given in the Microprocessor Control CentreManual and with operational requirements by pressingthe ‘Program’ key. The chilled liquid temperature controlsettings need to be set according to the unit model andrequired operating conditions. The following table givessuggested settings.

Date & time: Programme the date and time by firstensur ing that the CLK jumper J18 on themicroprocessor board is in the ON position (top twopins). Then press the ‘Clock Set Time’ key and set thedate and time (see Microprocessor Control CentreManual).

Start/Stop schedule: Programme the daily and holidaystart/stop by pressing the ‘Set Schedule/Holiday’ key(see Microprocessor Control Centre Manual).

Set-point and Remote offset: Set the required leavingchilled liquid temperature set-point and control range(see table above for recommended control ranges). Ifremote temperature reset (offset) is to be used, themaximum reset must be programmed by pressing the‘Remote Reset Temp’. key (see Microprocessor ControlCentre Manual).

5.2 First Time Start-up

When reading the following text rememberthat for systems 3 and 4 a communicationdelay exists with the main panel ,communicat ions taking place atapproximately 10 second intervals. Thus thevalues displayed for systems 3 and 4 are notin real time and may be up to 10 seconds old.

During the commissioning period there shouldbe sufficient heat load to run the YAEP unitunder stable full load operation to enable theunit controls, and system operation to be setup correctly and a commissioning log taken.Read the following section in conjunction withthe Micro Based Control System Manual, thenproceed step by step as follows:

Interlocks: Verify that water is flowing through thecooler and that heat load is present (if heat recoverycondenser(s) are fitted, do not allow water flow throughthe condensers at this stage). Ensure that any remoterun interlocks are in the run position and that the runschedule requires the unit to run or is overridden.

System switches:Place the ‘Sys 1’and ‘Sys 2’switcheson the microprocessor board to the ON position - seeoperating sequence in the Microprocessor ControlCentre Manual.

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Unit Capacity Steps∆t through cooler at fullload / °C

4 7 4 7 4 7

Rate Control temp. /°CRate Sensitivity °C / minControl Range / °CAnti-Recycle timer / sec

Unit Capacity Steps∆t through cooler at fullload / °C

4 7 4 7

Rate Control temp. /°CRate Sensitivity °C / minControl Range / °CAnti-Recycle timer / sec

10, 11, 12 16

600

600

4 6 8

Start-up: Remove the locking device from the unitswitch which prevents unauthorised starting of the unitbefore commissioning. Press the ‘Status’ key, then turnthe unit switch to the "1" position to start the unit (theremay be a few seconds delay before the first compressorstarts because of the anti-recycle timer).Be ready wheneach compressor star ts to switch the unit offimmediately if any unusual noises or other adverseconditions develop. Also refer to the Micro BasedControl System Manual for the normal operatingsequence of the YAEP from start-up.

Oil pressure: When a compressor starts, press therelevant ‘System Pressures’ key and verify that oildifferential pressure is developed immediately. If oilpressure does not develop the automatic controls willshut down the compressor (see the Micro Based ControlSystem Manual for the flow chart of the automatic oilpressure safety system). Under no circumstancesshould a restart attempt be made on a compressorwhich does not develop oil pressure immediately.Switchthe unit switch to the "0" position.

Refrigerant flow: When a compressor starts a flow ofliquid refrigerant will be seen in the liquid line sight glass.After several minutes operation, and providing a fullcharge of refrigerant is in the system, the bubbles willdisappear and be replaced by a solid column of liquid.

Fan rotation: As the discharge pressure rises thecondenser fans will start as required. Verify that the fanrotation is correct and that airflow is in the upwarddirection.

If fan operation is not in the correct direction, stop theunit, switch off the main customer disconnecting deviceto the unit, and reverse (or arrange to have reversed) twoof the three main supply phases.

General operation: Check the system operatingparameters are normal by selecting the variousreadouts of pressure, temperature, etc.

Superheat: Check the compressor suction superheatvalue only when pull down is complete and steady fullload operation has been established. It is also importantthat there are no bubbles showing in the liquid line sightglass. Suction line temperature should be measured onthe copper line about 150 mm before the compressorservice valve. Suction pressure should be measured atthe compressor service valve with a suitably calibratedgauge. Suction superheat at the compressor should bebetween 5oC and 6oC for R22 and between 4oC and 5oCrelative to the `dew’ temperature for R407C.

Thermal expansion valve adjustment: Thermalexpansion valves are factory set and should not needadjustment. If the superheat is out of range, however, theexpansion valve adjusting screw should be adjusted nomore than 1 turn at a time (`in’ to increase superheat,`out’ to decrease superheat), allowing at least 10minutes for the valve to stabilise before rechecking thevalue of superheat.

Subcooling: Check the amount of subcooling leavingthe condenser coils only when pull down is completeand steady full load operation has been established. It isalso important that all fans are running, giving full airflowacross the condenser coils. Liquid line temperatureshould be measured on the copper line between theliquid line service valve and the filter/drier. Liquidpressure should be measured at the liquid line servicevalve with a suitably calibrated gauge.Liquid subcoolingshould be between 7oC and 10oC for R22 and between6oC and 8oC relative to the ‘bubble’ temperature forR407C. If necessary, add or remove refrigerant to obtainthe correct level of subcooling. Do not overcharge theunit.

Acoustic compressor enclosure option: To preventdamage to panels and to ease commissioning the twoside and front acoustically lined panels are shippedstrapped to the condenser frame.

After commissioning, the panels require mounting inposition by fixing the top of the side panels into locatingtangs and securing the bottom of the side panels withthe self-tapping bolts provided. The front panel issecured with the self-tapping bolts provided.

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6 UNIT OPERATION

6.1 General Description

YAEP packaged chillers are designed to workindependently, or in conjunction with other equipmentvia a York ISN building management system or otherautomated control system. When operating, the unitcontrols monitor the chilled liquid system temperature atthe unit and takes appropriate action to maintain thistemperature within desired limits.This action will involverunning one or both compressors at a suitable load stepto match the cooling effect of the refrigerating systemsto the heat load on the liquid system. The heat removedfrom the chilled liquid is then rejected from the air cooledcondenser coils, or can optionally be recovered into ahot water system.

The following sections give an overview of the operationof a YAEP unit. For detailed information, referenceshould be made to the Microprocessor Control SystemManual for this product.

6.2 Start-up

Ensure the mains power to the unit and controls is ON,the microprocessor 'Sys 1', 'Sys 2', 'Sys 3' and 'Sys 4'circuit board switches are in the 'ON' position, allrefr igerant serv ice stop valves are open(anti-clockwise), and the chilled liquid flow has beenestablished (unless the unit chilled liquid pump startcontrol is being used, in which case just ensure thepump supply is on)

Press the ‘STATUS’ key on the keypad and then switchtheunit switch on the control section door to the '1' (ON)position.

The controller will perform a pre-check to ensure that thedaily/holiday schedule and any remote interlocks willallow the unit to run, that all safety cut-outs are satisfiedand that cooling load is required (i.e. that the chilledliquid temperature is outside the set limits). Anyproblems encountered by the pre-check will bedisplayed if present. If no problems are present andcooling duty is required `START SEQUENCE’ will bedisplayed and after a short delay the lead compressorwill start on its first capacity step.

The display will show the anti-coincidence timer statusfor 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 fullyautomatic. After an initial period at minimum capacitystep on the lead compressor, the control system willadjust the unit load step depending on the chilled liquidtemperature and rate of temperature change. If highheat load is present, the controller will increase thenumber of active cylinders on the lead compressorand/or star t-up the lag compressor (`STARTSEQUENCE’ will be displayed for the lag compressor,followed by the same sequence as for the leadcompressor).

If very little heat load is present, however, the leadcompressor will continue at minimum step, or maysimply stop again to avoid overcooling the liquid. If thelatter is the case, one compressor will restar tautomatically should the liquid temperature rise again.

When a compressor is running, discharge pressurerises as refrigerant is pumped into the air cooledcondenser coils.This pressure is controlled by stages offans to ensure maximum unit efficiency whilstmaintaining sufficient pressure for correct operation ofthe condensers and expansion valves.

As soon as a compressor is running the controllermonitors oil pressure, motor current, and various othersystem parameters such as discharge pressure, chilledliquid temperature, etc. Should any problems occur thecontrol system will immediately take appropriate actionand display the nature of the fault (see MicroprocessorControl System Manual for full details).

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6.4 Compressor Capacity Control

York PC Semi-Hermetic Compressors are each capableof operating at various stages of loading to allow themicroprocessor control system to accurately match thecooling effect of the YAEP to the heat load on thesystem. This is achieved by activating and deactivatingcompressor cylinders in order to adjust the overallrefrigerant pumping capacity. All compressors have twopermanently loaded cylinders to ensure that when acompressor is running there is always sufficientrefrigerant gas flow to cool the main drive motor.Remaining cylinders are unloaded in pairs by energisingsolenoid actuating valves which route high pressure oilor gas (depending on model of compressor) to theunloader mechanisms in the compressor.

6.5 Discharge Pressure Fan Control

Each refrigerant system has an independent air cooledcondenser section with its own cooling fans. The fansare controlled by the Microprocessor Control Centreand are switched on and off based on compressordischarge pressure whenever a compressor is running.Control is independent of compressor load status withthe fans being operated in stages to maintain thedischarge pressure within a preset range.Some optionsmay also cause fans to run in the reverse direction forthe first stage of control. For pressure setting values ofeach stage of fan control for individual models - refer tothe Micro Base Control System Manual.

6.6 Shutdown

The unit can be stopped at any time by switching the unitswitch just below the keypad to the ‘0’ (off) position. Tostop each system with a pumpdown, first set the systemswitches to ‘OFF’ and wait for a pumpdown. Thecrankcase heaters will then energise to prevent thecompressor oil becoming saturated with refrigerant. Ifmains power is to be switched off, e.g., for a shutdownperiod, the compressor suction and discharge servicestop valves should be closed (clockwise) and, if there isa possibility of liquid freezing due to low ambienttemperatures, the heat exchanger(s) should be drained.

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7 MAINTENANCE

7.1 General Requirements

The York YAEP range of liquid chillers have beendesigned to operate continuously provided they areregularly maintained and operated within the limitationsgiven in this manual. Each unit should be included in aroutine schedule of daily maintenance checks by theoperator/customer, backed up by regular serviceinspection and maintenance visits by a suitably qualifiedService Engineer.

It is entirely the responsibility of the owner to provide forthese regular maintenance requirements and/or enterinto a maintenance agreement with York Internationalservice organisation to protect the operation of the unit.If damage or a system failure occurs due to impropermaintenance during the warranty period, York shall notbe liable for costs incurred to return the unit tosatisfactory condition.

This maintenance section applies only to thebasic YAEP chiller unit and may, on individualcontracts, be supplemented by additionalrequirements to cover any modifications orancillary equipment as applicable.

The Safety Section of this manual shouldbe read carefully before attempting anymaintenance operations on the unit. Thissection should be read in conjunction withthe Micro Based Control System Manual.

7.2 Daily Maintenance

The following maintenance checks should be carriedout on a daily basis by the operator/customer. Pleasenote, however, that YAEP units are not generally userserviceable and no attempt should be made to rectifyfaults or problems found during daily checks unlesscompetent and equipped to do so. If in any doubt,contact your local York Service Agent.

Unit status: press the ‘STATUS’ key on the keypad andensure no fault messages are displayed (refer to theMicro Based Control System Manual for explanation ofmessages and the Trouble Shooting section for coursesof action).

Refrigerant leaks: visually check the heat exchangers,compressors and pipework for damage and gas leaks.

Airflow obstructions: check the air cooled condensercoil intakes and adjacent areas are clear of foreignmaterials or obstructions, e.g., paper, leaves, etc.

Operating conditions: read the operating pressuresand temperatures at the control panel using the displaykeys and check that these are within the limitationsgiven this manual.

Compressor oil level: Check the compressor oil levelafter the compressor has been operating on "FULLLOAD" for approximately 15 minutes. The maximumacceptable operating oil level is the middle of the topsight glass and the minimum acceptable operating oillevel is the middle of the bottom sight glass. When thecompressor is operating for long periods at "PARTLOAD" the level may fall as far as the middle of thebottom sight glass but should not fall below this level.

Do not overfill the PC style compressor with oilas this could cause damage to thecompressor.

For units fitted with acoustic enclosures it isrecommended to access the compressors byremoving the side panels and using a torchand mirror to view the oil levels.

Refrigerant charge: when a system starts up, orsometimes after a change of capacity step, a flow ofbubbles will be seen in the liquid line sight glass. After afew minutes of stable operation the bubbles should clearleaving just liquid refrigerant showing in the sight glass.

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Maximum Acceptable Operating Oil Level

Minimum Acceptable Operating Oil Level

7.3 Scheduled Maintenance

The maintenance operations detailed in the following table should be carried out on a regular basis by asuitably 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 operatingschedule.Normally a `minor’service should be carried out every three to six months and a `major’service oncea year. It is recommended, however, that York Service is contacted for recommendations for individual sites.

Standard Units

SERVICE SCHEDULE MINOR SERVICE MAJOR SERVICEAll items under Minor Service plus:

Unit general: Check thermal insulation Check main structure

Check vibration isolators Check paint-work

Refrigerant systems general: Check relief valves Change filter/drier cores

Check fusible plugs Check solenoid valves

Check for pipework damage

Check for leaks

Check moisture indicator

Check suction superheat

Check liquid subcooling

Compressors: Check oil level Check big ends

Check oil pressure Check sump for white metal

Check unloader operation Check suction valves and springs

Check crankcase heater Check discharge valves and springs

Check condition of oil Check cylinder sleeves

Check suction strainer

Check oil filter

Check pistons and rings

Change compressor oil

Evaporator: Check water flow Check water pH / glycol strength

Check water pressure drop

Check heater mats

Air cooled condensers: Check for airflow obstructions Brush fins

Check fins Check fan motor bearings

Check fans and fan guards

Power & Control system general: Check panel condition Check all connections

Check mains and control wiring Check compressor contactors

Check sensor locations Check fan contactors / overloads

Check mechanical HP cut-outs Check sensor / transducer calibration

Check emergency stop Check motor protectors

Check residual current devices Check contactor contacts

Microprocessor controls: Check fault history Check fan control function

Check program settings Check ambient cut-out function

Check HP / LP cut-out functions Check LTL cut-out function

Check pump-down function Check low oil pressure function

Check load / unload function

7.4 Vessels In-Service Inspection

There is no corrosion on the refrigerant side therefore in-service inspection on the refrigerant side is not necessary.

For the water side, if the water used is treated in accordance with Section 4.5, in-service inspection is not necessary.In the design of the vessels used in the unit, a 1 mm corrosion allowance has been used to consider slight corrosionon 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, YorkInternational recognises that national regulations may require such testing to be conducted.

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8 TROUBLE SHOOTING

8.1 Competent Persons Trouble Shooting Guide

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PROBLEM POSSIBLE CAUSE ACTION

No display on panel - unit will notoperate

Mains supply to control system off.

Emergency stop device off.

Undervoltage relay tripped.

No supply to -T3.

No 24 V ac supply to power board.

No +12 V output from power board.

Switch on mains supply if safe to do so.

Check if control panel emergency stop switch and anyremote emergency stop devices are in the ‘OFF’ position.Turn to ‘ON’ position (1) if safe to do so.

Check mains supply.

Check emergency stop switch fuses -F1 and -F4 (whenfitted).

Check wiring from -T3 to power board and fuse -F3.

Replace power board or isolate excessive load on theboard.

NO RUN PERM displayed No liquid flow through the cooler.

Flow switch contacts are not made.

Remote cycling device open.

Ensure that liquid pumps are running, valves are correctlyset and flow is established.

Check the flow switch is functional and is installed as perthe manufacturers instructions.

Note: on some systems the pump starter may be wired tothe unit and controlled to start with the unit.

Check cycling devices connected to terminals 11 & 14(SYS 1) and 12 & 15 (SYS 2) on the opto interface boardare closed.

OIL TEMP INHIBIT displayed Oil temperature has not reachedworking temperature fol lowingpower-up.

Compressor crankcase heater notworking.

Liquid flooding.

Measured temperature incorrect.

Use the oil temperature display key to confirm that the oiltemperature is slowly rising. The warning message shouldclear when the oil temperature has reached the correctworking temperature.

Check the operation of the heater. Measure the currentdrawn by the heater (should be 1A).

Check expansion valve operation, especially duringunloading steps.

Check sensor calibration, location and wiring.

CHILLER FAULT: LOW AMBIENTTEMP displayed

Ambient air temperature is lower thanthe programmed operating limit.

Measured temperature is incorrect.

Use the ‘ambient temp.’ key to display the temperature andconfirm that the displayed value is approximately correct.The warning message should clear when the ambient airtemperature reaches the programmed operating limit.

Check the programmed settings are correct for the optionsfitted to the unit.

Check sensor calibration, location and wiring.

CHILLER FAULT: HIGH AMBIENTTEMP displayed

Ambient air temperature is higherthan the programmed operating limit.

Residual heat is not being dissipated.

Measured temperature is incorrect.

Use the ‘ambient temp.’ key to display the temperature andconfirm that the displayed value is approximately correct.The warning message should clear when the ambient airtemperature falls below the programmed operating limit.

Check the programmed settings are correct for the optionsfitted to the unit.

Check fan is operating correctly and the rotation is correct.

Check sensor calibration, location and wiring.

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PROBLEM POSSIBLE CAUSE ACTION

CHILLER FAULT: LOW WATERTEMP displayed

Leaving liquid drops below theprogrammed low limit faster than theunit can unload.

Unit is not unloading.

Measured temperature is incorrect.

Check for restrictions in the liquid flow line.Check the liquid flow is stable.

Check the electrical supply to the unloader valvesolenoids.Check the compressor unloads correctly.

Check sensor calibration, location and wiring.

CHILLER FAULT: LWT SENSFAULT displayed

LWT sensor out of range. Check sensor calibration. Check sensor wiring foropen/short circuit.

CHILLER FAULT: POWERFAILURE MANUAL RESETdisplayed

Incorrect mains supply voltage. Check mains supply voltage is stable and withinpermissible limits. Check voltage drop on compressorstart.

SYS # HIGH DSCH displayed Discharge high pressure trip due topoor airflow through the condensercoils.

Excessive refrigerant charge.

Measured pressure is incorrect.

Check for airflow restrictions caused by blockages onintake faces of air coils.Check for damaged fins/return bends.Check for correct fan operation and direction of rotation.

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

Check discharge transducer calibration and wiring.

SYS # DSCH LIMITING displayed Discharge pressure unloading due tounit operating above load limit. Seealso SYS # HIGH DSCH.

Check chilled liquid temperature is within range. Check ifambient air temperature is above design conditions.

SYS # OIL PRESS displayed Oil loss. Oil pump wear or failure.

Too much refrigerant in the oil.

Measured pressure incorrect.

Check oil level, particularly at minimum load step.Replace oil pump.

Check crankcase heater operation and output (currentshould be in excess of 1 amp).Check operation of expansion valve for liquid flooding(especially during unloading steps).

Check suction/oil pressure transducer calibration andwiring.

SYS # LOW SUCTION displayed Insufficient liquid flow through chiller.

Badly adjusted or faulty expansionvalve.

Reduced evaporator performance.

Low refrigerant charge.

Measured pressure incorrect.

Check operation of liquid pumps.Check valves are correctly set.Check liquid filter for blockages.Check liquid line suction valve is operating correctly.

Check superheat.

Check for fouled tube surfaces.

Check refrigerant charge level.Check for leaks.

Check suction pressure transducer calibration and wiring.

SYS # CURRENT/MP/HPXdisplayed

Compressor current too high or toolow.

Measured current is incorrect.

Compressor motor protector signalfailure (no MP light on opto board).

Mechanical high pressure cut-out trip(standard and heat recoverysystems).

Check compressor mains supply, fuses, contactors andwiring. Check mains supply voltage is within tolerance.

Check for defective current transformer (resistance shouldbe between 58 and 68 Ohms).Check calibration resistor is correctly fitted.

Check motor protector and wiring.Check compressor motor.

Check compressor discharge valve is open.Check cut-out setting and wiring.Check for restricted liquid flow in heat recovery system.Check discharge line solenoid valve operation (includingpressure regulator setting).

SYS # PUMPDOWN FAIL displayed(Failure to pump down)

Liquid line solenoid valve not closed.

Leak on low pressure side of system.Measured pressure incorrect.

Check operation of valve.Check wiring to valve.

Check low pressure side for air/liquid leaks.Check suction pressure transducer calibration and wiring.

8.2 Compressor Components

PC Compressors Unloading Valves(oil pressure actuated)

Oil Pump-end Components

Optional Compressor Liquid Injection CoolingSystem

On PC style 6 and 8 cylinder compressors that unload totwo operational cylinders the compressor is fitted with aliquid injection system. This consists of solenoid valve,filter and ball valve mounted on the side of thecompressor which controls the feed of liquid refrigerantinto the compressor’s unloaded suction plenumsthrough an orifice in each plenum.

The liquid feed to the compressor is directly from themain liquid line.

The operation of the solenoid valve is controlled by thecompressor crankcase oil temperature as sensed by themicro panel. If the oil temperature is above 60 °C and thecompressor is operating then the liquid injectionsolenoid valve is energised. When the oil temperature isbelow 55 °C the liquid injection solenoid valve isde-energised, it is also de-energised when thecompressor is not operating.

(02/04)

035L02537-100 Rev. 0 8-3

PROBLEM POSSIBLE CAUSE ACTION

SYS # CURR LIMITING displayed High compressor motor current hasactivated unloading.See also SYS # CURRENT/MP/HPX

Check liquid temperature is within operating limits. Check ifambient air temperature is above operating limits.

A To Oil Pressure Transducer

B Oil Pump Priming and Pressure Access Valve

C Oil Level Sight Glasses

D Oil Charging and Drain Valve

E Oil Heater

F Oil Temperature Sensor

8.3 Sensor Calibration Charts

(02/04)

8-4 035L02537-100 Rev. 0

0 - 200 psig Transducer 0 - 400 psig TransducerPressure psig Voltage V dc Pressure psig Voltage V dc

0 0,5 0 0,525 1,0 50 1,050 1,5 100 1,575 2,0 150 2,0

100 2,5 200 2,5125 3,0 250 3,0150 3,5 300 3,5175 4,0 350 4,0200 4,5 400 4,5

Red wire = 5 V, Black wire = 0 V, White or Green wire = signal

Pressure Transducers

Temperature °C Resistance Ω Voltage Vdc-10 16598 1,45-8 14896 1,57-6 13388 1,69-4 12047 1,80-2 10856 1,930 9795 2,052 8849 2,174 8005 2,306 7251 2,428 6575 2,54

10 5970 2,6620 3748 3,2230 2417 3,6940 1598 4,05

Microboard test points: -BCLT Leaving Water: J11-7/1-BMLT Mixed Leaving Water J17-11/1 YDAJ

Leaving Water Temperature Sensor (LWT)

Temperature °C Resistance Ω Voltage Vdc-10 55330 0,97-5 42227 1,200 32650 1,455 25390 1,72

10 19900 2,0015 15710 2,2920 12490 2,5825 10000 2,8530 8057 3,1135 6530 3,3540 5327 3,57

Microboard test point: - BAMB Ambient Air: J11-9/31-BOT Sys.1 Oil Temp: J11-8/22-BOT Sys.2 Oil Temp: J16-6/3

Ambient Temperature Sensorand 10 k Oil Temperature Sensor

9 TECHNICAL DATA

9.1 Flow Rate/Pressure Drop Charts

9.2 Operating Limitations

(02/04)

035L02537-100 Rev. 0 9-1

140

120

100

80

60

50

40

30

20

10

8

5

5 6 8 10

Flow Rate (l/S)

55S66S

44M

77X88X99X

Pre

ssu

reD

rop

(kP

a)

20 30 40 50 604

608L09L

Cooler Water Pressure Drops

Min. °C (°F) Max. °C (°F)Leaving Chilled Liquid Temperature - R22 Units 4 (39) 12 (54)Leaving Chilled Liquid Temperature - R407C Units 6 (43) 12 (54)Chilled Liquid Temperature Difference 3.3 (6) 8 (15)

Standard Units -4 (25) 52 (125)Units with Low Ambient Kit -18*(0) 52 (125)

Electrical Power Supply 380/400/415 V, 3Ø, 50 Hz V 342 440

All YAEP Models

Air EnteringCondenser

Model Pressure Drop Calculation

55S,

66S

77X,

88X, 99X

Pressure Drop [kPa] = 0.2101 x (Flow Rate [l/s]1.6914)

Pressure Drop [kPa] = 0.1103 x (Flow Rate [l/s]1.7282)

08L,09L

Pressure Drop [kPa] = 0.2133 x (Flow Rate [l/s]1.7018)

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

Pressure drop applies to each cooler on 4 Circuit Models(i.e. the total unit flow should be divided by 2 to obtain theflow rate through each cooler).

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

Model YAEP 5555S 6666S 7777X 8888X 8899X 9999XMinimum Cooler Flow l/s (gpm) 9.4 (150) 9.4 (150) 15.8 (250) 15.8 (250) 15.8 (250) 15.8 (250)Maximum Cooler Flow l/s (gpm) 40.5 (640) 40.5 (640) 50.7 (805) 50.7 (805) 50.7 (805) 50.7 (805)Minimum Unit Flow l/s (gpm) 18.8 (300) 18.8 (300) 31.6 (500) 31.6 (500) 31.6 (500) 31.6 (500)Maximum Unit Flow l/s (gpm) 81 (1280) 81 (1280) 101.4 (1610) 101.4 (1610) 101.4 (1610) 101.4 (1610)Minimum System Volume l (Usg) 3235 (920) 3735 (1065) 4335 (1235) 5140 (1465) 5910 (1680) 6265 (1785)

4 circuit units are fitted with 2 coolers. The table details flow rate for each cooler and total flow rate for the unit.

4 Circuit Units

2 Circuit Units1 Circuit Units

9.3 Physical Data - R22 Models

(02/04)

9-2 035L02537-100 Rev. 0

08LA7C 09LC9C 44MA7C 55SC7C 66SC9C 77XC9C 88XB7C 99XB7C 99XD9CUnit Number of Capacity Steps 4 4 4 4 4 4 6 6 6

Cylinders per Compressor 8 8 4 4 6 6 8 8 8

Oil Capacity per Compressor l 11 11 11 11 11 11 11 11 11

Coolers per Unit 1 1 1 1 1 1 1 1 1

Cooler Refrigerant Circuits per Cooler 1 1 2 2 2 2 2 2 2

Water Capacity per Cooler l 90 90 135 150 150 205 205 205 205

Condenser Face Area m2 11.9 11.9 11.9 11.9 11.9 11.9 23.8 23.8 23.8

Quantity 4 4 4 4 4 4 8 8 8

Power (each) kW 2.2 3.8 2.2 2.2 3.8 3.8 2.2 2.2 3.8

Total Airflow m3/s 30.4 34.8 30.4 30.4 34.8 34.8 60.8 60.8 69.6

Systems 1 kg 39.0 42.0 42.0 49.0 49.0 49.0 57.0 57.0 64.0

Systems 2 kg 42.0 49.0 49.0 49.0 57.0 57.0 64.0

Shipping kg 3550 3665 4000 4200 4350 4495 5222 5222 5422

Operating kg 3640 3640 4135 4350 4500 4700 5427 5427 5627

Shipping kg 3740 3955 4190 4490 4640 4785 5797 5797 5997

Operating kg 3830 4045 4325 4640 4790 4990 6002 6002 6202

Length mm 2969 2969 2969 2969 2969 2969 5703 5703 5703

Width mm 2241 2241 2241 2241 2241 2241 2241 2241 2241

Height mm 2466 2466 2466 2466 2466 2466 2466 2466 2466

Dimensions

Compressor

WeightAluminium Fins

Copper Fins

1 Circuit UnitsYAEP

Refrigerant Charge

Fans

2 Circuit Units

5555SC7C 6666SC9C 7777XC9C 8888XB7C 8899XB7C 9999XD9CUnit Number of Capacity Steps 8 8 8 12 12 12

Cylinders per Compressor 4 6 6 8 8 8

Oil Capacity per Compressor l 11 11 11 11 11 11

Coolers per Unit 2 2 2 2 2 2

Cooler Refrigerant Circuits per Cooler 2 2 2 2 2 2

Water Capacity per Cooler l 150 150 205 205 205 205

Condenser Face Area m2 23.8 23.8 23.8 47.6 47.6 47.6

Quantity 8 8 8 16 16 16

Power (each) kW 2.2 3.8 3.8 2.2 2.2 3.8

Total Airflow m3/s 60.8 69.6 69.6 121.6 121.6 139.2

Systems 1/2 kg 49.0 49.0 49.0 57.0 57.0 64.0

Systems 3/4 kg 49.0 49.0 49.0 57.0 57.0 64.0

Shipping kg 8400 8700 8990 10444 10444 10844

Operating kg 8700 9000 9400 10854 10854 10844

Shipping kg 8980 9280 9570 11594 11594 10844

Operating kg 9280 9580 9980 12004 12004 10844

Length mm 6128 6128 6128 11705 11705 11705

Width mm 2241 2241 2241 2241 2241 2241

Height mm 2466 2466 2466 2466 2466 2466

Fans

Weight

4 Circuit UnitsYAEP

Dimensions

Compressor

Aluminium Fins

Copper Fins

Refrigerant Charge

9.4 Physical Data - R407C Models

(02/04)

035L02537-100 Rev. 0 9-3

5555SC9B 6666SC9B 7777XC9B 7777XF7B 8888XD7B 8899XD7B 9999XD9BUnit Number of Capacity Steps 8 8 8 8 12 12 12

Cylinders per Compressor 4 6 6 6 8 8 8

Oil Capacity per Compressor l 11 11 11 11 11 11 11

Coolers per Unit 2 2 2 2 2 2 2

Cooler Refrigerant Circuits per Cooler 2 2 2 2 2 2 2

Water Capacity per Cooler l 150 150 205 205 205 205 205

Condenser Face Area m2 23.8 23.8 23.8 35.6 47.6 47.6 47.6

Quantity 8 8 8 12 16 16 16

Power (each) kW 3.8 3.8 3.8 2.2 2.2 2.2 3.8

Total Airflow m3/s 69.6 69.6 69.6 89.4 121.6 121.6 139.2

Systems 1/2 kg 49.0 49.0 49.0 53.0 57.0 57.0 64

Systems 3/4 kg 49.0 49.0 49.0 53.0 57.0 57.0 64

Shipping kg 8400 8700 8990 9970 9970 9970 9970

Operating kg 8700 9000 9400 9970 9970 9970 9970

Shipping kg 8980 9280 9570 9970 9970 9970 9970

Operating kg 9280 9580 9980 9970 9970 9970 9970

Length mm 6128 6128 6128 8586 11705 11705 11705

Width mm 2241 2241 2241 2241 2241 2241 2241

Height mm 2466 2466 2466 2466 2466 2466 2466

4 Circuit UnitsYAEP

Aluminium Fins

Copper Fins

Dimensions

Weight

Fans

Compressor

Refrigerant Charge

08LA7B 09LC9B 44MC7B 55SC9B 66SC9B 77XC9B 77XF7B 88XD7B 99XD9BUnit Number of Capacity Steps 4 4 4 4 4 4 4 6 6

Cylinders per Compressor 8 8 4 4 6 6 6 8 8

Oil Capacity per Compressor l 11 11 11 11 11 11 11 11 11

Coolers per Unit 1 1 1 1 1 1 1 1 1

Cooler Refrigerant Circuits per Cooler 1 1 2 2 2 2 2 2 2

Water Capacity per Cooler l 90 90 135 150 150 205 205 205 205

Condenser Face Area m2 11.9 11.9 11.9 11.9 11.9 11.9 17.8 23.8 23.8

Quantity 4 4 4 4 4 4 6 8 8

Power (each) kW 2.2 3.8 2.2 3.8 3.8 3.8 2.2 2.2 3.8

Total Airflow m3/s 30.4 34.8 30.4 34.8 34.8 34.8 44.7 60.8 69.6

Systems 1 kg 39.0 42.0 42.0 49.0 49.0 49.0 53.0 57.0 64.0

Systems 2 kg 42.0 49.0 49.0 49.0 53.0 57.0 64.0

Shipping kg 3550 3665 4000 4200 4350 4495 4985 5222 5422

Operating kg 3640 3640 4135 4350 4500 4700 5190 5427 5627

Shipping kg 3740 3955 4190 4490 4640 4785 5400 5797 5997

Operating kg 3830 4045 4325 4640 4790 4990 5605 6002 6202

Length mm 2969 2969 2969 2969 2969 2969 4193 5703 5703

Width mm 2241 2241 2241 2241 2241 2241 2241 2241 2241

Height mm 2466 2466 2466 2466 2466 2466 2466 2466 2466

2 Circuit Units1 Circuit UnitsYAEP

Dimensions

Compressor

WeightAluminium Fins

Copper Fins

Refrigerant Charge

Fans

9.5 Electrical Data - R22 Models

9.6 Electrical Data - R407C Models

(02/04)

9-4 035L02537-100 Rev. 0

YAEP Model 35°C/7°CNom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V

08LC7B 1 97 144 190 189 188 293 268 266 264 689 725 75209LC9B 1 123 150 228 226 224 293 268 266 264 689 725 75244MC7B 2 105 125 197 195 193 275 231 225 221 398 409 418

(55)55SC9B 2/4 137 163 246 244 242 322 296 292 286 504 522 533(66)66SC9B 2/4 149 185 280 278 276 356 336 332 328 626 648 672(77)77XC9B 2/4 187 227 348 346 342 422 412 406 400 755 781 800(77)77XF7B 2/4 177 225 331 329 327 427 417 411 405 758 784 803(88)88XB7B 2/4 200 288 386 380 374 580 530 526 522 954 988 1013

200 288 386 380 446 580 530 526 522 954 988 1013244 288 450 448 446 580 530 526 522 954 988 1013

(99)99XD9B 2/4 250 300 457 455 453 595 545 541 537 961 995 1020

YAEP Model 35°C/7°CNom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V

44MC7B 2 52 62 98 97 96 137 115 112 110 283 297 30855SC9B 2 69 82 123 122 121 161 148 146 143 356 376 39066SC9B 2 75 93 140 139 138 178 168 166 164 458 482 50877XC9B 2 94 114 174 173 171 211 206 203 200 549 578 60077XF7B 2 89 113 166 165 164 214 209 206 203 549 578 60088XB7B 2 100 144 193 190 187 290 265 263 261 689 725 75299XD9B 2 125 150 228 227 226 297 272 270 268 689 725 752

5555SC9B 4 65 82 123 122 121 161 148 146 143 356 376 3906666SC9B 4 71 93 140 139 138 178 168 166 164 458 482 5087777XC9B 4 90 114 174 173 171 211 206 203 200 549 578 6007777XF7B 4 91 113 166 165 164 214 209 206 203 549 578 6008888XB7B 4 100 144 193 190 187 290 265 263 261 689 725 752

8899XB7B Main 2 100 144 193 190 187 290 265 263 261 689 725 7528899XB7B Aux 2 122 144 225 224 223 290 265 263 261 689 725 752

9999XD9B 4 125 150 228 227 226 297 272 270 268 689 725 752

Circuits

2+2

Power Requirement per Panel - 1, 2 and 4 Refrigerant Circuit Units with Single Point Power Supply - Disconnect Switch (CE) or Terminal Block Option (Non CE)(Data includes one/both compressors and associated fans)

Note: To obtain the total unit power requirements on four circuit models 5555SC9B / 6666SC9B / 7777XC9B / 7777XF7B / 8888XB7B / 9999XD9B multiply the panel values by 2.

Note: To obtain the total unit power requirements on four circuit model 8899XB7B the panel values should be added together.

Nominal. Amps Maximum. Amp Part Wind Inrush

Nominal. Amps Maximum. Amp Part Wind Inrush

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

Circuits

(88)99XB7B

YAEP Model 35°C/7°CNom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V

08LA7C 1 101 144 195 194 193 293 268 266 264 689 725 75209LC9C 1 122 150 228 226 224 293 268 266 264 689 725 75244MC7C 2 107 125 197 195 193 275 231 225 221 398 409 420

(55)55SC7C 2/4 137 163 239 237 235 315 289 285 279 500 518 532(66)66SC9C 2/4 149 185 278 276 274 356 336 332 328 626 648 674(77)77XC9C 2/4 189 227 348 344 342 422 408 404 400 753 780 802(88)88XB7C 2/4 228 300 410 408 406 580 530 526 522 954 988 1015

99XB7C 2 270 300 480 470 466 580 530 526 522 954 988 1015228 300 410 408 406 580 530 526 522 954 988 1015270 300 480 470 466 580 530 526 522 954 988 1015

(99)99XD9C 2/4 250 300 469 463 461 595 545 541 537 961 995 1020

YAEP Model 35°C/7°CNom. kW Max. kW 380 V 400 V 415 V 342 V 380 V 400 V 415 V 380 V 400 V 415 V

44MC7C 2 53 62 98 97 96 137 115 112 110 283 297 30855SC7C 2 69 82 119 118 117 157 144 142 139 356 376 39066SC9C 2 75 93 139 138 137 178 168 166 164 458 482 50877XC9C 2 95 114 174 172 171 211 204 202 200 549 578 60088XB7C 2 114 150 205 204 203 290 265 263 261 689 725 75299XB7C 2 135 150 240 235 233 290 265 263 261 689 725 75299XD9C 2 125 150 234 231 230 297 272 270 268 689 725 752

5555SC7C 4 65 82 119 118 117 157 144 142 139 356 376 3906666SC9C 4 71 93 139 138 137 178 168 166 164 458 482 5087777XC9C 4 91 114 174 172 171 211 204 202 200 549 578 6008888XB7C 4 114 150 205 204 203 290 265 263 261 689 725 752

8899XB7C Main 2 114 150 205 204 203 290 265 263 261 689 725 7528899XB7C Aux 2 135 150 240 235 233 290 265 263 261 689 725 752

9999XD9C 4 125 150 234 227 230 297 272 270 268 689 725 752

Power Requirement per Panel - 1, 2 and 4 Refrigerant Circuit Units with Single Point Power Supply - Disconnect Switch (CE) or Terminal Block Option (Non CE)(Data includes one/both compressors and associated fans)

Note: To obtain the total unit power requirements on four circuit models 5555SC7C / 6666SC9C / 7777XC9C / 8888XB7C / 9999XD9C multiply the panel values by 2.

Note: To obtain the total unit power requirements on four circuit model 8899XB7C the panel values should be added together.

Nominal. Amps Maximum. Amp Part Wind Inrush

Nominal. Amps Maximum. Amp Part Wind Inrush

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

Circuits

8899XB7C 2+2

Circuits

9.7 Control Circuit Electrical Data

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

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

9.10 Fan Data - (All values per fan)

(02/04)

035L02537-100 Rev. 0 9-5

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

Comp. 380 V 400 V 415 V 342 V 380 V 400 V 415 V Part Wind

Size Nom kw Max kw Nom. Amps Nom. Amps Nom. Amps Max. Amp Max. Amps Max. Amps Max. Amps Inrush

4 49 58 86 85 84 125 103 98 98 283

5 61 74 107 106 105 145 132 128 127 356

6 67 85 123 122 122 162 152 148 148 482

7 87 106 158 154 155 195 190 184 184 578

8 99 135 180 178 180 265 240 238 236 725

9 110 135 196 195 194 265 240 238 236 725

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

35°C/7°C

Fans per Power (kW) Current (A) Power (kW) Current (A)R22 R407C Circuit per Fan per Fan per Fan per Fan

08MA7C 08MC7B 1 4 2.2 6.2 2.2 6.209MC9C 09MC9B 1 4 3.8 8.2 3.8 8.244MA7C 44MC7B 1 and 2 2 2.2 6.2 2.2 6.255SC7C 55SC9B 1 and 2 2 2.2 6.2 3.8 8.266SC9C 66SC9B 1 and 2 2 3.8 8.2 3.8 8.277XC9C 77XC9B 1 and 2 2 3.8 8.2 3.8 8.2

77XF7B 1 and 2 3 2.2 6.288XB7C 88XB7B 1 and 2 4 2.2 6.2 2.2 6.299XB7C 1 and 2 4 2.2 6.299XD9C 99XD9B 1 and 2 4 3.8 8.2 3.8 8.2

5555SC7C 5555SC9B 1, 2, 3 and 4 2 2.2 6.2 3.8 8.26666SC9C 6666SC9B 1, 2, 3 and 4 2 3.8 8.2 3.8 8.27777XC9C 7777XC9B 1, 2, 3 and 4 2 3.8 8.2 3.8 8.2

7777XF9B 1, 2, 3 and 4 3 3.8 8.28888XB7C 8888XD7B 1, 2, 3 and 4 4 2.2 6.2 2.2 6.28899XB7C 8899XD7B 1, 2, 3 and 4 4 2.2 6.2 2.2 6.29999XD9C 9999XD9B 1, 2, 3 and 4 4 3.8 8.2 3.8 8.2

R407C UnitsR22 UnitsYAEP Model Circuit

Comp. 380 V 400 V 415 V 342 V 380 V 400 V 415 V Part Wind

Size Nom kw Max kw Nom. Amps Nom. Amps Nom. Amps Max. Amp Max. Amps Max. Amps Max. Amps Inrush

4 48 58 86 85 84 125 103 98 98 283

5 61 74 107 106 105 145 132 128 127 356

6 67 85 123 122 122 162 152 148 148 482

7 82 106 149 145 146 195 190 184 184 578

8 91 135 168 164 162 265 240 238 236 725

9 110 135 196 195 194 265 240 238 236 725

35°C/7°C

9.11 Fuse Ratings and Lug Sizes

(02/04)

9-6 035L02537-100 Rev. 0

Multi PointTerminal Block Power Supply

(Non CE) (Non CE)Input Rating Input Rating Din NH Max. 5 S Contactor

R22 R407C Lug Size Ie (A) Lug Size (A) Size Interrupt (A) Lug Size08MA7C 08MC7B M12 630 M12 355 2 2200 M1009MC9C 09MC9B M12 630 M12 355 2 2200 M1044MA7C 44MC7B M10 500 M12 160 1 810 M1055SC7C 55SC9B M10 500 M12 200 1 1000 M1066SC9C 66SC9B M10 500 M12 250 1 1300 M1077XC9C 77XC9B M10 500 M12 250 1 1300 M10

77XF7B M10 500 M12 250 1 1300 M1088XB7C 88XB7B M12 630 M12 355 2 2200 M1099XB7C M12 630 M12 355 2 2200 M1099XD9C 99XD9B M12 630 M12 355 2 2200 M10

5555SC7C 5555SC9B M10 500 M12 200 1 1000 M106666SC9C 6666SC9B M10 500 M12 250 1 1300 M107777XC9C 7777XC9B M10 500 M12 250 1 1300 M10

7777XF9B M10 500 M12 250 1 1300 M108888XB7C 8888XD7B M12 630 M12 355 2 2200 M108899XB7C 8899XD7B M12 630 M12 355 2 2200 M108899XB7C 8899XD7B M12 630 M12 355 2 2200 M109999XD9C 9999XD9B M12 630 M12 355 2 2200 M10

Units with Single Point Power SupplyDisconnect Switch

YAEP ModelMax IEC 269-2-1 gG fuse Size

System Fuses(CE)

9.12 Clearances

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

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

The enclosure height should not exceed the height of the units except that only one adjacent wall may be higher thanthe unit. Horizontal obstructions or overhangs should not be closer than 15 metres above the top of any unit and noobstructions are allowed directly above the unit

(02/04)

035L02537-100 Rev. 0 9-7

3 m 2 m

1.3

m2

m

2 m

2m

2m

1.3

m

1.3 m

2m

2m

2 m

2 m 2 m

9.13 Dimensions

Models - YAEP 08L - 09L

(02/04)

9-8 035L02537-100 Rev. 0

2969

2172

AV

MP

OS

ITIO

NS

148

446

520

8401990

2241

946

2897

1778

500

1911

AV

MC L

493

AV

M335

2466

Models - YAEP 44M - 77XC

(02/04)

035L02537-100 Rev. 0 9-9

2466.4

493

2241

449

1911

2108

(216

0on

44M

)

2897

407(382on44Mand446on77XC)

2172

AV

MP

OS

ITIO

NS

702

2969

340

(314

on44

M)

Model - YAEP 77XF

(02/04)

9-10 035L02537-100 Rev. 0

2241

493

702

2166

AV

MP

OS

NS

.

446

1707

AV

MP

OS

NS

.16

76A

VM

PO

SN

S.

2108

1631

4187

4250

2467 312

Models - YAEP 88X - 99X

(02/04)

035L02537-100 Rev. 0 9-11

2426

199

AV

M24

38A

VM

PO

SIT

ION

S

40 446

2108

634

5407

1220

AV

M12

57A

VM

292

AV

M

8381153

124

221

5700

1800

702

2241C

OM

PR

ES

SO

RS

YS

TE

M2

SY

ST

EM

1C

OM

PR

ES

SO

RR

EM

OV

ED

FO

R D

RA

WIN

GC

LAR

ITY

2166

AV

MP

OS

ITIO

NS

Models - YAEP 5555S - 7777XC

(02/04)

9-12 035L02537-100 Rev. 0

WITH ALUMINIUM / PHENOLIC COATEDCONDENSER COILSMOUNT POSITIONA B C D E F G H TOTAL77SB7 POINT LOAD 775 788 795 916 715 766 773 832 6360MOUNT TYPE CP-2-28 CP-2-31 CP-2-31 CP-2-31 CP-2-28 CP-2-28 CP-2-31 CP-2-3188XB7 POINT LOAD 828 846 853 978 820 904 919 952 7100MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-32 CP-2-31 CP-2-31 CP-2-31 CP-2-3199XB7 POINT LOAD 828 846 853 978 820 904 919 952 7100MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-32 CP-2-31 CP-2-31 CP-2-31 CP-2-3199XD9 POINT LOAD 847 865 872 998 838 922 938 970 7250MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-32 CP-2-31 CP-2-31 CP-2-31 CP-2-32

WITH COPPER FINNED CONDENSER COILSMOUNT POSITIONA B C D E F G H TOTAL77SB7 POINT LOAD 892 905 912 1033 832 883 890 949 7296MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-31 CP-2-28 CP-2-28 CP-2-31 CP-2-3188XB7 POINT LOAD 894 905 913 1035 833 883 896 954 7313MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-32 CP-2-31 CP-2-31 CP-2-31 CP-2-3199XB7 POINT LOAD 945 963 970 1095 937 1021 1036 1069 8036MOUNT TYPE CP-2-31 CP-2-31 CP-2-31 CP-2-32 CP-2-31 CP-2-32 CP-2-32 CP-2-3299XD9 POINT LOAD 996 1014 1021 1147 987 1071 1087 1119 8442MOUNT 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

MODEL

MODEL

1911

AV

MP

OS

.

2466

2897

2108

1911

AV

MP

OS

.

2897

2108

493

340

300

493

340

2172

AV

MP

OS

ITIO

NS

406(446on7777XC)

2241

6232

8401150

Model - YAEP 7777XF

(02/04)

035L02537-100 Rev. 0 9-13

2241

702

2172

2108

1631

1676

4187

1707

312

8675

1631

2108

312

1676

1707

4187

493

2467

446

8812

300

Models - YAEP 8888X - 9999X

(02/04)

9-14 035L02537-100 Rev. 0

2426 29229

240 446

1257

AV

M12

20A

VM

2664

5407

2108

2438

AV

MP

OS

ITIO

NS

699

1568

RE

F.

1257

AV

M

292

292

1153 838

702

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2,3

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2166

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10 SPARE PARTS

10.1 Recommended Spares

It is recommended that the following common spareparts are held for preventive or corrective maintenanceoperations.

Other spare parts vary depending on the product modelnumber.

For further details on unit spare parts refer to RenewalParts List 035L02601-100 Rev. 0. For details ofcompressor spare parts refer to Illustrated PartsCatalogue 035L02426-000.

(02/04)

035L02537-100 Rev. 0 10-1

DESCRIPTION PART NUMBER

Heater, Crankcase (350W) 025L02296-000Valve, Solenoid, Unloading 025L02488-000Oil See Section 2Heater, Crankcase (450W) (Optional part) 025L02297-000

Core, Drier 026-37540-000Coil, Solenoid, Replacement 025L02027-DANPowerhead, Valve, Expansion, Replacement 025-32902-000

Coil, Solenoid, Replacement (Optional part) 025-29139-001Fuse 025L02645-000Fuse 025L02431-000Fuse 025L02434-000Fuse 025L02428-000

Key, Door 021L00736-000Sensor, Temperature, Water, Mix (Duplex Units only) 025L02168-000Sensor, Temperature, Air, Outside 025L01963-000Compound, Conductive, Heat 013-00898-000Switch, Flow, Water (Optional part) 024-26116-000

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

025-34177-000

021L00724-000

025-34120-990

Key, Door

Sensor, Temperature, Water

Sensor, Temperature, Oil

Transducer, Pressure, Discharge 025-29139-001

Transducer, Pressure, Suction 025-29583-000

Transducer, Pressure, Oil 025-29583-000

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

Switch, Pressure, High (External Manual Reset) (Optional part)

025L02168-000

10.2 Compressor Top Head Rebuild Kit

It is recommended that a top head compressor rebuild isperformed after 5000 hours of compressor operation.The top head rebuild kit consists of top head andmanifold gaskets, discharge and suction valves andsprings, valve retaining clip and self locking nut andbuilt-in discharge cage assembly. The tables belowdetail the kit part numbers.

All Models

Compressor Kit Part Number

4 Cylinder PC Compressor 398L00654-001

6 Cylinder PC Compressor 398L00654-002

8 Cylinder PC Compressor 398L00654-003

10.3 Associated Drawings

(02/04)

10-2 035L02537-100 Rev. 0

Model YAEP 08L - 09L 44M - 77XC 77XF 88X - 99X035L02594-000 035L02593-000 035L02622-000 035L02532-000

Model YAEP 5555S - 7777XC 7777XF 8888X - 9999X035L02621-000 035L02623-000 035L02539-000

System 1 & 2 System 3 & 4Schematic 035L02534-000 035L02574-000

Connection 035l02535-000 035L02575-000Legend/Notes

Product Drawing

Product Drawing

Process & Instrumentation Diagram 035L02533-000

WiringDiagrams

035L02384-GB1

11 DE-COMMISSIONING, DISMANTLINGAND DISPOSAL

Never release refrigerant to theatmosphere when emptying therefrigerating circuits. Suitable retrievalequipment must be used. If reclaimedrefrigerant cannot be re-used. It must bereturned to the manufacturer throughauthorised agencies.

Never discard used compressor oil, as itcontains refrigerant in solution. Returnused oil to the oil manufacturer throughauthorised agencies.

Unless otherwise indicated, the operations describedbelow can be performed by any properly trainedmaintenance technician.

11.1 General

Isolate all sources of electrical supply to the unitincluding any control system supplies switched by theunit. Ensure that all points of isolation are secured in the‘OFF’ position. The supply cables may then bedisconnected and removed. For connection points referto Section 4.

Remove all refrigerant from each system of the unit intoa suitable container using a refrigerant reclaim orrecovery unit. This refrigerant may then be re-used, ifappropriate, or returned to the manufacturer fordisposal. Under NO circumstances should refrigerantbe vented to atmosphere. Drain the refrigerant oil fromeach system into a suitable container and dispose ofaccording to local laws and regulations governing thedisposal of oily wastes. Any spilt oil should be moppedup and similarly disposed of.

Isolate the unit heat exchanger(s) from all external watersystems and drain the heat exchanger section(s) of thesystem. If no isolation valves are installed it may benecessary to drain the complete system(s).

If glycol or similar solutions have beenused in the water system(s), or chemicaladditives are contained, the solutionMUST be disposed of in a suitable and safemanner. Under NO circumstances shouldany system containing glycol or similarsolutions be drained directly into domesticwaste or natural water systems.

After draining, the water pipework can be disconnectedand removed.

Packaged units can generally be removed in one pieceafter disconnection as above. Any fixing down boltsshould be removed and then the unit should be liftedfrom position using the points provided and equipmentof adequate lifting capacity.

Reference should be made to Section 4 for unitinstallation instructions, Section 9 for unit weights andSection 3 for handling.

Units which cannot be removed in one piece afterdisconnection as above must be dismantled in position.Special care should be taken regarding the weight andhandling of each component. Where possible unitsshould be dismantled in the reverse order of installation.

Residual refrigerant oil and glycol orsimilar solutions may remain in someparts of the system. These should bemopped up and disposed of as describedabove.

It is important to ensure that whilst components arebeing removed the remaining parts are supported in asafe manner.

Only use lifting equipment of adequatecapacity.

After removal from position the unit parts may bedisposed of according to local laws and regulations.

(02/04)

035L02537-100 Rev. 0 11-1

Subject to change without notice. ALL RIGHTS RESERVED

Part No. 035L02537-100 Rev. 0 (02/04)YORK

EMEAYORK INTERNATIONALGardiners Lane South, Basildon, Essex SS14 3HE, England

GB