YCAV Air-Cooled Chiller Conversion Case Study

June 11, 2026

Location: Hotel – Fort Lauderdale, Florida



Overview:

A 6-year-old York YCAV air-cooled chiller serving a hotel experienced premature condenser coil 

failure. Out of 10 total coils, 4 had already failed (40%), with the remaining coils showing active 

corrosion. The unit operates continuously, making reliability critical for guest comfort

Challenges:

- Coastal environment (humidity, salt air, pollutants)

- Microchannel aluminum coils susceptible to corrosion

- Thin wall design prone to leaks

- Continuous 24/7 operation accelerating deterioration

- Vibration from fans and compressors causing fatigue and cracking

Solution:

A full conversion from microchannel to copper tube / aluminum fin coils was performed:

- Replaced all 10 coils with custom-engineered coils

- Designed to match original chiller performance

- Factory-applied protective coating for corrosion resistance

Benefits:

- Increased durability and resistance to corrosion

- Copper tubes better withstand vibration and mechanical stress

- Coils are repairable (unlike microchannel)

- Improved reliability for continuous operation

- Restored heat transfer and system efficiency

Results:

- Eliminated refrigerant leaks

- Restored system performance

- Reduced compressor strain and energy use

- Avoided full chiller replacement

- Extended equipment life by 10+ years

Key Takeaway:

In coastal, high-runtime applications, microchannel coils can fail prematurely due to corrosion and 

vibration. Converting to coated copper tube/aluminum fin coils provides a long-term, reliable 

solution

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