INSTALLATION Supersedes: Nothing Form 150.70-NM2.

1 (398)
REMOTE EVAPORATOR OPTION FOR
250 - 350 TON AIR COOLED CHILLERS
60 HZ MODELS
YEAJ777PX6, YEAJ878PX6, YEAJ888RX6, YEAJ999RY6
50 HZ MODELS
YEAJ777PX7, YEAJ977PX7, YEAJ979RX7, YEAJ999RX7
STYLE A*
200, 230, 460-3-60
26214A
*With EPROMS & (Standard, Brine & Metric Models, Combined)
MASTER* SLAVE*
* For EPROMs See Page 10.
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YORK INTERNATIONAL
REMOTE EVAPORATOR OPTION
GENERAL
The Remote Evaporator option allows an architect to place
the evaporator inside the conditioned space. This helps
eliminate the possibility of water line freezing. Addition-
ally, interior noise is reduced as a result of the compres-
sors and fans being placed outside.
The unit and remote evaporator will be pressure tested,
evacuated, and given a holding charge of Refrigerant R-
22 or Nitrogen. Refer to tags on unit and evaporator. An
initial oil charge will also be included in the compressor.
CAUTION: THE FIELD PIPING SYSTEM MUST BE
EVACUATED BEFORE CHARGING.
After placing the system in operation, it is important to
verify that the proper refrigerant charge has been installed
by checking sub-cooling. See page 70 of Form 150.65-
NM2.
This form is intended to be used as a supplement to
Form 150.65-NM2. Use Form 150.65-NM2 for all installa-
tion, start-up, and operation instructions not outlined in
this supplement.
Inventory the parts included with the Remote Cooler
Option and compare them to the list in Table 1. Assure
that all parts have been included.
REFRIGERANT PIPING
PROPER PIPING SYSTEM DESIGN AND INSTALLA-
TION IS THE RESPONSIBILITY OF THE END USER.
YORK ASSUMES NO WARRANTY RESPONSIBILITY
FOR SYSTEM OPERATION OR FAILURES DUE TO
IMPROPER PIPING OR PIPING DESIGN.
General When the unit has been located in its final
position, the unit piping may be connected. Normal in-
stallation precautions should be observed in order to en-
sure reliable operation and serviceability. System piping
should conform to ASHRAE guidelines.
Threaded Connections on the cooler refrigerant piping
are NOT intended for threaded field connection. They are
used for pressure testing at the factory only. Brazed con-
nections must be made in the field.
For piping guidelines, refer to ASHRAE 1994 Refrigera-
tion Handbook, Chapter 2, System Practices for Halo-
carbon Refrigerants.
Hand stop valves should be installed where needed to
facilitate servicing of unit. Avoid eliminating service valves
in favor of cost cutting.
WARNING: Any section of a line that has a potential to
be subject to hydrostatic expansion must
be relieved.
Piping Connection Points Each system liquid line
will include a field connection shutoff valve (stop valve)
with charging port located on each condenser circuit (See
Fig. 1). Suction line connections are provided on each
compressor at the suction valve (See Fig. 1). Field refrig-
erant piping can be connected to the condensing unit
without loss of the holding charge in the unit.
Liquid Line Solenoids and Expansion Valve Mount-
ing Liquid line solenoids and expansion valves must
be mounted with the arrow on the devices pointing in the
direction of refrigerant flow. The expansion valve sensing
bulbs should be mounted and clamped securely on a
newly cleaned pipe in the 4 or 8 oclock position. The
bulb and pipe must then be properly insulated.
All expansion valves, filter driers, sight glasses, and liq-
uid line solenoid valves are YORK supplied and installed
by others. Refrigerant field piping is supplied and installed
by others (See Fig. 1).
For liquid lengths greater than 60 feet, a liquid line re-
ceiver may be required to accommodate the additional
refrigerant charge quantity of the system, otherwise the
total condenser pumpdown capacity may be exceeded.
ITEM QTY DESCRIPTION
1 2 Temperature Sensor
2 6 Contact Socket
3 4 Contact Receptacle
4 4 Rubber Collar
5 2 Connector (Plug Housing)
6 3 Solenoid Valve (Liquid)
7 6 Cartridge (Dehydrator)
8 3 Dehydrator (Less Core)
9 3 Thermo Expansion Valve*
10 3 S.G.W. / Moisture Indicator
* Sized for air conditioning duty only. Contact YORK for alternate
valve selection if chilled water temperatures below 44F are de-
sired.
TABLE 1 PARTS LIST
WARNING
OPERATION WITH IMPROPER THERMAL EXPAN-
SION VALVE SIZE WILL VOID WARRANTY.
FORM 150.70-NM2.1
3
YORK INTERNATIONAL
INTERCONNECTING PIPING CONSIDERATIONS
FOR REMOTE EVAPORATORS
NOTE: As a component supplier, YORK assumes no
warranty responsibility for system operation
or failures associated to improper or inad-
equate piping design or valve selection.
In the case of field-assembled direct expansion refriger-
ation systems, we wish to present these concerns to
bring awareness to the consulting engineer, the mechani-
cal contractor, the control manufacturer, and the con-
struction and service mechanics, of the need to take
proper steps in the design and installation of such refriger-
ation components, to minimize the problems and assure
continued satisfactory operation of the air conditioning
system.
For more specific details on how to address the engi-
neering concerns listed below, refer to York Design Data,
Form 215.05 TM or ASHRAE 1994 Refrigeration Hand-
book, Chapter 2, System Practices for Halocarbon Re-
frigerants.
GENERAL
When designing piping system for split system air condi-
tioning, consideration must be given to the following
principal concerns:
1. Suction line pressure drop due to friction.
2. Liquid line pressure drop due to friction, and the pres-
sure drop associated with a vertical rise, or pressure
gain associated with a vertical drop, which is typically
encountered in the liquid refrigerant line(s).
3. Pipe lines for vertical suction piping (upward flow) must
be designed and selected so that gas flow velocity at
minimum step of compressor capacity will allow proper
oil return. The ASHRAE Handbook contains tables for
checking this. The system designer may need to in-
corporate a double-riser to ensure continuous oil re-
turn over the various operating conditions.
4. Typically, all horizontal vapor lines should be pitched
at least 1/4 inch per foot in the direction of refrigerant
flow to aid oil return to the compressor. When not fea-
sible, a dead end suction trap must be used, and the
line should be pitched towards the trap.
5. All vertical lines (upward flow) exceeding 3 feet should
have a P Trap at the bottom.
6. Selection, location and piping of refrigerant accesso-
ries.
7. Pipe routing and isolation to minimize vibration and
sound transmission; insulation concerns must be ad-
dressed also.
SPECIAL CONCERNS FOR YORK RECIP CHILLERS
YORK compressors are equipped with a capacity control
system that will automatically adjust (reduce) the com-
pressor pumping capacity by unloading one or more
cylinder banks. It is important to understand that the pip-
ing system for unloading type compressors must include
proper design features to provide oil return at full load
capacity as well as minimum capacity flow rates. The
following table (Table 2) lists the flow rate in tons capac-
ity for JG and JS compressors operating at air condition-
ing conditions.
* Compressors may have some or all steps of unloading capacity.
Approximate flow rates for Style JG and JS compres-
sors are listed above and may be used for suction line
sizing on comfort cooling (44F chilled liquid) in conjuction
with ASHRAE 1994 Refrigeration Handbook, Chapter 2,
System Practices for Halocarbon Refrigerants. Lower
operating temperatures will result in corresponding lower
tonnages.
YORK
LOADED CAPACITY
COMPRESSOR % LOAD
MODEL*
CYLINDERS (TONS)
6 68 100
JG/JS 63 4 45 66
2 22 33
6 83 100
JG/JS 64 4 55 66
2 28 33
8 92 100
JG/JS 83
6 79 75
4 46 50
2 23 25
8 110 100
JG/JS 84
6 82 75
4 55 50
2 27 25
TABLE 2
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YORK INTERNATIONAL
NOTES:
1. See Table 1 for YORK Supplied Parts List.
2. This wire may be red or white in color.
3. Refer to Interconnecting Piping Consider-
ations on Page 3.
4. Apply heat conductive compound in well
to insure reliable thermocontact between
bulb & cooling liquid.
5. Evaporator should be installed at or below
the base of the condensing unit.
FORM 150.70-NM2.1
5
YORK INTERNATIONAL
FIG. 1 SUCTION LINES
LD02730
6
YORK INTERNATIONAL
6. TWO (2) chilled water flow switches, (either by YORK or others) MUST be installed in the leaving water piping of
each cooler. There should be a straight horizontal run of at least 5 diameters on each side of the switch. Adjust the
flow switch paddles to the size of pipe in which it is to be installed. (See manufacturers instructions furnished with
switch). The switches are to be wired to terminals in the control panels as shown in the WIRING DIAGRAM as
shown on pages 24 and 30 of the IOM. Two sets of contacts MUST be wired to the chiller; one pair of contacts to
the master panel and one pair of contacts to the slave panel. This is necessary to allow both micros to shut down
all 3 compressors immediately, when the flow switch opens. Otherwise, a time delay on complete chiller shutdown
will occur due to delays in communication on the RS-485 communication link and the possibility of evaporator
damage. NEVER connect a single flow switch contact to both control panels. It is important that the power
supplies in each control panel remain electrically isolated.
WARNING: Flow switch must not be used to stop and start chiller. It is intended only as a safety switch.
LD02736
YORK SUPPLIED PIPING COMPONENTS
FORM 150.70-NM2.1
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YORK INTERNATIONAL
FIG. 2 LIQUID LINES
LD02731
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YORK INTERNATIONAL
ELECTRICAL WIRING
General The chiller is shipped with all factory mounted
controls and power wiring for all components located in
the chiller package. Field control wiring will be necessary
for the flow switch, liquid line solenoid valve, water temp
sensors, and the cooler heater.
All other wiring connections (incoming power, etc.) will
be covered in the Installation, Operation, and Service
Manual, Form 150.65-NM2.
Field Control Wiring The field mounted and remote
cooler components listed below will require connection
to the control panel.
1. Flow Switch
A chilled water flow switch, (either by YORK or others)
must be installed in the leaving water piping of the
cooler. There should be a straight horizontal run of at
least 5 diameters on each side of the switch. Adjust
the flow switch paddle to the size of the pipe in which
it is installed. (See manufacturers instructions fur-
nished with the switch.)
WARNING: The flow switch must not be used to stop
and start the chiller. It is intended only as
a safety switch. Interlock the flow switch
with the start/stop contacts. If the start/
stop contacts are activated by an induc-
tive load (water pump contactor, etc.), the
relay/contactor coil must be suppressed.
Use Suppressor 031-00808-000.
YORK ASSUMES NO WARRANTY RESPONSIBIL-
ITY FOR DAMAGE CAUSED BY EQUIPMENT
CYCLED DIRECTLY FROM A FLOW SWITCH.
Flow switch controls should be connected to TB3 ter-
minal block of the control panel between terminals 13
and 14 (Fig. 1).
Flow switch wiring should be 2-CONDTR (20 AWG
300V) with foil shield and drain wire: ALPHA 5462,
BELDEN 9320, or QUABBIN 0165 (supplied by oth-
ers). The drain wire at the panel should be connected
to the panel chassis; the opposite end at the switch
should be left unconnected and taped off.
2. Entering Water Temp Sensor
Fill the temperature well (Fig. 1) to a depth of 3 inches
with heat conductive compound. Insert the sensor in
the well and ensure it is placed on the bottom of the
well.
Assemble a proper length cable as shown in Fig. 2
between the sensor and plug J11 of the microproces-
sor board. Follow the instructions provided in Fig. 2 for
assembly. Assure that the proper wire and tools noted
are utilized.
Connect the cable to the sensor and plug J11 of the
microprocessor board, as shown in Fig. 1.
3. Leaving Water Temp Sensor
Fill the temperature well to depth of 3 inches with heat
conductive compound. Insert the sensor in the well
and ensure it is placed on the bottom of the well.
Assemble a proper length cable as shown in Fig. 2
between the sensor and plug J11 of the microproces-
sor board. Follow the instructions provided in Fig. 2 for
assembly. Assure that the proper wire and tools noted
are utilized.
Connect the cable to the sensor and plug J11 of the
microprocessor board as shown in Fig. 1.
4. Liquid Line Solenoid Valves
Connect SYS 1 Liquid Line Solenoid Valve wiring to
terminals SP1 and 2 (J compressors) in Compressor
No. 1 Motor Terminal Box. See Fig. 3. The control panel
will supply a 115VAC signal to energize the solenoid
valve. An RC Suppressor (P/N 031-00808-000) MUST
be connected across terminals SP1 and 2 (J com-
pressors).
Connect SYS 2 Liquid Line Solenoid Valve wiring to
terminals SP1 and 2 (J compressors) in Compressor
No. 2 Motor Terminal Box. See Fig. 3. The control panel
will supply a 115VAC signal to energize the solenoid
valve. An RC Suppressor (P/N 031-00808-000) MUST
be connected across terminals SP1 and 2 (J com-
pressors).
5. Cooler Heater
Connect the Cooler Heater wiring to terminals SP2
and 2 in Compressor No. 1 Motor Terminal Box. See
Fig. 3. An RC Suppressor (P/N 031-00808-000) MUST
be connected across terminals SP2 and 2.
FORM 150.70-NM2.1
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YORK INTERNATIONAL
FIG. 3 TEMP. SENSOR CABLE CONSTRUCTION DETAILS
SENSOR END PLUG ASSY
(See Fig. 1 for J11 Plug Connection)
NOTES:
1. All cable components supplied (except as noted)
2. Hand tools required to terminate contact terminals:
AMP Service Tool No. 1 #90287-1 or For Terminal
AMP Super Champ Ft. #69758-2 (AMP #173707-1)
AMP Service Tool #724651-1
For Terminal
(AMP #170362-1)
3. It is absolutely necessary to orient wires per data shown above
and cable connection info chart in Fig. 1.
}
}
LD01409(r)
LD02729
YORK SUPPLIED ELECTRICAL PARTS
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YORK INTERNATIONAL
FIG. 4 COMPRESSOR TERMINAL BOX WIRING
TABLE 3 EPROMS
EPROMS FOR 3-MODULE UNITS
USAGE MASTER PANEL SLAVE PANEL
STANDARD R-22 031-01652-010 031-01652-011
R-134A 031-01652-012 031-01652-013
LD02732
FORM 150.70-NM2.1
11
YORK INTERNATIONAL
P.O. Box 1592, YORK, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA
Copyright by YORK International Corporation 1997 ALL RIGHTS RESERVED
Form 150.70-NM2.1 (398)
Supersedes: Nothing