INSTALLATION Supersedes: Nothing Form 150.70-NM2.1 (398)

REMOTE EVAPORATOR OPTION FOR250 - 350 TON AIR COOLED CHILLERS

60 HZ MODELSYEAJ777PX6, YEAJ878PX6, YEAJ888RX6, YEAJ999RY6

50 HZ MODELSYEAJ777PX7, YEAJ977PX7, YEAJ979RX7, YEAJ999RX7

STYLE A*

200, 230, 460-3-60

26214A

*With EPROMS & (Standard, Brine & Metric Models, Comb ined)

MASTER* SUBORDINATE** For EPROM’s See Page 10.

2 YORK INTERNATIONAL

REMOTE EVAPORATOR OPTION

GENERAL

The Remote Evaporator option allows an architect to placethe evaporator inside the conditioned space. This helpseliminate 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. Aninitial oil charge will also be included in the compressor.

CAUTION: THE FIELD PIPING SYSTEM MUST BEEVACUATED BEFORE CHARGING.

After placing the system in operation, it is important toverify that the proper refrigerant charge has been installedby checking sub-cooling. See page 70 of Form 150.65-NM2.

This form is intended to be used as a supplement toForm 150.65-NM2. Use Form 150.65-NM2 for all installa-tion, start-up, and operation instructions not outlined inthis supplement.

Inventory the parts included with the Remote CoolerOption and compare them to the list in Table 1. Assurethat 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 RESPONSIBILITYFOR SYSTEM OPERATION OR FAILURES DUE TOIMPROPER PIPING OR PIPING DESIGN.

General – When the unit has been located in its finalposition, the unit piping may be connected. Normal in-stallation precautions should be observed in order to en-sure reliable operation and serviceability. System pipingshould conform to ASHRAE guidelines.

Threaded Connections on the cooler refrigerant pipingare NOT intended for threaded field connection. They areused 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 tofacilitate servicing of unit. Avoid eliminating service valvesin favor of cost cutting.

WARNING: Any section of a line that has a potential tobe subject to hydrostatic expansion mustbe relieved.

Piping Connection Points – Each system liquid linewill include a field connection shutoff valve (stop valve)with charging port located on each condenser circuit (SeeFig. 1). Suction line connections are provided on eachcompressor at the suction valve (See Fig. 1). Field refrig-erant piping can be connected to the condensing unitwithout loss of the holding charge in the unit.

Liquid Line Solenoids and Expansion Valve Mount-ing – Liquid line solenoids and expansion valves mustbe mounted with the arrow on the devices pointing in thedirection of refrigerant flow. The expansion valve sensingbulbs should be mounted and clamped securely on anewly cleaned pipe in the 4 or 8 o’clock position. Thebulb and pipe must then be properly insulated.

All expansion valves, filter driers, sight glasses, and liq-uid line solenoid valves are YORK supplied and installedby others. Refrigerant field piping is supplied and installedby others (See Fig. 1).

For liquid lengths greater than 60 feet, a liquid line re-ceiver may be required to accommodate the additionalrefrigerant charge quantity of the system, otherwise thetotal condenser pumpdown capacity may be exceeded.

ITEM QTY DESCRIPTION1 2 Temperature Sensor2 6 Contact Socket3 4 Contact Receptacle4 4 Rubber Collar5 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 alternatevalve selection if chilled water temperatures below 44°F are de-sired.

TABLE 1 – PARTS LIST

WARNING

OPERATION WITH IMPROPER THERMAL EXPAN-SION VALVE SIZE WILL VOID WARRANTY.

FORM 150.70-NM2.1

3YORK INTERNATIONAL

INTERCONNECTING PIPING CONSIDERATIONSFOR REMOTE EVAPORATORS

NOTE: As a component supplier, YORK assumes nowarranty responsibility for system operationor 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 tobring awareness to the consulting engineer, the mechani-cal contractor, the control manufacturer, and the con-struction and service mechanics, of the need to takeproper steps in the design and installation of such refriger-ation components, to minimize the problems and assurecontinued satisfactory operation of the air conditioningsystem.

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 followingprincipal 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 pressuregain associated with a vertical drop, which is typicallyencountered in the liquid refrigerant line(s).

3. Pipe lines for vertical suction piping (upward flow) mustbe designed and selected so that gas flow velocity atminimum step of compressor capacity will allow properoil return. The ASHRAE Handbook contains tables forchecking 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 pitchedat least 1/4 inch per foot in the direction of refrigerantflow to aid oil return to the compressor. When not fea-sible, a “dead end suction trap” must be used, and theline should be pitched towards the trap.

5. All vertical lines (upward flow) exceeding 3 feet shouldhave a “P Trap” at the bottom.

6. Selection, location and piping of refrigerant accesso-ries.

7. Pipe routing and isolation to minimize vibration andsound transmission; insulation concerns must be ad-dressed also.

SPECIAL CONCERNS FOR YORK RECIP CHILLERS

YORK compressors are equipped with a capacity controlsystem that will automatically adjust (reduce) the com-pressor pumping capacity by “unloading” one or morecylinder banks. It is important to understand that the pip-ing system for unloading type compressors must includeproper design features to provide oil return at full loadcapacity as well as minimum capacity flow rates. Thefollowing 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 linesizing on comfort cooling (44°F chilled liquid) in conjuctionwith ASHRAE 1994 Refrigeration Handbook, Chapter 2,“System Practices for Halocarbon Refrigerants”. Loweroperating temperatures will result in corresponding lowertonnages.

YORKLOADED CAPA CITY

COMPRESSOR % LOADMODEL*

CYLINDERS (TONS)

6 68 100JG/JS 63 4 45 66

2 22 336 83 100

JG/JS 64 4 55 66

2 28 338 92 100

JG/JS 836 79 75

4 46 502 23 258 110 100

JG/JS 846 82 754 55 502 27 25

TABLE 2

4 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 betweenbulb & cooling liquid.

5. Evaporator should be installed at or belowthe base of the condensing unit.

FORM 150.70-NM2.1

5YORK 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 ofeach 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 subordinate 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

7YORK INTERNATIONAL

FIG. 2 – LIQUID LINES

LD02731

8 YORK INTERNATIONAL

ELECTRICAL WIRING

General – The chiller is shipped with all factory mountedcontrols and power wiring for all components located inthe chiller package. Field control wiring will be necessaryfor the flow switch, liquid line solenoid valve, water tempsensors, and the cooler heater.

All other wiring connections (incoming power, etc.) willbe covered in the Installation, Operation, and ServiceManual, Form 150.65-NM2.

Field Control Wiring – The field mounted and remotecooler components listed below will require connectionto 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 thecooler. There should be a straight horizontal run of atleast 5 diameters on each side of the switch. Adjustthe flow switch paddle to the size of the pipe in whichit is installed. (See manufacturer’s instructions fur-nished with the switch.)

WARNING: The flow switch must not be used to stopand start the chiller. It is intended only asa safety switch. Interlock the flow switchwith the start/stop contacts. If the start/stop contacts are activated by an induc-tive load (water pump contactor, etc.), therelay/contactor coil must be suppressed.Use Suppressor 031-00808-000.

YORK ASSUMES NO WARRANTY RESPONSIBIL-ITY FOR DAMAGE CAUSED BY EQUIPMENTCYCLED DIRECTLY FROM A FLOW SWITCH.

Flow switch controls should be connected to TB3 ter-minal block of the control panel between terminals 13and 14 (Fig. 1).

Flow switch wiring should be 2-CONDTR (20 AWG300V) 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 connectedto the panel chassis; the opposite end at the switchshould 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 inthe well and ensure it is placed on the bottom of thewell.

Assemble a proper length cable as shown in Fig. 2between the sensor and plug J11 of the microproces-sor board. Follow the instructions provided in Fig. 2 forassembly. Assure that the proper wire and tools notedare utilized.

Connect the cable to the sensor and plug J11 of themicroprocessor board, as shown in Fig. 1.

3. Leaving Water Temp Sensor

Fill the temperature well to depth of 3 inches with heatconductive compound. Insert the sensor in the welland ensure it is placed on the bottom of the well.

Assemble a proper length cable as shown in Fig. 2between the sensor and plug J11 of the microproces-sor board. Follow the instructions provided in Fig. 2 forassembly. Assure that the proper wire and tools notedare utilized.

Connect the cable to the sensor and plug J11 of themicroprocessor board as shown in Fig. 1.

4. Liquid Line Solenoid Valves

Connect SYS 1 Liquid Line Solenoid Valve wiring toterminals SP1 and 2 (“J” compressors) in CompressorNo. 1 Motor Terminal Box. See Fig. 3. The control panelwill supply a 115VAC signal to energize the solenoidvalve. An RC Suppressor (P/N 031-00808-000) MUSTbe connected across terminals SP1 and 2 (“J” com-pressors).

Connect SYS 2 Liquid Line Solenoid Valve wiring toterminals SP1 and 2 (“J” compressors) in CompressorNo. 2 Motor Terminal Box. See Fig. 3. The control panelwill supply a 115VAC signal to energize the solenoidvalve. An RC Suppressor (P/N 031-00808-000) MUSTbe connected across terminals SP1 and 2 (“J” com-pressors).

5. Cooler Heater

Connect the Cooler Heater wiring to terminals SP2and 2 in Compressor No. 1 Motor Terminal Box. SeeFig. 3. An RC Suppressor (P/N 031-00808-000) MUSTbe connected across terminals SP2 and 2.

FORM 150.70-NM2.1

9YORK 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 TerminalAMP 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

10 YORK INTERNATIONAL

FIG. 4 – COMPRESSOR TERMINAL BOX WIRING

TABLE 3 – EPROMS

EPROMS FOR 3-MODULE UNITSUSAGE MASTER PANEL SUBORDINATE PANEL

STANDARD R-22 031-01652-010 031-01652-011R-134A 031-01652-012 031-01652-013

LD02732

FORM 150.70-NM2.1

11YORK INTERNATIONAL

Proud Sponsorof the 1998U.S. Olympic Team

36USC380

P.O. Box 1592, YORK, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USACopyright © by YORK International Corporation 1997 ALL RIGHTS RESERVEDForm 150.70-NM2.1 (398)Supersedes: Nothing