Johnson Controls YORK YPC Series Installation Manual Download Page 3

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JOHNSON CONTROLS

FORM 155.17-N1

ISSUE DATE: 4/1/2013

CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls’ policy for contin-

uous product improvement, the information contained

in this document is subject to change without notice.

Johnson Controls makes no commitment to update or

provide current information automatically to the man-

ual owner. Updated manuals, if applicable, can be ob-

tained by contacting the nearest Johnson Controls Ser-

vice office or accessing the Johnson Controls QuickLIT

website at

http://cgproducts.johnsoncontrols.com

Operating/service personnel maintain responsibility for

the applicability of these documents to the equipment.

If there is any question regarding the applicability of

these documents, the technician should verify whether

the equipment has been modified and if current litera-

ture is available from the owner of the equipment prior

to performing any work on the chiller.

CHANGE BARS

Revisions made to this document are indicated with a

line along the left or right hand column in the area the

revision was made. These revisions are to technical in-

formation and any other changes in spelling, grammar

or formatting are not included.

MANUAL DESCRIPTION

FORM NUMBER

Service Policy

50.15-NM

Operation and Maintenance - York - Two-Stage Direct-Fired and Steam Absorption Chillers/Heaters

155.17-OM1

Field Control Modifications Diagram For Millennium™ YPC Control Center

155.17-PA1

Wiring Diagram - York- Two-Stage Direct-Fired Absorption Chiller

155.17-W1

Wiring Diagram - York- Two-Stage Steam-Fired Absorption Chiller

155.19-W1

ASSOCIATED LITERATURE

Summary of Contents for YORK YPC Series

Page 1: ...C FA 12SC THROUGH YPC FZ 19S AND STEAM FIRED YPC ST 14SC THROUGH YPC ST 19S TWO STAGE ABSORPTION CHILLERS INSTALLATION Supersedes 155 17 N1 900 Form 155 17 N1 413 LD17247 LD17267 Issue Date April 1 2013 Steam Fired Direct Fired ...

Page 2: ...ls This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to specific situations Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken Indicates a potentially haza...

Page 3: ...arding the applicability of these documents the technician should verify whether the equipment has been modified and if current litera ture is available from the owner of the equipment prior to performing any work on the chiller CHANGE BARS Revisions made to this document are indicated with a line along the left or right hand column in the area the revision was made These revisions are to technica...

Page 4: ...7 208 3 60 28 230 3 60 46 460 3 60 50 380 3 60 Size 12SC through 19S Heat Source With Power Flame Burners FN Direct Fired Natural gas only FD Direct Fired Natural gas No 2 oil FO Direct Fired No 2 oil only FX Direct Fired Other Fuels FL Direct Fired Natural gas with low NOx FGR only FP Direct Fired Natural gas with low NOx FGR No 2 oil With Weishaupt Burners FE Direct Fired Natural gas only FZ Dir...

Page 5: ...Water Piping 24 Tower Water Cross Over Line 24 Three way Mixing Valve 26 SECTION 7 TOWER WATER TREATMENT 27 SECTION 8 RUPTURE DISK PIPING INSTALLATION 29 SECTION 9 HIGH TEMPERATURE GENERATOR INLET STEAM PIPING 31 Pressure 31 Flow 31 Piping 31 Inlet steam piping components 31 Manual Block Valve 31 Automatic Shut Off Valve 31 Steam Separator 32 Steam Strainer 32 Pressure Regulator Not Shown in Fig 1...

Page 6: ...D COMBUSTION BURNER FRESH AIR INTAKE DUCT SIZING 57 ACFM SCFM x 460 TAIR F 57 537 57 SECTION 19 CHIMNEY DESIGN AND DRAFT THEORY 59 Draft 59 Draft control serves two important functions for the ParaFlowTM Direct Fired units 59 Draft depends on two important factors 59 Temperature Difference 59 Chimney Height 59 Chimney Design Theory 60 Available Draft Da 60 Theoretical Draft Dt 60 Pressure Drop dP ...

Page 7: ... 75 Oil Piping Design 75 SECTION 27 SIMULTANEOUS OPERATION WHERE APPLICABLE 77 Direct Fired 77 SECTION 28 TYPICAL NOISE AND VIBRATION LEVELS 79 SECTION 29 ELECTRICAL CONNECTIONS 81 Electrical Connections 81 Wiring the Purge Pump 81 Field Control Modifications and Safety Devices 81 Flow Switches 82 Control of Customer System Pumps 82 Energy Management Systems Wir ing 83 SECTION 30 INSULATION 85 Ins...

Page 8: ...FIGURE 28 Theoretical Stack Effect 61 FIGURE 29 Manual Motorized Backdraft Damper With FGR Connection 63 FIGURE 30 Gauge Pressure Profile Chimney System With Barometric Control 65 FIGURE 31 Barometric Control 66 FIGURE 32 Gauge Pressure Profile Chimney System With Sequential Draft Control 67 FIGURE 33 Sequential Draft Control 68 FIGURE 34 Gas Train Valve Testing 73 FIGURE 35 Gas Piping Design 74 F...

Page 9: ...ty Of 0 60 89 TABLE 8 Correction Factors 89 TABLE 9 Equivalent Length Of Fittings Ft 89 TABLE 10 Oil Pump Suction Capacity And Filter Selection Chart For Power Flame Burners 90 TABLE 11 Combustion Air Requirements For Power Flame Burners 90 TABLE 13 Electrical Data Steam Fired Units 90 TABLE 12 Weishaupt Burner Oil Pump Capacities 91 TABLE 14 Electrical Data Direct Fired Units 92 TABLE 15 S Unit R...

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Page 11: ...oblems or contamination of other systems Follow standard engineering practice in designing the piping systems and other services Adequate support must be provided for system piping so that no weight is placed on the unit s water boxes and connecting nozzles This manual provides the installing contractor with all the necessary information to do the following 1 Define the scope of his work 2 Accurat...

Page 12: ...um of 42 inches of service space is rec om mend ed along each side of the unit Tube pull space equivalent to one unit length must be provided on at least one end of the main unit shell The end opposite the tube pull end should be allowed 60 inches of ser vice clear ance Refer to Appendix A Unit Weights and Dimensions for specific Unit Clearance Data Leave at least 20 inches of space above the unit...

Page 13: ...TION OF UNIT VERIFICATION OF UNIT HOLDING CHARGE OR VACUUM When a unit is charged with lithium bromide a nitro gen blanket is ap plied to the unit which is indicated on the unit s pres sure gauge by a black mark This pres sure gauge must be inspected when the unit ar rives at the jobsite to ensure that no leakage has oc curred during ship ment If the needle on the pressure gauge is significantly l...

Page 14: ...pture disk piping is completed and meets all local building codes NO strain on Rupture disk flange 11 Chilled and condenser water hot water or steam flow available to meet unit design re quirements 12 All pressure relief devices including unit rup ture disk are vented to a safe area 13 All appropriate flow devices are installed and functional 14 All operating valves are open 15 Purge pump is mount...

Page 15: ...stem been leak tested and purged of air 4 Is the proper oil pressure available at the inlet to the controls e electrical wiring 1 Wiring completed from customers main power supply fused disconnect switch to power panel on unit 2 External control wiring completed from control panel to flow switches vacuum pump motor etc in accordance with YORK wiring diagram Direct fired 155 17 W1 or Steam fired 15...

Page 16: ...quired through no fault of Johnson Controls Month Day Year Name Phone customer contractor signature _______________________________________ form completed by _______________________________________ _______________________________________ title contractor s responsiBilities and instructions to use forM This installation checklist provides a quick way to check if all necessary installation work was ...

Page 17: ... brack ets pumps valves pipes fittings etc 6 Do not lift the unit using the holes at the corners of the end sheets These holes are manufacturing lift ing holes and are not designed for lifting the com bined weight of a completely as sem bled unit FOUNDATION Unit foundations are usually made from concrete with a compressive strength rating of not less than 4000 psi and are able to support the full ...

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Page 19: ...n units re quire specialized handling when cutting or welding Only trained John son Controls personnel are considered qualified to su per vise or perform this work ASSEMBLY GUIDELINES 1 Never allow the introduction of dirt or foreign particles into the unit during the reassembly pro cess 2 Never weld on any pressure vessel or when the pressure vessel is in a vacuum 3 Always open valves when weldin...

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Page 21: ...HEET WATER LEVEL S style units are built on a skid and require that the unit be level within 1 inch in 1000 S style units also have punch marked and scribed level lines on the tube sheet which are identified by a lev el ing sticker at each line on the chill er tube sheets LEVELNESS CHECK Use a transparent or semitransparent flexible hose As shown in Figure 4 on page 21 check the lev els of points ...

Page 22: ... the foundation with anchor bolts after leveling the unit See Figure 4 on page 21 BOTTOM OF UNIT ANCHOR BOLT 4 12 3 8 FLOOR MIN 4 Figure 6 S MODEL UNITS ld05300 ANCHOR BOLT BOTTOM OF UNIT B C FLOOR A D Figure 7 G MODEL UNITS ld05301 Table 1 ANCHORING DIAGRAM DIMENSIONS UNIT A B C D 18G 19 1 2 5 minimum 19 1 2 4 19G 19 1 2 5 minimum 19 1 2 4 19GL 19 1 2 5 minimum 19 1 2 6 20G 19 1 2 5 minimum 19 1 ...

Page 23: ...th offsets for flex i bil i ty and adequately supported and braced indepen dently of the unit to avoid strain on the unit and vibra tion trans mis sion Hangers must allow for alignment of pipe Iso la tors by others in the piping are not nec es sary but may be desirable and may be required by customer spec i fi ca tions Upon completion of the unit piping a connection in each line as close to the un...

Page 24: ...re differential switch is to ensure both the sam ple points are on the same elevation with other If one connection is higher than the other then static pressure becomes a factor into the total differential across the switch The switch could be reading a differential un der this con di tion even when there is no flow STRAINERS Permanent strainers supplied by others are required in all the absorptio...

Page 25: ...le to the size of the pipe in which it is to be used Trim extended pad 2 row mark on side of casting must point in same direction as liquid flow 3 The Flow Switch can be installed in either the in let flow or outlet flow connections 4 Before installing Item 2 make sure it is 1 inch long maximum DIAMETER OF PIPE INCHES L DIMENSION INCHES 5 4 5 8 6 5 5 8 8 and Larger Full Paddle ITEM DESCRIPTION 1 S...

Page 26: ...Up section of this doc u ment is recommended to con trol tow er wa ter tem per a ture This valve could be installed at either the inlet side di vert ing flow or outlet side mixing flow of the cool ing tower The sizing of this valve is crit i cal and should be left up to the build ing pip ing en gi neer to prop er ly size the valve so that de sign chill er flow can be maintained under all op er at ...

Page 27: ...tions must not cause deposits on the metal surfaces and must remain effective under a broad range of pH temperature water quality and heat flux Furthermore the inhibitor package must prevent scale formation and disperse deposits while having a minimal environ mental impact when discharged Water samples should be collected and analyzed on at least a monthly basis by the water treatment spe cialist ...

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Page 29: ...isk itself Never run the rupture disk vent piping at a higher el e va tion than the rupture disk doing so will im pose an un de sir able stat ic head back pres sure which the unit must first over come before re liev ing the in ter nal pressure within the unit Run the rup ture disk vent pip ing over to a floor drain and ter mi nate about 10 12 inch es above the drain as shown in Figure 11 on page 2...

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Page 31: ...be giv en to steam flow ve loc i ty especially in those ap pli ca tions where noise is a factor Generally speaking steam ve loc i ties up to 6 000 fpm 30 m s will not pro duce an objectionable noise lev el Always pitch the steam sup ply line to pre vent steam or water ham mer ing The factory supplied steam control valve must be in stalled as close as possible to the high temperature generator stea...

Page 32: ...d from these two gauges increases to an unacceptable level the steam strainer should be re moved and cleaned PRESSURE REGULATOR NOT SHOWN IN FIG 12 A pressure regulator is not needed in all cases It is only necessary if the steam supply pres sure to the unit will exceed 128 PSIG 8 83 bar If the steam supply pressure is known to fluctuate it is rec om mend ed that a steam pressure regulator be used...

Page 33: ...ONDENSATE COOLER S NEEDLE VALVE CONDENSATE SOLENOID VALVE 8 SPOOL PIECE ADJUSTABLE CONDENSATE BACK PRESSURE VALVE GLOBE VALVE CONDENSATE OUTLET PRESSURE INDICATOR STEAM INLET PRESSURE GAUGE STEAM CONTROL VALVE SUPPLIED BY YORK RELIEF VALVE STEAM SEPARATOR STEAM SUPPLY INLET MANUAL BLOCK VALVE AUTOMATIC SHUT OFF VALVE FAIL CLOSE STEAM TRAP 50 MESH STRAINER CONDENSATE RETURN SYSTEM H 1 H 2 ...

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Page 35: ...s customer supplied adapt er must be installed at the outlet condensate flange of the unit A flow me ter will be temporarily installed at this lo ca tion dur ing start up to fine tune the condensate flow setting valve CONDENSATE OUTLET PRESSURE INDICATOR Customer supplied The pres sure immediately before the Con den sate Back Pressure Valve must be read at this lo ca tion ADJUSTABLE CONDENSATE BAC...

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Page 37: ...and develop action plans based on these anal yses A third party consulting company can help over see the treatment programs in order to properly protect the physical plant and avoid costly downtime It is equally important that the owner operator of the equipment performs an inspection of the genera tor tubes at the frequencies recommended in the Tube Maintenance Section the Preventive Maintenance ...

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Page 39: ...nd proven with combustion test equipment to provide the highest practical carbon dioxide with a clean flame All ParaFlowTM standard shipment absorption units have the burn er preinstalled at the Johnson Controls factory The units are shipped with the burner pre wired to the appropriate con trol pan el A remote fuel oil pump is shipped sep a rate ly on gas oil units Gas train components will always...

Page 40: ...Shut off Cock Main Gas Pressure Regulator Low Gas Pressure Switch Redundant Main Gas Solenoid Valve Gas Train Junc tion Box Main Gas Valve w Proof of Clo sure Switch Manual Gas Check ing Cock Gas Valve Leak Test Valves Flow Direction Figure 14 TYPICAL BURNER ASSEMBLY FOR DIRECT FIRED S MODEL UNITS LD05307 ITEM NAME 01 Base For Oil Pump Unit 02 Support For Oil Pump 03 Gas Supply Piping 04 Oil Suppl...

Page 41: ... Off Valve 17 Oil Pump Unit 18 Oil Filter 19 Oil Compound Gauge 20 Burner Unit 21 Burner Control Panel NOTE SOME OF THE EQUIPMENT LISTED MAY NOT BE APPLICABLE TO ALL INSTALLATIONS SHELL CENTER LINE SHELL CENTER LINE SHELL CENTER LINE SHELL CENTER LINE OIL RETURN OIL SUPPLY YORK YORK YORK 21 11 19 14 15 17 6 1 19 18 5 4 10 16 6 15 20 2 3 2 13 12 9 8 7 6 Figure 15 TYPICAL BURNER ASSEMBLY FOR DIRECT ...

Page 42: ...LEFT SIDE VIEW Pilot Assembly Access Flame Sensor Combustion Blower Motor Burner Junc tion Box Pilot Solenoid Valves Air Proving Switch Pre mix Air Adj Knob Ignition Cable Pilot Ignition Transformer 00271VIP Figure 18 TYPICAL BURNER COMPONENTS FRONT END Air Diffusers Flame Retention Firing Head Oil Nozzle Over Fire Draft Port 00272VIP DETAIL ...

Page 43: ...IP Combustion Blower Motor Low Oil Pressure Switch Oil By pass Pres sure Gauge Burner Junc tion Box Oil Modulating Valve Flame Sight Glass Oil Solenoid Valves Pilot Ignition Transformer Pilot Gas Regulator Pilot Gas Valves Firing Rate Modulating Motor Motorized Gas Valve Figure 19 TYPICAL BURNER COMPONENTS BACK END ...

Page 44: ... TAP USE TAPPED VALVE UNLESS TAPPED NIPPLE IS SUPPLIED DIRT LEG WITH CAP EXTEND TO FLOOR MAIN GAS SHUTOFF COCK WITH HANDLE MAIN GAS PRESSURE REGULATOR GAS SUPPLY PILOT SHUT OFF COCK PILOT PRESSURE REGULATOR VENT TO ATMOSPHERE DO NOT USE TEFLON TAPE GAS TRAIN TO BE PREPIPED FACTORY PIPED FIELD PIPED CAUTION ALL FIELD PIPING MUST BE MOUNTED IN THE PROPER LOCATION AND IN PROPER DIRECTION OF GAS FLOW ...

Page 45: ...ers the max i mum main gas train and or pilot gas train com po nents pressure is 1 2 PSIG 14 W C Refer to the tables in Appendix A Tables at the back of this doc u ment for information relating to the sizing of gas supply piping These tables are based on the general flow char ac ter is tics of commercially produced black wrought iron pipe If in doubt regarding the flow capabilities of a cho sen li...

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Page 47: ...commended that the connec tion to the pump be of copper tubing complete with a vibration damp en ing loop on both the suction and return lines Copper tubing with flare fittings or iron pipe is to be used on all installations All units must utilize the proper size and type of suction line oil fil ters See Table 10 on page 90 in Appendix A at the back of this document for prop er oil filter usage So...

Page 48: ...TIONAL S STANDARD SCOPE OF SUPPLY PROJECT SPECIFIC BURNER SUBMITTAL WILL BE SUPPLIED UNDER SEPARATE COVER LD05312 Figure 24 OIL PIPING SCHEMATIC FOR WEBSTER C STYLE PUMP LD05313 DO NOT USE TEFLON TAPE FACTORY PIPED FIELD PIPED CAUTION ALL FIELD PIPING MUST BE MOUNTED IN THE PROPER LOCATION AND IN PROPER DIRECTION OF GAS FLOW NOTE THIS DRAWING DEPICTS YORK INTERNATIONAL S STANDARD SCOPE OF SUPPLY P...

Page 49: ...ARD RETURN END DETAIL A CIRCULATING OIL RESERVOIR MAY BE PLACED HORIZONTALLY SEE DETAIL A RETURN TO TANK INLET FROM TANK STANDBY EQUIPMENT SAME AS BELOW FILL TEE WITH PLUG HIGHEST POINT VENT VACUUM BREAKER PRESSURE GAUGE COMPOUND GAUGE SNUBBER OIL STRAINER OR FILTER FUSIBLE VALVE CHECK VALVE SHUTOFF VALVE COMPOUND GAUGE CHECK VALVE POWER FLAME PUMP SET RETURN LINE PRESSURE TEST BURNER FUSIBLE VALV...

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Page 51: ...stance the fuel unit is above the top of the tank add 1 of vacuum for every 1 foot of lift 6 Add the two values obtained in steps 4 and 5 7 If the total obtained in step 6 is over 10 vacu um move to the next graph to the right increase tubing size and re calculate the total inches of vacuum 8 These instructions do not allow for any added restrictions such as the line filter elbows sharp corners ch...

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Page 53: ...as been used with fuel heavier than 2 fuel oil the entire system should be thorough ly cleaned and flushed before filling the tank with the new 2 fuel oil for the first time If iron pipe oil lines are used on underground tanks swing joints utilizing nipples and elbows must be used and joined together making certain the piping con nections are tightened as the tank settles Keep swing joints in the ...

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Page 55: ...der to make cer tain of com pli ance the con trol ling au thor i ties should be con sulted The following is standard field practice and should be used as a minimum All confined mechanical rooms and spaces shall be pro vid ed with two permanent openings one com menc ing within 12 inches 30cm of the ceiling and one com menc ing 12 inches 30cm from the floor Refer to Figure 27 on page 56 for differen...

Page 56: ...ts func tion with in this 180 second time frame so that the burner pan el s Main Flame On con tacts can close Oth er wise a Warning Burner Pan el Mal func tion will ap pear on the YORK pan el dis play and the burn er will need to be manually restarted Consult the Power Flame As Built wiring schematic for location of where the air proving connection ter mi nals are located It is preferred to interl...

Page 57: ... for the chiller in stal la tion a burner intake adapter flange kit can be pur chased through a Power Flame representative The data found in the Com bus tion Air Re quire ments table See Appendix A Tables will offer the field engineer the air intake re quire ments for his burn er at the proper operating conditions For combustion air design temperatures other than what s listed in the Combustion Ai...

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Page 59: ...ed Tem perature differences cause drafts be cause gases such as air occupy different volumes at dif fer ent temperatures For example One cubic foot of air weights 0 0834 lbs at 0 F 17 8 C This same cubic foot of air at 450 F 232 2 C weighs only 0 0422 lbs The amount of mass per specific volume is referred to as density Density decreases as temperature increases and lighter lower density air rises ...

Page 60: ...n Dt is smallest to win ter am bi ent con di tions when Dt is greatest Be cause ParaFlowTM chiller heaters are typ i cal ly required to op erate at high fire throughout the summer months it is im por tant to de sign the chimney system for summer ambient de sign conditions to avoid undersizing When designing the chimney it is recommended to de sign it for a Da of 0 zero inches of water column This ...

Page 61: ... 2013 STACK TEMPERATURE 550 F 287 8 C 500 F 260 0 C 450 F 232 2 C 400 F 204 4 C 350 F 176 7 C 300 F 148 9 C 0 10 20 30 40 50 60 70 80 90 100 0 7 0 6 0 5 0 4 0 3 0 2 0 1 0 DRAFT EFFECT INCHES WATER HEIGHT FEET ABOVE BURNER 60 F 15 6 C AMBIENT TEMPERATURE Figure 28 THEORETICAL STACK EFFECT LD05317 ...

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Page 63: ... conditions re quire Figure 29 on page 63 illustrate two different types of manual backdraft dampers One of these dampers will be supplied by Pow er Flame and shipped loose with each chill er ship ment C D D D H ATTACH TAG PWF 253 TO OUTLET STACK SENSING PORT 2 EACH 12 4 150 FLANGE 12SC 14SC 6 150 FLANGE 15SL 19GL A x 1 2 DRAIN PORT 18 1 4 G B x 1 2 B x 1 4 F TYP 4 SIDES M DIA N HOLES B J TYP I K ...

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Page 65: ...em per a tures drop Dt would in crease If not for the baro met ric draft regulator in place me chanical room air is introduced into the chim ney as in response to the in creased draft thus stabilizing the gauge pressure just upstream of the baro met ric reg u la tor Most barometric regulators can main tain 0 06 inch es water gauge pres sure when properly sized for a particular ap pli ca tion With ...

Page 66: ...ETY SWITCH 1 8 NPT MANUAL DAMPER ASSEMBLY YORK CHILLER HEATER DRAIN VALVE FLANGE A FLANGE A PARAFLOW EXHAUST FLANGE DIMENSIONS PER SUBMITTAL INFORMATION OR SEE APPROPRIATE YORK FORM FLANGE B ROUND END FLANGE OF REMOVABLE TRANSITION PIECE ID DETERMINED BY CHIMNEY SYSTEM DESIGNER ID FLANGE B POINT B BAROMETRIC DRAFT REGULATOR Figure 31 BAROMETRIC CONTROL LD05320 ...

Page 67: ...pplied manual backdraft damper can be modified in the factory if ordered or in the field to mount the motor driver The motor is controlled from a draft control panel which senses the pressure at the out let of the high temperature genera tor The draft control panel is available from Johnson Controls to ship with the chiller see Figure 29 on page 63 for drawing of the motorized damper The pan el is...

Page 68: ...D BY CHIMNEY SYSTEM DESIGNER ID DRAIN VALVE YORK CHILLER HEATER POINT A DAMPER MOTOR YORK SUPPLIED IF ORDERED TEMPERATURE STUB FLANGE FLANGE POINT C POINT B TRANSITION SECTION FITTING FOR TEMPERATURE SAFETY SWITCH DRAFT SENSING LINE STACK DAMPER ACTUATOR WIRING ALL DRAFT PANEL CONNECTIONS MUST BE COMPLETED IN THE FIELD INTERFACE TO BURNER PANEL PANEL SUPPLIED FOR WALL MOUNTING PEDESTAL OPTIONAL DR...

Page 69: ...ld installed into the chimney breech ing be fore the man u al backdraft damp er if pos si ble If this is not pos si ble the probe should be as close as pos si ble down stream of the manual backdraft damp er The probes wires must be connected to the temperature controller in the burner panel The probe will require a 1 8 NPTI coupling which must be sup plied by the field in stall er SECTION 23 HIGH ...

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Page 71: ...e tween 1 0 inch of water column through 6 inches of wa ter column and even high er pressures with some burner mod els 2 The modulating gas butterfly valve normally found on the gas train for Power Flame burn ers is an in te gral part of the Weishaupt burn er mounted directly on the burner hous ing The butterfly valve is spring loaded to fully close the valve if the drive linkage is disconnected 3...

Page 72: ...the number of conduits for the field wiring including the number of wires for each con duit It is recommended that the flame scan ner wires are run in a separate conduit and not in multi wire ca bles Maximum line length for UV monitoring is 97 feet 30 meters For de tails re fer to the flame safe guard man u al Swinging Open The Burner If it becomes necessary to open the burner please fol low the b...

Page 73: ...com po nents with each ship ment However for general in formation and a bet ter understanding of the burner s gas train Figure 35 on page 74 shows the general location of various com po nents in a typ i cal gas train The gas train in Figure 35 on page 74 will vary ac cord ing ly due to local codes firing rates of the burner or gas sup ply pres sure Gas Pilot Line pipe into the main gas train line ...

Page 74: ...DO NOT USE TEFLON TAPE GAS FLOW GAS FLOW GAS BUTTERFLY AND LOCATION OF HIGH GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE SAFETY SHUT OFF VALVE SSOV2 VENT VALVE IF REQUIRED DRIP LEG BY OTHERS MANUAL SHUT OFF VALVE GAS REGULATOR LOW GAS PRESSURE SWITCH IF REQUIRED LOW GAS PRESSURE GAUGE IF REQUIRED SAFETY SHUT OFF VALVE SSOV1 ...

Page 75: ...ter is installed in the oil return line there must be pro tec tion provided for safe ty in the form of a relief valve A blocked oil meter could lead to a burst oil hose or dam age to the oil pump It is rec om mend ed that any shut off device in the oil sup ply and oil return lines be pro tect ed from un in tend ed in di vid u al clo sure Non return valves must not be installed in the oil re turn l...

Page 76: ...ROLS 76 Section 26 Oil Piping Design FORM 155 17 N1 ISSUE DATE 4 1 2013 Figure 37 OIL PIPING SCHEMATIC OIL TANK LOCATED LOWER THAN BURNER LD05325 OIL TANK h BURNER FILTER MANUAL SHUT OFF VALVES MECHANICALLY LINKED ...

Page 77: ...lve in the full by pass position and stopping the hot water circulating pump if the leaving chilled water temperature rises to a preset level usually 50 F indi cating that too much en er gy is being used to make hot water and the chiller can not meet the chilling demand Since the unit operation is controlled by the chilling load the amount of available heating capacity as well as the hot water tem...

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Page 79: ...93 89 6 87 5 UNITS dB AT 1 METER DISTANCE FROM THE CHILLER NOISE LOCATION NUMBER 1 2 3 4 HORIZONTAL 4 3 3 3 5 VERTICAL 3 3 2 5 3 AXIAL 2 5 3 2 4 UNITS MICRONS Figure 40 TYPICAL NOISE AND VIBRATION LEVELS STEAM FIRED UNITS ALL MODELS LD05328 NOISE LEVEL VIBRATION LEVEL NOISE LOCATION NUMBER 1 2 3 4 A SCALE 84 83 82 82 5 B SCALE 86 5 85 84 84 5 C SCALE 88 87 87 87 5 UNITS dB AT 1 METER DISTANCE FROM...

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Page 81: ... conduits are used for the incoming three phase power they should contain an equal number of wires from each phase in each con duit to prevent overheating Use copper conductors only Do not use aluminum con duc tors Flexible conduit for final connection to the power panel should used in the extreme case of unit vi bra tion The unit must be grounded in accordance with ap plicable codes Use only copp...

Page 82: ... at 115 volts A C CONTROL OF CUSTOMER SYSTEM PUMPS Since ab sorp tion chillers require a dilution cycle of an unpredictable length of time it is mandatory that the ParaFlowTM micro panel control the operation of the following system pumps Condenser Water Tower water Chilled Water Hot Water when applicable YORK s prescribed method to employ this pump con trol is to hard wire the pump starter contro...

Page 83: ...ludes unit status con tacts provisions for remote temperature setpoint reset and starting and stopping of the unit All field control wiring modifications are to be fur nished and installed by others To learn more about what safety devices and chiller controls can be wired remotely refer to the mi cro panel wir ing di a gram YORK Form 155 17 PA1 YORK Form 155 17 W1 for gas oil fired units or YORK F...

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Page 85: ...se areas are filled in with a charcoal gray in the in su la tion drawings located in Appendix C Insulation Illustrations of this document For cold surfaces YORK recommends using 3 4 inch closed cell foam insulation Cold surfaces that need foam insulation are the evaporator shell refrigerant piping refrigerant pumps and the refrigerant tank Cold sur fac es are indicated on the insulation drawings w...

Page 86: ...the factory warranty NEVER insulate over electrical wiring the heat generated within the unit will melt the insulation on the wiring Water boxes or cover plates must be removed or opened from time to time for tube clean ing Valves pumps and nozzles must be acces sible for servicing and operation Insulate auxiliary and instrument piping by wrapping glass wool around it ADDITIONAL COMMENTS Before in...

Page 87: ... 2 to each end for overall length 3 Marine water boxes with flanges will add height length and width to the unit dimensions For details see the appropriate Johnson Con trols publication as listed at the beginning of this document Table 4 PARAFLOW TYPICAL CHARGES UNIT MODEL REFRIGERANT SOLUTION ALCOHOL STEAM DIRECT FIRED STEAM DIRECT FIRED DRUMS LBS GALS DRUMS LBS GALS DRUMS LBS GALS DRUMS LBS GALS...

Page 88: ...act design Table 6 POWER FLAME ABSORPTION BURNER SIZES UNIT MODEL NOM TONS BURNER SIZE MAX FIR ING RATE MBH MIN FIR ING RATE MBH MAX OIL FLOW GPH GAS PRESS REQUIRED W C MIN MAX SEPARATE DRIVEN OIL PRESSURE PUMP MOTOR HP SUCTION CAPACITY GPH S UNITS 12SC 13S 200 CR2 G O 20B 2 553 750 22 4 8 14 1 3 40 13SC 14S 230 CR3 G O 20 2 891 900 26 5 9 14 1 2 105 14SC 15S 300 CR3 G O 25 3 613 900 33 7 7 0 14 1...

Page 89: ...00 150 120 250 380 710 1130 2000 4100 175 110 225 350 650 1050 1850 3800 200 100 210 320 610 980 1700 3500 Use correction factor table for other specific gravities and pressure drops Table 8 CORRECTION FACTORS SPECIFIC GRAVITY MULTIPLIER PRESSURE DROP MULTIPLIER 0 50 1 10 0 1 0 577 0 60 1 00 0 2 0 815 0 70 0 926 0 3 1 00 0 80 0 867 0 4 1 16 0 90 0 817 0 6 1 42 1 00 0 775 0 8 1 64 PROPANE AIR 1 0 1...

Page 90: ... 718 4 064 903 951 1 258 1 346 1 435 1 523 1 612 1 700 CR4 G O 25 6 300 5 427 1 206 1 270 1 679 1 797 1 916 2 034 2 152 2 270 CR4 G O 30 7 840 6 753 1 501 1 580 2 090 2 237 2 384 2 531 2 678 2 825 CR5 G O 30 10 500 9 044 2 010 2 117 2 799 2 996 3 193 3 390 3 587 3 784 Based on 20 excess air dry at 77 F Table 13 ELECTRICAL DATA STEAM FIRED UNITS CHILLER MODEL VOLTAGE MAX DUAL ELEMENT FUSE CUSTOMER ...

Page 91: ...g h 70 psi 5 0 bar 190 F 90 C GL7 up to 40 0 GPH J6 72 GPH 230 kg h 30 psi 2 0 bar 160 F 70 C GL7 up to 46 0 GPH J7 116 GPH 370 kg h 30 psi 2 0 bar 160 F 70 C RGL7 up to 46 0 GPH TA2 165 GPH 525 kg h 70 psi 5 0 bar 190 F 90 C GL8 up to 60 0 GPH J7 116 GPH 370 kg h 30 psi 2 0 bar 160 F 70 C RGL8 up to 60 0 GPH TA3 247 GPH 785 kg h 70 psi 5 0 bar 190 F 90 C GL9 up to 68 0 GPH J7 116 GPH 370 kg h 30 ...

Page 92: ... 230 3 60 80 90 80 80 56 8 60 4 53 7 57 3 63 1 66 7 60 0 63 6 380 3 50 50 50 45 50 31 8 33 4 30 4 32 0 35 6 37 2 34 2 35 8 460 3 60 40 45 40 40 28 5 30 3 27 0 28 8 31 6 33 4 30 1 31 9 16SL 17S 18S 200 208 3 60 125 125 125 125 89 7 93 8 86 4 90 4 99 9 103 9 96 6 100 6 230 3 60 125 125 110 125 80 6 84 2 77 5 81 1 89 8 93 4 86 7 90 3 380 3 50 60 60 60 60 42 8 44 4 41 4 43 0 47 5 49 2 46 2 47 8 460 3 ...

Page 93: ...JOHNSON CONTROLS 93 Appendix A Tables A FORM 155 17 N1 ISSUE DATE 4 1 2013 ...

Page 94: ...JOHNSON CONTROLS 94 FORM 155 17 N1 ISSUE DATE 4 1 2013 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 95: ...ame plane while the slings on the right side will be staggered 60 OR LESS 60 OR LESS B A C Figure 44 RIGGING FOR 12SC THROUGH 19S DIRECT FIRED AND STEAM UNITS LD05332 Table 15 S UNIT RIGGING UNIT MODEL DIMENSION A INCHES DIMENSION B INCHES DIMENSION C MINIMUM INCHES 12SC 13S 55 53 1 2 55 13SC 14S 55 53 1 2 55 14SC 15S 71 3 4 53 1 2 71 3 4 15SL 94 1 2 72 1 2 94 1 2 16S 94 1 2 72 1 2 94 1 2 16SL 103...

Page 96: ...one at each end of the main shell When lifting keep unit level LESS THAN 60 Figure 45 RIGGING FOR 16G THROUGH 18G DIRECT FIRED UNITS LD05333 NOTE For lifting units sling vertically Use extreme care so as not to sling against or on any projecting brackets pipes fittings etc Use four slings and spreader bar as shown one sling on each end of the first stage generator and one on each end of the main s...

Page 97: ...c Use four slings and spreader bar as shown one sling on each end of the high temperature generator and one on each end of the main shell LD05335 STEAM INLET END Figure 48 RIGGING FOR 19G THROUGH 22GL STEAM FIRED UNITS NOTE For lifting units sling vertically Use extreme care as not to sling against or on any projecting brackets pipes fittings etc Use spreader bar as shown and two slings Sling arou...

Page 98: ...JOHNSON CONTROLS 98 FORM 155 17 N1 ISSUE DATE 4 1 2013 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 99: ...not cover pump motors with insulation 6 Do not use weld pins to attach insulation Table 18 YORK PARAFLOW ABSORPTION CHILLER INSULATION AREA SQ ME TERS UNIT MODEL DIRECT FIRED STEAM FIRED HOT COLD HOT COLD 12SC 16 0 18 0 13SC 18 0 8 0 14SC 24 0 11 0 25 0 11 0 15SL 33 0 13 0 16S 33 0 13 0 16SL 37 0 16 0 37 0 16 0 17S 37 0 16 0 37 0 16 0 18S 44 0 19 1 44 0 19 1 19S 47 0 22 0 47 0 22 0 PROPER INSULATI...

Page 100: ...NTROLS 100 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 49 INSULATION DIAGRAM MODEL YPC DF 12SC 15S LD05337 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 101: ...S 101 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD FIGURE 49 INSULATION DIAGRAM MODEL YPC DF 12SC 15S CONT D LD05337A REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 102: ...ROLS 102 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 50 INSULATION DIAGRAM MODEL YPC DF 12SC 13S 15S LD05338 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 103: ...103 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD FIGURE 50 INSULATION DIAGRAM MODEL YPC DF 12SC 13S 15S CONT D LD05338A REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 104: ...NTROLS 104 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 51 INSULATION DIAGRAM MODEL YPC DF 15SL 19S LD05339 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 105: ...S 105 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD FIGURE 51 INSULATION DIAGRAM MODEL YPC DF 15SL 19S CONT D LD05339A REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 106: ...NTROLS 106 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 52 INSULATION DIAGRAM MODEL YPC DF 15SL 19S LD05340 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 107: ...S 107 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD FIGURE 52 INSULATION DIAGRAM MODEL YPC DF 15SL 19S CONT D LD05340A REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 108: ...ROLS 108 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 53 INSULATION DIAGRAM MODEL YPC ST 14S 16SL 19S LD05341 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 109: ...109 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD REFER TO METHODS AND PRACTICES ON PAGE C1 FIGURE 53 INSULATION DIAGRAM MODEL YPC ST 14S 16SL 19S CONT D LD05341A ...

Page 110: ...ROLS 110 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 54 INSULATION DIAGRAM MODEL YPC ST 14S 16SL 19S LD05342 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 111: ...111 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD FIGURE 54 INSULATION DIAGRAM MODEL YPC ST 14S 16SL 19S CONT D LD05342A REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 112: ... CONTROLS 112 Appendix C Insulation Illustrations FORM 155 17 N1 ISSUE DATE 4 1 2013 LEGEND HOT INTERMEDIATE COLD Figure 55 INSULATION DIAGRAM AUXILLARY VIEWS LD05355 REFER TO METHODS AND PRACTICES ON PAGE C1 ...

Page 113: ...JOHNSON CONTROLS 113 Appendix C Insulation Illustrations C FORM 155 17 N1 ISSUE DATE 4 1 2013 NOTES ...

Page 114: ...ania USA 17405 1592 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2013 www johnsoncontrols com ALL RIGHTS RESERVED Form 155 17 N1 413 Issue Date April 1 2013 Supersedes 155 17 N1 900 ...

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