Johnson Controls YORK YPC Series

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JOHNSON CONTROLS

FORM 155.17-N1

ISSUE DATE: 4/1/2013

THIS PAGE INTENTIONALLY LEFT BLANK.

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Table of Contents5
Section 1 - Introduction11
Section 2 - Pre and Initial Inspection of Unit13
- Installation Checklist13
- FIGURE 1 - Example of Pressure Gauge on Unit with Nitrogen Charge13
- FIGURE 2 - Location of Pressure Gauge on S-Model Unit13
Section 3 - Unit Rigging17
- Foundation17
- FIGURE 3 - Foundation Pad17
Section 4 - Knockdown Shipment Units19
- Important Steps to Follow During Reassembly19
- Assembly Guidelines19
- Leak Checking19
Section 5 - Leveling the Unit21
- FIGURE 4 - Leveling and Anchoring the Unit21
- FIGURE 5 - Jacking Point21
- Levelness CHECK21
- FIGURE 6 - S-Model Units22
- FIGURE 7 - G-Model Units22
- TABLE 1 - Anchoring Diagram Dimensions22
- FIGURE 8 - Typical Water Piping Schematic, All Units - Models 12SC through 22G23
- Absorber and Condenser Water Piping24
- Flow Switches24
- Pressure Differential Switches24
- Strainers24
- Tower Water Cross-Over Line24
- FIGURE 9 - Installation of Flow Switch25
- FIGURE 10 - Piping for Tower Water - Three-Way Mixing Valve26
- Three-Way Mixing Valve26
Section 6 - Unit Water Piping and Hook-Up23
Section 7 - Tower Water Treatment27
FIGURE 11 - Typical Rupture Disk Vent Piping29
Section 8 - Rupture Disk Piping Installation29
Section 9 - High-Temperature Generator Inlet Steam Piping31
- Pressure31
- Flow31
- Piping31
- Inlet Steam Piping Components31
- Manual Block Valve31
- Automatic Shut-Off Valve31
- Steam Separator32
- Steam Strainer32
- Pressure Regulator (Not Shown in Fig. 12)32
- Pressure Relief Valve32
- Steam Control Valve32
- FIGURE 12 - Steam Piping Schematic33
Section 10 - Steam Condensate Return System35
- Steam Condensate Drain Cooler35
- Condensate Flow Setting Valve35
- Steam Condensate Drain Solenoid Valve35
- Flange Adapter (Spool Piece)35
- Condensate Outlet Pressure Indicator35
- Adjustable Condensate Back-Pressure Valve35
Section 11 - Steam / Condensate Purity37
Section 12 - Burner Installation (Power Flame Burners)39
- Model Identification39
- Unpacking and Handling39
- FIGURE 13 - Typical Gas Train Components40
- FIGURE 14 - Typical Burner Assembly for Direct-Fired, S-Model Units40
- FIGURE 15 - Typical Burner Assembly for Direct-Fired, G-Model Units41
- FIGURE 16 - Typical Burner Components (Right-Side View)41
- FIGURE 17 - Typical Burner Components (Left-Side View)42
- FIGURE 18 - Typical Burner Components (Front End)42
- FIGURE 19 - Typical Burner Components (Back End)43
- FIGURE 20 - Standard U.L. Gas Train44
Section 13 - Gas Piping Design45
FIGURE 21 - Typical Schematic Gas Piping45
Section 14 - Oil Piping Design47
FIGURE 22 - Typical Schematic Oil Piping47
FIGURE 23 - Oil Piping Schematic for Webster "D" Style Pump48
FIGURE 24 - Oil Piping Schematic for Webster "C" Style Pump48
FIGURE 25 - Typical Oil Piping Schematic for Multiple Burners49
Section 15 - Oil Line Sizing51
- Instructions for Using Oil Line Sizing Graphs51
- FIGURE 26 - Oil Line Sizing Graphs51
Section 16 - Oil Tanks53
Section 17 - Combustion Air Requirements55
- Louvers and Grills55
- Air Proving Switch56
- FIGURE 27 - Combustion and Ventilation Air in Mechanical Rooms56
Section 18 - Sealed Combustion57
(Burner Fresh Air Intake Duct Sizing)57
- ACFM = SCFM X57
- Air57
Section 19 - Chimney Design and Draft Theory59
- Draft59
- Temperature Difference59
- Chimney Height59
- Chimney Design Theory60
- Wind and Weath er60
- Inadequate System Installation60
- FIGURE 28 - Theoretical Stack Effect61
TABLE 2 - Manual Backdraft Diagram63
FIGURE 29 - Manual & Motorized Backdraft Damper with FGR Connection63
Section 20 - Draft Control63
FIGURE 30 - Gauge Pressure Profile / Chimney System with Barometric Control65
Section 21 - Barometric Dampers65
FIGURE 31 - Barometric Control66
SECTION 22 - SEQUENTIAL DRAFT CONTROL (Motorized Draft Control)67
- Backdraft Damper67
Section 23 - High Stack Temperature Probe69
Section 24 - Burner Installation (Weishaupt Burners)71
- Model Identification71
- Field Wiring72
  - Swinging Open the Burner72
  - Closing the Burner72
Section 25 - Gas Piping Design73
- Gas Train Sizing73
  - Installing the Gas Train73
- Gas Train Leak Check Procedure73
- FIGURE 34 - Gas Train Valve Testing73
- FIGURE 35 - Gas Piping Design74
Section 26 - Oil Piping Design75
- Oil Piping Design75
- FIGURE 36 - Oil Piping Schematic - Oil Tank Located Higher than Burner75
- FIGURE 37 - Oil Piping Schematic - Oil Tank Located Lower than Burner76
Section 27 - Simultaneous Operation (Where Applicable)77
- Direct-Fired77
- FIGURE 38 - Suggested Piping Schematic for Simultaneous Operation (All Piping & Controls by Others)77
Section 28 - Typical Noise and Vibration Levels79
FIGURE 39 - Typical Noise and Vibration Levels - Direct-Fired Units, All Models79
FIGURE 40 - Typical Noise and Vibration Levels - Steam-Fired Units, All Models79
Section 29 - Electrical Connections81
- Electrical Connections81
- Wiring the Purge Pump81
- Field Control Modifications and Safety Devices81
- Flow Switches82
- Control of Customer System Pumps82
- FIGURE 41 - Relay Board Contacts82
- Energy Management Systems wir Ing83
- FIGURE 42 - Wiring the Purge Pump83
- FIGURE 43 - Flow Switch Connections83
Section 30 - Insulation85
- Insulation Tips85
- Other Insulation Guidelines86
- Additional Comments86
TABLE 3 - Unit Weights and Dimensions87
TABLE 4 - Paraflow™ Typical Charges87
Appendix A - Tables87
TABLE 5 - Chiller Tube Volumes88
TABLE 6 - Power Flame Absorption Burner Sizes88
TABLE 7 - Capacity of Pipe - Natural Gas (Cfh) with Pressure Drip of 0.3" W.C. and Specific Gravity of89
TABLE 8 - Correction Factors89
TABLE 9 - Equivalent Length of Fittings (Ft.)89
TABLE 10 - Oil Pump Suction Capacity and Filter Selection Chart for Power Flame Burners90
TABLE 11 - Combustion Air Requirements for Power Flame Burners90
TABLE 13 - Electrical Data - Steam Fired Units90
TABLE 12 - Weishaupt Burner Oil Pump Capacities91
TABLE 14 - Electrical Data - Direct-Fired Units92
TABLE 15 - S-Unit Rigging95
Appendix B - Rigging Illustrations95
FIGURE 44 - Rigging for 12SC through 19S Direct-Fired and Steam Units95
FIGURE 45 - Rigging for 16G through 18G Direct-Fired Units96
FIGURE 46 - Rigging for 19G through 19Gl Direct-Fired Units96
FIGURE 47 - Rigging for 20G Direct-Fired Units97
FIGURE 48 - Rigging for 19G through 22Gl Steam-Fired Units97
TABLE 16 - Absorption Insulation Legend99
TABLE 17 - York Paraflow™ Absorption Chiller Insulation Area (Sq. Feet)99
TABLE 18 - York Paraflow™ Absorption Chiller Insulation Area (Sq. Meters)99
Appendix C - Insulation Illustrations99
FIGURE 49 - Insulation Diagram, Model YPC-DF-12SC-15S100
FIGURE 50 - Insulation Diagram, Model YPC-DF-12SC-13S-15S102
FIGURE 51 - Insulation Diagram, Model YPC-DF-15SL-19S104
FIGURE 52 - Insulation Diagram, Model YPC-DF-15SL-19S106
FIGURE 53 - Insulation Diagram, Model YPC-ST-14S, 16SL-19S108
FIGURE 54 - Insulation Diagram, Model YPC-ST-14S, 16SL-19S110
FIGURE 55 - Insulation Diagram, Auxillary Views112

Johnson Controls YORK YPC Series - Page 10

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