Johnson Controls YORK SOLUTION LD09624 Instructions and recipes

InstallatIon and staRtUP InstRUCtIons
YORK SOLUTION
AIR HANDLING UNITS
Supersedes 102.20-N1 (1108) Form 102.20-N1 (1109)
OUTDOOR UNIT
INDOOR UNIT
LD09624
LD09688
YORK SOLUTION INDOOR AND OUTDOOR MODELS
Renewal Parts
Form 102.20-RP1
With P/N contact Balt. Parts
[phone]
Manufactured or specialty parts
contact Airside [phone]

This equipment is a relatively complicated apparatus.
During installation, operation, maintenance or service,
individuals may be exposed to certain components or
conditions including, but not limited to: refrigerants,
oils,andmaterialsunderpressure,rotatingcomponents,
and both high and low voltage. Each of these items
has the potential, if misused or handled improperly,
to cause bodily injury or death. It is the obligation
and responsibility of operating/service personnel to
identify and recognize these inherent hazards, protect
themselves, and proceed safely in completing their
tasks. Failure to comply with any of these requirements
could result in serious damage to the equipment and
the property in which it is situated, as well as severe
personal injury or death to themselves and people at
the site.
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this
individual possesses independent training that will
enable them to perform their assigned tasks properly
and safely. It is essential that, prior to performing any
task on this equipment, this individual shall have read
and understood this document and any referenced
materials. 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 areas of concern:
CAUTION identies a hazard which
could lead to damage to the machine,
damage to other equipment and/or
environmental pollution. Usually an
instructionwillbegiven,togetherwith
a brief explanation.
NOTE is used to highlight additional
information that may be helpful to
you.
DANGER indicates an imminently
hazardous situation, which if not
avoided, will result in death or seri-
ous injury.
WARNING indicates a potentially
hazardous situation, which if not
avoided, could result in death or seri-
ous injury.
IAQ
Consider for IAQ compliance per
ASHRAE STANDARD 62-2001
External wiring, unless specied as an optional connection in the manufacturer’s product
line,isNOT tobeconnectedinsidethecontrolpanelcabinet.Devicessuchasrelays,switches,
transducersand controls may NOT beinstalled inside thecontrol panel. NO external wiring
is allowed to run through the control panel. All wiring must be in accordance with John-
son Controls published specications and must be performed ONLY by qualied Johnson
Controls personnel. Johnson Controls will not be responsible for damages/problems result-
ing from improper connections to the controls or application of improper control signals.
Failure to follow this will void the manufacturer’s warranty and cause serious damage to
property or injury to persons.

3
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
In complying with Johnson Controls policy for
continuous product improvement, the information
contained in this document is subject to change
without notice. While Johnson Controls makes no
commitment to update or provide current information
automatically to the manual owner, that information, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service ofce.
CHANGEABILITY OF THIS DOCUMENT
It is the responsibility of operating/service personnel
to verify the applicability of these documents to the
equipment in question. If there is any question in
the mind of operating/service personnel as to the
applicability of these documents, then prior to working
on the equipment, they should verify with the owner
whether the equipment has been modied and if current
literature is available.
NOTICE TO CUSTOMER/CONTRACTOR
PROTECT YOUR WARRANTY PRIOR TO
STARTUP.
• Read and follow the Installation and Start-up
Instructions provided with this equipment.
• Storage of this equipment MUST be on a at
surface and protected from the weather.
• Protect this equipment from damage, construction
dirt, debris and water.
DO NOT OPERATE DOORS WHEN UNIT
IS NOT ON A FLAT SURFACE.
• Isolate this equipment from pressure testing of
water, steam, gas and air piping.
• Do not test, clean and ush piping through coils
in this equipment.
• Isolate this equipment from temporary building
power.
• Contact local Johnson Controls Service for pur-
chaseof StartupServicewith twoweeksadvance
notice. Provide current job site contact.
• To perform a careful and thorough startup, verify
the following:
– Reliable power will be available for
startup.
– Ductwork is complete.
– Controls are complete.
– Shipping splits completely re-assembled,
sealed and wired.
– Filters are installed and secured.
– All shipping materials have been removed.
METAL TAB USED TO SECURE
DOOR IS A SAFETY DEVICE. DO
NOT DISCARD IT.
– Start-up will be performed according to that
outlined in Section 3 of the Installation and
Start-up Instructions provided.
• Temporary use of air handler requires startup
performed according to that outlined in Section
3 of the Installation and Start-up Instructions
provided.
• A qualied startup technician must complete
the “AIR HANDLING UNITS START-UP
CHECK LIST” Form 100.00-CL1 and le a
copy at the local YORK Service Ofce. This
formisprovidedin theinformationpackagewith
each air handler.
• Rotate fans every four (4) weeks beginning upon
arrival.

JOHNSON CONTROLS
4
FORM 102.20-N1 (1109)
THIS PAGE INTENTIONALLY LEFT BLANK

5
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES......................................................................................................................2
CHANGEABILITY OF THIS DOCUMENT...........................................................................................................3
TABLE OF CONTENTS.......................................................................................................................................5
LIST OF FIGURES.............................................................................................................................................11
LIST OF TABLES...............................................................................................................................................15
INTRODUCTION................................................................................................................................................17
GENERAL....................................................................................................................................................17
TYPICAL YORK SOLUTION OPERATION IN “HVAC”SYSTEM..............................................................17
Ventilation System.................................................................................................................................17
Economizer System - Typical................................................................................................................18
Heating Operation..................................................................................................................................18
Cooling Operation..................................................................................................................................18
HAND IDENTIFICATION.............................................................................................................................18
SEGMENT IDENTIFICATION......................................................................................................................19
Unit Identication...................................................................................................................................21
Unit ID Label......................................................................................................................................21
Skid ID Label .....................................................................................................................................21
Segment Identication Box..............................................................................................................21
Loose Component ID Label .............................................................................................................22
Filter ID Label....................................................................................................................................22
Direction of Airow ................................................................................................................................22
1.0 PRE-INSTALLATION..................................................................................................................................1-1
RECEIVING ................................................................................................................................................1-1
RIGGING OF INDOOR AND OUTDOOR UNITS.......................................................................................1-1
Off-Loading............................................................................................................................................1-2
Crane And Spreader Bars ....................................................................................................................1-2
Fork Lift..................................................................................................................................................1-2
Come-A-Longs or Power Pull ..............................................................................................................1-2
Shackles.................................................................................................................................................1-3
INSPECTION..............................................................................................................................................1-4
Check For Damage................................................................................................................................1-4
Receiver Responsibility ..................................................................................................................1-4
Indoor Units......................................................................................................................................1-4
Outdoor Units...................................................................................................................................1-4
Checking for Non Mounted Parts........................................................................................................1-4
STORAGE ..................................................................................................................................................1-4
Short-Term Storage...............................................................................................................................1-4
Long-Term Storage ...............................................................................................................................1-5
Preventive Maintenance Prior to Long Term Storage ..................................................................1-5
Periodic Fan Check..........................................................................................................................1-5

JOHNSON CONTROLS
6
FORM 102.20-N1 (1109)
2.0 INSTALLATION...........................................................................................................................................2-1
SITE PREPARATION .................................................................................................................................2-1
Outdoor Units (Site Prep).....................................................................................................................2-1
Mounting......................................................................................................................................2-2
Curb .............................................................................................................................................2-2
Steel Frame .................................................................................................................................2-3
Indoor Units (Site Prep)........................................................................................................................2-3
Clearance..........................................................................................................................................2-5
Mounting...........................................................................................................................................2-5
Floor.............................................................................................................................................2-5
Housekeeping Pad......................................................................................................................2-5
Ceiling Suspended Units ...........................................................................................................2-6
UNIT INSTALLATION.................................................................................................................................2-7
Tools Needed.........................................................................................................................................2-7
Ship Loose Parts...................................................................................................................................2-8
Assembly of Outdoor Unit..................................................................................................................2-13
Installing Single Piece Outdoor Unit............................................................................................2-13
Installing Multiple Piece Outdoor Unit ........................................................................................2-13
Assembly of Indoor Unit.....................................................................................................................2-17
Installing Multiple Piece Indoor Unit ...........................................................................................2-17
Installation of Tiered Unit..............................................................................................................2-21
Assembly of End Channel Shipping Split ...................................................................................2-23
HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS............................................................2-24
OUTDOOR AIR TEMPERATURE AND/OR HUMIDITY SENSORS ........................................................2-24
ACTUATOR INSTALLATION ...................................................................................................................2-25
INSTALLATION OF MULTIZONE (MZ) DAMPERS.................................................................................2-26
Damper Installation.............................................................................................................................2-26
Actuator Installation Mutlizone (MZ) - Field Supplied .....................................................................2-27
INERTIA FAN BASE FILL INSTRUCTION ..............................................................................................2-27
HUMIDIFIERS...........................................................................................................................................2-27
UVC EMITTER LIGHTS ...........................................................................................................................2-28
AIR MEASURING DEVICE CONNECTIONS (WHEN PROVIDED).........................................................2-29
Air Measuring at The Fan Inlets.........................................................................................................2-29
Air Measuring at Unit Inlets................................................................................................................2-29
PIPE CHASE INSTALLATION .................................................................................................................2-30
Tools Required ....................................................................................................................................2-30
Materials Required..............................................................................................................................2-30
Procedure ............................................................................................................................................2-30
Condensate Drain Arrangement...................................................................................................2-35
ELECTRICAL - GENERAL.......................................................................................................................2-36
TABLE OF CONTENTS (CONT'D)

7
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
POWER CONNECTIONS.........................................................................................................................2-37
Single Point Power..............................................................................................................................2-37
Motors for Supply Fan, Return Fan, Exhaust Fan............................................................................2-37
Energy Recovery Wheel Option.........................................................................................................2-37
Gas Heat Option..................................................................................................................................2-38
Electric Heat Option............................................................................................................................2-39
Available Power Options...............................................................................................................2-39
Electric Heat Disconnect Switch Options....................................................................................2-39
Available Control Options.............................................................................................................2-40
Installation......................................................................................................................................2-40
APPLICATION INFORMATION................................................................................................................2-40
MECHANICAL INSTALLATION...............................................................................................................2-40
ELECTRICAL INSTALLATION ................................................................................................................2-42
Humidier Option (Electric) ...............................................................................................................2-43
Humidier Option................................................................................................................................2-43
PIPING CONNECTIONS ..........................................................................................................................2-44
Coil Piping ...........................................................................................................................................2-45
Staggered Coils...................................................................................................................................2-45
Water...............................................................................................................................................2-46
Water Coils - Hot Water and Chilled Water.............................................................................2-46
Hot and Chilled Water Coil Performance................................................................................2-46
Water Treatment........................................................................................................................2-48
Steam..............................................................................................................................................2-48
Steam Coils...............................................................................................................................2-48
Steam Distributing Coils..........................................................................................................2-48
Steam Control...........................................................................................................................2-48
Steam Traps ..............................................................................................................................2-49
VIFB and IFB .............................................................................................................................2-50
Refrigeration...................................................................................................................................2-54
Direct Expansion Coils (DX) ....................................................................................................2-54
DX Coil Types............................................................................................................................2-55
Combined Coil Types ...............................................................................................................2-55
DX Coil Circuiting .....................................................................................................................2-55
DX Coil Circuiting And Staging ...............................................................................................2-57
Thermostatic Expansion Valves (TXV) ...................................................................................2-59
Hot Gas Bypass .............................................................................................................................2-59
Maintaining Adequate Airow ...............................................................................................2-59
VAV Systems.............................................................................................................................2-59
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS
8
FORM 102.20-N1 (1109)
Drains And Traps.................................................................................................................................2-61
Condensate Drain Piping..............................................................................................................2-61
Condensate Drain Trap..................................................................................................................2-61
Elevating Unit for Gravity Floor Drain Connections..............................................................2-62
Duct Connections ...............................................................................................................................2-62
Duct Connection Guidelines.........................................................................................................2-62
Duct Connections ....................................................................................................................2-63
Flanged Ducts or Sleeves .......................................................................................................2-63
Raw or Straight Edge Ducts or Sleeves .................................................................................2-63
Sound and Vibration Transmission..............................................................................................2-64
Front and Rear Discharge Outdoor Unit Duct Installation.........................................................2-64
Air Filters .............................................................................................................................................2-65
Filter Types.....................................................................................................................................2-65
Maintenance and Replacement ....................................................................................................2-65
Filter Latches..................................................................................................................................2-66
Installation of 2” Perfectpleat, Premium or Premium HM..........................................................2-68
Installation of Spring Latches ................................................................................................2-68
Installation of 4” Amair 300x Pleated Filter .................................................................................2-69
Installation of SH Single Headered Filters...................................................................................2-70
Installation of Latches .............................................................................................................2-70
Installation of a 2” Prelter In Combination with a Single Header Final Filter.........................2-70
Installation of Latches .............................................................................................................2-70
Installation of a Varicel DH Double Headered Filter ...................................................................2-71
Installation of Spring Latches ................................................................................................2-71
Installation of a 2” and 4" Prelter in Combination With a Double Header Final Filter...........2-72
Installation of Spring Latches ................................................................................................2-72
Installation of Prelter Latches ..............................................................................................2-72
HEPA Filters....................................................................................................................................2-74
Welded Bevel Seal Frame........................................................................................................2-74
Visual Control Filter Clamps....................................................................................................2-74
TABLE OF CONTENTS (CONT'D)

9
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
TABLE OF CONTENTS (CONT'D)
3.0 STARTUP....................................................................................................................................................3-1
PRE START-UP..........................................................................................................................................3-2
PRE START UP FAN ASSEMBLY INSPECTION ......................................................................................3-3
Motors - ODP vs. TEFC ........................................................................................................................3-3
Isolators.................................................................................................................................................3-4
Preparing Fan Isolators for Operation...........................................................................................3-4
START-UP ..................................................................................................................................................3-5
CHECK OPERATION OF FANS.............................................................................................................3-5
Check Operation of Dampers...............................................................................................................3-5
Airow Control Dampers.................................................................................................................3-5
Typical Actuators Locations ...........................................................................................................3-6
Basic Actuators Installation............................................................................................................3-6
Damper Blade Orientation .........................................................................................................3-6
Energize Fan Motor(s) ..........................................................................................................................3-7
Variable Speed Drive (VSD)..................................................................................................................3-7
Set Up of a Non-Factory Mounted VFD.....................................................................................3-7
Check Doors and Latches for Proper Adjustment.............................................................................3-8
Sheaves..................................................................................................................................................3-8
General Guidelines for Replacing an Adjustable Sheave with a Fixed Sheave:........................3-8
Energy Recovery Wheel.......................................................................................................................3-9
Unit Conguration ...........................................................................................................................3-9
Indoor Units.................................................................................................................................3-9
Outdoor Units..............................................................................................................................3-9
Start-Up Procedure for Energy Recovery Wheel..........................................................................3-9
Indirect Fired Gas Heat Start Up........................................................................................................3-11
Introduction....................................................................................................................................3-11
Identify the Unit Type.....................................................................................................................3-11
Preliminary Coordination..............................................................................................................3-12
Tools Recommended.....................................................................................................................3-12
Air Handler Pre Start Checks........................................................................................................3-12
Burner Pre Start Checks ...............................................................................................................3-12
Burner Start-Up Procedure...........................................................................................................3-14
Condensate Drain Arrangement...................................................................................................3-15
Electric Heat Startup...........................................................................................................................3-25
Airow Requirements....................................................................................................................3-25

JOHNSON CONTROLS
10
FORM 102.20-N1 (1109)
THIS PAGE INTENTIONALLY LEFT BLANK

11
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
LIST OF FIGURES
FIG. 1 – CUTAWAY OF YORK SOLUTION SHOWING VARIOUS SEGMENTS........................................17
FIG. 2 – UNIT AND COIL HAND IDENTIFICATION....................................................................................18
FIG. 3 – UNIT ID LABEL.............................................................................................................................21
FIG. 4 – SKID ID LABEL.............................................................................................................................21
FIG. 5 – SEGMENT ID BOX EXAMPLE .....................................................................................................21
FIG. 6 – LOOSE COMPONENT ID LABELS..............................................................................................22
FIG. 7 – FILTER LABELS ...........................................................................................................................22
FIG. 1-1 – RECOMMENDED LIFTING WITH FOUR LIFTING POINTS....................................................1-1
FIG. 1-2 – RECOMMENDED LIFTING WITH MULTIPLE POINTS............................................................1-1
FIG. 1-3 – TYPICAL COME-A-LONG TYPES............................................................................................1-2
FIG. 1-4 – PROPER LIFTING WITH SHACKLE AT CORNER..................................................................1-3
FIG. 1-5 – PROPER LIFTING WITH SHACKLE AT LIFTING LUG...........................................................1-3
FIG. 1-6 – RECOMMENDED LIFTING WITH BASERAIL .........................................................................1-3
FIG. 1-7 – LONG-TERM STORAGE REQUIREMENT - FIELD PREPARATION ......................................1-6
FIG. 1-8 – LONG-TERM STORAGE PERIODIC CHECKLIST AND LOGS ..............................................1-7
FIG. 2-1 – MINIMUM SERVICE CLEARANCES........................................................................................2-1
FIG. 2-2 – TYPICAL CURB ASSEMBLY....................................................................................................2-4
FIG. 2-3 – NO BASERAIL – HOUSEKEEPING PAD REQUIRED TO ACCOMMODATE
TRAP HEIGHT...........................................................................................................................2-5
FIG. 2-4 – NO HOUSEKEEPING PAD – BASERAIL REQUIRED TO ACCOMMODATE
TRAP HEIGHT...........................................................................................................................2-5
FIG. 2-5 – WITH BASERAIL AND HOUSEKEEPING PAD ......................................................................2-5
FIG. 2-6 – CEILING SUSPENDED UNIT ...................................................................................................2-6
FIG. 2-7 – TOOLS TYPICALLY USED FOR ASSEMBLY OF SHIPPING SPLITS....................................2-7
FIG. 2-8 – SECOND TIER TIE-DOWN FASTENER PACK P/N 386-03419-000........................................2-8
FIG. 2-9 – BOTTOM RACEWAY SHIPPING SPLIT FASTENER PACKP/N 386-03418-000...........................2-8
FIG. 2-10 – BASERAIL SHIPPING SPLIT FASTENER PACK P/N 386-03417-000...........................................2-8
FIG. 2-11 – TOP RACEWAY SPLIT FASTENER PACK ............................................................................2-8
FIG. 2-12 – PIPE CHASE, HOODS & SEAM CAPS..................................................................................2-9
FIG. 2-13 – MISCELLANEOUS PARTS FOR OPTIONS.........................................................................2-10
FIG. 2-14 – HARDWARE, GASKETING, CAULK, PAINT AND TAPE....................................................2-11
FIG. 2-15 – SHIPPING SPLIT EXAMPLES..............................................................................................2-12
FIG. 2-16 – SHIPPING SPLIT EXAMPLES FOR EXPANDED CABINET ...............................................2-12
FIG. 2-17 – APPLYING GASKET.............................................................................................................2-14
FIG. 2-18 – ELECTRICAL CONNECTIONS.............................................................................................2-14
FIG. 2-19 – REMOVE AND REPOSITION SHIPPING SPLIT ANGLE.....................................................2-15
FIG. 2-20 –BRINGING SECTIONS TOGETHER ....................................................................................2-16
FIG. 2-21 – APPLYING GASKET TO SHIPPINGSPLIT...........................................................................2-17
FIG. 2-22 – APPLYING GASKET TO DOOR FRAMEWHEN AT SHIPPING SPLIT................................2-17
FIG. 2-23 – ASSEMBLY OF END CHANNEL SHIPPING SPLIT (EXPANDED CABINET).....................2-18
FIG. 2-24 – REMOVE AND REPOSITION SHIPPING SPLIT ANGLE.....................................................2-18
FIG. 2-25 – PLACING AND ANCHORING FIRST SECTION AND ATTACHING COME-A-LONGS.......2-19
FIG. 2-26 – REMOVE LIFTING LUGS AND SAVE HARDWARE............................................................2-19
FIG. 2-27 – ELECTRICAL CONNECTIONS.............................................................................................2-19

JOHNSON CONTROLS
12
FORM 102.20-N1 (1109)
FIG. 2-28 – INSTALLING BOLTS AFTER PULLING UNITS TIGHT TOGETHER ..................................2-20
FIG. 2-29 – TIERED UNIT ........................................................................................................................2-21
FIG. 2-30 – TIERED UNIT SECURED WITH BRACKETS ......................................................................2-21
FIG. 2-31 – APPLY GASKETS TO TOP PANEL BOTTOM TIER............................................................2-21
FIG. 2-32 – GUIDING BRACKETS TOGETHER......................................................................................2-22
FIG. 2-33 – ASSEMBLY OF END CHANNEL SHIPPING SPLIT.............................................................2-23
FIG. 2-34 – HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS ........................................2-24
FIG. 2-35 – DIRECT COUPLED ON JACKSHAFT..................................................................................2-25
FIG. 2-36 – MZ DAMPER/ACTUATOR ASSEMBLY................................................................................2-26
FIG. 2-37 – DAMPER SHAFT EXTENSION KIT......................................................................................2-27
FIG. 2-38 – V-MOD INSTALLATION........................................................................................................2-28
FIG. 2-39 – V-RAY INSTALLATION .........................................................................................................2-28
FIG. 2-40 – V-FLEX INSTALLATION .......................................................................................................2-28
FIG. 2-41 – INSTALL GASKET UNDER ROOF OVERHANG.................................................................2-30
FIG. 2-42 – APPLY GASKET TO PIPE CHASE.......................................................................................2-31
FIG. 2-43 – PIPE CHASE BASERAIL TO UNIT BASERAIL INSTALLATION .......................................2-31
FIG. 2-44 – SCREW PIPE CHASE TOPAND BOTTOM INTERNAL FLANGES TO AIR HANDLER .....2-31
FIG. 2-45 – BASERAIL CAULK APPLICATION..........................................................................................2-32
FIG. 2-46 – PIPE CHASE TO ROOF INSTALLATION.............................................................................2-32
FIG. 2-47 – PIPE CHASE TO AIR HANDLER CAULK APPLICATION......................................................2-32
FIG. 2-48 – INSTALL COVER ANGLE.....................................................................................................2-32
FIG. 2-49 – PROPER POSITIONING OF COVER ANGLE WITH NOTCH ON AIR HANDLER SIDE......2-33
FIG. 2-50 – PROPER PATTERN FOR INSTALLING SELF-DRILLING SCREWS TO
COVER ANGLE.....................................................................................................................2-33
FIG. 2-51 – BASERAIL COVER APPLICATION......................................................................................2-33
FIG. 2-52 – GAS FURNACE FUEL VENTING SYSTEM .........................................................................2-34
FIG. 2-53 – GAS FURNACE CONDENSATE DRAIN TRAP ...................................................................2-35
FIG. 2-54 – TYPICAL MOTOR DATA / NAMEPLATE..............................................................................2-37
FIG. 2-55 – TYPICAL POWER WIRING OF ENERGY RECOVERY WHEEL .........................................2-37
FIG. 2-56 – GAS BURNER COMPONENT LOCATIONS ........................................................................2-38
FIG. 2-57 – MAIN POWER AND CONTROL PANEL W/ COVER OPEN ................................................2-38
FIG. 2-58 – TYPICAL ELECTRIC HEAT CONTROL PANEL INTERIOR WIRING AND
COMPONENTS.....................................................................................................................2-39
FIG. 2-59 – TYPICAL FIELD CONTROL AND POWER CONNECTIONS...............................................2-39
FIG. 2-60 – PRESSURE PROBE DIRECTION ........................................................................................2-41
FIG. 2-61 – AIRFLOW SWITCH CONNECTIONS ...................................................................................2-41
FIG. 2-62 – TYPICAL HUMIDIFIER PANEL LAYOUT .............................................................................2-43
FIG. 2-63 – SUPPLY POWER KNOCKOUTS..........................................................................................2-43
FIG. 2-64 – HUMIDIFIER POINTS ...........................................................................................................2-43
FIG. 2-65 – PIPE CHASE ENCLOSURE ................................................................................................2-44
FIG. 2-66 – FACTORY COIL CONNECTIONS.........................................................................................2-44
FIG. 2-67 – STAGGERED COIL CONFIGURATIONS .............................................................................2-45
FIG. 2-68 – CHILLED WATER COIL CONNECTIONS ............................................................................2-46
FIG. 2-69 – HOT WATER PIPING - 2 WAY VALVE..................................................................................2-47
LIST OF FIGURES (CONT'D)

13
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
FIG. 2-70 – HOT WATER PIPING WITH DIVERTING VALVE.................................................................2-47
FIG. 2-71 – STEAM COIL PIPING ARRANGEMENTS............................................................................2-49
FIG. 2-72 – INTEGRAL FACE AND BYPASS COIL (HORIZONTAL; TUBES, STEAM SHOWN)..........2-50
FIG. 2-73 – VERTICAL INTEGRAL FACE AND BYPASS COIL ............................................................2-50
FIG. 2-74 – HOT WATER PIPING FOR 2 ROW COIL VIFB....................................................................2-52
FIG. 2-75 – HOT WATER PIPING FOR IFB.............................................................................................2-52
FIG. 2-76 – STEAM PIPING FOR VIFB COIL..........................................................................................2-53
FIG. 2-77 – TYPICAL PIPING AND SUNDRIES AT THE DX COIL.........................................................2-54
FIG. 2-78 – DX COIL CIRCUITING TYPES .............................................................................................2-55
FIG. 2-79 – NON-STACKED COIL DESIGN - SQ SPECIAL...................................................................2-56
FIG. 2-80 – NON-STACKED COIL DESIGN - STANDARD.....................................................................2-56
FIG. 2-81 – STACKED COIL DESIGN - STANDARD ..............................................................................2-57
FIG. 2-82 – STACKED COIL DESIGNS - SQ SPECIAL..........................................................................2-57
FIG. 2-83 – STACKED COIL CIRCUITING..............................................................................................2-57
FIG. 2-84 – ONE COIL CIRCUIT PERREFRIGERANT CIRCUIT............................................................2-58
FIG. 2-85 – TWO COIL CIRCUITS PERREFRIGERANT CIRCUIT.........................................................2-58
FIG. 2-86 – DO NOT USE THE ABOVE CONFIGURATION. ..................................................................2-58
FIG. 2-87 – THREE COMPRESSOR YCUL.............................................................................................2-58
FIG. 2-88 – DO NOT USE THE ABOVE CONFIGURATION. ..................................................................2-58
FIG. 2-89 – SIX COMPRESSOR YCUL ...................................................................................................2-59
FIG. 2-90 – DRAIN TRAP SHOWING WATER LOCATION DURING DRAW THROUGH
OPERATION STAGES ..........................................................................................................2-61
FIG. 2-91 – TRAP DETAIL FOR DRAW THROUGH APPLICATION.......................................................2-61
FIG. 2-92 – TRAP DETAIL FOR BLOW THROUGH APPLICATION.......................................................2-61
FIG. 2-93 – COMBINING DRAIN LINES..................................................................................................2-62
FIG. 2-94 – RECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS
ARE REQUIRED....................................................................................................................2-62
FIG. 2-95 – RECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS
ARE REQUIRED....................................................................................................................2-63
FIG. 2-96 – DUCT PENETRATION OF ROOF.........................................................................................2-64
FIG. 2-97 – ROOF TO DUCT INSTALLATION - HORIZONTAL DISCHARGE........................................2-64
FIG. 2-97A – TYPICAL FILTERS .............................................................................................................2-65
FIG. 2-98 – FILTER LATCHES.................................................................................................................2-66
FIG. 2-99 – CORRECTLY INSTALLED LATCH P/N 026-35778-000.......................................................2-68
FIG. 2-100 – FULLY INSTALLED FILTER ...............................................................................................2-68
FIG. 2-101 – CORRECTLY INSTALLED LATCH P/N 026-35778-007.....................................................2-69
FIG. 2-102 – PLACE THE END OF THE LATCH OVER THE FILTER FRAME, SECURING
THE FILTER TO THE FRAME.............................................................................................2-69
FIG. 2-103 – INSTALLED CARTRIDGE FILTER.....................................................................................2-70
FIG. 2-104 – INSTALL LATCH P//N 026-35778-007................................................................................2-70
FIG. 2-105 – INSTALLED CARTRIGE W/PLEATS..................................................................................2-70
FIG. 2-106 – CORRECT USE OF KNOCKOUTS ....................................................................................2-71
FIG. 2-107 – CORRECT LATCH/KNOCKOUT CONFIGURATION. .......................................................2-71
LIST OF FIGURES (CONT'D)

JOHNSON CONTROLS
14
FORM 102.20-N1 (1109)
FIG. 2-108 – FRAME WITH 4 LATCHES INSTALLED. ..........................................................................2-71
FIG. 2-109 – SPRING LATCH SHOULD BE PULLED AND FASTENED IN HOLE IN THE
HEADER OF THE FILTER. .................................................................................................2-71
FIG. 2-110 – CORRECT LATCH/KNOCKOUT CONFIGURATION. P/N 026-35778-006........................2-72
FIG. 2-111 – FRAME WITH 4 LATCHES INSTALLED ............................................................................2-72
FIG. 2-112 – PREFILTER LATCH AFTER INSTALLATION ONTO FILTER HEADER............................2-72
FIG. 2-113 – POSITION PREFILTER IN FRONT OF THE FINAL FILTER.
(2" W/026-36339-000 LATCH SHOWN) ..............................................................................2-73
FIG. 2-114 – SPRING THE END OF THE LATCH SO THAT IT FITS OVER THE EDGE OF
THE PREFILTER. (4" W/026-36339-000 LATCH SHOWN) ................................................2-73
FIG. 2-115 – COMPLETED ASSEMBLY..................................................................................................2-73
FIG. 2-116 – HEPA FILTER FRAME CROSS SECTION VIEW ...............................................................2-74
FIG. 2-117 – VISUAL CONTROL FILTER CLAMPS................................................................................2-74
FIG. 2-118 – HEPA FILTER INSTALLATION ...........................................................................................2-75
FIG. 2-119 – WELDED BEVEL SEAL FILTER INSTALLATION..............................................................2-75
FIG. 3-1 – TERMINATION CHART INSIDE ENCLOSURE DOOR............................................................3-2
FIG. 3-2 – FAN AND MOTOR ISOLATOR SUPPORT FRAME.................................................................3-3
FIG. 3-3 – ODP (OPEN DRIP PROOF)......................................................................................................3-3
FIG. 3-4 – TEFC (TOTALLY ENCLOSED FAN COOLED).........................................................................3-4
FIG. 3-5 – SPRING ISOLATOR..................................................................................................................3-4
FIG. 3-6 – SEISMIC SNUBBER .................................................................................................................3-4
FIG. 3-7 – EXAMPLE OF SWEEP BALANCE RESULTS .........................................................................3-7
FIG. 3-8 – TYPICAL DRIVE KIT DATA TAG..............................................................................................3-8
FIG. 3-9 – INDOOR UNIT - VERTICAL WHEEL........................................................................................3-9
FIG. 3-10 – OUTDOOR UNIT - HORIZONTAL WHEEL.............................................................................3-9
FIG. 3-11 – ENERGY RECOVERY WHEEL - PULLEY SIDE..................................................................3-10
FIG. 3-12 – SEGMENT RETAINER..........................................................................................................3-10
FIG. 3-13 – DIAMETER SEAL ADJUSTMENT........................................................................................3-10
FIG. 3-14 – OPEN FUSE DISCONNECTS...............................................................................................3-12
FIG. 3-15 – SET ID FAN DAMPER ..........................................................................................................3-13
FIG. 3-16 – CHECK MAIN GAS SUPPLY PRESSURE...........................................................................3-13
FIG. 3-17 – DRAFT OVER FIRE TEST PORT.........................................................................................3-14
FIG. 3-18 – FLUE (STACK) COMBUSTION TEMPERATURE AND EFFICIENCY TEST PORT............3-14
FIG. 3-19 – DAMPER ACTUATOR...........................................................................................................3-15
FIG. 3-20 – CONDENSATE DRAIN .........................................................................................................3-15
FIG. 3-21 – GAS FURNACE CONDENSATE DRAIN TRAP ...................................................................3-16
FIG. 3-22 – GAS FURNACE FUEL VENTING SYSTEM .........................................................................3-20
FIG. 3-23 – GAS FURNACE FUEL VENTING SYSTEM .........................................................................3-21
FIG. 3-24 – TYPICAL WIRING DIAGRAM...............................................................................................3-22
FIG. 3-25 – MINIMUM AIR VELOCITY REQUIRED FOR SAFE OPERATION .......................................3-25
FIG. 3-26 – PRESSURE PROBE DIRECTION ........................................................................................3-26
FIG. 3-27 – AIRFLOW SWITCH CONNECTIONS ...................................................................................3-26
FIG. 3-28 – AIR HANDLER START-UP CHECKLIST..............................................................................3-27
LIST OF FIGURES (CONT'D)

15
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
LIST OF TABLES
TABLE 1 – SEGMENT IDENTIFICATION...................................................................................................17
TABLE 2 – UNIT NOMENCLATURE...........................................................................................................18
TABLE 1-1 - SPACING REQUIREMENTS FOR OFFLOADING LONG UNITS........................................1-2
TABLE 3-1 – TORQUE FOR TIGHTENING SETSCREWS.......................................................................3-3
TABLE 3-2 – NATURAL GAS PRESSURE REQUIREMENTS (INCHES WC) .......................................3-18
TABLE 3-3 – PIPE SIZE REQUIRED.......................................................................................................3-19
TABLE 3-4 – BURNER TEPERATURE RISE..........................................................................................3-23
TABLE 3-5 – INSPECTION REQUIREMENTS........................................................................................3-29

JOHNSON CONTROLS
16
FORM 102.20-N1 (1109)
THIS PAGE INTENTIONALLY LEFT BLANK

17
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
GENERAL
This manual has been prepared as a guide for
installing, operating and maintaining YORK Solution
Air Handling Units. Johnson Controls has produced a
quality product that is adaptable to almost any comfort
or industrial application. However, proper installation,
operation and maintenance must be followed to realize
the full capacity and life of the units.
This instruction contains general recommendations,
but specic requirements may apply to the individual
installation. Such requirements are outlined in federal,
stateandlocalsafetycodes.Strictcompliancewiththese
codes and strict adherence to these instructions are the
responsibility of the user. Particular attention should
be given to electrical wiring and other safety elements
such as design working pressures and requirements
of the Government Clean Air Act Amendments as it
applies to refrigerant types and charges. General safety
practices are covered in AMCA Publication 410-90.
Read the entire instruction before installing or operating
the air handler. Specic details and requirements apply
that require careful consideration to avoid damage to
the equipment and injury to the installer or operator.
The YORK Solution features segmented construction
and is factory assembled. Segment arrangements will
vary to suit job application (see Fig. 1). Heavy gauge
galvanized steel is used on the exterior and interior of
the unit. Access doors are provided for accessibility
to the various sections. Removable access panels are
standard in lieu of doors on Commercial Performance
units. Panels and doors are double wall construction.
Panels, doors and structural frame are insulated with
spray-injected foam.
TYPICAL YORK SOLUTION OPERATION IN
“HVAC”SYSTEM
The operation of these units can be divided into sys-
tems:
1. Ventilation system.
2. Economizer system (return air/mixing box sec-
tion).
3. Heating system.
4. Cooling system.
Ventilation System
A ventilation system simply replaces the air in a given
space. Usually the purpose is to remove air that is
substandardtocreaturecomfortoraprocessandreplace
it with suitable air. Depending on the application the
system will operate at various specied rates, volumes
andconditions. Aventilationsystemmayemploy anair
handler with a supply fan working in conjunction with
other remote exhaust fan(s). A more effective method
would employ both a supply fan and an exhaust fan in
the air handler.
INTRODUCTION
FIG. 1 – CUTAWAY OF YORK SOLUTION SHOWING VARIOUS SEGMENTS LD13764

JOHNSON CONTROLS
18
FORM 102.20-N1 (1109)
Economizer System - Typical
The Economizer system could typically consist of:
• Outdoor and return air dampers.
• Damper actuator.
• Enthalpy control.
• Minimum outdoor air adjustment.
• Exhaust air control.
The Economizer system provides the rst stage of
cooling whenever the outdoor air is cool and dry
enough to satisfy the internal cooling demand. The
outdoor and the return air dampers are operated by
individual actuators. As the outdoor air dampers are
opened by the damper actuator, the return air dampers
are closed.
If the economizer operation cannot satisfy the space
demand for cooling, stages can be energized as
needed.
Heating Operation
Various types of heating may be applied. Hot water
or steam coils maybe specied typically. Electric heat
and fuel burner heat are available.
Cooling Operation
Various types of cooling may be utilized. Factory
mounted chilled water coils or direct expansion
refrigerant coils may be specied for the YORK
Solution unit.
HAND IDENTIFICATION
Coil connections and other components are located and
described as left or right hand. The proper orientation
to describe the proper hand is when airow is at your
back, as shown in Fig. 2.
FAN SECTION
LEFT HAND (LH)
COIL CONNECTION
RIGHT HAND (RH)
COIL CONNECTION
RETURN AIR
INLET SECTION
OUTSIDE AIR
DRIVE HAND AND COIL HAND DETERMINED
BY FACING THE INLET SECTION
RIGHT
REAR
LEFT
FRONT
FIG. 2 – UNIT AND COIL HAND IDENTIFICATION
LD08004

19
JOHNSON CONTROLS
FORM 102.20-N1 (1109)
SEGMENT IDENTIFICATION
Refer to Tables 1 and 2 for segment identication and nomenclature.
TABLE 1 – SEGMENT IDENTIFICATION
FAN SEGMENTS





(BELT AND DIRECT DRIVE)





(BELT AND DIRECT DRIVE)





(BELT AND DIRECT DRIVE)
COIL SEGMENTS




HEAT SEGMENTS



ENERGY RECOVERY

FILTER SEGMENTS







INLET SEGMENTS







ACCESSORY SEGMENTS













JOHNSON CONTROLS
20
FORM 102.20-N1 (1109)
TABLE 2 – UNIT NOMENCLATURE
-
X
-
DESIGN
A
XT CODE
12 17
I INDOOR UNIT 27
O OUTDOOR UNIT 28
40 44 46
50
58 63
0 NO 1 YES
27,30,33,36,39,42,45,48,51,54,57 A NONE. A 0
27,30,33,36,39,42,45,48,51,54,57,60 B DWDI FC FAN w/o MOTOR CONTROLLER. B 1/2
30,33,36,39,42,45,48,51,54,57,60,63,66,69
C DWDI FC FAN w/SERVICE DISCONNECT ONLY. C 3/4
30,33,36,39,42,45,48,51,54,57,60,63,66,69,72 D DWDI FC FAN w/MOTOR STARTER. D 1
33,36,39,42,45,48,51,54,57,60,63,66,69,72,75,78 E DWDI FC FAN w/VARIABLE FREQUENCY DRIVE. E 1 1/2
36,39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,84 F DWDI AF FAN w/o MOTOR CONTROLLER. F 2
36,39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,84,87 G DWDI AF FAN w/SERVICE DISCONNECT ONLY. G 3
39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,87,90 H DWDI AF FAN w/MOTOR STARTER. H 5
42,45,48,51,54,57,60,63,66,69,72,75,78,81,84,87,90,93,96,99
J DWDI AF FAN w/VARIABLE FREQUENCY DRIVE. J 7 1/2
45,48,51,54,57,60,63,66,69,72,75,78,81,84,87,90,93,96,99,102 K SWSI PL FAN w/o MOTOR CONTROLLER. K 10
48,54,60,66,72,78,84,90,102,108 L SWSI PL FAN w/SERVICE DISCONNECT ONLY. L 15
48,54,60,66,72,78,81,84,90,96,102,108 M SWSI PL FAN w/MOTOR STARTER. M 20
51,57,63,69,75,81,87,90,93,99,105,111,117 N SWSI PL FAN w/VARIABLE FREQUENCY DRIVE. N 25
54,60,66,72,78,84,90,96,102,108,114,120 P SWSI PL FAN DIRECT DRIVE w/o MOTOR CONTROLLER. P 30
51,57,63,69,75,81,87,93,96,99,105,108,111,117,123 Q SWSI PL FAN DIRECT DRIVE w/SERVICE DISCONNECT ONLY. Q 40
54,60,66,72,78,84,90,96,102,108,114,120,126,132 R SWSI PL FAN DIRECT DRIVE w/MOTOR STARTER. R 50
57,63,69,75,81,87,93,99,105,111,117,120,123,129,135 S SWSI PL FAN DIRECT DRIVE w/VARIABLE FREQUENCY DRIVE. S 60
60,66,72,78,84,90,96,102,108,114,120,126,132,138,144 T 75
60,66,72,78,84,90,96,102,108,114,120,126,132,138,144 U 100
66,72,78,84,90,96,102,108,114,120,126,132,138,144 V 125
72,78,84,90,96,102,108,114,120,126,132,138,144
72,78,84,90,96,102,108,114,120,126,132,138,144
78,84,90,96,102,108,114,120,126,132,138,144
84,90,96,102,108,114,120,126,132,138,144
90,96,102,108,114,120,126,132,138,144
90,96,102,108,114,120,126,132,138,144
96,102,108,114,120,126,132,138
Notes: 1.The height and width numbers only correspond to each other in the same row.
2. The height and width numbers will always be (3) characters long in the model number.
132
MOTOR HORSEPOWER
114
120
126
90
96
102
108
72
84
60
63
66
69
54
57
75
78
42
45
48
51
30
33
36
39
H
27
048
075
A
PRIMARY
VOLTAGE
CODE
46
D
C
M
FACTORY
MOUNTED END
DEVICES
SUPPLY FAN
OPTIONS
RETURN FAN
OPTIONS
SUPPLY FAN
MOTOR HP
440-3-50
575 - 3 - 60
DEFINITION
ORIGINAL UNIT DESIGN
NAMEPLATE VOLTAGE
120 - 1 - 60
200 or 208 - 3 - 60
277 - 1 - 60
230 or 240 - 3 - 60
380 - 3 - 60
FAN OPTIONS
Solution Unit Model Number.
RETURN FAN
MOTOR HP
0
K
DESIGN
SERIES
460 - 3 - 60
380 or 415 - 3 - 50
220 - 3 - 50
FACTORY MOUNT END DEVICES.
WIDTH
PRIMARY
IDENTIFIER
XT
ENVIRONMENT
I
NOMINAL
HEIGHT
NOMINAL
WIDTH
003-001.xls Rev New
LD13350