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