York AHU Installation guide

LD17323
AIR HANDLING UNITS
OPERATION AND MAINTENANCE New Release Form 102.20-OM2 (615)
Issue Date:
June 1, 2015
LD09624
OUTDOOR SOLUTION XT AHUINDOOR SOLUTION XT AHU
YORK CUSTOM AHU
LD13282
Renewal Parts
With P/N contact Balt. Parts
[phone]
Manufactured or specialty
parts, contact Airside Technical
Services [phone]

JOHNSON CONTROLS
2
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, materials under pressure,
rotating components, 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 rigging, instal-
lation, and 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
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
rigging, installation, and operating/service personnel. It
is expected that these individuals possess 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 the on-prooduct labels,
this document, and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.

JOHNSON CONTROLS 3
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, installation, and op-
erating/service personnel to verify the applicability of
these documents to the equipment. If there is any ques-
tion regarding the applicability of these documents,
rigging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the unit.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
ASSOCIATED LITERATURE
MANUAL DESCRIPTION FORM NUMBER
Solution XT Air Handling Units Installation and Assembly 102.20-N1
York Custom Air Handling Units Installation and Assembly 102.20-N3
Steps to Protect New Equipment Warranty 102.20-CL1
Air Handling Units Start-up Checklist 100.00-CL1
Long-Term Storage Requirement - Field Preparation - Air Handling Units 50.20-NM3
Long-Term Storage Periodic Checklist and Logs - Air Handling Units 50.20-CL3
Limited Warranty 50.05-NM2
Electric Motor Warranty 50.05-NM2.2
Air Cooled Condensing Unit DX Coil Split System Applications and Piping Guidelines 50.40-ES3
Air Modulator Service & Warranty Procedure SI0262

JOHNSON CONTROLS
4
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SOLUTION XT UNIT MODEL NOMENCLATURE
XT
PRIMARY IDENTIFIER
XT
ENVIRONMENT
I=Indoor
O=Outdoor
I
NOMINAL
HEIGHT
27 to 132
NOMINAL
WIDTH
27 to 288
075
048 xD
SUPPLY AND RETURN/EXHAUST FAN OPTIONS
A=None
B=DWDI FC Fan without Motor Controller
C=DWDI FC Fan with Service Disconnect Only
D=DWDI FC Fan with Motor Starter
E=DWDI FC Fan with Variable Frequency Drive (VFD)
F=DWDI AF Fan without Motor Controller
G=DWDI AF Fan with Service Disconnect Only
H=DWDI AF Fan with Motor Starter
J=DWDI AF Fan with VFD
K=SWSI PL Fan without Motor Controller
L=SWSI PL Fan with Service Disconnect only
M=SWSI PL Fan with Motor Starter
N=SWSI PL Fan with VFD
P=SWSI PL Fan Direct Drive without Motor Controller
Q=SWSI PL Fan Direct Drive with Service Disconnect Only
R=SWSI PL Fan Direct Drivee with Motor Starter
S=SWSI PL Fan Direct Drive with VFD
C
FACTORY MOUNTED
END DEVICES
0=No
1=Yes
046
M
MOTOR HORSEPOWER
SUPPLY AND RETURN/EXHAUST
FAN
A=0
B=1/2
C=3/4
D=1
E=1 1/2
F=2
G=3
H=5
J=7 1/2
K=10
L=15
M=20
N=25
P=60
Q=40
R=50
S=60
T=75
U=100
V=125
K
VOLTAGE CODE
12=120-1-60
17=200 or 208-3-60
27=277-1-60
28=230 or 240-3-60
40=360-3-60
44=440-3-50
46=460-3-60
50=380 or 415-3-50
58=575-3-60
63=220-3-50
A
DESIGN
A=Original Unit Design
Note: The terms skid and section have the same meaning in this document;
Variable Speed Drive (VSD) and Variable Frequency Drive (VFD) do as well.

JOHNSON CONTROLS 5
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
TABLE OF CONTENTS
SECTION 1 - GENERAL INFORMATION AND SAFETY.......................................................................................13
Introduction.....................................................................................................................................................13
About This Manual..........................................................................................................................................13
Warranty .........................................................................................................................................................13
Responsibility For Safety................................................................................................................................ 13
SECTION 2 - START-UP AND OPERATION..........................................................................................................15
Before Start-Up ..............................................................................................................................................15
Inspecting Fan Assembly ......................................................................................................................16
Inspecting Belts and Sheaves ...............................................................................................................17
Checking Isolators.................................................................................................................................17
Start-Up .................................................................................................................................................19
Checking Operation of Fans..................................................................................................................19
Checking Operation of Dampers ...........................................................................................................19
Energize Fan Motors .............................................................................................................................29
Variable Frequency Drive (VFD) ..........................................................................................................29
Check Doors And Latches.....................................................................................................................29
Energy Recovery Wheel........................................................................................................................29
Indirect Fired Gas Heat Start Up ..........................................................................................................34
Starting the Electric Heater ...................................................................................................................46
Operation........................................................................................................................................................50
Test And Balance...................................................................................................................................50
Setting Limits.........................................................................................................................................50
Checking Motors, Belts and Sheaves ...................................................................................................51
P-Cone®................................................................................................................................................51
SECTION 3 - MAINTENANCE................................................................................................................................53
General Requirements ...................................................................................................................................53
Inspect Parts ..................................................................................................................................................54
Cabinet ..................................................................................................................................................54
Door Hardware and Gaskets.................................................................................................................54
Panels ...................................................................................................................................................54
Hoods and Louvers ...............................................................................................................................54
Bird Screens..........................................................................................................................................54
Optional Moisture Eliminators ...............................................................................................................54
Outdoor Air Hood...................................................................................................................................54
Fan Segment (Supply, Return or Exhaust) ....................................................................................................55
Removing the Fan .................................................................................................................................55
Checking the Fan ..................................................................................................................................55
Operating Adjustable Motor Base ..................................................................................................................55
Standard................................................................................................................................................55
Checking Belt Tension...........................................................................................................................57
Aligning Sheaves ...........................................................................................................................................57
Using a Straightedge.............................................................................................................................58
Using a String........................................................................................................................................58
Belt Replacement Tensioning and Sheave Alignment for Top Mount.............................................................58
Lubrication......................................................................................................................................................60
Fan Bearing Lubrication ........................................................................................................................61

JOHNSON CONTROLS
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FORM 102.20-OM2
ISSUE DATE: 6/01/2015
TABLE OF CONTENTS (CONT'D)
Checking Condition of Extended Lubrication Lines...............................................................................61
Recommended Lubricant for Bearings..................................................................................................61
Proper Interval and Quantity .................................................................................................................61
Lubricating the Fan Segment and Motor ........................................................................................................62
Checking Condition of Mounting Hardware, Adjustable Motor Base and Motor....................................63
Checking Electrical Connections...........................................................................................................63
Keep Motor Bearing Lubricated.............................................................................................................63
UVC Emitter Lamps........................................................................................................................................ 64
Three Types of Lamps...........................................................................................................................65
Maintaining and Replacing Filter Segments ..................................................................................................65
Replacing the Filters..............................................................................................................................66
Economizer Segment (Dampers) ...................................................................................................................66
Cleaning Procedure...............................................................................................................................66
Hardware Check....................................................................................................................................66
Coil Segment Cleaning...................................................................................................................................66
Tools, Equipment and Materials ...........................................................................................................66
Cleaning Procedure...............................................................................................................................67
Condensate Drain Pan, Trap and Line Cleaning ...........................................................................................67
Tools, Equipment and Materials ............................................................................................................67
Schedule and Conditions ......................................................................................................................67
Cleaning Procedure ..............................................................................................................................68
Coil Freeze Protection...........................................................................................................................68
Energy Recovery Wheel................................................................................................................................. 68
Airxchange®..................................................................................................................................................68
Tools and Materials ..............................................................................................................................68
Cleaning the Wheel ...............................................................................................................................69
Adjusting Air Seals ................................................................................................................................69
Inspect Wheel Drive Components.........................................................................................................70
NovelAire®Technologies ................................................................................................................................70
Cleaning the Wheel ...............................................................................................................................70
Adjusting Air Seals ................................................................................................................................71
Inspect Wheel Drive Components.........................................................................................................71
How to Measure, Assemble and Install .................................................................................................71
Thermotech®..................................................................................................................................................72
Cleaning the Wheel ...............................................................................................................................72
Adjusting Air Seals ................................................................................................................................72
Inspect Wheel Drive Components.........................................................................................................73
Innergy Tech®................................................................................................................................................73
Cleaning the Wheel ...............................................................................................................................73
Adjusting Air Seals ................................................................................................................................73
Inspect Wheel Drive Components.........................................................................................................74
ECONO-DISK®..............................................................................................................................................75
Maintenance Instructions ......................................................................................................................75
P-Cone®.........................................................................................................................................................75
Maintenance of P-Cone®......................................................................................................................75

JOHNSON CONTROLS 7
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SECTION 4 - SERVICE AND REPAIR....................................................................................................................77
Service Tools and Equipment.........................................................................................................................77
Service Information ........................................................................................................................................78
Troubleshooting..............................................................................................................................................78
Pitot Tube .......................................................................................................................................................78
Inclined Manometer........................................................................................................................................79
Filter Gauge....................................................................................................................................................79
U-Tube Manometer ........................................................................................................................................79
Duct Pressures...............................................................................................................................................80
Velocity ..................................................................................................................................................80
Static Pressure ......................................................................................................................................81
Total Pressure .......................................................................................................................................81
Requesting Assistance ...................................................................................................................................81
Adjusting, Removing, and Installing Sheaves ................................................................................................82
Fixed Pitch Sheaves (T.B Woods With Sure Grip Bushings) ............................................................... 82
Adjustable Pitch Sheaves (T.B. Woods - Model JVS) ...........................................................................84
Adjustable Pitch Sheaves (T.B. Woods - Model FHP)...........................................................................85
SECTION 5 - WIRING DIAGRAMS ........................................................................................................................87
Installing Kit (If Applicable) .............................................................................................................................92
APPENDIX A – START-UP CHECKLIST..............................................................................................................107
APPENDIX B – LONG-TERM STORAGE............................................................................................................ 111
Temperature ................................................................................................................................................. 116
TABLE OF CONTENTS (CONT'D)

JOHNSON CONTROLS
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FORM 102.20-OM2
ISSUE DATE: 6/01/2015
LIST OF FIGURES
FIGURE 1 - Solution XT Seismic Isolator................................................................................................................15
FIGURE 2 - Example of a Solution XT Termination Chart....................................................................................... 16
FIGURE 3 - Fan and Motor Isolator Support Frame................................................................................................17
FIGURE 4 - Spring Isolator......................................................................................................................................17
FIGURE 5 - Spring Isolator Set-Up .........................................................................................................................18
FIGURE 6 - Counterbalance Locked into Place for Shipping..................................................................................19
FIGURE 7 - Counterbalance Unlocked for Start-Up................................................................................................19
FIGURE 8 - Front of a 2X2 Fan Array .....................................................................................................................20
FIGURE 9 - Back of a 2X2 Fan Array......................................................................................................................20
FIGURE 10 - Front of a 1X2 Fan Array ...................................................................................................................20
FIGURE 11 - High And Low Connections for an In Fan Air Monitoring System ......................................................23
FIGURE 12 - High And Low Connections and Associated Tubing for Fan Mounted Air Monitoring System........... 24
FIGURE 13 - Port Locations for Fan Mounted Air Monitoring System ....................................................................24
FIGURE 14 - Ductwork Inlet Requirements.............................................................................................................25
FIGURE 15 - Ductwork Radius................................................................................................................................25
FIGURE 16 - 25% Sensing Option..........................................................................................................................25
FIGURE 17 - 25%/75% Sensing Option..................................................................................................................25
FIGURE 18 - 25%/75% Sensing Option..................................................................................................................26
FIGURE 19 - Example of Sweep Balance Results Label On Fan Housing.............................................................29
FIGURE 20 - Metal Spacers on Solution XT Doors.................................................................................................29
FIGURE 21 - Vertical Wheel for Indoor AHU ...........................................................................................................29
FIGURE 22 - Horizontal Wheel for Outdoor AHU....................................................................................................30
FIGURE 23 - Energy Recovery Wheel - Pulley Side...............................................................................................31
FIGURE 24 - Segment Retainer..............................................................................................................................32
FIGURE 25 - Diameter Seal Adjustment .................................................................................................................32
FIGURE 26 - Purge Angle Detail.............................................................................................................................33
FIGURE 27 - Purge Angle Detail.............................................................................................................................34
FIGURE 28 - Gas Furnace Condensate Drain Trap................................................................................................ 36
FIGURE 29 - Open Fuse Disconnects ....................................................................................................................37
FIGURE 30 - Set Id Fan Damper ............................................................................................................................37
FIGURE 31 - Check Main Gas Supply Pressure.....................................................................................................37
FIGURE 32 - Draft Over Fire Test Port....................................................................................................................38
FIGURE 33 - Flue Combustion Temperature and Efciency Test Port- ID Blower ..................................................38
FIGURE 34 - Damper Actuator................................................................................................................................38
FIGURE 35 - Example Solution XT Gas Furnace Fuel Venting System .................................................................43
FIGURE 36 - Typical Wiring Diagram......................................................................................................................44
FIGURE 37 - Minimum Air Velocity Required for Safe Operation............................................................................48
FIGURE 38 - Pressure Probe Direction...................................................................................................................49
FIGURE 39 - Air Flow Switch Connections .............................................................................................................49
FIGURE 40 - V-Belt Drive Kit Label.........................................................................................................................51
FIGURE 41 - Remove Mist Eliminator.....................................................................................................................54
FIGURE 42 - Weather Hood Installation .................................................................................................................54
FIGURE 43 - Typical Drive Kit Data Tag..................................................................................................................55
FIGURE 44 - Solution XT Adjustable Motor Base ...................................................................................................55
FIGURE 45 - Solution XT Adjustable Motor Base (Top Mount) ............................................................................... 56
FIGURE 46 - Belt Tensioning ..................................................................................................................................57
FIGURE 47 - Belt Tensioning Gauge.......................................................................................................................57

JOHNSON CONTROLS 9
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
FIGURE 48 - Alignment Using Straight Edge..........................................................................................................58
FIGURE 49 - Alignment Using String ......................................................................................................................58
FIGURE 50 - Sheave Angular Misalignment ...........................................................................................................59
FIGURE 51 - Motor Base Lowered..........................................................................................................................59
FIGURE 52 - Sheave Angular Alignment.................................................................................................................59
FIGURE 53 - Sheave Angular Misalignment ...........................................................................................................60
FIGURE 54 - Sealed Bearing ..................................................................................................................................60
FIGURE 55 - Bearing with Set Screw Type Locking Device ...................................................................................60
FIGURE 56 - Bearing with Eccentric Cam...............................................................................................................60
FIGURE 57 - Split Bearing (Assembled) .................................................................................................................61
FIGURE 58 - Optional Lubrication Lines .................................................................................................................61
FIGURE 59 - Open Drip Proof (ODP) Motor ...........................................................................................................63
FIGURE 60 - Totally Enclosed Fan Cooled (TEFC) Motor ......................................................................................63
FIGURE 61 - UV Lamps..........................................................................................................................................65
FIGURE 62 - Installing V-Mod Lamp .......................................................................................................................65
FIGURE 63 - Installing V-Ray and V-Max Grid Lamps............................................................................................65
FIGURE 64 - V-Max Grid Lamps .............................................................................................................................65
FIGURE 65 - Typical Filter Types ............................................................................................................................65
FIGURE 66 - Installing Angle Filters........................................................................................................................66
FIGURE 67 - Installing Side Load Filters.................................................................................................................66
FIGURE 68 - Rinse Segments ................................................................................................................................69
FIGURE 69 - Diameter Seal Adjustment .................................................................................................................69
FIGURE 70 - Airxchange®Energy Recovery Wheel With Bearing Support Beam Side ........................................70
FIGURE 71 - How to Measure.................................................................................................................................71
FIGURE 72 - Disassembly ......................................................................................................................................71
FIGURE 73 - Assembly ...........................................................................................................................................71
FIGURE 74 - Installation..........................................................................................................................................72
FIGURE 75 - Loosen Screws Before Adjusting Seals.............................................................................................72
FIGURE 76 - ERW Seal Locations..........................................................................................................................73
FIGURE 77 - Airloop™ Labyrinth Seal Adjustment .................................................................................................74
FIGURE 78 - Plenum Fan Tap Location and Connection Illustration ......................................................................75
FIGURE 79 - Maintenance Requirements...............................................................................................................76
FIGURE 80 - Construction of Pitot Tube .................................................................................................................78
FIGURE 81 - Pitot Tube...........................................................................................................................................78
FIGURE 84 - Magnehelic Filter Guage....................................................................................................................79
FIGURE 82 - Inclined Manometer ...........................................................................................................................79
FIGURE 83 - Minihelic Filter Gauge........................................................................................................................79
FIGURE 85 - U-Tube Manometers..........................................................................................................................80
FIGURE 86 - Slack Tube Manometer......................................................................................................................80
FIGURE 87 - Static Pressure Air System ................................................................................................................81
FIGURE 88 - Inserting Cap Screws.........................................................................................................................82
FIGURE 89 - Standard Mounting ............................................................................................................................82
FIGURE 90 - Reverse Mounting..............................................................................................................................83
FIGURE 91 - Adjustable Pitch Sheave (JVS)..........................................................................................................84
FIGURE 92 - Adjustable Pitch Sheave (FHP) .........................................................................................................85
FIGURE 93 - Full Voltage Starter ............................................................................................................................88
FIGURE 94 - Full Voltage Starter With Single Point Power Connection (204195) ..................................................90
LIST OF FIGURES (CONT'D)

JOHNSON CONTROLS
10
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
LIST OF FIGURES (CONT'D)
FIGURE 95 - Outside Air Damper Kit (Relay Installation) .......................................................................................92
FIGURE 96 - Solution XT Termination Chart Inside Enclosure Door ......................................................................93
FIGURE 97 - Typical FPC Wiring Diagram..............................................................................................................94
FIGURE 98 - Transformer Enclosure Wiring Detail (Shown Open).........................................................................96
FIGURE 99 - Transformer Wiring Diagram..............................................................................................................97
FIGURE 100 - UV Control Panel Wiring (8 amps)...................................................................................................99
FIGURE 101 - UV Control Panel Wiring ( greater than 8 amps) ........................................................................... 100
FIGURE 102 - Gas Heat, Single Phase, 1500Va Transformer Wiring Diagram ....................................................102
FIGURE 103 - Gas Heat, Three Phase, 1000Va Transformer Wiring Diagram.....................................................103
FIGURE 104 - Gas Heat, Three Phase, 500Va Transformer Wiring Diagram.......................................................104
FIGURE 105 - Typical Wiring Diagram for Electric Heat Control Type Vermier ....................................................105
FIGURE 106 - Typical Wiring Diagram for Control Type Full SCR........................................................................106

JOHNSON CONTROLS 11
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
LIST OF TABLES
TABLE 1 - Torque for Tightening Set Screws..........................................................................................................16
TABLE 2 - Air Measuring Device Connections........................................................................................................21
TABLE 3 - Indoor Unit Example ..............................................................................................................................27
TABLE 4 - Outdoor Unit Example ...........................................................................................................................28
TABLE 5 - Gas Heat Segment Model Number Nomenclature ................................................................................39
TABLE 6 - Natural Gas Pressure Requirements (Inches Wc) ................................................................................40
TABLE 7 - Natural Gas Pressure Requirements (Inches Wc) ................................................................................41
TABLE 8 - Inlet Size (NPT) .....................................................................................................................................42
TABLE 9 - Burner Temperature Rise ......................................................................................................................45
TABLE 10 - Maximum Current for 75°C Copper Wire.............................................................................................47
TABLE 11 - Minimum / Maintenance Requirements According to ASHRAE...........................................................53
TABLE 12 - Fan Bearing Re-Lubrication Intervals for Ball Bearing Pillow Blocks .................................................. 62
TABLE 13 - Fan Bearing Lubrication Intervals for Spherical Roller Bearing Solid Pillow Blocks............................ 62
TABLE 14 - Fan Bearing Lubrication Intervals for Spherical Roller Bearing Split Pillow Blocks............................. 62
TABLE 15 - Fan Bearing Lubrication Intervals for Dodge ISN Bearings................................................................. 62
TABLE 16 - Motor Bearing Lubrication Intervals..................................................................................................... 64
TABLE 17 - Motor Bearing Service Conditions .......................................................................................................64
TABLE 18 - Motor Bearing Lubrication Interval Multiplier .......................................................................................64
TABLE 19 - Cap Screw Torque Values ..................................................................................................................83
TABLE 20 - Set Screw Torque Values.....................................................................................................................83
TABLE 21 - SI Metric Conversion ......................................................................................................................... 116

JOHNSON CONTROLS
12
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SERVICE TASK REFERENCE
Adjustable Motor Base
Operation 55
Air Louvers
Inspection 54
Air Modulator
Start-Up 29
Belts
Checking Tension 58
Bird Screen
Inspection 54
Cabinet Maintenance
Cleaning 54
Coils
Cleaning 66
Controls
Control Wiring 94
Dampers
Checking Operation 19
Blade Orientation 28
Cleaning 66
Hardware Check 66
Damper Actuator
Installation 28
Direct Coupled Mounting 28
Doors
Start-Up Inspection 29
Drain Lines
Cleaning 67
Freeze Protection 68
Drain Pan
Field Testing 67
Freeze Protection 68
Drain Trap
Cleaning 67
Freeze Protection 68
Drive Kit
Inspection 55
Electric Heat
Control Wiring 105
Energy Recovery Wheel
Control Wiring 29
Start-Up 32
External Lube Lines 61
Fan Assembly
Pre Start-Up Inspection 16
Cleaning 55
Maintenance Inspection 55
Fan Bearing
Types 60
Lubrication 61
Fan Motor
Energizing at Start-up 28
Inspection and Maintenance 62
Bearing Lubrication 63
Fan
Cleaning 55
Inspection 55
Gas Heat
Control Wiring 44
Filters (AF, FF, RF)
Types 65
Maintenance And Replacement 65
Inserting into Side Load Filter Tracks 66
Motors
Check Amperage after Air Balancing 51
Sheaves
Replacing after Air Balancing 51
Alignment 57
Start-up
Start-Up Checklist 19
Test and Balance
Air Balance 50
Dynamic Balance 50
Variable Frequency Drive (VFD)
Set-Up of Non Factory Mounted VFD 29

JOHNSON CONTROLS 13
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
1
INTRODUCTION
The YORK air handling unit (AHU) is manufactured
to the highest design and construction standards to en-
sure high performance, reliability and adaptability to
all types of air handling installations.
ABOUT THIS MANUAL
This manual and any other document supplied with the
AHU are the property of Johnson Controls, which re-
serves all rights. This manual may not be reproduced,
in whole or in part, without prior written authorization
from an authorized Johnson Controls representative.
In addition, this manual:
• Includes suggested best working practices and
procedures, which are issued for guidance only,
and they do not take precedence over the above
stated individual responsibility and/or local safety
regulations.
• Contains all the information required for correct
installation and commissioning of the AHU, to-
gether with operating and maintenance instruc-
tions.
• Should be read thoroughly before attempting to
operate or service the AHU.
• Contains detailed procedures, including installa-
tion, commissioning and maintenance tasks that
must only be performed by suitably trained and
qualiedpersonnel.
The manufacturer will not be liable for any injury or
damage caused by incorrect installation, commission-
ing, operation, or maintenance resulting from a failure
to follow the procedures and instructions detailed in
the manual.
WARRANTY
Johnson Controls warrants YORK AHUs in accor-
dance with the limited warranty engineered systems
equipment procedure. Refer to the Air Side Limited
Warranty and Limited Warranty (Form 50.05-NM2)
for more information.
Johnson Controls warrants all equipment and materi-
als against defects in workmanship and materials for
a period of 18 months from the date of shipment or
12 months from the date of start-up, whichever comes
first, unless labor or extended warranty has been pur-
chased as part of the contract.
The warranty is limited to parts only replacement and
shipping of any faulty part or subassembly, which has
failed due to defects in workmanship and materials. All
claims must be supported by evidence that the failure
has occurred within the warranty period, and that the
AHU was operated within the designed parameters
specified.
All warranty claims must specify the AHU model, se-
rial number, order number, and run hours/starts. Model
and serial number information is printed on the AHU
identification plate.
The AHU warranty will be void if any modification to
the AHU is carried out without prior written approval
from Johnson Controls. For warranty purposes, the fol-
lowing conditions must be satisfied:
• Only genuine YORK approved spare parts must
be used.
• All of the scheduled maintenance operations de-
tailed in this manual must be performed at the
specied times by suitably trained and qualied
personnel.
• Failure to satisfy any of these conditions will au-
tomatically void the warranty. Refer to Air Side
Limited Warranty and Limited Warranty (Form
50.05-NM2) for details.
RESPONSIBILITY FOR SAFETY
Every care has been taken in the design and manufac-
ture of the AHU to ensure compliance with the safety
requirements. However, the individual operating or
working on any equipment is primarily responsible for:
• Personal safety, safety of other personnel, and the
equipment.
• Correct utilization of the equipment in accordance
with the procedures detailed in this manual.
SECTION 1 - GENERAL INFORMATION AND SAFETY

JOHNSON CONTROLS
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FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SECTION 1 - GENERAL INFORMATION AND SAFETY
THIS PAGE INTENTIONALLY LEFT BLANK.

JOHNSON CONTROLS 15
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
2
SECTION 2 - START-UP AND OPERATION
• All shipping splits are sealed and secured
properly.
• For outdoor AHUs, Pipe chase floor is sealed
at penetrations.
• All shipping bolts and other materials were
removed.
• Visually inspect the roof curb for tight seal around
the outdoor AHU.
• Ensurecleanairltersareinstalledandsecured.
properly.
• Inspectalleldprovidedwiringcompletely.
• Do not remove the functional bolts from the seis-
mic isolators as shown in Figure 1 on page 15.
FIGURE 1 - SOLUTION XT SEISMIC ISOLATOR
LD09636a
• Ensure the damper linkage is tight and is in the
correct power off position.
• If the return air dampers are closed, loosen the
actuator or crank arm on the jackshaft, open the
dampers, and retighten the actuator or crank arm.
• Verify the following controls installation are com-
plete:
• Contractor Furnished Controls - Controls
contractor is responsible for safe and proper
control of the AHU.
• Factory Furnished Controls - Refer to the
Factory Engineered Controls/Factory Pack-
aged Controls (FEC/FPC).
• Make sure the termination chart is attached to the
inside of the control enclosure door as shown in
Figure 2 on page 16.
Never use silicone caulk/sealant or caulk/
sealant containing silicone in or on any
air handling equipment.
BEFORE START-UP
Perform a general inspection. Identify and perform the
appropriate the lock out/tag out and safety rules. Re-
fer to the AHU Start-up Checklist, (Form 100.00.CL1)
provided with the information package shipped with
the AHU.
For more information about the steps below, refer to
the Solution XT - Installation and Assembly Manual
(Form 102.20-N1) and Custom AHU - Installation and
Assembly Manual (Form 102.20-N3). For an AHU
equipped with a Variable Frequency Drive (VFD), re-
fer to the specific VFD literature for additional start-up
requirements.
• Check for damage to the AHU's interior and ex-
terior.
• Ensure the terminal screws and wiring connec-
tions are secure in the control, electric and air
modulator panels.
• Verify that the:
• Equipment was received as ordered.
• AHU was installed on flat and level surface
and with proper clearances.
• Air hoods are installed properly.
• Condensate drains are properly trapped.
• All wiring and tubing connections are com-
plete at shipping splits.
• All field piping connections are completed.
• All shipped loose parts are installed.
• All ductwork is complete and available for
full airflow.
• Installer removed all dirt, debris, hardware,
mold, etc. from interior of the AHU and its
ducts.
• Filter gauge is set to zero.

JOHNSON CONTROLS
16
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SECTION 2 - START-UP AND OPERATION
FIGURE 2 - EXAMPLE OF A SOLUTION XT TERMINATION CHART
LD16563b
Inspecting Fan Assembly
Use the following instructions to inspect the fan assem-
bly.
1. When the AHU is removed from long term stor-
age, purge the moisture-laden bearing grease, and
replenish the AHU with fresh grease, according to
the lubrication label.
2. Meg the motor to verify that the resistance is at a
satisfactory level, compared to the value recorded
prior to storage.
3. Check the torque for bearings and locking collars
as shown in Table 1 on page 16.
TABLE 1 - TORQUE FOR TIGHTENING SET
SCREWS
SETSCREW
DIAMETER
(IN)
HEX SIZE
ACROSS
FLATS (IN)
MINIMUM RECOMMEND-
ED TORQUE
IN LB FT LB
1/4 1/8 66 - 85 5.5 - 7.08
5/16 5/32 126 - 164 10.5 - 13.7
3/8 3/16 228 - 296 19.0 - 24.7
7/16 7/32 348 - 452 29.0 - 35.7
1/2 1/4 504 - 655 42.0 - 54.6
5/8 5/16 1104 - 1435 92.0 - 119.6
4. Verify that the fan wheel is properly aligned, is
tight on the shaft, and moves freely.
5. Make sure the fan bearings are properly lubricat-
ed. Refer to SECTION 3 - MAINTENANCE in this
manual for more information.

JOHNSON CONTROLS 17
SECTION 2 - START-UP AND OPERATION
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
2
6. On Solution units, verify that the tie down bolts
are removed from the four corners of the fan base
assembly as shown in Figure 3 on page 17. For
small AHUs, the tie down bolts may only be ap-
plied to three corners of the fan base since one
corner is not accessible.
Do not remove the shipping bolts if there
are no springs.
FIGURE 3 - FAN AND MOTOR ISOLATOR
SUPPORT FRAME
LD09638
Tie Down Bolts
Inspecting Belts and Sheaves
1. Verify that the sheaves are properly aligned and
tight on the shaft. Improper sheave alignment
and belt tension are potential causes of excessive
noise and vibration, and shortened belt and bear-
ing life. Refer to SECTION 3 - MAINTENANCEin
this manual for more information.
2. Check the belt tension. If not familiar with the
process, refer to SECTION 3 - MAINTENANCE
in this manual.It is normal for belts to loosen af-
ter start-up. The new belts will run in or take a set
by seating slightly deeper into the grooves of the
sheaves. Recheck the tension after one day, and
three days.
3. Make sure the motor mounting bolts and adjust-
able motor base bolts are tight.
Checking Isolators
Solution XT Isolators
Check the fan base isolators and thrust restraints for
proper adjustment.
• Standard fan isolation consists of spring isolators
as shown in Figure 4 on page 17 mounted un-
der the internal fan assembly.
• For thrust restraint adjustment procedures, if ap-
plicable, refer to the service manual.
• Prepare the fan isolators for operation, using the
following instructions:
1. After removing the tie down bolts from the
internal fan assembly, check the blower/mo-
tor frame for the correct height, and that the
frame is level.
2. To adjust the isolators as shown in Figure 4
on page 17,
a. Loosen the cap screws on top of the ad-
justment bolt.
b. Turn the adjusting bolt.
c. Check the operational height and level
of the frame. Repeat this procedure until
the height and frame are level.
d. Tighten the cap screws. Refer to the ser-
vice manual for additional instructions.
• Verify the fan is aligned with the AHU discharge.
• Readjust the isolators as necessary.
FIGURE 4 - SPRING ISOLATOR
LD09637

JOHNSON CONTROLS
18
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SECTION 2 - START-UP AND OPERATION
Place tubes on studs, and place shoulder washer (shoul-
der up) on studs. Place one nut on each stud and tighten
it on shoulder washer.
Place remaining nuts on studs, and tighten to lower nut
to lock in place.
Custom AHU Isolators
Fan Hold-Down/Spring Isolator Set-Up
All fans are internally spring isolated and will be bolt-
ed down for unit shipping. After unit is in place, assem-
bled and leveled, Fan Hold-Down can be disassembled
by removing two nuts and one washer from each side.
Remove tubes from wire and discard wire.
STUD
STUD
TUBE
TUBE
1/2”
NUTS
NUTS
SHOULDER
WASHER
SHOULDER
WASHER
OPERATING POSITION
SIDE VIEW
EXPANDED ASSEMBLY
VIEW
WIRE
TUBE
STUD
NUTS
SHOULDER
WASHER
SHIPPING POSITION
SIDE VIEW
P-STYLE PLUG FAN
7.25 OPERATING HGT 8.1875 OPERATING HGT
FAN (PLENUM SHOWN)
SHIPPED POSITION
SHIPPING BLOCK
SHIPPING BOLT
BUY-OUT ISOLATORS
1. Remove the 7/8 nut as shown in the operating position
view.
2. Loosen the 7/8 jam nut between the isolator housing
and the fan base support angle until the desired level is
achieved.
3. Repeat step two until all isolators are set at the proper
elevation and the fan base is level.
FIGURE 5 - SPRING ISOLATOR SET-UP

JOHNSON CONTROLS 19
SECTION 2 - START-UP AND OPERATION
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
2
START-UP
Do not be operate this AHU until after
start-up is completed as outlined in these
instructions. Do not allow the AHU to run
on unreliable temporary power, which
could turn the AHU on/off periodically
or rapidly, and to protect it from irregular
voltages and surges.
It is recommended that the start-up technician use the
AHU Start-up Checklist (Form 100.00-CL1), included
with the AHU, and record the gathered information in
the appropriate fields. If there are questions, refer to
Table 11 on page 53 for inspection requirements.
Install the provided or temporary filter media prior to
start-up to adequately protect the components in the air
stream and duct system.
If the AHU is equipped with an energy recovery wheel,
rotate the wheel when the AHU is in service to prevent
clogging.
Checking Operation of Fans
Check of the operation of the fans by:
1. Verifying the correct voltage, phase and cycles.
2. Energizing the power to the AHU disconnect
switch.
3. Energizing the fan motor(s), briey (bump) and
check for correct fan rotation.
If the fan rotation is incorrect:
1. On three-phase equipment, reverse any two motor
leads at the load side of the last starter component.
2. On single-phase equipment, follow the wiring
diagram on the motor housing or on the inside of
the motor terminal box.
3. Recheck for correct fan rotation.
Checking Operation of Dampers
Most units are shipped with dampers in
closed position. Release and adjustment
is to be done by eld technician only
Make sure the AHU will not operate with all dampers
closed.
Linkage design and/or damper linkage is optional. Air-
flow control dampers may be operated with pneumatic
or electric actuator/controllers.
Prior to occupancy, test the ventilation system to en-
sure that the outdoor air dampers operate properly in
accordance with the system design.
Back Draft Dampers for Dual Fans and Fan
Arrays
The counterbalance is locked into place for shipping
as shown in Figure 6 on page 19. Before startup,
the counterbalance will have to be released. To do this,
loosen the set screws and slide the counterbalance off
the end of the shaft. Flip the counterbalance and slide
it back on the shaft. Rotate the counterbalance above
the damper as shown in Figure 7 on page 19, and
then tighten the set screws. The counterbalance should
be free to rotate.
FIGURE 6 - COUNTERBALANCE LOCKED INTO
PLACE FOR SHIPPING
LD17103
FIGURE 7 - COUNTERBALANCE UNLOCKED FOR
START-UP
LD17198

JOHNSON CONTROLS
20
FORM 102.20-OM2
ISSUE DATE: 6/01/2015
SECTION 2 - START-UP AND OPERATION
Airow Control Dampers
Many combinations of damper sizes are available to
control the flow. Mixing the return and outside air in
the AHU's air inlet section may be supplied as follows:
• 100% outside air, 100% return air.
• 100% outside air, 0% return air.
• 0% outside air, 100% return air.
• Economizer section - 100% outside air, 100% re-
turn air, 100% exhaust air or mixed air.
Check the dampers, actuators, controls and linkage
prior to applying power to the operators, to make sure
nothing will obstruct the operation of the dampers.
Do not overdrive the damper actuators
because this may damage the dampers.
Exception: Actuators with over drive
preset option.
Return air dampers may be closed for shipping. Loosen
the actuator or crank arm on the jackshaft, open the
dampers, and retighten the actuator or crank arm. The
field is responsible for adjustments.
Air Measuring Device Connections
Calculating Flow Rate
For a Piezoring:
CFM=k*ΔP2
ΔP=Thedifferentialinstaticpressureacrossthefan
(inches w.g.)
k = See the table below
This assumes a standard air density of .075 lbs / cubic
foot at sea level.
For a Cometer:
CFM=k*ΔPn
ΔP=Thedifferentialinstaticpressureacrossthefan
(inches w.g.)
k = See the table below
n = See the table below
This assumes a standard air density of .075 lbs / cubic
foot at sea level.
Examples of Fan Arrays
FIGURE 8 - FRONT OF A 2X2 FAN ARRAY
LD17226
FIGURE 9 - BACK OF A 2X2 FAN ARRAY
LD17227
FIGURE 10 - FRONT OF A 1X2 FAN ARRAY
LD17230