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LD09624
Indoor unit
LD09688
Outdoor unit
IMPORTANT!
Read BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This equipment is a relatively complicated apparatus. This document is intended for use by owner-authorized
During installation, operation, maintenance or service, operating/service personnel. It is expected that this
individuals may be exposed to certain components or individual possesses independent training that will
conditions including, but not limited to: refrigerants, enable them to perform their assigned tasks properly
oils, and materials under pressure, rotating components, and safely. It is essential that, prior to performing any
and both high and low voltage. Each of these items task on this equipment, this individual shall have read
has the potential, if misused or handled improperly, and understood this document and any referenced
to cause bodily injury or death. It is the obligation materials. This individual shall also be familiar with
and responsibility of operating/service personnel to and comply with all applicable governmental standards
identify and recognize these inherent hazards, protect and regulations pertaining to the task in question.
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.
Safety symbols
The following symbols are used in this document to alert the reader to areas of concern:
IAQ
johnson controls 3
FORM 102.20-N1 (1109)
4 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 Identification....................................................................................................................................21
Unit ID Label.......................................................................................................................................21
Skid ID Label......................................................................................................................................21
Segment Identification Box...............................................................................................................21
Loose Component ID Label..............................................................................................................22
Filter ID Label.....................................................................................................................................22
Direction of Airflow.................................................................................................................................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 5
FORM 102.20-N1 (1109)
6 johnson controls
FORM 102.20-N1 (1109)
johnson controls 7
FORM 102.20-N1 (1109)
8 johnson controls
FORM 102.20-N1 (1109)
johnson controls 9
FORM 102.20-N1 (1109)
10 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 – P
ROPER LIFTING WITH SHACKLE AT CORNER...................................................................1-3
FIG. 1-5 – P
ROPER LIFTING WITH SHACKLE AT LIFTING LUG............................................................1-3
FIG. 1-6 – R
ECOMMENDED 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 – W
ITH 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 – S
ECOND TIER TIE-DOWN FASTENER PACK P/n 386-03419-000........................................2-8
FIG. 2-9 – B
OTTOM RACEWAY SHIPPING SPLIT FASTENER PACKP/n 386-03418-000. ..........................2-8
FIG. 2-10 – B
ASERAIL 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 – R
EMOVE 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 – R
EMOVE AND REPOSITION SHIPPING SPLIT ANGLE.....................................................2-18
FIG. 2-25 – P
lacing and anchoring first section and attaching come-a-longs........2-19
FIG. 2-26 – R
EMOVE LIFTING LUGS AND SAVE HARDWARE.............................................................2-19
FIG. 2-27 – ELECTRICAL CONNECTIONS.............................................................................................2-19
johnson controls 11
FORM 102.20-N1 (1109)
johnson controls 13
FORM 102.20-N1 (1109)
14 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 – P
IPE SIZE REQUIRED........................................................................................................3-19
Table 3-4 – B
URNER TEPERATURE RISE...........................................................................................3-23
TABLE 3-5 – INSPECTION REQUIREMENTS.........................................................................................3-29
johnson controls 15
FORM 102.20-N1 (1109)
16 johnson controls
FORM 102.20-N1 (1109)
introduction
GENERAL TYPICAL YORK SOLUTION OPERATION IN
“HVAC” SYSTEM
This manual has been prepared as a guide for
installing, operating and maintaining YORK Solution The operation of these units can be divided into sys-
Air Handling Units. Johnson Controls has produced a tems:
quality product that is adaptable to almost any comfort 1. Ventilation system.
or industrial application. However, proper installation,
2. Economizer system (return air/mixing box sec-
operation and maintenance must be followed to realize
tion).
the full capacity and life of the units.
3. Heating system.
This instruction contains general recommendations, 4. Cooling system.
but specific requirements may apply to the individual
installation. Such requirements are outlined in federal, Ventilation System
state and local safety codes. Strict compliance with these
codes and strict adherence to these instructions are the A ventilation system simply replaces the air in a given
responsibility of the user. Particular attention should space. Usually the purpose is to remove air that is
be given to electrical wiring and other safety elements substandard to creature comfort or a process and replace
such as design working pressures and requirements it with suitable air. Depending on the application the
of the Government Clean Air Act Amendments as it system will operate at various specified rates, volumes
applies to refrigerant types and charges. General safety and conditions. A ventilation system may employ an air
practices are covered in AMCA Publication 410-90. handler with a supply fan working in conjunction with
other remote exhaust fan(s). A more effective method
Read the entire instruction before installing or operating would employ both a supply fan and an exhaust fan in
the air handler. Specific details and requirements apply the air handler.
that require careful consideration to avoid damage to
the equipment and injury to the installer or operator.
LD13764
johnson controls 17
FORM 102.20-N1 (1109)
FaN SectioN
Right
REAR
riGht haND (rh)
coiL coNNectioN
oUtSiDe air
lEFt
iNLet SectioN
Drive haND aND coiL haND DeterMiNeD
BY FaciNG the iNLet SectioN
FROnt
LD08004
18 johnson controls
FORM 102.20-N1 (1109)
SEGMENT IDENTIFICATION
Refer to Tables 1 and 2 for segment identification and nomenclature.
johnson controls 19
20
Solution Unit Model Number.
PRIMARY
IDENTIFIER
ENVIRONMENT
NOMINAL
HEIGHT
NOMINAL
WIDTH
SUPPLY FAN
OPTIONS
RETURN FAN
OPTIONS
SUPPLY FAN
MOTOR HP
RETURN FAN
MOTOR HP
FACTORY
MOUNTED END
DEVICES
PRIMARY
VOLTAGE
CODE
DESIGN
SERIES
XT I - 048 X 075 - D C M K 0 46 A
DESIGN DEFINITION
A ORIGINAL UNIT DESIGN
XT
CODE NAMEPLATE VOLTAGE
TABLE 2 – UNIT NOMENCLATURE
12 120 - 1 - 60
17 200 or 208 - 3 - 60
I INDOOR UNIT 27 277 - 1 - 60
O OUTDOOR UNIT 28 230 or 240 - 3 - 60
40 380 - 3 - 60
44 440-3-50
46 460 - 3 - 60
50 380 or 415 - 3 - 50
58 575 - 3 - 60
63 220 - 3 - 50
LD13350
johnson controls
FORM 102.20-N1 (1109)
FORM 102.20-N1 (1109)
AHU 9-10
25 38 47.5 80
HEAT RECOVERY WHEEL MOTOR RATING (INDIVIDUAL LOAD)
HP FLA M.C.A. MAX. O.C. PROT.
N/A N/A N/A N/A
ELECTRIC HEAT RATINGS GAS HEAT RATINGS Estimated Weight:
N/A N/A
LIGHTS & OUTLETS
VOLTS / PH / HZ
120/1/60
M.C.A.
20
MAX. O.C. PROT.
20
4,100 pounds
COIL DATA
HOT WATER COIL MAX. INLET WATER TEMP. 200 F (FR) Bolded indicates skid 1 of 5 is a Return
STEAM COIL MAX. OPERATING PRESSURE.
Fan and is placed first in the direction of airflow.
50
See Segment ID box example.
EVAPORATOR COIL DESIGN PRESSURE. 325 PSI LD11729A
FIG. 4 – SKID ID LABEL
EVAPORATOR COIL REFRIGERANT USED. _____
MANUFACTURING LOCATION
YORK INTERNATIONAL - East York FACILITY segments* used on a multi piece unit. The contents of
1499 E PHILADELPHIA ST each skid are indicated by segment(s) surrounded by
YORK PA 17403 parenthesis (see Fig. 5 below).
USE COPPER WIRES ONLY. CLEARANCE FROM COMBUSTIBLE SURFACE: UNIT IS 0 INCHES,
DUCT IS 0 INCHES. MAXIMUM INLET TEMPERATURE; 100^ F / MAXIMUM OUTLET
TEMPERATURE; 200^ F. EXTERNAL STATIC PRESSURE RANGE OF 0.25'' - 5.00'' WG. CONFORMS
TO UL STD 1995 AND CERTIFIED TO CSA STD C22.2 NO 236
(Skid 5 of 5) (Skid 3 of 5) (Skid 1 of 5)
(Skid 4 of 5) (Skid 2 of 5)
(FS)(CC-HM)(XA-IC-XA-RF)(EE)(FR)
9800071
johnson controls 21
FORM 102.20-N1 (1109)
LD13942
FIG. 7 – filter LABELS
AHU 9-10
One of six hoods installed on (EE) skid/segment.
LD11751A
FIG. 6 – LOOSE COMPONENT ID LABELS
22 johnson controls
FORM 102.20-N1 (1109)
1.0 pre-installation
RECEIVING RIGGING OF INDOOR AND OUTDOOR UNITS
All units leaving the plant have been inspected to ensure All lifting points must be used to avoid
the shipment of quality products. All reasonable means personal injury or death and to avoid
are utilized to properly package the air handling units. damage to the equipment.
1
Johnson Controls will NOT be respon-
sible for any damage or loss of parts
in shipments or at the job site. Re- SHIPPED LOOSE DAMPERS. When
ceiver is solely responsible for noting large units are ordered with MZ seg-
Bill of Lading and filing freight claims ments in rear discharge location (on
IMMEDIATLY. Refer to Shipping the end of the unit), the units will
Damage Claims Form 50.15-NM ship with the top section (hot deck)
available from Johnson Controls Sales separated. In these cases, the com-
representative. plete multizone damper assembly (hot
deck and cold deck together) will ship
loose.
LD13769
RIGGING INSTRUCTIONS
FOR LIFTING AIR HANDLERS WITH LIFTING LUGS, USE 60°min.
SPREADER BARS AND CABLES AS INDICATED. DO NOT USE
A FORKLIFT. ALL LIFTING LUGS MUST BE USED TO AVOID
DAMAGE. LD13765B
LD09613
Shackles
Refer to Fig. 1-4 for proper lifting with hook and
shackle at corners. Refer to Fig. 1-5 for proper lifting
with hook and shackle at lifting lugs.
LD13768
FIG. 1-5 – P
ROPER LIFTING WITH SHACKLE
AT LIFTING LUG
LD13767
FIG. 1-4 – P
ROPER LIFTING WITH SHACKLE AT
CORNER
LD13766
FIG. 1-6 – R
ECOMMENDED LIFTING WITH
BASERAIL
INSPECTION STORAGE
FIG. 1-7 – L
ONG-TERM STORAGE REQUIREMENT - FIELD PREPARATION, FORM 50.23-NM3
FIG. 1-8 – L
ONG-TERM STORAGE PERIODIC CHECKLIST AND LOGS, FORM 50.23-CL3
2.0 INSTALLATION
Do not weld or use torches on the ex- Never use silicone caulk/sealant or
terior or interior of the unit housing. caulk/sealant containing silicone in or
The housing contains polyurethane on any air handling equipment. [Only
insulation, which under combustion exception is when provided (high tem-
will produce harmful, toxic gases re- perature) with gas heat venting].
sulting in personal injury or death.
SITE PREPARATION
This instruction is written to provide
general information. The product Outdoor Units (Site Prep)
line allows many variations and the Location of unit(s) should be away from building
installer is fully responsible for ad- flue stacks or exhaust ventilators to prevent possible
justing his actions as needed. If any introduction of contaminated air through the outside 2
questions regarding the content of air intakes (see Fig. 2-1 for service clearances).
this manual, or if any information is
not covered, contact local Johnson
Allow sufficient space around the unit
Controls Service.
for removing the access panels and
various parts of the unit. A minimum
Surface must be level on all installa-
clearance equal to the width of the unit
tions.
must be provided on one side of the
unit for removing the coil or fan as-
sembly. Add dimension of pipe chase,
air hoods, ducts, control/electrical
panels, etc. to minimum clearances.
If your unit has HEPA filters the fil- Allow additional clearance as required
ter frames, filter bulkheads and filter by local and national codes. Consider
segment panels are factory sealed Coil Access Panel for coil removal on
and must remain sealed for NO air outdoor units.
bypass.
A Fan Section
36"
H B Coil Section
36" C Face and Bypass Damper Section
D Filter Section - Door should open 180°
36" A B C D E F
E Inlet Section
F Rain Hood (add to unit width or length)
G
UNIT WIDTH G Pipe Chase Enclosure (add to unit width)
LD6328-4
Mounting Curb
Units must be installed in such a manner as to provide The curb, which supports the unit, will be shipped
enough elevation for properly designed condensate unassembled. It will be necessary to assemble the curb
traps (see Section 2 “Drain - Condensate Drain parts on the job site. Assembly drawing and a hardware
Trap”). package are shipped with each curb package. It is
important the curb be installed square. If applicable,
Installation Site: Area of roof on which ensure pitch orientation is correct.
curb is to be installed must be structur-
ally adequate to support the combined This “Curb Assembly and Installation Instruction” is
weight of curb, unit and system fluids. typical. Use it in conjunction with the specific drawing
supplied with each curb.
With these combined weights in place,
the resting surface for the unit MUST
Should there be any questions as to
be flat and level.
the number of pieces of curb parts or
assembling of the curb, notify Johnson
Concrete pads often are not as flat
Controls immediately.
as they should be. Shimming and/or
grouting may be necessary. Whether
Curb, nailer, and gasket are supplied.
under the unit base or under the curb,
All other parts such as wood or fiber
this is to ensure the unit base is on a
cant strips, roofing felts, roofing mate-
perfectly flat plane.
rial, caulking and curb-to-roof fasten-
ers are to be field supplied.
Curb Assembly and Installation Instructions When unit is shipped in sections, the
See Fig. 2-2 curb gasket is to be replaced with caulk
provided by contractor.
1. Unpack shipping package, layout pieces and
parts according to the exploded views and check
against Bill of Materials.
5. After verifying curb is square and level, tighten
2. Layout all channel pieces as shown. Make certain all bolts and then anchor as appropriate.
that all channel tabs are located on inside of mat-
ing channel If bolts are tightened after anchoring,
curb will be pulled, twisted and torqued
Make certain that all curb walls ac- out of square.
cessories and flanges, which may
have been distorted in handling, are
straightened before assembly. 6. Pipe Chase Curb Assembly - once curb is square 2
and level mark the exact location for the pipe
chase curb. Drill and assemble.
3. Attach curb walls together to form rectangular
perimeter as shown, leaving bolts loose. Pipe Chase Curb Location:
Unit submittal drawing package has
After the curb is set in place, ensure a Johnson Controls curb drawing
proper consideration has been given showing dimensions of curb and pipe
to the air duct openings through the chase.
roof.
7. The curb should be insulated and roofed as re-
quired. Refer to SMACNA for counter flash.
4. The curb installation drawing (see Fig. 2-2) Steel Frame
shows a gasket that is mounted between the curb
When a steel frame is used to support the unit, it must
and the unit. This gasket is shipped with the curb
be level, flat without uneven steel frame joints, and
parts. Install the curb gasket before setting the
support the unit around the full perimeter. As a general
unit on the curb. The gasket forms an air seal
rule, cross members should be placed every 96" in
between the unit and the curb and serves as a
addition to every shipping split.
dampener, preventing metal-to-metal contact
between the unit and curb. However, the gasket Indoor Units (Site Prep)
should not be used as a vibration isolator where
Concrete pads often are not as flat
the prevention of noise and vibration transmis-
sion into the building is critical.
as they should be. Shimming and/or
grouting may be necessary. This is to
ensure the unit base is on a perfectly
flat plane.
CURB SUPPORTS
D
UNIT WALL as required
RIGHT HAND
A PIPE CHASE
UNIT RACEWAY B
B C
1-7/8" Note 1
CURB REST
1-7/8" 1-1/2"
CURB GASKET "A"
2" x 4" NAILER
Note 1
DETAIL B
PIPE CHASE CURB CONNECTION
TO UNIT CURB
WALL PANEL
Notes:
1. Curbs available in 14", 18", 22", 26", 30" & 34" heights 3. Curb material is galvanized steel, unpainted, and may vary in gage
2. Outdoor Base Rails are available in 6", 8" & 10" heights. based on the unit load and the Qty. of cross bracing provided.
Contractor is responsible for providing ductwork to include Base Rail height. 4. If curb space used as plenum, Seal all joints and seams with suitable sealer
such as urethane caulk (YORK P/N 013-02966-011)
LD09616G
Clearance
Allow sufficient space around the unit
for removing the access panels and
various parts of the unit. A minimum
clearance equal to the width of the
unit must be provided on one side of
the unit for removing the coil or fan
assembly.
Mounting
Units must be installed in such a manner as to provide
enough elevation for properly designed condensate
traps.
Housekeeping Pad
The housekeeping pad must be flat and level (see Fig's
2-3, 2-4 and 2-5).
LD05372
LD05374
FIG. 2-5 – W
ITH BASERAIL AND HOUSEKEEPING
PAD
BDW COOLING
BDW COOLING
FAN SECTION FS
MC RF CC RF
MB MB
FAN SECTION FS
LD09619a
ELEVATION VIEW ELEVATION VIEW
3/8" Flat
Washer
Size = 3/16" 3/8" Lock Washer
Allen Wrench
LD11029A
Bracket p/n 086-11146-001
FIG. 2-8 – S
ECOND TIER TIE-DOWN FASTENER PACK
P/n 386-03419-000 (4 each per pack) 1/2" Flat
1/2" Nut
Washer
1/2" Lock
Washer
LD11032A
FIG. 2-10 – B
ASERAIL SHIPPING SPLIT FASTENER PACK
P/n 386-03417-000 (4 each per pack)
1/2" x 5-1/2"
Hex Cap
Screw (2)
.56" ID x 1.38"
Raceway Lifting Lugs 1/2" Hex OD Flat
(assembled) 3/8" Flat Nut Lock Washer (2) Washer (2)
Washer LD13349
3/8" Lock
FIG. 2-11 – TOP RACEWAY SPLIT FASTENER PACK
Washer LD11030A
P/n 386-04747-000 (2 each per pack)
FIG. 2-9 – B
OTTOM RACEWAY SHIPPING
SPLIT FASTENER PACK
P/n 386-03418-000 (4 each per pack)
2-8 johnson controls
FORM 102.20-N1 (1109)
SEAM CAP
• 1/4" x 2" Neoprene Gasket, P/N 028-15954-010
• 1/4"-14 x 1" Phillips Pan Head Tek Screw, P/N 021-19560-000
• 1/4"-14 x 1" Hex Head w/ Washer & Gasket Tek Screw 2
P/N 021-30530-052 for Outdoor Wall.
ROOF SEAM CAP
• 1/4" x 2" Neoprene Gasket, P/N 028-15954-010
Apply 2" Gasket • 1/4"-14 x 1" Hex Head w/ Washer & Gasket Tek Screw
& Caulk P/N 021-30530-052 for Outdoor Roof.
PIPE CHASE
• 1/4" x 2" Neoprene Gasket, P/N 028-15954-010
• 1/4"-14 x 1" Hex Head w/ Washer & Gasket Tek Screw
P/N 021-30530-052
Apply Caulk
Apply Caulk
PIPE CHASE BASERAIL COVER HOOD
P/N 086-23998-001
• 1/4"-14 x 1" Hex Head w/ Washer & Gasket Tek Screw
• 3/16" x 3/4" Butyl Tape
LD13770A
HUMIDIFIERS
Optional Steam humidifiers, when selected are
provided with dispersion equipment factory mounted
inside the air handling unit. The steam injection or
generating equipment, metering devices and sundries
are shipped loose.
FLUE CAP
CONTAINMENT
BAND
UV
UV
LIGHT
LIGHT
TUBE
TUBE
1/4”-14 X 1”
PHILLIPS PAN HEAD
SELF DRILLING SCREW
P/N 021-19560-000
1/4”-14 X 1”
SPARE FAN BELT HEX HEAD
(Attached to Fan)
SELF DRILLING SCREW
W/ EDPM WASHER
P/N 021-30530-052
LD13771
TOP SPLIT
CURB REST
BASE CHANNEL
e) Make sure all wiring and/or control tubing 6. Place the next section on the curb about 4" from
connection pig tails are secured out of the the section already placed.
path of the shipping split mating surfaces to 7. At this time feed the electrical and control con-
prevent damage. nections from section to section and ensure that
f) Apply 3.5" x 3.5" separate gasket squares, they will be accessible after the sections are
placing one square at each corner of the face joined. Assemble the electrical connectors and/
of one section. Apply 1/4" x 2" foam gasket or pneumatic tubes each according to their labels.
to face perimeter from 3.5" square to 3.5" Do this before joining sections if access will be
square. Apply this gasket 1/4" from outside a problem later. Refer to Fig. 2-18.
edge of mating surface (nearest to exterior of
air handler). This is to allow for a 1/4" bead
of caulk. Refer to Fig. 2-17. Connectors
LD13773A
The gasket application should provide a continuous seal from
side to side and the top of the unit roof to the bottom of the unit
base where it meets the curb. LD13372A
After wiring connections are made Ensure chain does not apply pressure
and before proceeding with assembly, to drain connection. Improper posi-
the top shipping split angle will need tioning of chain may cause damage
to be removed and repositioned (see to unit.
Fig. 2-19).
LD13775 LD13777
LD13776 LD13778
13. Apply a 1/4" bead of caulking to the exterior If a roof seam cap has a tab on one
of the seam. Trowel the bead level with the air end only, the end without the tab goes
handler exterior. This is to be done on roof and above the pipe chase location.
both sides (see Fig. 2-20).
14. Apply 1/4" bead of caulking to the seam inside
the unit on the floor.
15. Apply 1/4" x 2" foam gasket to the underside of 16. Repeat this procedure for each additional section
the seam caps and install them over the joints to be placed in making up the complete unit.
using 1/4"-14 x 1" hex head screws provided. 17. Install 1-1/2" Corner Connector Plugs on bottom
Painted seam caps are applied over the joints on raceway corners.
the sides and roof of the exterior and galvanized
seam caps are applied on the floor of the interior Only needed on units or sections with-
only. out baserails.
Assembly of Indoor Unit d) Make sure all wiring and/or control tubing
connection pig tails are secured out of the
See rigging suggestions and details path of the shipping split mating surfaces to
in Section 1. Failure to follow these prevent damage.
guidelines may result in damage to
equipment. e) Apply 1/4" x 2" neoprene gasket material
TO ONE SIDE ONLY of each shipping
split. Be sure the entire perimeter is covered
Do not damage factory installed pipe with gasket material, including the foamed
corners. Any void, depression or protrusion
chase, electrical cabinet, hoods, pipe
will allow air or water leakage. Gasket must
stubs, door handles or roof over- be continuous through the corners. Make any
hang. splices on a straight run. Refer to Fig. 2-21
and 2-22.
See “Ship Loose Parts” to identify 2
gaskets and hardware items.
a) Verify the correct sections and orientation of FIG. 2-22 – APPLYING GASKET TO DOOR FRAME
each section. WHEN AT SHIPPING SPLIT
b) Remove cross brace(s) (shipping supports)
from each section’s shipping split. f) For expanded cabinet with end channel
shipping split see fig. 2-23
c) Remove plastic shipping covers and their
supports.
REMOVE SHIPPING
BRACKETS
LD14262
Remove ShippingSplit
Remove Shipping SplitAngle
Angle
after completion
after completion ofofwiring
wiringand
and
tubing placement
tubing placement and
and
reposition before
reposition before proceeding
proceeding
with assembly of
with assembly shipping
of shipping
splits.
splits.
LD14097
FIG. 2-24 – R
EMOVE AND REPOSITION SHIPPING
SPLIT ANGLE
LD13773A
LD13782
FIG. 2-25 – P
lacing and anchoring first
section and attaching come-a-
longs
BASE CHANNEL
LD13374
FIG. 2-26 – R
EMOVE LIFTING LUGS AND SAVE
HARDWARE
7. Start pulling the sections together. Pull evenly 10. Fasten top raceway brackets with 1/2" x 5-1/2"
on both sides. bolts.
a) Be sure all of the electrical or control wires 11. Apply 1/4" x 2" foam gasket to the underside of
or tubes are clear. the seam caps and install them over the joints us-
ing 1/4"-14 x 1" hex head screws provided. Seam
b) Guide the top raceways together by placing
caps are provided for sides, top and floors.
rods or drift pins through the holes in the
top guide angles. When the raceways are 12. Repeat previous steps for each additional section
together, install the long bolts provided. to be placed in making up the complete unit.
13. Install 1-1/2" Corner Connector Plugs in bottom
c) Guide the bottom raceway/baserails together
raceway corners.
using rods or drift pins through the holes in
the lifting lugs on opposing sections. Do this
on each side of the unit simultaneously. Only needed on units or sections with-
out baserails.
d) If any difficulty aligning due to racking of
one section or the other, use another come-a-
long diagonally on the inside of that section
at the shipping split or across the tops of
opposing sections..
e) If any difficulty aligning due to top and
bottom not pulling together simultaneously,
apply shims under the unit sections as needed
to compensate for uneven placement area.
8. Complete pulling the sections together.
9. Fasten bottom, lifting lugs together with 1/2" x
4" bolts provided. See Fig. 2-28.
LD13781
Be sure all of the electrical or control 7. Lower the top tier onto bottom tier so that mount-
wires or tubes in both tiers are clear. ing brackets mate. Guide brackets together using
rods or drift pins through the bolt holes (see Fig.
2-32).
LD09626
See “Ship Loose Parts” to identify 5. Apply 1/4" x 2" neoprene gasket to all raceway
gaskets and hardware items. mating surfaces of one mating section. Include
two gaskets side by side on intermediate raceway
surfaces (large units).
6. Ensure that the sections are not racked and will
line up properly.
Assembly of End Channel Shipping Split
Attach sections as follows:
The assembly is the same regardless of
1. Make sure assembly surface is clean and level
what sections are being connected to-
to allow the sections to slide freely. If surface
gether. The vertical Energy Recovery is irregular, use metal shims under sections as
Wheel shown in Fig. 2-33 is a common necessary to align mating surfaces.
example
2. Pull sections together using a come along, draw-
ing the base together.
Prior to pulling sections together:
3. Attach the sides of the sections. Beginning at the
2
1. Remove baserail support plate (large units). bottom of the sections secure the end channel as-
2. Remove shipping brackets in corners. sembly brackets together using 3/8" x 3/4" Allen
3. Remove screws in raceway corners at ends of all head bolts, lock washers hex nuts at each bracket
segments joining together (as shown in Detail A . Continue securing the end channel assembly
of Fig. 2-33). brackets together, working from bottom to top,
4. Clean the metal surface where gasket is to be pulling the sections tight.
applied with mineral spirits or rubbing alcohol. 4. After the sides are secured, secure the brackets on
top of the unit with the same hardware mentioned
in step 3.
FIG. 2-33 – ASSEMBLY OF END CHANNEL SHIPPING SPLIT (ENERGY RECOVERY WHEEL SHOWN)
Apply Butyl
Apply Caulk
Clip
Mist Eliminator LD13783
or Filter
FIG. 2-34 – HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS
HOOD INSTALLATION WITH OPTIONAL MIST 7. Each hood is to be centered over the width of
ELIMINATORS the opening. All hoods, especially those con-
taining barometric dampers, MUST be installed
See “Ship Loose Parts” for identifica- square.
tion of gaskets and hardware.
8. Seal each hood gutter to the unit panel with
Polyurethane Caulk provided.
9. When multiple hoods are installed in a stack
space the hoods approx. 1.5" apart so the bot-
1. Identify correct hood and respective location tom hood will extend 6" below the bottom of the
(see example on Fig 5 “Loose Component ID opening.
Labels” found in the Unit Identification section 10. Install optional mist eliminators.
of this Manual). Each hood is labeled for easy
identification. a) Remove the clip(s) from the leading edge of
2. Correct orientation is with the tracks or bird the hood.
screens to the bottom. The mounting flanges are b) Insert the proper size mist eliminator or filter
predrilled. into the tracks.
3. Each hood is fitted with a factory installed bird c) Reinstall the clip(s) on the leading edge of
screen unless mist eliminator option is selected. the hood.
4. Apply provided 3/16" x ¾" Butyl tape to the
predrilled hood flanges and back wall angle that
contact the unit panels. OUTDOOR AIR TEMPERATURE AND/OR
HUMIDITY SENSORS
5. Use ¼"-14 x 1" Hex Head Self Drilling Screws
w/EPDM washer provided. When Outside Air Hoods are shipped loose on units
6. Each damper opening in the unit panels should be that include Factory Packaged Controls, these sensors
completely covered by its respective hood. The will be dismounted and pulled back into the air handler.
bottom of the hood should extend approximately The contractor is to find them secured with tape inside
6" below the opening in the unit panel. and put them through their respective penetration to
the exterior and mount them to the bracket provided.
ACTUATOR INSTALLATION
See Fig. 2-35
1. Remove the bearing plate from the damper frame 6. Manually operate the actuator to its fully actu-
and jackshaft. ated position using the crank arm provided with
2. Slide the damper actuator onto the open end of the actuator. Then release the spring to allow
the shaft making sure that the proper spring return the damper to go back to its original position.
position on the face of the actuator matches the This will verify the actuators spring rotation and
damper shafts rotation. If not, then reinstall the stroke.
actuator with it flipped over. 7. Set the damper actuators rotation selector switch
3. Reinstall the bearing plate to the damper frame to the proper rotation required to actuate the
and jackshaft. Make sure spring hose clamps hold damper.
the jackshaft securely.
4. Slide the damper actuator mounting bracket into Damper actuator rotation will always
the actuator mounting grooves and fasten to the be opposite the spring return rota- 2
damper frame using self drilling screws. tion.
5. Tighten the actuator shaft clamp to the damper
jackshaft. Make sure at this point, the damper
shaft is completely rotated to its proper posi-
tion.
JACKSHAFT TO
BLADE LINKAGE
DAMPER
ACTUATOR SELF
ACTUATOR DRILLING
SHAFT CLAMP SCREWS
BEARING PLATE
EDGE CLIP
025-39067-002
ROTATION
SELECTOR
ccw
cw
MOUNTING
GROOVES
MOUNTING BKT
JACKSHAFT
ACTUATOR
MANUAL
CRANK
SPRING HOSE
CLAMP(S)
LD12144
ACTUATOR
ACTUATOR EXTENSION PIN
025-39032-002
025-39032-002
MOUNTING
FLANGES COLD DECK
DAMPER
Actuator Installation Mutlizone (MZ) - Field • Actuators and actuator mounting brackets are
Supplied to be supplied by the contractor. Part numbers
available upon request.
When actuators are field supplied on multizone
dampers, the following information is intended to aid • On rear mount (discharge through end of unit);
in sizing and selection: always mount the actuators on the top of the up-
per (hot) deck.
• Torque required is 7 inch pounds per square foot
of damper area up to 2500 FPM velocity. • Do not allow duct insulation to restrict damper
blades or external linkage.
• Damper blades are 6" wide and vary in height.
• Direct coupled actuators are recommended.
• Calculate the torque by number and size of blades
in each individual zone. Remember there are • Duct connections are to be made at the zone
hot deck blades directly connected to cold deck dividers without damper blade restriction.
blades.
• Blades per zone are to be determined by system INERTIA FAN BASE FILL INSTRUCTION
CFM and static pressure requirements for each Inertia fan bases are pre-engineered according to fan 2
zone by the Engineer’s construction docu- and motor size. Each cavity having a pre-installed
ments. corrugated bottom is to be filled to the top with wet
• The blade linkage (flat rods) connecting all blades concrete. The contractor must take care not to get
of each deck are to be cut at the appropriate places concrete mix on the bolts and adjusting parts of the
to divide the decks into correct size zones. These adjustable motor base, sheaves, belts or on the floor
blade linkage rods are mounted externally on the under the edges of the isolated fan base. The amount
assembly. Be sure to cut a section of the flat con- of concrete can be calculated by measuring the overall
necting rod out. This is to prevent interference length and width of the fan base assembly cavities
when zones modulate in opposite directions. that have the corrugated metal bottoms. The standard
• One Damper Shaft Extension Kit is provided for depth of the cavity is 4 inches.
each zone per the Factory Order Form (see Fig.
2-37). HUMIDIFIERS
Optional Steam humidifiers, when selected are provided
with dispersion equipment factory mounted inside the
air handling unit. The steam injection or generating
equipment, metering devices and sundries are shipped
loose with the unit. Humidifier manufacturer’s
installation, operation and maintenance information
is packaged with the respective humidifier. It is the
responsibility of the installing contractor(s) to make
use of the instructions and preserve same for turn-
over to the end user. All required steam supply piping,
condensate piping and wiring are the responsibility of
the installing contractor(s).
There three different types of lamps used in YORK FIG. 2-39 – V-RAY INSTALLATION
Solution Air Handlers: V-Mod, V-Ray and V-Flex.
V-Flex lamps (tubes) fit inside the opening at a slight
V-Mod lamps are installed in the same manner as angle (with the pins aligned with the lamp holder).
standard fluorescent lamps with 2 contact prongs on You then “snap” the lamp base in by holding with
each end. Engage the prongs into the slotted fixtures slight pressure the end of the lamp you have placed
and rotate the lamp (tube) 90 degrees. inside the module with one hand and straightening up
the other end of the lamp with your other hand until
you hear the click.
• Screw Gun
• Complete set of mechanics hand tools.
Materials Required
Washers.
Procedure
LD11564
Never use silicone caulk/sealant or FIG. 2-41 – INSTALL GASKET UNDER ROOF
caulk/sealant containing silicone in or OVERHANG
on any air handling equipment. [Only
b) Apply gasket provided by curb vendor to top
exception is when provided (high tem-
of curb.
perature) with gas heat venting]
c) Apply 1/4" x 2" neoprene gasket to the pipe
The top and bottom flanges are inside chase (vertical gaskets first, then horizontal
pipe chase. Separate cover angles are gaskets). Keep the gasket aligned with the
outside edges of the pipe chase housing (see
used on external vertical seams.
Fig. 2-42).
3 gaskets
Horizontal gaskets
completely overlap
overlap
vertical gaskets
vertical gaskets in
in
PIPE
PIPE CHASE
CHASE all four
all four corners
corners
RIVET NUT
(installed by factory)
PIPE CHASE
CHASE
3
3 with self
Install with self drilling
drilling screws.
screws. Insert
Insert screws
screws
LD12560A
into, and
into, and between,
between,all allpre-punched
pre-punchedholes
holes in
in
FIG. 2-42 – APPLY GASKET TO PIPE CHASE flange. Typical for both top and bottom
flange. bottom
flanges.
flanges.
AIR HANDLER
AIR HANDLER
PIPE CHASE
LD12565
FIG. 2-47 – P
IPE CHASE TO AIR HANDLER CAULK
LD12035A
APPLICATION
FIG. 2-45 – BASERAIL CAULK APPLICATION
Cover angles must be installed before
Line up self-drilling the caulk from step 4 dries.
screws with existing
screws on roof.
AIR HANDLER
5
3
1
2
4 Install self-drilling a) Apply 1/4" x 2" neoprene gasket to contact side
screws starting in of cover angle.
middle and working
towards ends. b) Remove top and bottom self-drilling screws from
PIPE CHASE pipe chase and set aside for later use.
FIG. 2-46 – P
IPE CHASE TO ROOF INSTALLATION c) Place cover angles in vertical corners of pipe
chase and unit wall.
b) Add a small bead of caulking to the exterior
vertical seam between the air handler and
the pipe chase to insure complete seal.
Pay special attention to the top and bottom
corners, raceway and baserail engagements
and under the roof overhang (see Fig.'s 2-45 AIR HANDLER
AIR HANDLER
PIPE CHASE
PIPE CHASE
and 2-47).
c) Starting at the center, and working toward
each end, run 1/4"-14 x 1" hex head self-
Install Cover
Install Cover
drilling screws down through the air handler Angle between
Angle between
overhang into the top of the pipe chase Cover Angle
Cover Angle Air Handler
Air Handler and
and
shown with
shown with Pipe Chase
Pipe Chase
through the gasket. Use caution not to strip before caulk
gasket side
gasket side before caulk
the 20-gage housing with the screws. Line out
out dries
dries LD12564
up self-drilling screws with double row of
FIG. 2-48 – INSTALL COVER ANGLE
screws on top of unit raceway, plus one
spaced evenly between each (see Fig. 2-46)
(No caulking required here.) Notch on cover angle must be on the
air handler side (see Fig. 2-48).
5. Install the Cover Angles
(See Fig. 2-48)
PIPE CHASE
AIR HANDLER
FIG. 2-49 – P
ROPER POSITIONING OF COVER
Alternating between Air
ANGLE WITH NOTCH ON AIR Handler and Pipe Chase,
HANDLER SIDE install remaining self-drilling
screws starting at the top and
2
working toward the bottom.
d) Attach the cover angle to the air handler and
pipe chase panels. Install self drilling screws
removed earlier to top and bottom holes on
cover angle.
e) Starting at the top and alternating between
the air handler and pipe chase, continue
installing self drilling screws until reaching
the bottom. Use caution not to strip the LD12562
2-34
STEP 1 FLUE CAP STEP 2
42"L VSI PIPE SPLIT CLAMP
SPLIT PLATE (NOT INSULATED)
(Factory Installed)
Installation
PIPE CHASE
CURB
PIECE
RACEWAY
IVSI PIPE
SIDE (INSULATED PIPE)
PANEL
CONTAINMENT
BAND SET &
GASKET, 1" THK X 3"W X LG,
6"L SLIP INSULATION FIBER STEP 4
JOINT
0.43" CLEARANCE
GAS FURNACE WITH CASING 7.75
TRANSITION
PIECE
12" ID
EXT. FAN
STORM
COLLAR
LD13326
NOTES:
HAT 1. On outdoor Air Handling units the external flue/vent piping parts above the pipe chase are factory installed on units
CHANNEL
having an overall height of less than 102”, including the vent piping.
2. Outdoor Air Handling units over 102” high will have the external vent piping parts shipped loose for field mounting.
5.50
3. On all outdoor Air Handling units the vent piping parts internal to the pipe chase will be factory mounted.
FIG. 2-52 – GAS FURNACE FUEL VENTING SYSTEM
johnson controls
FORM 102.20-N1 (1109)
FORM 102.20-N1 (1109)
BURNER
ASSY
ID
MOTOR
FLOW 2
1
3
4
2
3 2
PITCH
4 Foot
LD12912
1
ELECTRICAL - GENERAL
All field wiring must conform to the DO NOT PENETRATE any main or
National Electrical Code (N.E.C.) and auxiliary drain pan.
possible local codes that may be in DO NOT PENETRATE roof of out-
addition to N.E.C. door unit.
LD11591
00495VIP
Panel locations and sizes vary based upon unit size and
burner configurations.
Safety Limits
ID Fan
ID Fan Motor
LD11596B
FIG. 2-56 – GAS BURNER COMPONENT LOCATIONS
• 460V-3PH.
• 208/230V-3PH.
• 380V-3PH.
• 575V-3PH.
Electric Heat Disconnect Switch Options
LD11595
• Fused Disconnect.
• Non-fused Disconnect. LD11595
FIG. 2-59 – TYPICAL FIELD CONTROL AND 2
Knockouts are provided on the top and bottom of the POWER CONNECTIONS
enclosure for field penetrations. The YORK Solution
foam panel will have to be drilled to utilize these Hook up power (see Fig. 2-59 for power terminals
knockout locations. Refer to IOM Section 5 “Field and Fig. 2-58 for control panel component location).
Penetrations for Piping and Electrical Connections”. Terminals shown are for a 2 stage 24 VAC control
interface. Terminals may also require 120VAC
Main Disconnect
control interface based upon options selected. See
Switch & Field wiring diagram on inside cover of electric heat control
Power Connections panel.
(see Fig.
(see Fig. 2-59)
2-52).
Electrical conduits that penetrate the
exterior (walls, pipe chase or floors)
of the unit will need to be externally
High
Temperature and internally sealed so that uncon-
Cutout ditioned air will not be drawn into
Control the unit through and around conduit.
Airflow Voltage This unconditioned air will result in
Proving Transformer
Switch condensation that will fail components
prematurely.
Staging
Contactors
All accessible electrical connections
must be checked for tightness prior to
the actual startup. Many of the con-
nections contain several strands of
wire, and while they were tightened at
Knockouts the time of assembly, they should be
checked and re-tightened if needed.
The danger of a poor connection is
overheating and component failure.
LD11594A
DO NOT PENETRATE any main or
FIG. 2-58 – TYPICAL ELECTRIC HEAT CONTROL auxiliary drain pan.
PANEL INTERIOR WIRING AND
COMPONENTS
Available Control Options 2. The maximum air inlet temperature for open coil
heaters is 100°F, and for finned tubular heaters,
• Staging - No controller, but contactors are 80°F.
energized by providing control power to each
3. Sufficient working space must be provided per
contactor from external BMS source.
paragraph 110-26 of the NEC.
• Step Controller - device to receive a 0- to 10 VDC
4. This electric heater is not designed for or intended
or 4 to 20 mA signal and step on heat stages.
to be used for temporary heat prior to system
• Vernier SCR - completely electronically con- startup / balancing.
trolled by varying signal and varying output
between stages. Increases power to a stage by
modulation until another stage is needed. Ener- MECHANICAL INSTALLATION
gizes another stage and modulates power until 1. All heaters will contain an adjustable airflow
another stage is needed. 0 to 10 VDC or 4 TO switch in the heater control panel. This switch
20 mA. Less expensive than Full SCR. This will be preset to close at a differential pressure of
system utilizes a step controller and one SCR approximately 0.3" W.C.
that modulates and resets for each stage.
In all cases the switch will be connected to a pres-
• Full SCR - completely electronically controlled sure probe positioned in the airstream. This probe
by varying signal and varying output of a control- has an arrow stamped on it that is viewable from
ler. Like a VFD for electric heat. 0 to 10 VDC or inside of the control panel. When the heater is
4 to 20 mA. The controller modulates a separate located upstream of the fan this arrow will point
SCR for each stage. away from the fan. When the heater is located on
Installation the downstream side of the fan the arrow will again
point away from the fan or with airflow.
Rotating parts and electrical shock
If it is incorrectly installed, remove the (2) screws
hazards exist. Lock out and tag out
holding the pressure probe in place and rotate 180°
the fan motor(s) and heat power and reinstall. The airflow switch pressure port that
disconnects before servicing. FOL- is not connected to this pressure probe will be run
LOW THE LATEST “LOCKOUT to the exterior of the air handling unit to source a
TAGOUT” PROCEDURE. Failure to reference differential pressure. In some situations
follow proper safety precautions may it may be necessary to adjust this airflow switch
result in serious injury or death setting to allow for proper operation. Precautions
must be made at this time to make sure that the
airflow switch does not provide a false indication
APPLICATION INFORMATION
of airflow. Failure to meet this requirement may
1. Follow the procedure given in this instruction to result in serious damage or nuisance thermal cutout
find the minimum air velocity for safe operation tripping (see Fig. 2-60 and 2-61).
(see Fig. 3-25). At least this minimum velocity 2. A visual inspection of the heater elements should
must be provided at all points over the heater face be made prior to use of the heater. If physical
area. Failure to meet this requirement may result damage is evident, a Megohm test should be used
in serious damage or nuisance thermal cutout trip- to validate the heater elements are safe for use. If
ping. a minimum value of 10 megohms is not achieved
then any damaged elements or ceramic insulators
must be replaced prior to operation.
BLOWER HEATER
AIRFLOW
BLOWER
HEATER
AIRFLOW
FIG. 2-60 – P
RESSURE PROBE DIRECTION
MOUNTING C
BRACKET
NO
NC
LD14270
ELECTRICAL INSTALLATION
1. Follow the wiring diagram on the inside of the 7. When connecting heaters with more than one stage,
terminal box. wire stage No. 1 so that it is the first stage on and
2. Supply connections must be made with copper the last stage off.
wiring rated for 75° C minimum. 8. The heater must be wired so that it cannot operate
3. If supply connections are for 250 volts or greater, unless air is flowing over it. This can be accom-
all wiring must be insulated for 600 volts. plished by using a built-in airflow switch and a
remote interlock. See the accompanying wiring
4. When making line connections to heater element
diagram for the method used with this heater and
terminals FOR FINNED TUBULAR HEATERS
provide appropriate interlock wiring as illustrated.
ONLY, apply a 1/4" wrench to flat section of termi-
This diagram will be located inside of the electric
nal immediately below threads. Otherwise damage
heater control panel.
to terminal may result.
9. If not supplied as part of this heater, install a
5. Supply conductors for heaters rated less than 50
line disconnect switch or main circuit breaker in
KW, must be sized at 125% of rated load. On heat-
accordance with the National Electrical Code.
ers rated 50 KW and more, the supply conductors
Depending upon the heater’s location and acces-
may be sized at 100% of rated load, if indicated
sibility, a built-in disconnect switch may meet this
on the wiring diagram. The line current for either
requirement.
a single or three phase load is calculated as fol-
lows: 10. All electrical connections in the heater, including
both field and factory made connections, should be
KW x 1000 checked for tightness before operating the heater.
Single Phase Line Current = In addition, after a short period of operation, all
Voltage
connections should again be checked for tight-
ness.
KW x 1000
Three Phase Line Current = 11. If heater is wired to a heating / cooling thermostat,
Voltage x 1.73
use a thermostat with isolating circuits to prevent
6. The following table shows the maximum current possible interconnection of Class 2 outputs.
for 75 °C copper wire with not more than 3 con-
ductors in a raceway. It is based on the National 12. If the heating elements are divided into several
Electrical Code Table 310-16. The amperages sections with resistance wire between two or more
shown are for 125% and 100% wire sizing. If there sections, maximum KW per sq. ft. should be cal-
are more than 3 conductors in a raceway, derate culated as follows:
these amperages per Table 310-15(b)(2)(a).
Heater nameplate KW
MAXIMUM CURRENT FOR COPPER WIRING
Number of heated sections x
area of one heated section
AMPS WIRE AMPS WIRE AMPS WIRE
SIZE SIZE SIZE
125% 100% AWG/ 125% 100% AWG/ 125% 100% AWG/
MCM MCM MCM
12 14 80 100 3 184 230 4/0
16 12 92 115 2 204 255 250
24 10 104 130 1 228 285 300
40 8 120 150 0 248 310 350
52 65 6 140 175 2/0 268 335 400
68 85 4 160 200 3/0 304 380 500
Humidifier Option
Control wiring diagrams are located in the humidifier
manufacturer's IOM found inside control panel or
attached. Factory package control drawings may not
include humidifier points.
LD11726
LD06340-1
Coil Piping
Do not test, clean and flush piping Application Notes - All connections are male piping
through this equipment. thread except DX coils, which are solder. Drain and vent
taps on water coils are pipe thread shipped with plugs
Isolate this equipment from pressure installed. These taps are installed approximately two
testing of water, steam gas and air inches back from the end of the threaded connections.
piping.
Pipe for balanced flow and assure even
airflow.
Consult the job specifications and submittal drawings
for specific piping requirements, coil connection sizes
and location. The unit should be level to assure proper
venting and draining of coils. The piping arrangements
must provide for a balanced flow in multiple coil
installations (see Fig. 2-66 showing factory coil Staggered Coils 2
connections). Staggered Coils in Expanded Cabinet size units will
have connections brought to the unit exterior for liquid
Support all connecting piping independently of the or steam coils. DX coils are not included.
coils. Provide swing joints or flexible fittings in all • The external connections are either threaded pipe
piping connections, particularly adjacent to heating or grooved pipe for the contractor to make his
coils, to absorb expansion and contraction strains. connections when the media is liquid.
Rigid piping connections can cause coil damage.
• The external connections are threaded pipe for the
The coil supply and the return pipe connections are contractor to make his connections when the media
labeled. When attaching piping to the coil header, is steam.
make the connection only tight enough to prevent • The installing contractor is responsible for insulat-
leaks. Excessive tightening may cause damage to the ing piping extensions we provided inside the air
header. A backup wrench should be firmly held on the handler.
coil connection so that in tightening the connecting
piping the torque is not transmitted to the coil header,
thus damaging the coil connection.
Water
Water Coils - Hot Water and Chilled Water Hot and Chilled Water Coil Performance
Connect the water supply to the header connection on The temperature rise of the air (hot water coil) or
the leaving air side of the coil to achieve the counter temperature fall of the air (chilled water coil) leaving
flow of water and air. The return pipe will be connected the coil is dependent on the airflow across the coil, the
to the remaining coil connection. gallons of water flow through the coil and the entering
water temperature into the coil. Consult the submittal
Install an air vent in place of the top pipe plug on the for each job for the specific information.
return header. In order to provide for drainage, install
a drain line and shutoff valve in the supply near the coil
or in place of the plug in the supply connection. See
Figs 2-68, 2-69 and 2-70 for typical piping diagrams.
ECCENTRIC CHILLED
RETURN REDUCER WATER
UNION RETURN
COIL
SUPPLY
STRAINER
CHILLED
DRAIN REDUCING WATER
TEE SUPPLY
GLOBE
UNION VALVE
RETURN
COIL
SUPPLY
PT GATE
PLUG VALVE
FIG. 2-68 – CHILLED WATER COIL CONNECTIONS Example - NOT for construction
ECCENTRIC HOT
RETURN REDUCER WATER
RETURN
COIL
SUPPLY
STRAINER
HOT
DRAIN WATER
SUPPLY
GLOBE
UNION VALVE
RETURN 2
COIL
SUPPLY
PT GATE
PLUG VALVE
FIG. 2-69 – HOT WATER PIPING - 2 WAY VALVE Example - NOT for construction
HOT
RETURN WATER
RETURN
UNION
COIL
ECCENTRIC
SUPPLY
REDUCER STRAINER
HOT
DRAIN 3 WAY CONTROL WATER
DIVERTING VALVE SUPPLY
GLOBE 1 Inlet, 2 Outlets
UNION VALVE
RETURN
COIL
SUPPLY
PT GATE
PLUG VALVE
GATE VALVE W/
HOSE BIB LD13792
FIG. 2-70 – HOT WATER PIPING WITH DIVERTING VALVE Example - NOT for construction
Steam Traps
Float and Thermostatic (F and T) traps are recommended It is preferable to provide an individual trap for each
for all low or medium pressure applications. Use coil but a single trap may be used for coils operating in
thermostatic traps only for air venting, for outdoor parallel with respect to the airflow. Coils in series with
applications where an F and T trap might be subject to respect to airflow must be supplied with individual traps.
freezing. Use bucket traps only for a non-modulated Locate the trap at least 12 inches below the coil return
steam supply. Size the steam traps in accordance with connection and even lower when freeze protection is
the manufacturer's recommendations (usually several required. Do not attempt to lift condensate modulated
times the steady state steam flow). Use the actual steam supply.
operating conditions (coil pressure vs. return pressure)
for the selection of a trap.
SU
P PL
YM
DRIP TRAP
STEAM COIL
BREAKER
1/2" CHECK
GATE VALVE
2
FOR END VALVE
PITCHED IN (OPTIONAL)
OR LOW CASIN G
VENT TO POINT OF
ATMOSPHERE SUPPLY
CLOSE TO MAIN DIRT
UNIT POCKET
(NOT ON (FULL STRAINER
VACUUM SIZE OF
SYSTEMS) RN COIL
TU N
RE MAI 12" MIN. CONN.)
DIRT POCKET
SINGLE COIL (FULL SIZE OF
VERTICAL AIR FLOW COIL CONN.) IN FLOAT AND
MA
RN THERMOSTATIC
U
R ET TRAP
AIN
YM
PLY PPL
SUP IN SU
MA
W
FLO
AIR FLO
W
AIR 12" MIN.
12" MIN.
12" MIN.
COILS IN SERIES
AIR FLOW MUST HAVE
COILS IN PARALLEL AIR FLOW INDIVIDUAL TRAPS AND
MAY HAVE COMMON SUPPLY CONTROL VALVES IN
AND SINGLE TRAP MA
IN RN
(INDIVIDUAL COIL TRAP PREFERRED) MA U
RN RET
TU
RE
LD04887A
STEAM IN
ACTUATOR
FACE
DAMPERS
CLOSED
BYPASS
OPEN
STEAM OUT
LD09630
FIG. 2-72 – INTEGRAL FACE and BYPASS COIL (HORIZONTAL; TUBES, STEAM SHOWN)
Make return connection full size as required and On 100% outside air capable applications, locate low
reduce only at trap. Do not use reducing bushing on limit at least 24" downstream of leaving edge of VIFB/
coil return connection. IFB casing. Low limit element must cross both face
and bypass areas, parallel to headers.
3/4" (19.1mm)
AUTOMATIC AIR
VENT IN TOP
HEADER
VIFB AIR
COIL FLOW
HOT WATER
SUPPLY
HOT WATER
RETURN
FLEXIBLE
CONNECTOR
DRAINS
LD09632
3/4" (19.1)
AUTOMATIC AIR
VENT IN TOP
HEADER
R
AI W
O
FL
HOT WATER RETURN
LD09633
T
VIFB AIR
STRAINER COIL FLOW
AIR VENT TO ATMOSPHERE ON OPEN
GRAVITY RETURN SYSTEM ONLY.
MINIMUM 1" (25.4) PIPE
8" (203.2) MINIMUM
T
8" (203.2) 2
CHECK STRAINER
VALVE
FLEXIBLE CONNECTOR INSTALLED
COMBINATION FLOAT AND PARALLEL TO COIL HEADER AND
RETURN MAIN
THERMOSTATIC TRAP AS CLOSE AS POSSIBLE TO COIL
CONDENSATE CONNECTION.
Non-venting Traps
(Steam Pressure Below 15 PSIG Or 103.4 KPa)
CONDENSATE CONDENSATE
FLOW FLOW
T
VIFB AIR
1/4" (6.4) 12" MIN. COIL FLOW
PETCOCK CRACKED (304.8)
OPEN FOR
STRAINER CONTINUOUS AIR
VENTING
8" (203.2) MINIMUM
T
8" (203.2)
CHECK STRAINER
VALVE
FLEXIBLE CONNECTOR INSTALLED
INVERTED PARALLEL TO COIL HEADER AND
RETURN MAIN AS CLOSE AS POSSIBLE TO COIL
BUCKET
TRAP CONDENSATE CONNECTION.
NOTE : DIMENSIONS ARE IN INCHES.
DIMENSIONS IN PARENTHESIS ARE IN MILLIMETERS.
LD09634
Refrigeration
TO INSULATED SUCTION
LINE CONDENSING UNIT
INSULATED HOT GAS LINE FROM CONDENSING UNIT PITCH 1/2" PER 10' IN
PITCH 1/2" PER 10' IN DIRECTION OF FLOW DIRECTION OF FLOW
LIQUID
LINE DRIER LIQUID LINE FROM
CONDENSING UNIT
SPORLAN
ASC HOT GAS CHECK THERMAL
FITTING VALVES EXPANSION
VALVE
LIQUID LINE
SIGHT GLASS SOLENOID VALVE
TXV Equalizer
Line
SIGHT GLASS
TXV Equalizer
Line
SUCTION LINE
1-7/8"
45°
LD05171A
REFRIGERANT IN
LEGEND
LD13319B
FIG. 2-78 – DX COIL CIRCUITING TYPES
johnson controls 2-55
Installation
FORM 102.20-N1 (1109)
H2
H1
D2 H2
D1 D2
D1 H1
2 Distributor 2 Distributor
Circuits Face Split Circuits Row Split
SQ Required SQ Required
H6 H5 H2 H1
D2 D2 H3 H1 D6 D2
H2 H1
D4 D5 D1
D2
D3 D1
D4 H8 H7 H4 H3
D8 D4
D1 H4 H3 D3 D1
D7 D3
D3 H4 H2
D2 2
H2 H1 2
D1 4
D4 1
H4 H3 1
D3 3
FIG. 2-81 – STACKED COIL DESIGN - STANDARD FIG. 2-83 – STACKED COIL CIRCUITING
H2
Single H2 Single
HDR H1
HDR H1 D2 H2 Body
Body D2
D1 H1 Single D1 D2
HDR
Body
D1 D1 H1
H6 H2 H1 H6 H5 H2 H1
Single D2 H3 H1 D6 D2
HDR D2
Body D6 D5 D1
D4 D2 D1
D3
Single
HDR
Body H5 H4 H3 H8 H7 H4 H3
D4 D8 D4
D1 D3 D1 D5
D3 D7 D3
H4 H2
compressor #1
100% Capacity
txv LLSv
compressor #3
Feeds both Circuits
FIG. 2-85 – TWO COIL CIRCUITS PER The first three compressors (see Fig. 2-89) would
REFRIGERANT CIRCUIT
be tied into LLSV1, TXV1 and TXV2. This would
compressor #1 provide full-face control of the coil at even the lowest
cooling loads. Both distributors on each of the coil
txv LLSv
circuits would include auxiliary side connectors for
HGBP.
txv LLSv
compressor #2 condensing Unit
The second set of 3 compressors would be tied into
dx Coil LLSV2, TXV3 and TXV4 to maintain full-face control
LD09150
at higher loads. Reference Form 050.40-ES3 Section 9
FIG. 2-86 – DO NOT USE THE ABOVE for compressor staging solutions.
CONFIGURATION.
When the condensing unit has three compressors The more control stages used, the more precise
per circuit, two coil circuits should be used for each the control of the air temperature will be. Smaller
refrigerant circuit (Fig. 2-87). Each coil circuit must incremental changes in capacity will result in a more
have a dedicated TXV and distributor to handle one coil consistent DX coil leaving air temperature. This will
circuit and the LLSV should be sized to handle the full eliminate temperature swings in the conditioned space
capacity of the refrigerant circuit. The hot gas bypass and improve the comfort level, but more importantly, a
line should be connected to all of the distributors in the consistent space temperature is crucial to many process
coil circuit. applications. The smaller changes in capacity that
Compressor #1
result from using a greater number of control stages
will also extend equipment life. The most important
TXV
thing to remember is to maintain full-face control of
Compressor #3 the coil at all cooling loads. When row split coils are
Feeds both Circuits LLSV used, make sure that the first LLSV is energized with
the last coil circuit in the leaving air stream. This is
TXV
Compressor #2 Condensing Unit
always the last one de-energized too.
DX Coil LD09151
There are four basic components in a VAV system - In the air-handling unit a decrease in airflow through
an air-handling unit with airflow control (i.e. variable- the DX coil will result in a corresponding decrease in
speed drives), VAV boxes, zone thermostats and duct the suction gas pressure while an increase in airflow
static pressure sensors. All of these components must will result in an increase in the suction gas pressure.
work together to provide good temperature control and a Since the system is designed to maintain a constant
comfortable environment. The zone thermostats control suction gas pressure, the compressors will be staged
the VAV boxes. As the zone temperature increases, the on or off as needed to meet the increase or decrease
VAV boxes open to allow greater airflow into the space in load demand. The system should be designed to
and as the zone temperature decreases, the VAV boxes operate smoothly avoiding transients that could upset
close to decrease the airflow to the space. system balance and cause liquid flood back.
As the VAV boxes in the system open and close the Problems can arise if the airflow de-
static pressure in the ductwork changes. When a box creases more quickly than the com-
opens, the duct static pressure decreases, and when a pressor control can respond to the load
box closes, the duct static pressure increases. The duct
change. Therefore, airflow should
static pressure sensor controls the air handling unit
never change at a rate faster than 3%
supply fan. Since an increase in duct pressure relates
to a decrease in the zone airflow required, the supply per minute on VAV systems.
fan volume decreases in response. Conversely, a lower
duct static pressure indicates a need for increased zone This limitation will promote stable control of the
airflow; therefore, the supply fan volume increases system and minimize fluctuations in zone temperature.
in response. The change in supply air volume is Under any circumstances, a minimum of 350 FPM
accomplished using a Variable Frequency Drive or face velocity across the coil must be maintained for
similar device. DX split systems.
DRAIN
PAN TRAP "H" must be at least
DRAIN 1 inch plus fan total Drain
NIPPLE Connection
static pressure
NO.1 - FAN OFF
DRAIN
PAN
DRAIN
PAN
FIG. 2-90 – DRAIN TRAP SHOWING WATER FIG. 2-92 – TRAP DETAIL FOR BLOW THROUGH
LOCATION DURING DRAW THROUGH APPLICATION
OPERATION STAGES
Two or more drains on same side of unit must be trapped Duct Connection Guidelines
individually before drain lines can be combined and See Fig. 2-94.
routed to a suitable drain (see Fig. 2-93). Duct connections to the unit may be made directly
except when the unit has external isolation. Then duct
connections should be flexible material and should be
installed so they are sufficiently loose. Duct connections
should be designed and installed according to AMCA
Standards 200 and 201 as a minimum. Duct turns and
transitions must be made carefully to hold friction loss
TRAPS to a minimum. Avoid short turns. Duct elbows should
contain splitters or turning vanes.
LD06345-1
LD06335-2
FIG. 2-94 – R
ECOMMENDED DISCHARGE DUCT
ARRANGEMENT WHEN TURNS ARE
REQUIRED
DETAIL A
GASKET OR
SEALANT
GASKET OR SEALANT
FLANGED DUCT
FIG. 2-95 – R
ECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS ARE REQUIRED
The performance ratings of coils will be met only if UPPER DUCT SECTION NOT
the airflow is uniform over the face of the coils. High CONTINUOUS THROUGH ROOF
air velocity spots on the coil may cause the carry-over SEALANT UPPER SECTION
EXTENDS 3" TO 4"
of moisture from the coil. High or low air velocity WOOD NAILER BELOW TOP OF CURB.
NOMINAL 2 X 4
areas of the coil will not deliver the published ratings.
FLASHING RECEIVER
The duct connections must be designed to provide for
uniform flow of air across the face of the coil. The LOWER DUCT SECTION
DECK
Sound and Vibration Transmission CANT STRIP
Installation CURB
FRONT OR REAR
DISCHARGE UNIT
• Roof penetrations by ducts should utilize counter SEAL ALL DUCT WALL
flashed curbs. (Typical arrangements are shown PENETRATIONS AT POINTS OF
SUPPORT ATTACHMENT AND
in Fig. 2-96.) REINFORCE ATTACHMENT
ROOF SUPPORT
• All penetrations into ducts should be sealed
ELEVATE BOTTOM OF DUCT
watertight. Attachment of supports should use a LD06337B
minimum number of duct penetrations.
FIG. 2-97 – R
OOF TO DUCT INSTALLATION -
• Duct systems should not be pressurized without HORIZONTAL DISCHARGE
sufficient time for curing of sealant systems. Fol-
low sealant manufacturer's recommendations for
application of the sealant.
Air Filters
It is mandatory that filters be in place in the filter frames A list of filter part numbers, sizes and
of each unit before putting the unit into operation to quantities are shown on a label lo-
protect the coils and keep them clean. cated on each filter segment of each
air handler.
Due to the wide variety of filters, it is not possible to
cover all of them in this section.
If your unit has HEPA filters the filter
Be sure to install all filters in the cor- frames, filter bulkheads and filter seg-
rect orientation with regard to airflow ment panels are factory sealed and
and with pleats or pockets vertical must remain sealed for NO air by-
wherever possible. See IOM Section pass.
4, “Filter Segments”.
Most YORK Solution air handling units will be Bag Filter 12" Cartridge
2
shipped without filters. The Johnson Controls Sales
office is responsible for the order and delivery of filters
in a timely manner. It is important for the contractor
or commissioning agent to be in touch with Johnson Cartridge
Filter Latches
Typically when filters are by others, so
are the filter clips.
2-13-16"
2-13/16"
P/N
P/N --026-35778-000
026-35778-000
P/NP/N- -026-36339-001
026-36399-001
4-11/16"
4-11/16"
P/N
P/N --026-36339-000
026-36399-000
Used with 4” Prefilter in combination with a Double
Header Final Filter.
P/N
P/N - -026-35778-006
026-35778-000
DOUBLE SILVER
DOUBLE FILTER SILVER
FILTER
CLAMPS
(T.CLAMPS
SECTION)
(T. SECTION)
NOTE: Typically when filters are by others, so are the filter clips.
Installation of 2” Perfectpleat, Premium or 4. Repeat the installation process with the remaining
Premium HM latches in the other three corners.
These instructions are for installing a 2” filter (typically 5. Rotate all of the latches outward, and insert the
PerfectPleat) into 16 ga. galvanized holding frames. filter into the frame.
• Latches needed for these applications are four 6. After the filter has been placed into the frame, grasp
(4) P/N 026-35778-000, as shown in Fig.2-98. the circular end of the latch and rotate it across the
corner of the filter.
• A single latch should be installed at each of the
four (4) corners of the frame. Push the end of the latch towards the filter, until the
latch catches beneath the knockout on the frame.
• The latch fits into the set of knockouts, which
consists of two (2) rows of three (3) knockouts. Repeat for the remaining latches.
The row of knockouts closest to the gasketing 7. The filter should now be securely installed into the
should be used for nominal 1” filters or filters frame (see Fig.2-100).
with a 13/16” single header. The second set of
knockouts should be used for nominal 2” fil-
ters.
Installation of Spring Latches
LD010171
Fig. 2-99 – C
orrectly installed latch P/N
026-35778-000.
LD010177
Fig. 2-101 – C
orrectly installed latch P/N
026-35778-007
LD010148
LD010160
Fig. 2-103 – installed CARTRIDGE filter
Fig. 2-105 – installed CARTRIGE W/PLEATS
2-70 johnson controls
FORM 102.20-N1 (1109)
Installation of a Varicel DH Double Headered 4. Repeat the latch installation with the remaining
Filter latches. Note the orientation of the latch to the
knockouts in Fig.2-107.
These instructions are for the installation of a VariCel
DH filter (nominal 12” deep double header) into 16 ga. After the latches have been installed, the frame
galvanized holding frames. should be configured like that shown in Fig.2-
• The latches needed for this application are four 108.
(4) spring latches, P/N 026-35778-006 (as shown
in Fig.2-98.
• Two latches should be attached on each side of
the filter frame.
• The latches should only be installed, two (2) per
side of the frame. There should be no latches
used on the top or bottom. This is done to match
the holes in the filter frame, used to secure the
latch to the filter. See Fig.2-106 for the sets of 2
knockouts that should be used for the latches.
LD010183
Installation of Spring Latches 5 Insert the VariCel DH filter into the frame. While
holding the filter in the frame, grasp the loop on
1. Insert the straight end of the latch between the the end of the latch and pull it until it stretches
knockouts furthest from the corner. over the header and rests into the pre-drilled hole
2. Using a moderate amount of pressure, force the in the header of the filter (see Fig.2-109). Repeat
latch over the third knockout. this with the remaining latches.
3. The latch installation should now be complete. The 6. The filter should now be securely installed into the
latch should now be “trapped” within the three (3) frame.
knockouts.
LD010184
Installation of a 2” and 4" Prefilter in 4. Repeat the latch installation with the remaining
Combination With a Double Header Final latches; note the orientation of the latch to the
Filter knockouts on Fig.2-110.
These instructions are for installing either a 2” or 4" 5. Insert the VariCel DH filter into the frame. While
prefilter (typically PerfectPleat, Premium or Premium holding the filter in the frame, grasp the loop on
HM pleated filters) used in combination with a the end of the latch and pull it until it stretches
VariCel DH (nominal 12” deep) final filter into 16 ga. over the header and rests into the pre-drilled hole
galvanized holding frames. in the header of the filter (see Fig.2-111). Repeat
this with the remaining latches.
• Two sets of latches are needed for these applica-
tions. Four (4) spring latches, P/N 026-35778-
006 are used to hold the VariCel DH into the
frame. In addition, four (4) prefilter latches, P/N
026-36339-001 are used to hold the 2” and P/N
026-36339-000 are used to hold the 4” prefilter
onto the face of the VariCel DH filter.
• For the spring latches, two (2) latches should be
attached on each side of the filter frame.
• The latches should only be installed, two (2) per
side of the frame. There should be no latches
used on the top or bottom. This is done to match
the holes in the filter frame, used to secure the
latch to the filter. LD010156
LD010163
LD010154
Fig. 2-112 – Prefilter latch after
Fig. 2-110 – C
orrect latch/knockout Installation onto filter
configuration. P/N 026-35778-006 header.
LD010165
LD010190
Application: Holds one Astrocel I 11.5" D filter along frame sides. (See Fig. 2-117, 2-118 & 2-119 for application)
029-22082 Latch, HEPA Double 11-1/2"
Application: Holds one Astrocel I 11.5" D filter along frame middle. (See Fig. 2-117, 2-118 & 2-119 for application)
DOUBLE T-SECTIONS
FILTER
CLAMP
2
DOUBLE PERIMETER
FILTER SECTION
CLAMPS
T-SECTION
LD09657
SPRING
DUCTWORK
AIRFLOW
BEVEL SEAL
CELL SIDE
FRAME
(PERIMETER
EXTRUSION)
MEDIA PACK
BEVEL SEAL FRAME
GASKET BEVEL
RECESSED SEALING
CELL SIDE SURFACE
LD06646A
3.0 STARTUP
Rotating parts and electrical shock While it is a common practice to oper-
hazards exist. Lock out and tag out ate the fan as soon as possible (air
the fan motor(s) and heat power movement during construction is al-
disconnects before servicing. FOL- ways preferred by contractors) on the
LOW THE LATEST "LOCKOUT job site, the incomplete ductwork and
TAGOUT" PROCEDURE. Failure missing diffuser grilles will greatly
to follow proper safety precautions reduce air resistance and will allow the
may result in serious injury or death. fan to operate beyond design param-
Refer to general safety guidelines and eters. This practice may result in water
safety symbols located at the front of carry over and flooding of the unit.
this Manual. Also, the motor may over Amp and
become damaged.
Always replace metal tab on access Fan manufacturers describe the rota-
doors that provide access to moving tion of the fan impeller as being
parts. This mechanical protection “clockwise” or “counterclockwise” for
from moving parts is required by UL- centrifugal fans when viewing the
1995. drive side (see AMCA Standard
2406).
When internal safety catch is not used, 3
always replace metal tab on access If your unit has HEPA filters the filter
doors that provide access to pressur- frames, filter bulkheads and filter seg-
ized areas. This mechanical protection ment panels are factory sealed and
is to prevent accidental release of ac- must remain sealed for NO air by-
cess doors under positive pressure. pass.
PRE START UP FAN ASSEMBLY INSPECTION In small units the tie down bolts may
When the unit is removed from long- only be applied to three corners of
term storage moisture laden bearing the fan base since one corner is not
grease should be purged and replen- accessible.
ished with fresh grease per lubrication
decal. The motor should be meggered
to verify that the resistance is still at TIE DOWN BOLTS
Grommet
Snubber,
Seismic
LDO9639 LDO9636
FIG. 3-4 – TEFC (TOTALLY ENCLOSED FAN COOLED) FIG. 3-6 – SEISMIC SNUBBER
LDO9637
Typical Actuators Locations With the actuator shaft clamp tightened to the damper
jackshaft, and the damper shaft is completely rotated
Johnson Controls standard actuators are direct coupled
to its proper position, manually operate the actuator to
on damper jackshaft.
its fully actuated position using the crank arm provided
Basic Actuators Installation with the actuator. Then release the spring to allow the
A basic procedure for installing Johnson Controls damper to go back to its original position. This will
actuators is included in Section 2"Installation". verify the actuators spring rotation and stroke.
Set the damper actuators rotation selector switch to the
Damper Blade Orientation proper rotation required to actuate the damper.
Return Air and Mixing Dampers with Power Off Damper actuator will always be op-
Position the blades so that they will be open once the posite the spring return rotation.
actuator is installed. This will be the dampers spring
return position. Note whether the damper shaft is
rotated fully clockwise or counter clockwise.
Outside Air and Exhaust Air Dampers
Position the damper blades so that they will be closed
with power off. This will be the dampers spring return
position. Note whether the damper shaft is rotated
fully clockwise or counter clockwise.
FIG. 3-7 – E
XAMPLE OF SWEEP BALANCE RESULTS
Check Doors and Latches for Proper General Guidelines for Replacing an Adjustable
Adjustment Sheave with a Fixed Sheave:
See IOM Section 5 “Door Handle/Latch Replacement • Measure the outside diameter of a belt while it is
and Adjustment”. seated into at least one half the circumference of
an adjustable sheave groove. Use this measure-
Plastic spacers must be removed be- ment as the sheave "pitch diameter". Order a
tween doors and doorframes before sheave or sheave and bushing combination that
Start-up. matches pitch diameter, belt cross section and
bore size. Order a sheave of good quality and
require that it is prebalanced.
FILTER
ELEVATION VIEW
COOLING HEATING
COIL COIL
ENERGY R/A DAMPER
WHEEL
O/A
BYPASS
SUPPLY FAN
EXHAUST FAN
ACCESS
WHEEL
ROTATION
BEARING SUPPORT
BEAM - PULLEY SIDE
BALL
BEARINGS (2)
BEARING ACCESS
COVER (2)
2. Before applying power to drive motor, confirm 4. If wheel has difficulty starting, turn power off and
wheel segments are fully engaged in wheel frame inspect for excessive interference between the
and segment retainers are completely fastened wheel surface and each of the four (4) diameter
(see Fig. 3-12). seals. To correct, loosen diameter seal adjusting
3. With hands and objects away from moving screws and back adjustable diameter seals away
parts, activate unit and confirm wheel rotation. from surface of wheel. Apply power to confirm
Wheel rotates clockwise (as viewed from the wheel is free to rotate, then re-adjust and tighten
pulley side). hub and diameter seals (see Fig. 3-13).
SEGMENT RETAINER
CATCH
2 ROTATE AWAY
FROM WHEEL RIM
ROTATION
TO REMOVE
SPOKE
DIAMETER
SEAL
1 PUSH
TOWARD
CENTER
TO ADJUST
WHEEL RIM
CENTER
OF
WHEEL
DIAMETER SEAL
ADJUSTING SCREWS FEELER
LD09643 GAGE
LD09644
• Honeywell - S7800A Test Module - For use FIG. 3-14 – OPEN FUSE DISCONNECTS
on (Honeywell-7800) Series Relay Module.
(Available through Airside Parts - 800-545-7814,
2. Check all wire terminations for tightness.
Ext.12).
• Flue Gas Analyzer (CO2 and O2) 3. Check that the incoming voltage(s) are correct.
• Stack Thermometer (0°F - 1000°F approx.) Compare measured voltages to burner motor and
• Digital Manometer (replaces Magnehelic ID motor nameplates and the “Burner Test Report”.
Gauge). Reset fuse disconnects.
Digital Manometer
Cat. #475-1 FM-AV 4. Check for correct rotation of 3 phase burner motor
Series: 475-1 Mark III and ID motor.
Range: 0 to 19.99 In. W.C.
Dwyer Instruments, Inc. 5. Verify that contractor has purged new gas lines of
air up to manual valve on gas train.
7. The flue (stack) damper is located at the discharge 10. Visually check that the high temperature safety
of the ID blower and closed for shipping. Release limit is set for a 200-230°F range. The limit switch
the locking mechanism and set the damper to match is typically mounted behind the burner control
the position indicated by the scribed markings. panel.
Lock in place (see Fig. 3-15).
11. Connect a 0-15" gas pressure gauge or other suit-
Check Draft Test Port able instrument to the gas manifold port. The gas
ID fan
rotation pressure will be measured when running (refer to
step 4 of Burner Start-up Procedure).
Damper
Adjustment and
Indicator Plate On Powerflame burners this test port
BURNER PANEL
is downstream of the main regulator,
typically on a standard tee fitting in the
main gas line.
7. Using the signal generator, cycle the burner to Do not change set up of factory preset
check capacity modulation. Observe valve/damper air inlet dampers on Power Flame
actuator operation. burner.
Damper
Actuator
Any questions should be directed to
your local Service office or Johnson
Controls Product Tech Support, before
contacting the burner manufacturer.
Marked by factory,
future reference for
actuator set up.
LD12909
BURNER
ASSY
ID
MOTOR
FLOW 2
1
3
4
2
3
PITCH
4 Foot
LD12912
1
Failure to follow these guidelines may 5. Condensate drain and trap discharge should be
cause excessive condensation build up pitched away from the equipment at a slope of 1/4”
resulting in water damage to the facil- per linear foot or as local code dictates.
ity and/or a cracked heat exchanger.
6. For outdoor or unconditioned space installations
local climate may dictate the need to heat trace
1. Observe local jurisdiction codes for gravity con-
and/or insulate the exposed drain lines and trap.
densate drainage requirements.
Frozen drain lines and/or trap will cause build up
of condensate inside the heat exchanger resulting
2. Be sure the air handler is installed at an elevation
in leakage and damage to the air handler and pos-
that enables proper condensate drainage and trap-
sibly to the facility.
ping dimensions as provided in Fig. 3-21. Mini-
mum trap dimensions MUST be accommodated. 7. Provide unions in drain lines to allow removal of
trap for periodic cleaning of drain lines as well
3. Condensate drain line size must be the full line size as the trap. When the burner is operated at low
of the heat exchanger drain connection. capacity for extended periods, more condensate
is generated and with it deposits of solids in the
4. Drain lines, fittings and supports should conform condensate drainage system.
to local codes and be suitable for the application.
8. Provide the ability to prime the trap. During initial
and seasonal start up, trap inspection and priming
is required. Condensate in the trap will evaporate
during long periods of non-use.
3-16 johnson controls
GAS HEAT SEGMENT MODEL NUMBER NOMENCLATURE
B 100 U 3 L G G A A
REV DF SIZE/ CODE BURNER UNIT HAND ID FAN UNIT CONTROL BURNER
LEVEL CAPACITY COMPLIANCE TDR YORK HOUSING VOLTAGE VOLTAGE MOD
MBH DESIGNATION (T'STAT VOLTAGE) CONTROL
johnson controls
A 15 150 A ANSI 3 3:1 L Left G Galvanized A 120/1/60 A 24 A 2-10 vdc
200 or
B 20 200 U UL 10 10:1 R Right S Stainless B B 120 B 4-20 mA
208/3/60
0-135
C 25 250 F FM 25 25:1 C 277/1/60 C
Ohms
230 or
30 300 R IRI D
240/3/60
35 350 E 380/3/60
40 400 F 440/3/50
45 450 G 460/3/60
380 or
50 500 H
415/3/50
60 600 J 575/3/60
75 750 K 220/3/50
85 850
100 1000
125 1250
150 1500
175 1750
200 2000
225 2250
250 2500
275 2750
300 3000
325 3250
350 3500
375 3750
400 4000
3-17
FORM 102.20-N1 (1109)
3
3-18
Startup
johnson controls
FORM 102.20-N1 (1109)
FORM 102.20-N1 (1109)
CONTAINMENT FURNACE A
GAS FURNACE WITH CASING OUTPUT
BAND SET &
GASKET, 1" THK X 3"W X LG, 15 21.83
INSULATION FIBER 20 21.83
25 21.83
6"L SLIP JOINT 40 23.66
7.75 0.43" CLEARANCE 50 23.65
H
75 28.15
100 28.14
TRANSITION
PIECE 125 35.12
12" ID
EXT. FAN 150 35.12
175 35.12
200 35.12
A 250 41.36
300 41.36
350 47.36
400 47.36
HAT CHANNEL
NOTES:
1. SEE SECTION 026-004 TO
5.50 DETERMINE LENGTH OF IVSI PIPES.
FLOOR PANEL
W
LD13304
FIG. 3-22 – GAS FURNACE FUEL VENTING SYSTEM
johnson controls
FORM 102.20-N1 (1109)
STEP 3
STEP 1 FLUE CAP
STEP 2
42"L VSI PIPE SPLIT CLAMP
SPLIT PLATE (NOT INSULATED)
johnson controls
PIPE CHASE
CURB PIECE
RACEWAY
IVSI PIPE
SIDE PANEL (INSULATED PIPE)
SEE NOTE 1
CONTAINMENT
BAND SET &
GASKET, 1" THK X 3"W X LG,
INSULATION FIBER STEP 4
6"L SLIP
JOINT
12" ID
EXT. FAN TRANSITION
PIECE
STORM COLLAR
HAT CHANNEL
5.50
NOTES:
3-21
FORM 102.20-N1 (1109)
3
Startup
FORM 102.20-N1 (1109)
Connect Signal
Generator here for test
and start up
Jumper may be
required here for test
and start up
LD13315
INTERNAL INTERNAL
PRESSURE PRESSURE
CFM Temperature Rise (°F) CFM Temperature Rise (°F)
DROP “ DROP “
WC WC
INTERNAL INTERNAL
PRESSURE PRESSURE
CFM Temperature Rise (°F) CFM Temperature Rise (°F)
DROP “ DROP “
WC WC
30
14 28
26
12 24
A ir
let
22
° In
80
10 20
r
Ai
low
let
Be
In
18
0°
KW PER SQ. FT. FACE AREA
r
Ai
-9
et
KW PER SQ. FT. FACE AREA
8 16
81
nl
°I
00
-1
14
91
6 12
10
4 8
FINNED
6
TUBULAR OPEN COIL
2 CONSTRUCTION 4 CONSTRUCTION
0 0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
MINIMUM AIR VELOCITY REQUIRED
MINIMUM AIR VELOCITY REQUIRED
(FEET PER MINUTE)
(FEET PER MINUTE)
BLOWER HEATER
AIRFLOW
BLOWER
HEATER
AIRFLOW
MOUNTING C
BRACKET
NO
NC
LD14270
Rotating parts and electrical shock the heater is located on the downstream side of
hazards exist. Lock out and tag out the fan the arrow will again point away from the
the fan motor(s) and heat power fan or with airflow. If it is incorrectly installed,
disconnects before servicing. FOL- remove the (2) screws holding the pressure probe
LOW THE LATEST “LOCKOUT in place and rotate 180° and reinstall. The airflow
TAGOUT” PROCEDURE. Failure to switch pressure port that is not connected to this
pressure probe will be run to the exterior of the
follow proper safety precautions may
air handling unit to source a reference differential
result in serious injury or death
pressure. In some situations it may be necessary
to adjust this airflow switch setting to allow for
APPLICATION INFORMATION
proper operation. Precautions must be made at
1. Follow the procedure given in this instruction to this time to make sure that the airflow switch does
find the minimum air velocity for safe operation not provide a false indication of airflow. Failure to
(see Fig. 1). At least this minimum velocity must meet this requirement may result in serious damage
be provided at all points over the heater face area. or nuisance thermal cutout tripping.
Failure to meet this requirement may result in seri- 2. A visual inspection of the heater elements should
ous damage or nuisance thermal cutout tripping. be made prior to use of the heater. If physical
2. The maximum air inlet temperature for open coil damage is evident, a Megohm test should be used
heaters is 100° F, and for finned tubular heaters, to validate the heater elements are safe for use. If
80° F. a minimum value of 10 megohms is not achieved
3. Sufficient working space must be provided per then any damaged elements or ceramic insulators
paragraph 110-26 of the NEC. must be replaced prior to operation.
4. This electric heater is not designed for or intended
to be used for temporary heat prior to system ELECTRICAL INSTALLATION
startup / balancing. 1. Follow the wiring diagram on the inside of the
terminal box.
MECHANICAL INSTALLATION 2. Supply connections must be made with copper
1. All heaters will contain an adjustable airflow wiring rated for 75° C minimum.
switch in the heater control panel. This switch 3. If supply connections are for 250 volts or greater,
will be preset to close at a differential pressure of all wiring must be insulated for 600 volts.
approximately 0.3" W.C. In all cases the switch 4. When making line connections to heater element
will be connected to a pressure probe positioned terminals FOR FINNED TUBULAR HEATERS
in the airstream. This probe has an arrow stamped ONLY, apply a 1/4" wrench to flat section of termi-
on it that is viewable from inside of the control nal immediately below threads. Otherwise damage
panel. When the heater is located upstream of the to terminal may result.
fan this arrow will point away from the fan. When
FORM 102.20-N1 (509)
5. Supply conductors for heaters rated less than 50 7. When connecting heaters with more than one stage,
KW, must be sized at 125% of rated load. On heat- wire stage No. 1 so that it is the first stage on and
ers rated 50 KW and more, the supply conductors the last stage off.
may be sized at 100% of rated load, if indicated 8. The heater must be wired so that it cannot operate
on the wiring diagram. The line current for either unless air is flowing over it. This can be accom-
a single or three phase load is calculated as fol- plished by using a built-in airflow switch and a
lows: remote interlock. See the accompanying wiring
diagram for the method used with this heater and
KW x 1000 provide appropriate interlock wiring as illustrated.
Single Phase Line Current =
Voltage This diagram will be located inside of the electric
heater control panel.
KW x 1000 9. If not supplied as part of this heater, install a
Three Phase Line Current =
Voltage x 1.73
line disconnect switch or main circuit breaker in
6. The following table shows the maximum current accordance with the National Electrical Code.
for 75 °C copper wire with not more than 3 con- Depending upon the heater’s location and acces-
ductors in a raceway. It is based on the National sibility, a built-in disconnect switch may meet this
Electrical Code Table 310-16. The amperages requirement.
shown are for 125% and 100% wire sizing. If there 10. All electrical connections in the heater, including
are more than 3 conductors in a raceway, derate both field and factory made connections, should be
these amperages per Table 310-15(b)(2)(a). checked for tightness before operating the heater.
In addition, after a short period of operation, all
AMPS WIRE AMPS WIRE AMPS WIRE
connections should again be checked for tight-
SIZE SIZE SIZE
125% 100% AWG/ 125% 100% AWG/ 125% 100% AWG/
ness.
MCM MCM MCM 11. If heater is wired to a heating / cooling thermostat,
12 14 80 100 3 184 230 4/0 use a thermostat with isolating circuits to prevent
16 12 92 115 2 204 255 250 possible interconnection of Class 2 outputs.
24 10 104 130 1 228 285 300
12. If the heating elements are divided into several
40 8 120 150 0 248 310 350
sections with resistance wire between two or more
52 65 6 140 175 2/0 268 335 400
sections, maximum KW per sq. ft. should be cal-
68 85 4 160 200 3/0 304 380 500
culated as follows:
Heater nameplate KW
Number of heated sections x
area of one heated section
2 johnson controls
FORM 102.20-N1 (509)
Calculate KW per square foot of duct area as: heater namplate KW (see step 12)
duct area (Sq.Ft.)
16 32
30
14 28
26
12 24
A ir
let
22
° In
80
10 20
r
Ai
low
t
nle
Be
18
I
0°
KW PER SQ. FT. DUCT AREA
r
Ai
-9
et
KW PER SQ. FT. DUCT AREA
8 16
81
nl
°I
00
-1
14
91
6 12
10
4 8
FINNED
6
TUBULAR OPEN COIL
2 CONSTRUCTION 4 CONSTRUCTION
0 0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
MINIMUM AIR VELOCITY REQUIRED
MINIMUM AIR VELOCITY REQUIRED
(FEET PER MINUTE)
(FEET PER MINUTE)
johnson controls 3
©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 102.20-N1 (509)
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