Specifications

ManualsBrandsYork ManualsAir CompressorCSA DH 036

InstallatIon and staRtUP InstRUCtIons

YORK SOLUTION

AIR HANDLING UNITS

Supersedes 102.20-N1 (1108)

Form 102.20-N1 (1109)

OUTDOOR UNIT

INDOOR UNIT

LD09624

LD09688

YORK SOLUTION INDOOR AND OUTDOOR MODELS

Renewal Parts

Form 102.20-RP1

With P/N contact Balt. Parts

(800) 932-1701

Manufactured or specialty parts

contact

Airside (800) 545-7814

Summary of content (140 pages)

PAGE 1
YORK Solution Air handling units Installation and STARTUP INSTRUCTIONS Supersedes 102.20-N1 (1108) Form 102.20-N1 (1109) YORK SOLUTION INDOOR AND OUTDOOR MODELS s al Part w e n e R P1 02.20-R 1 m r rts o F alt.
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IMPORTANT! Read BEFORE PROCEEDING! GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus. During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, and materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death.
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FORM 102.20-N1 (1109) NOTICE TO CUSTOMER/CONTRACTOR PROTECT YOUR WARRANTY PRIOR TO STARTUP. • Read and follow the Installation and Start-up Instructions provided with this equipment. • Storage of this equipment MUST be on a flat surface and protected from the weather. • Protect this equipment from damage, construction dirt, debris and water. DO NOT OPERATE DOORS WHEN UNIT IS NOT ON A FLAT SURFACE. • Isolate this equipment from pressure testing of water, steam, gas and air piping.
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FORM 102.
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FORM 102.20-N1 (1109) Table of contents GENERAL SAFETY GUIDELINES.......................................................................................................................2 CHANGEABILITY OF THIS DOCUMENT............................................................................................................3 Table of contents........................................................................................................................................5 list of figures...............
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FORM 102.20-N1 (1109) Table of contents (Cont'D) 2.0 INSTALLATION............................................................................................................................................2-1 SITE PREPARATION..................................................................................................................................2-1 Outdoor Units (Site Prep)......................................................................................................................
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FORM 102.20-N1 (1109) Table of contents (Cont'D) POWER CONNECTIONS..........................................................................................................................2-37 Single Point Power...............................................................................................................................2-37 Motors for Supply Fan, Return Fan, Exhaust Fan.............................................................................2-37 Energy Recovery Wheel Option............
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FORM 102.20-N1 (1109) Table of contents (Cont'D) Drains And Traps.................................................................................................................................2-61 Condensate Drain Piping...............................................................................................................2-61 Condensate Drain Trap...................................................................................................................
PAGE 9
FORM 102.20-N1 (1109) Table of contents (Cont'D) 3.0 STARTUP.....................................................................................................................................................3-1 PRE START-UP...........................................................................................................................................3-2 PRE START UP FAN ASSEMBLY INSPECTION.......................................................................................3-3 Motors - ODP vs.
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FORM 102.
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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....................................................................
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FORM 102.20-N1 (1109) list of figures (Cont'D) FIG. 2-28 – i nstalling bolts after pulling units tight together...................................2-20 FIG. 2-29 – TIERED UNIT.........................................................................................................................2-21 FIG. 2-30 – TIERED UNIT SECURED WITH BRACKETS.......................................................................2-21 FIG. 2-31 – APPLY GASKETS TO TOP PANEL BOTTOM TIER.......................................
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FORM 102.20-N1 (1109) list of figures (Cont'D) FIG. 2-70 – HOT WATER PIPING WITH DIVERTING VALVE..................................................................2-47 FIG. 2-71 – STEAM COIL PIPING ARRANGEMENTS.............................................................................2-49 FIG. 2-72 – INTEGRAL FACE and BYPASS COIL (HORIZONTAL; TUBES, STEAM SHOWN)...........2-50 FIG. 2-73 – V ERTICAL INTEGRAL FACE and BYPASS COIL .............................................................2-50 FIG.
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FORM 102.20-N1 (1109) list of figures (Cont'D) Fig. 2-108 – F rame with 4 latches installed. ...........................................................................2-71 Fig. 2-109 – S pring latch should be pulled and fastened in hole in the header of the filter...................................................................................................2-71 Fig. 2-110 – C orrect latch/knockout configuration. P/N 026-35778-006.........................2-72 Fig.
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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......................................................
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FORM 102.
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FORM 102.20-N1 (1109) introduction GENERAL This manual has been prepared as a guide for installing, operating and maintaining YORK Solution Air Handling Units. Johnson Controls has produced a quality product that is adaptable to almost any comfort or industrial application. However, proper installation, operation and maintenance must be followed to realize the full capacity and life of the units.
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FORM 102.20-N1 (1109) Economizer System - Typical Heating Operation The Economizer system could typically consist of: • Outdoor and return air dampers. • Damper actuator. • Enthalpy control. • Minimum outdoor air adjustment. • Exhaust air control. Various types of heating may be applied. Hot water or steam coils maybe specified typically. Electric heat and fuel burner heat are available.
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FORM 102.20-N1 (1109) SEGMENT IDENTIFICATION Refer to Tables 1 and 2 for segment identification and nomenclature.
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I INDOOR UNIT O OUTDOOR UNIT XT I - 048 X 075 - D NOMINAL WIDTH NOMINAL HEIGHT PRIMARY IDENTIFIER H WIDTH 27 27,30,33,36,39,42,45,48,51,54,57 30 27,30,33,36,39,42,45,48,51,54,57,60 33 30,33,36,39,42,45,48,51,54,57,60,63,66,69 30,33,36,39,42,45,48,51,54,57,60,63,66,69,72 36 39 33,36,39,42,45,48,51,54,57,60,63,66,69,72,75,78 42 36,39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,84 45 36,39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,84,87 48 39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,87,90 51 42,45,48,51,5
PAGE 21
FORM 102.20-N1 (1109) Unit Identification Unit ID Label Both indoor and outdoor units are labeled with a Unit ID Label, Skid ID Labels and Loose Component ID Labels. Indoor units are shrink wrapped with Skid ID Labels on the outside of the wrapping as well as on each skid. The Unit ID Label contains the Model number, Serial/ Date Code, Job Identification number, Segment Identification, the number of Skids, Unit Tag number, Electrical Ratings, Coil Data and Manufacturing Location (see Fig. 3).
PAGE 22
FORM 102.20-N1 (1109) Loose Component ID Label Filter ID Label Each loose component has a label showing where it is to be installed on the unit. The segment identification box on the label will show the skid that it is installed on. If the loose component goes on only one segment on that skid the segment in the box will be bolded (see Fig. 6). Figure 7 shows a typical Filter Label with Filter Segment and Filter List.
PAGE 23
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 the shipment of quality products. All reasonable means are utilized to properly package the air handling units. Johnson Controls will NOT be responsible for any damage or loss of parts in shipments or at the job site. Receiver is solely responsible for noting Bill of Lading and filing freight claims IMMEDIATLY. Refer to Shipping Damage Claims Form 50.
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Pre-installation FORM 102.20-N1 (1109) All lifting lugs must be used to avoid damage to unit. If unit does not have lifting lugs, use bottom corner connectors and intermediate raceway lifting lugs. Do not use top corner connectors. Off-Loading Proper rigging and handling of the equipment is mandatory during unloading and setting it into position to retain warranty status.
PAGE 25
FORM 102.20-N1 (1109) 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. Figures 1-4 and 1-5 show YORK Solution unit without baserails. When baserails are present, always use all lifting lugs pre-mounted on baserails. Do not lift by corners. 1 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.
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Pre-installation FORM 102.20-N1 (1109) INSPECTION STORAGE Check For Damage Short-Term Storage Indoor Units: Under no circumstances should outdoor storage be used Receiver Responsibility Receiver is solely responsible for noting freight bill and filling freight claims IMMEDIATLY (see “Receiving” in this section). Visible damage should be noted on the signed and dated bill of lading with a request that the carrier inspect the damage within 72 HRS. of notification.
PAGE 27
FORM 102.20-N1 (1109) Long-Term Storage Long-term storage is considered any period beyond six (6) months from date of shipment. If long-term storage is anticipated, contact the Johnson Controls Sales representative for the proper instructions and requirements for long-term storage. It is mandatory that a detailed record be maintained during this longterm period, such as, but not limited to: proper sealing of the cabinet, rotation of the blowers and bearings, and protection of all motors from moisture.
PAGE 28
Pre-installation FORM 102.20-N1 (1109) FIG. 1-7 – L ONG-TERM STORAGE REQUIREMENT - FIELD PREPARATION, FORM 50.
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FORM 102.20-N1 (1109) 1 FIG. 1-8 – L ONG-TERM STORAGE PERIODIC CHECKLIST AND LOGS, FORM 50.
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FORM 102.
PAGE 31
FORM 102.20-N1 (1109) 2.0 INSTALLATION Do not weld or use torches on the exterior or interior of the unit housing. The housing contains polyurethane insulation, which under combustion will produce harmful, toxic gases resulting in personal injury or death. Never use silicone caulk/sealant or caulk/sealant containing silicone in or on any air handling equipment. [Only exception is when provided (high temperature) with gas heat venting].
PAGE 32
Installation FORM 102.20-N1 (1109) Mounting Curb Units must be installed in such a manner as to provide enough elevation for properly designed condensate traps (see Section 2 “Drain - Condensate Drain Trap”). The curb, which supports the unit, will be shipped unassembled. It will be necessary to assemble the curb parts on the job site. Assembly drawing and a hardware package are shipped with each curb package. It is important the curb be installed square.
PAGE 33
FORM 102.20-N1 (1109) Curb Assembly and Installation Instructions See Fig. 2-2 1. Unpack shipping package, layout pieces and parts according to the exploded views and check against Bill of Materials. 2. Layout all channel pieces as shown. Make certain that all channel tabs are located on inside of mating channel Make certain that all curb walls accessories and flanges, which may have been distorted in handling, are straightened before assembly. 3.
PAGE 34
Installation FORM 102.20-N1 (1109) CURB SUPPORTS as required D UNIT WALL RIGHT HAND PIPE CHASE A UNIT RACEWAY B B C 1-7/8" CURB REST Note 1 1-7/8" CURB GASKET 2" x 4" NAILER 1-1/2" "A" Note 1 UNIT ROOF CURB Curb for Pipe Chase LEFT HAND PIPE CHASE "A" 2" 2" PIPE CHASE SECTION VIEW SECTION "A-A" Screw flange of pipe chase curb to unit roof curb 2" x 4" nailer. CURB CALCULATION FOR OUTSIDE DIMENSIONS A = Total unit length from YORKworks minus 0.
PAGE 35
FORM 102.20-N1 (1109) 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. See Section 2 “Piping Connections - Condensate Drain Trap.” 0 2 LD05373 FIG.
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Installation FORM 102.20-N1 (1109) STRUCTURE PERPENDICULAR TO AIRFLOW STRUCTURE PARALLEL TO AIRFLOW (Units under 5 ft. wide) FAN SECTION BDW COOLING BDW COOLING (Units over 5 ft. wide) FS AIR FLOW AIR FLOW PLAN VIEW PLAN VIEW MC RF CC MB FAN SECTION RF MB FS LD09619a ELEVATION VIEW ELEVATION VIEW FIG. 2-6 – CEILING SUSPENDED UNIT Ceiling Suspended Units It is recommended that support is structurally engineered to prevent flexing, sagging or twisting of air handlers.
PAGE 37
FORM 102.20-N1 (1109) Structure Positioned In the Direction of Airflow The unit base must be supported continuously, on both sides of the unit. UNIT INSTALLATION See Fig. 2-7. • • • • Tools Needed • • • • • • • Drill with adjustable torque. No. 3 Phillips bit. Allen wrench set. Nut setter - Sizes 1/4", 5/16", 3/8" and 9/16" or socket set. Wire cutters. Power pulls or come-a-longs. Slings. Pry bar. Drift pins and awls. Common hand tools. Caulking gun. Material not provided by Johnson Controls.
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Installation FORM 102.20-N1 (1109) Ship Loose Parts Look for label “Installation Instructions and Ship Loose Items Inside”. This label is normally located on the access door of the first fan section in the air stream. Only the parts listed in this section which are required for your unit are included.
PAGE 39
FORM 102.20-N1 (1109) Floor, Wall & Indoor Top Seam Cap Roof Seam Cap (Outdoor) 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. Apply 2" Gasket & Caulk • • ROOF SEAM CAP 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 for Outdoor Roof.
PAGE 40
Installation FORM 102.20-N1 (1109) CORNER CONNECTOR HOLE PLUG P/N 021-19568-000 DAMPER SHAFT EXTENSION KIT P/N 026-33715-002 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.
PAGE 41
FORM 102.20-N1 (1109) 1/4” X 3-1/2” x 3-1/2” SHIPPING SPLIT CORNER GASKET P/N 028-11883-010 (Outdoor Only) POLYURETHANE CAULK P/N 013-02966-011 GREY, P/N 013-03317-040 CHAMPAGNE Never useuse silicone Never siliconecaulk/sealcaulk/sealant ant or caulk/sealant containing or caulk/sealant containsilicone in or on any air handling ing silicone in or on any air equipment. Only exception handling equipment. [Onlyis when provided (high temperature) exception is when provided with(high gas heat venting.
PAGE 42
Installation FORM 102.20-N1 (1109) TOP SPLIT BOTTOM SPLIT - RACEWAY, BASERAIL W/ LUG BOTTOM SPLIT - RACEWAY W/ LUG CURB REST BOTTOM SPLIT - RACEWAY, BASERAIL W/ LUG & CURB REST BOTTOM SPLIT - RACEWAY W/ LUG AND CURB REST LD09620C FIG. 2-15 – SHIPPING SPLIT EXAMPLES WELDED CHANNEL FILLER BASE CHANNEL REMOVABLE LIFITING LUGS Remove lifting lugs before assembling shipping splits. Retain bolts,etc. and use to secure assembled shipping split.
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FORM 102.20-N1 (1109) Assembly of Outdoor Unit See rigging suggestions and details in Section 1. Failure to follow these guidelines may result in damage to equipment. Do not damage factory installed pipe chase, electrical cabinet, hoods, pipe stubs, door handles or roof overhang. See “Ship Loose Parts” to identify gaskets and hardware items. Installing Single Piece Outdoor Unit 1. Units should not be moved on a roof surface but should be lifted from the ground onto the curb or support framework.
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Installation FORM 102.20-N1 (1109) e) Make sure all wiring and/or control tubing connection pig tails are secured out of the path of the shipping split mating surfaces to prevent damage. f) Apply 3.5" x 3.5" separate gasket squares, placing one square at each corner of the face of one section. Apply 1/4" x 2" foam gasket to face perimeter from 3.5" square to 3.5" square. Apply this gasket 1/4" from outside edge of mating surface (nearest to exterior of air handler).
PAGE 45
FORM 102.20-N1 (1109) After wiring connections are made and before proceeding with assembly, the top shipping split angle will need to be removed and repositioned (see Fig. 2-19). Ensure chain does not apply pressure to drain connection. Improper positioning of chain may cause damage to unit. 9. Start pulling this section toward the first section. Pull evenly on both sides. a) Be sure all of the electrical or control wires or tubes are clear.
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Installation FORM 102.20-N1 (1109) LD13775 LD13777 LD13776 LD13778 FIG. 2-20 – BRINGING SECTIONS TOGETHER 13. Apply a 1/4" bead of caulking to the exterior of the seam. Trowel the bead level with the air handler exterior. This is to be done on roof and 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 the seam caps and install them over the joints using 1/4"-14 x 1" hex head screws provided.
PAGE 47
FORM 102.20-N1 (1109) Assembly of Indoor Unit See rigging suggestions and details in Section 1. Failure to follow these guidelines may result in damage to equipment. Do not damage factory installed pipe chase, electrical cabinet, hoods, pipe stubs, door handles or roof overhang. d) Make sure all wiring and/or control tubing connection pig tails are secured out of the path of the shipping split mating surfaces to prevent damage.
PAGE 48
Installation FORM 102.20-N1 (1109) HEAT WHEEL (ER) SEGMENT END SPLIT MOUNTING BRACKET SECURE TOGETHER USING 3/8" X 3/4" BOLT, LOCK WASHER & HEX NUT. REMOVE SHIPPING BRACKETS LD14262 FIG. 2-23 – ASSEMBLY OF END CHANNEL SHIPPING SPLIT (EXPANDED CABINET) 2. Place the first section in its final position and anchor or block it before placing the next section (see Fig. 2-25).
PAGE 49
FORM 102.20-N1 (1109) 3. Attach power pulls or come-a-longs to the first section. Use the lifting lugs on baserail (not at the shipping split) or holes in the two outside corners (see Fig. 2-25). For expanded cabinet with structural steel base remove lifting lugs within the shipping split. retain bolts and. nuts (see Fig. 2-26). Connectors 2 LD13773A LD13782 FIG. 2-25 – P lacing and anchoring first section and attaching come-alongs WELDED CHANNEL FILLER BASE CHANNEL LD13374 FIG.
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Installation FORM 102.20-N1 (1109) 7. Start pulling the sections together. Pull evenly on both sides. a) Be sure all of the electrical or control wires or tubes are clear. b) Guide the top raceways together by placing rods or drift pins through the holes in the top guide angles. When the raceways are together, install the long bolts provided. c) Guide the bottom raceway/baserails together using rods or drift pins through the holes in the lifting lugs on opposing sections.
PAGE 51
FORM 102.20-N1 (1109) These brackets are used to secure the top segment to the bottom segment. After final alignment, bolt the two brackets with hardware supplied. 1. Before placing top tier: a) Verify the correct orientation of top and bottom tier. b) Remove cross brace(s) (shipping supports) from top tier. c) Remove plastic shipping covers and their supports.
PAGE 52
Installation FORM 102.20-N1 (1109) Be sure all of the electrical or control wires or tubes in both tiers are clear. 7. Lower the top tier onto bottom tier so that mounting brackets mate. Guide brackets together using rods or drift pins through the bolt holes (see Fig. 2-32). 2. Install (4) shackles, one in each bottom corner connector or raceway lifting lug. 3. Fasten sling/chain to shackles. 4. Fasten other end of sling/chain to spreader bar (as needed). 5.
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FORM 102.20-N1 (1109) See “Ship Loose Parts” to identify gaskets and hardware items. 5. Apply 1/4" x 2" neoprene gasket to all raceway 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 The assembly is the same regardless of what sections are being connected together. The vertical Energy Recovery Wheel shown in Fig.
PAGE 54
Installation FORM 102.20-N1 (1109) Apply Butyl Apply Caulk Clip Mist Eliminator or Filter LD13783 FIG. 2-34 – HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS See “Ship Loose Parts” for identification of gaskets and hardware. 1. Identify correct hood and respective location (see example on Fig 5 “Loose Component ID Labels” found in the Unit Identification section of this Manual). Each hood is labeled for easy identification. 2.
PAGE 55
FORM 102.20-N1 (1109) ACTUATOR INSTALLATION See Fig. 2-35 1. Remove the bearing plate from the damper frame and jackshaft. 2. Slide the damper actuator onto the open end of the shaft making sure that the proper spring return position on the face of the actuator matches the damper shafts rotation. If not, then reinstall the actuator with it flipped over. 3. Reinstall the bearing plate to the damper frame and jackshaft. Make sure spring hose clamps hold the jackshaft securely. 4.
PAGE 56
Installation FORM 102.20-N1 (1109) Distortion will result in unreliable blade operation. INSTALLATION OF MULTIZONE (MZ) DAMPERS See Fig. 2-36 SHIPPED LOOSE MZ DAMPERS. If the MZ segment has a shipping split, a rear discharge (end of unit), and a multizone damper, then the multizone damper will be shipped loose. See “Ship Loose Parts” to identify gaskets and hardware items. Damper Installation 1. After the unit top tier is assembled to the unit bottom tier and sealed, install MZ damper assembly.
PAGE 57
FORM 102.20-N1 (1109) Actuator Installation Mutlizone (MZ) - Field Supplied When actuators are field supplied on multizone dampers, the following information is intended to aid in sizing and selection: • Torque required is 7 inch pounds per square foot of damper area up to 2500 FPM velocity. • Damper blades are 6" wide and vary in height. • Calculate the torque by number and size of blades in each individual zone. Remember there are hot deck blades directly connected to cold deck blades.
PAGE 58
Installation FORM 102.20-N1 (1109) UVC EMITTER LIGHTS When UV Lights are provided, the contractor is responsible for installing UV Lamps (tubes) and connecting a 120 volt power supply. The YORK Solution factory provides internal wiring with a magnetic door safety switch, a lockable disconnect switch with “Press to Test” pilot light and a latching circuit that has to be manually re-energized on the air handler exterior after a door has been opened and closed. This is all pre-wired.
PAGE 59
FORM 102.20-N1 (1109) AIR MEASURING DEVICE CONNECTIONS (when provided) Air Measuring at The Fan Inlets Air Measuring at Unit Inlets COMETER is a probe attached to the fan bearing support on Comefri Forward Curve fans from size 7 x 7 up to 18 x 18. The probe is located on the outboard side of the DWDI fan assembly. The probe is piped to the negative (-) port of a factory mounted transducer on the fan wall. The positive (+) port is left open to the fan section.
PAGE 60
Installation FORM 102.20-N1 (1109) PIPE CHASE INSTALLATION See “Ship Loose Parts” to identify gaskets and hardware items. Pipe chase should be installed before piping is connected. Tools Required 1. Preparation a) Pinpoint the exact location to attach the pipe chase. b) Ensure enough space will remain to apply pipe fittings with insulation, inside the pipe chase. c) The pipe chase height should align with the unit height. 2.
PAGE 61
FORM 102.20-N1 (1109) 3 3 2 LOCK WASHER, (typ.6) Install Install horizontal horizontal gaskets second second gaskets 3 PIPE CHASE CHASE PIPE 3/8"-16 X 1-1/2" BOLT, (typ.6) gaskets Horizontal gaskets completely overlap overlap vertical gaskets gaskets in vertical in all four four corners corners all UNIT BASERAIL RIVET NUT (installed by factory) BASERAIL COVER (installed later see see Fig.2-44) Fig.
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Installation FORM 102.20-N1 (1109) AIR HANDLER Caulk as shown by dotted line (visible) and dashed line (hidden). PIPE CHASE Apply caulk between Pipe Chase and Air Handler AIR HANDLER PIPE CHASE LD12565 LD12035A FIG. 2-45 – BASERAIL CAULK APPLICATION Line up self-drilling screws with existing screws on roof. AIR HANDLER 4 2 PIPE CHASE 1 3 Install self-drilling screws starting in middle and working towards ends.
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FORM 102.20-N1 (1109) Install (2) top and (2) bottom self-drilling screws first. AIR HANDLER PIPE CHASE PIPE CHASE AIR HANDLER Put notch on cover angle on Air Handler side. LD12563 FIG. 2-49 – P ROPER POSITIONING OF COVER ANGLE WITH NOTCH ON AIR HANDLER SIDE Alternating between Air Handler and Pipe Chase, install remaining self-drilling screws starting at the top and working toward the bottom. d) Attach the cover angle to the air handler and pipe chase panels.
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2-34 12" EXT. ID FAN 7.75 PIPE CHASE SPLIT CLAMP TRANSITION PIECE STEP 2 STEP 4 STORM COLLAR STEP 3 LD13326 3. On all outdoor Air Handling units the vent piping parts internal to the pipe chase will be factory mounted. 2. Outdoor Air Handling units over 102” high will have the external vent piping parts shipped loose for field mounting. 1.
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FORM 102.20-N1 (1109) BURNER ASSY ID MOTOR 1 2 FLOW 1 3 4 2 3 PITCH 4 1 2 Foot LD12912 FIG. 2-53 – GAS FURNACE Condensate drain trap Condensate Drain Arrangement The YORK Solution Indirect Fired gas heat exchanger has the potential to create highly acidic condensation, particularly during extended operation at low capacity or low firing rate conditions. To insure proper drainage the following guidelines should be followed (See Fig. 2-53).
PAGE 66
Installation FORM 102.20-N1 (1109) ELECTRICAL - GENERAL All field wiring must conform to the National Electrical Code (N.E.C.) and possible local codes that may be in addition to N.E.C. Unit is E.T.L. Listed. Some components are U.L. labeled. Any changes in the field may affect their validity. The current characteristics, phase, cycle and voltage are stamped on the nameplate of each component. Electrical conduit connections made to exposed boxes on units should be made on the bottom of the box.
PAGE 67
FORM 102.20-N1 (1109) POWER CONNECTIONS Energy Recovery Wheel Option Single Point Power Single Point Power when ordered provides the installer with a main disconnect switch. The line side of this switch (top) is where the installer is to land his main power wires. Devices included in the Single Point Power option are Supply Fan, Return Fan, Exhaust Fan, Energy Recovery Wheel, Gas Heat, Electric Heat and Ultra-violet Lights.
PAGE 68
Installation FORM 102.20-N1 (1109) Gas Heat Option Wiring of this device is the responsibility of the installer if Single Point Power was not selected. Terminal Strip for Power and Controls. Panel locations and sizes vary based upon unit size and burner configurations. Burner voltage is selected to match primary unit voltage. Modulation control voltage to be 2-10 VDC as standard. Electrical penetrations can come through the floor or side wall panels.
PAGE 69
FORM 102.20-N1 (1109) Electric Heat Option Wiring of this device is the responsibility of the installer if Single Point Power was not selected. Field Control Wiring Interface Terminals Main Disconnect Switch & Field Power Connections Available Power Options • • • • 460V-3PH. 208/230V-3PH. 380V-3PH. 575V-3PH. Electric Heat Disconnect Switch Options LD11595 • Fused Disconnect. • Non-fused Disconnect. LD11595 Knockouts are provided on the top and bottom of the enclosure for field penetrations.
PAGE 70
Installation FORM 102.20-N1 (1109) Available Control Options • Staging - No controller, but contactors are energized by providing control power to each contactor from external BMS source. • Step Controller - device to receive a 0- to 10 VDC or 4 to 20 mA signal and step on heat stages. • Vernier SCR - completely electronically controlled by varying signal and varying output between stages. Increases power to a stage by modulation until another stage is needed.
PAGE 71
FORM 102.20-N1 (1109) TOP VIEW OF UNIT POSITIVE PRESSURE / AIR BLOWN THROUGH HEATER BLOWER HEATER AIRFLOW 2 PICK UP TUBE TOWARDS BLOWER ATTACHED TO “HIGH” PORT OF AIRFLOW SWITCH NEGATIVE PRESSURE / AIR DRAWN THROUGH HEATER BLOWER HEATER AIRFLOW PICK UP TUBE TOWARDS BLOWER ATTACHED TO “LOW” PORT OF AIRFLOW SWITCH LD14268 FIG. 2-60 – P RESSURE PROBE DIRECTION MOUNTING BRACKET HIGH PORT C NO NC LOW PORT LD14270 FIG.
PAGE 72
Installation FORM 102.20-N1 (1109) ELECTRICAL INSTALLATION 1. Follow the wiring diagram on the inside of the terminal box. 2. Supply connections must be made with copper wiring rated for 75° C minimum. 3. If supply connections are for 250 volts or greater, all wiring must be insulated for 600 volts. 4. When making line connections to heater element terminals FOR FINNED TUBULAR HEATERS ONLY, apply a 1/4" wrench to flat section of terminal immediately below threads. Otherwise damage to terminal may result.
PAGE 73
FORM 102.20-N1 (1109) Humidifier Option (Electric) Wiring this device is the responsibility of the installer. This device is not included in any Single Point Power options. Fig. 2-62 represents a typical electric humidifier panel layout. The supply power knockout is located in the bottom of the electrical panel as seen in Fig. 2-63. All conduit beginning or ending inside pressurized or conditioned areas (i.e. air handler) must have all openings of conduit sealed to prevent air from passing through.
PAGE 74
Installation FORM 102.20-N1 (1109) PIPING CONNECTIONS Do not remove bottom panel in pipe chase. Penetrations through pipe chase floor must be flashed and sealed. Penetrations through panels must be sealed (see IOM Section 5 “Penetrations and Grommet Details”). Where piping is insulated, insulation should not be installed until after the flashing has been completed. When extended piping to or from coils, humidifiers, etc.
PAGE 75
FORM 102.20-N1 (1109) Coil Piping Do not test, clean and flush piping through this equipment. Isolate this equipment from pressure testing of water, steam gas and air piping. 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 connections).
PAGE 76
Installation FORM 102.20-N1 (1109) Water Water Coils - Hot Water and Chilled Water Hot and Chilled Water Coil Performance Connect the water supply to the header connection on the leaving air side of the coil to achieve the counter flow of water and air. The return pipe will be connected to the remaining coil connection.
PAGE 77
FORM 102.20-N1 (1109) VENT PT PLUG GLOBE VALVE 2 WAY CONTROL VALVE ECCENTRIC REDUCER RETURN HOT WATER RETURN COIL SUPPLY STRAINER HOT WATER SUPPLY DRAIN GLOBE VALVE UNION 2 RETURN COIL SUPPLY PT GATE PLUG VALVE GATE VALVE W/ HOSE BIB FIG.
PAGE 78
Installation FORM 102.20-N1 (1109) Water Treatment Steam Distributing Coils Any copper tube coils may be attacked by acid condensate. The practice of boiler water treatment should include CO2 removal to assure longer tube life. Do not bush or reduce the coil return pipe size. Use a full size return pipe to the bottom of a dirt pocket. The supply pipe may be reduced at the coil connection if necessary. Install the coil casing level with the return down.
PAGE 79
FORM 102.20-N1 (1109) Steam Traps Float and Thermostatic (F and T) traps are recommended for all low or medium pressure applications. Use thermostatic traps only for air venting, for outdoor applications where an F and T trap might be subject to freezing. Use bucket traps only for a non-modulated steam supply. Size the steam traps in accordance with the manufacturer's recommendations (usually several times the steady state steam flow). Use the actual operating conditions (coil pressure vs.
PAGE 80
Installation FORM 102.20-N1 (1109) STEAM IN ACTUATOR FACE DAMPERS CLOSED BYPASS OPEN STEAM OUT LD09630 FIG. 2-72 – INTEGRAL FACE and BYPASS COIL (HORIZONTAL; TUBES, STEAM SHOWN) VIFB and IFB A complete IOM is provided with each IFB or VIFB coil unit. Below 35°F, the Vertical Tube Integral Face and Bypass (VIFB) or Integral Face and Bypass (IFB) operates with full steam pressure or full water flow at all times. This prevents freeze-up and temperature stratification.
PAGE 81
FORM 102.20-N1 (1109) Shipping Bolts (VIFB Only) Return steam condensate headers or hot water supply and return headers are securely bolted to lower mounting brackets to prevent damage to header and tubes during shipment and piping of the coils. These bolts MUST be removed before applying steam or hot water but after all piping connections are made. Piping Suggestions (VIFB and IFB) See IOM Section 5, “Field Penetrations for Piping and Electrical Connections”.
PAGE 82
Installation FORM 102.20-N1 (1109) 3/4" (19.1mm) AUTOMATIC AIR VENT IN TOP HEADER HOT WATER SUPPLY VIFB COIL AIR FLOW HOT WATER RETURN FLEXIBLE CONNECTOR DRAINS LD09632 FIG. 2-74 – HOT WATER PIPING FOR 2 ROW COIL VIFB 3/4" (19.1) AUTOMATIC AIR VENT IN TOP HEADER R AI W O FL HOT WATER RETURN DRAIN HOT WATER SUPPLY LD09633 FIG.
PAGE 83
FORM 102.20-N1 (1109) STEAM PRESSURE BELOW 15 PSIG OR 103.4 KPA VACUUM BREAKER CHECK VALVE 1/2" (12.7)-15° STEAM MAIN DRIP TRAP STEAM MAIN T VIFB COIL STRAINER AIR FLOW AIR VENT TO ATMOSPHERE ON OPEN GRAVITY RETURN SYSTEM ONLY. MINIMUM 1" (25.4) PIPE 8" (203.2) MINIMUM T 2 8" (203.2) STRAINER CHECK VALVE RETURN MAIN FLEXIBLE CONNECTOR INSTALLED PARALLEL TO COIL HEADER AND AS CLOSE AS POSSIBLE TO COIL CONDENSATE CONNECTION.
PAGE 84
Installation FORM 102.20-N1 (1109) Refrigeration Direct Expansion Coils (DX) Do not leave piping open to the atmosphere unnecessarily. Water and water vapor are detrimental to the refrigerant system. Until the piping is complete, recap the system and charge with nitrogen at the end of each workday. Clean all piping connections before brazing joints. DX coils are divided into splits depending upon the unit size and coil circuiting.
PAGE 85
FORM 102.20-N1 (1109) DX Coil Types Face Split There are three basic types of coil arrangements used in field erected split systems, interlaced, row split and face split. Interlaced Interlaced coils are the most desirable type of coil “field erected” designs. Interlaced coils ensure the entire face of the coil is active with any number of compressors operating.
PAGE 86
Installation FORM 102.20-N1 (1109) Coil Design Fin Height Non-stacked 48" and less Stacked Greater than 48" H2 D2 Figs. 2-79 through 2-83 illustrate the available coil arrangements. Contact Coil Marketing for other arrangements not shown. D1 LD09143A FIG.
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FORM 102.20-N1 (1109) D2 H2 2 H1 2 D1 4 D4 1 H4 D3 1 H3 4 Distributor Circuits Face Split 50 - 50% Interlaced 3 LD09147A LD09145A FIG. 2-83 – STACKED COIL CIRCUITING FIG. 2-81 – STACKED COIL DESIGN - STANDARD DX Coil Circuiting And Staging If one coil circuit is used (Fig. 2-84), the LLSV and TXV must be sized to handle the full capacity of the refrigerant circuit. When two coil circuits are used per refrigerant circuit (Fig.
PAGE 88
Installation FORM 102.20-N1 (1109) compressor #1 100% Capacity txv LLSv compressor #3 Feeds both Circuits LD09148 FIG. 2-84 – O NE COIL CIRCUIT PER REFRIGERANT CIRCUIT txv LLSv txv compressor #2 condensing Unit LD09149 FIG. 2-85 – TWO COIL CIRCUITS PER REFRIGERANT CIRCUIT dx Coil LLSv txv LLSv compressor #2 condensing Unit LD09150 FIG. 2-86 – DO NOT USE THE ABOVE CONFIGURATION.
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FORM 102.20-N1 (1109) Comp 1 - 3 TXV1 TXV3 LLSV1 Comp 4 - 6 Comp 1 - 3 TXV2 LLSV2 Condensing Unit Maintaining Adequate Airflow TXV4 Comp 4 - 6 LD09153 DX Coils FIG. 2-89 – SIX COMPRESSOR YCUL Thermostatic Expansion Valves (TXV) Each coil distributor circuit requires its own Thermostatic Expansion Valve (TXV). Each condensing unit circuit requires its own liquid line solenoid valve (LLSV). TXV's are to be equipped with external equalizer tubes that are field connected to the suction line.
PAGE 90
Installation FORM 102.20-N1 (1109) There are four basic components in a VAV system an air-handling unit with airflow control (i.e. variablespeed drives), VAV boxes, zone thermostats and duct static pressure sensors. All of these components must work together to provide good temperature control and a comfortable environment. The zone thermostats control the VAV boxes.
PAGE 91
FORM 102.20-N1 (1109) Drains And Traps Heat trace and insulate traps where there is a risk of freezing to prevent blockage and/or damage due to freezing of the liquid in the trap. "H" must be at least 1 inch plus fan total static pressure H Auxiliary drain pans may not require traps. If the trap is not in constant use the water seal may evaporate causing air passage into or out of the air handler.
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Installation FORM 102.20-N1 (1109) Two or more drains on same side of unit must be trapped individually before drain lines can be combined and routed to a suitable drain (see Fig. 2-93). TRAPS Duct Connection Guidelines See Fig. 2-94. 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.
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DUCT CONNECTIONS FORM 102.20-N1 (1109) Ducts must have positive seal to unit openings. Installer is responsible for providing ductwork to include base rail height for curb mounted units. Duct Connections All duct work is to be supported independent of the connection to the unit. Ducts seal to unit the duct If themust entirehave unit ispositive mounted on isolation, connection be ﬂexible.
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Installation FORM 102.20-N1 (1109) The performance ratings of coils will be met only if the airflow is uniform over the face of the coils. High air velocity spots on the coil may cause the carry-over of moisture from the coil. High or low air velocity areas of the coil will not deliver the published ratings. The duct connections must be designed to provide for uniform flow of air across the face of the coil. The entering duct must provide a smooth transition from any high velocity effects.
PAGE 95
FORM 102.20-N1 (1109) Air Filters A list of filter part numbers, sizes and quantities are shown on a label located on each filter segment of each air handler. It is mandatory that filters be in place in the filter frames of each unit before putting the unit into operation to protect the coils and keep them clean. Due to the wide variety of filters, it is not possible to cover all of them in this section.
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Installation FORM 102.20-N1 (1109) Filter Latches Typically when filters are by others, so are the filter clips. 2-13-16" 2-13/16" P/N --026-35778-000 P/N 026-35778-000 026-36399-001 P/NP/N- -026-36339-001 Used with 2” Prefilter in combination with a Double Header Final Filter. Used with 2" Perfectpleat, Premium or Premium HM and SH Single Headered Filters. 4-11/16" 4-11/16" P/N 026-36399-000 P/N --026-36339-000 Used with 4” Prefilter in combination with a Double Header Final Filter.
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FORM 102.20-N1 (1109) YORK MATRIX: FILTERS AND FILTER FRAMES / LATCHES Single Filter Application 2” PerfectPleat, Premium or Premium HM 4” AmAir 300X VariCel SH or DriPak 2000 VariCel DH FILTER FRAME 12x24 - 16 ga. Galvanized X P/N 026-35778-000 X X P/N 026-35778-007 X P/N 026-35778-006 FILTER FRAME 24X24 - 16 ga.
PAGE 98
Installation FORM 102.20-N1 (1109) Installation of 2” Perfectpleat, Premium or Premium HM These instructions are for installing a 2” filter (typically PerfectPleat) into 16 ga. galvanized holding frames. • Latches needed for these applications are four (4) P/N 026-35778-000, as shown in Fig.2-98. • A single latch should be installed at each of the four (4) corners of the frame. • The latch fits into the set of knockouts, which consists of two (2) rows of three (3) knockouts.
PAGE 99
FORM 102.20-N1 (1109) Installation of 4” Amair 300x Pleated Filter These instructions are for installing a four inch (4") filter (typically AmAir 300X pleated filter) into 16 ga. galvanized holding frames. • Latches needed for these applications are four (4) P/N 026-35778-007, as shown in Fig. 2-98. • A single latch should be installed at each of the four (4) corners of the frame. • The latch fits into the set of knockouts, which consists of two (2) rows of three (3) knockouts.
PAGE 100
Installation FORM 102.20-N1 (1109) Installation of SH Single Headered Filters These instructions are for installing single header filter (typically VariCel SH or DriPak 2000 filter) into 16 ga. galvanized holding frames. • Latches needed for these applications are four (4) P/N 026-35778-000, as shown in Fig.2-98. • A single latch should be installed at each of the four (4) corners of the frame. • The latch fits into the set of knockouts, which consists of two (2) rows of three (3) knockouts.
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FORM 102.20-N1 (1109) Installation of a Varicel DH Double Headered Filter These instructions are for the installation of a VariCel DH filter (nominal 12” deep double header) into 16 ga. galvanized holding frames. • The latches needed for this application are four (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.
PAGE 102
Installation FORM 102.20-N1 (1109) Installation of a 2” and 4" Prefilter in Combination With a Double Header Final Filter These instructions are for installing either a 2” or 4" prefilter (typically PerfectPleat, Premium or Premium HM pleated filters) used in combination with a VariCel DH (nominal 12” deep) final filter into 16 ga. galvanized holding frames. • Two sets of latches are needed for these applications. Four (4) spring latches, P/N 026-35778006 are used to hold the VariCel DH into the frame.
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FORM 102.20-N1 (1109) 7. Repeat the installation for the remaining prefilter latches. 8. Place the prefilter against the face of the VariCel DH filter. The prefilter latches may have to be re-positioned as shown in Fig.2-113, to allow the proper placement of the prefilter. 2 LD010165 Fig. 2-113 – Position prefilter in front of the final filter. (2" w/026-36339000 latch shown) LD010167 Fig. 2-115 – Completed assembly 9.
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Installation FORM 102.20-N1 (1109) VISUAL CONTROL FILTER CLAMPS FOR HEPA FILTERS Part Number Latch Model Number Length (L) 029-22081-000 Latch, HEPA Single 11-1/2" Application: Holds one Astrocel I 11.5" D filter along frame sides. (See Fig. 2-117, 2-118 & 2-119 for application) Latch, HEPA Double 029-22082 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) HEPA Filters Visual Control Filter Clamps (See Fig. 2-117.
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FORM 102.20-N1 (1109) DOUBLE FILTER CLAMP T-SECTIONS 2 DOUBLE FILTER CLAMPS PERIMETER SECTION T-SECTION SINGLE FILTER CLAMP LD09657 FIG. 2-118 – HEPA FILTER INSTALLATION VISUAL CONTROL CLAMP (ADJUST BOLT HEAD FLUSH WITH CLAMP) SPRING DUCTWORK AIRFLOW BEVEL SEAL FRAME (PERIMETER EXTRUSION) CELL SIDE MEDIA PACK GASKET CELL SIDE BEVEL SEAL FRAME BEVEL RECESSED SEALING SURFACE LD06646A FIG.
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FORM 102.
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FORM 102.20-N1 (1109) 3.0 STARTUP Rotating parts and electrical shock hazards exist. Lock out and tag out the fan motor(s) and heat power disconnects before servicing. FOLLOW THE LATEST "LOCKOUT TAGOUT" PROCEDURE. Failure to follow proper safety precautions may result in serious injury or death. Refer to general safety guidelines and safety symbols located at the front of this Manual.
PAGE 108
Startup FORM 102.20-N1 (1109) PRE START-UP Refer to air handler start-up checklist, Form 100.00. CL1 provided with information package shipped with unit. Perform a general inspection. Identify and perform appropriate “lock out/tag out” and safety rules. For details on points below, see appropriate section of this Installation Instruction and IOM 102.20-NOM1. For VFD equipped air handlers, refer to the VFD literature for additional start-up requirements. 1. Verify equipment received as ordered. 2.
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FORM 102.20-N1 (1109) PRE START UP FAN ASSEMBLY INSPECTION When the unit is removed from longterm storage moisture laden bearing grease should be purged and replenished with fresh grease per lubrication decal. The motor should be meggered to verify that the resistance is still at a satisfactory level compared to the value recorded prior to storage. In small units the tie down bolts may only be applied to three corners of the fan base since one corner is not accessible. TIE DOWN BOLTS 1.
PAGE 110
Startup FORM 102.20-N1 (1109) See Fig. 3-4 for TEFC. Cap Screw Spring Rail Screw, Hex, 3/8-16" UNC-2A x 5" Adjustment Bolt Washer, Flt, 3/8" ID x 7/8" OD End Rail Grommet Snubber, Seismic Washer, Flt., 3/8" ID x 7/8" OD Nut Lock, Hex, 3/8"-16 Isolator Spring (4) Screw, Hex, 3/8-16" Iso Rail (4) Nut Lock, Hex, 3/8"-16 LDO9636 LDO9639 FIG. 3-4 – TEFC (TOTALLY ENCLOSED FAN COOLED) FIG.
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FORM 102.20-N1 (1109) START-UP Temporary Operation: This equipment should not be operated until after complete Start-up as outlined in this guide. Do not allow the unit to run on temporary power that is not reliable and could be off/on periodically or rapidly. Also, protect it from irregular voltages and surges. We strongly recommend the startup technician use the checklist provided and record the gathered information in the appropriate fields.
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Startup FORM 102.20-N1 (1109) Typical Actuators Locations Johnson Controls standard actuators are direct coupled on damper jackshaft. Basic Actuators Installation A basic procedure for installing Johnson Controls actuators is included in Section 2"Installation". Damper Blade Orientation Return Air and Mixing Dampers with Power Off Position the blades so that they will be open once the actuator is installed. This will be the dampers spring return position.
PAGE 113
FORM 102.20-N1 (1109) Energize Fan Motor(s) 1. Observe fan(s) for smooth operation. 2. Check motor nameplate Full Load Amp rating. 3. Immediately, check current draw of each leg of each motor. Variable Speed Drive (VSD) YORK Air‑Modulator (Variable Frequency Drive) YORK Air Modulators are provided with Start-up service. See Installation and Start-up Guide provided with the YORK Air Modulator. Set Up of a Non-Factory Mounted VFD Refer to manufacturers Start Up Guide.
PAGE 114
Startup FORM 102.20-N1 (1109) Check Doors and Latches for Proper Adjustment See IOM Section 5 “Door Handle/Latch Replacement and Adjustment”. Plastic spacers must be removed between doors and doorframes before Start-up. Sheaves If optional adjustable sheaves provided, we strongly recommend they be replaced with correctly sized fixed sheave immediately after system air balance is performed. It is not unusual for an adjustable sheave at some point in time to create damaging vibration in the fan assembly.
PAGE 115
FORM 102.20-N1 (1109) Keep hands away from rotating wheel! Contact with rotating wheel can cause physical injury. Energy Recovery Wheel Unit Configuration Indoor Units All indoor units will accommodate vertical Energy Recovery Wheel segments on horizontal (see Fig. 3-9). Start-Up Procedure for Energy Recovery Wheel Outdoor Units 1. With power off, by hand, turn wheel clockwise (as viewed from the pulley side), to verify wheel turns freely through 360° rotation (see Fig. 3-11).
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Startup FORM 102.20-N1 (1109) WHEEL ROTATION BEARING SUPPORT BEAM - PULLEY SIDE BALL BEARINGS (2) BEARING ACCESS COVER (2) BEARING SUPPORT BEAM - MOTOR SIDE DIAMETER SEAL ADJUSTING SCREWS DRIVE MOTOR REMOVABLE ENERGY TRANSFER SEGMENT (8) BELT DRIVE PULLEY LD09642 FIG. 3-11 – ENERGY RECOVERY WHEEL - PULLEY SIDE 2. Before applying power to drive motor, confirm wheel segments are fully engaged in wheel frame and segment retainers are completely fastened (see Fig. 3-12). 3.
PAGE 117
FORM 102.20-N1 (1109) Indirect Fired Gas Heat Start Up For your safety and satisfaction, this product requires check, test and startup adjustment by a qualified HVAC technician. Do not use for temporary heat prior to start-up. Review burner control literature, including wiring, piping, cut sheets and drawings before attempting to start this unit. All factory test start up burner specifications are located on a laminated “Factory Specification Sheet" located on the inside of the control panel door”.
PAGE 118
Startup FORM 102.20-N1 (1109) Preliminary Coordination Contact contractor/customer who requested start-up. • Verify air handler has had proper start-up. • Ensure air handler and system is capable of design airflow for gas heat start-up. • Ensure reliable power is available. • Verify gas lines are purged of air to equipment valve. • Verify controls are complete. • Verify flue (stack) is correctly installed if parts were shipped loose (see Fig's 3-22 and 3-23).
PAGE 119
FORM 102.20-N1 (1109) 7. The flue (stack) damper is located at the discharge of the ID blower and closed for shipping. Release the locking mechanism and set the damper to match the position indicated by the scribed markings. Lock in place (see Fig. 3-15). Check ID fan rotation Draft Test Port Damper Adjustment and Indicator Plate BURNER PANEL Main Condensate Connection LD12910 FIG. 3-15 – sET ID FAN DAMPER 8.
PAGE 120
Startup FORM 102.20-N1 (1109) Burner Start-Up Procedure Prior to starting burner, technician must verify incoming gas pressure. A minimum pressure is listed on the “Burner Test Report”. The maximum pressure is listed in Table 3-2. 1. Open manual gas valves on gas supply and pilot line. 2. Initiate a call for heat or use jumper to create call for heat (see Fig. 3-24 for typical wiring diagram). 3. Turn burner panel off-on switch to on.
PAGE 121
FORM 102.20-N1 (1109) 7. Using the signal generator, cycle the burner to check capacity modulation. Observe valve/damper actuator operation. Do not change set up of factory preset air inlet dampers on Power Flame 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 FIG. 3-19 – DAMPER ACTUATOR 8.
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Startup FORM 102.20-N1 (1109) BURNER ASSY ID MOTOR 1 2 FLOW 1 3 4 2 3 PITCH 1 4 Foot LD12912 FIG. 3-21 – GAS FURNACE Condensate drain trap Failure to follow these guidelines may cause excessive condensation build up resulting in water damage to the facility and/or a cracked heat exchanger. 1. Observe local jurisdiction codes for gravity condensate drainage requirements. 2.
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johnson controls 350 400 450 500 600 750 850 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 30 35 40 45 50 60 75 85 100 125 150 175 200 225 250 275 300 325 350 375 400 { 300 25 C GAS 250 20 B R F U A IRI FM UL ANSI 25 10 3 3 BURNER TDR U CODE COMPLIANCE GAS LP = 2,500 BTU/ CU FT. NATURAL = 1,000 BTU/ CU FT. Output is approx.
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3-18 OPTION FEATURE NA 035 NA NA 375 400 NA NA NA NA NA NA NA NA 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 14.00 14.00 14.00 14.00 NA NA NA NA 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA 3:1 FM FM 3 F03 U10 F10 R10 A25 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.00 27.
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FORM 102.20-N1 (1109) TABLE 3-3 – PIPE SIZE REQUIRED Inlet Size (NPT) A03 U03 F03 R03 A10 U10 F10 R10 A25 U25 F25 R25 GAS BURNER PIPING/GAS BURNER TURN DOWN Furnace UL FM IRI ANSI UL FM IRI ANSI UL FM IRI 3 3 3 3 10 10 10 10 25 25 25 25 ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI 3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1 015 0.75 NA NA NA 1.00 NA NA NA NA NA NA NA 020 0.75 NA NA NA 1.
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3-20 ROOF PEAK FLOOR PANEL W HAT CHANNEL GAS FURNACE WITH CASING ROOF PANEL FIG. 3-22 – GAS FURNACE FUEL VENTING SYSTEM H 1.60 44.40 TYP. (36.00 MIN) END OF FLUE PIPE 5.50 SIDE PANEL A RACEWAY 12" EXT. ID FAN 7.75 CURB PIECE PIPE CHASE TRANSITION PIECE FURNACE OUTPUT 15 20 25 40 50 75 100 125 150 175 200 250 300 350 400 21.83 21.83 21.83 23.66 23.65 28.15 28.14 35.12 35.12 35.12 35.12 41.36 41.36 47.36 47.36 A H=UNIT HEIGHT W=UNIT WIDTH LD13304 1.
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johnson controls SIDE PANEL RACEWAY 12" ID EXT. FAN 7.75 6"L SLIP JOINT PIPE CHASE SPLIT CLAMP TRANSITION PIECE 0.43" CLEARANCE CONTAINMENT BAND SET & GASKET, 1" THK X 3"W X LG, INSULATION FIBER IVSI PIPE (INSULATED PIPE) SEE NOTE 1 CURB PIECE 42"L VSI PIPE (NOT INSULATED) FLUE CAP FIG. 3-23 – GAS FURNACE FUEL VENTING SYSTEM 5.50 HAT CHANNEL GAS FURNACE WITH CASING SPLIT PLATE STEP 1 STEP 2 STEP 4 1. SEE SECTION 026-004 TO DETERMINE LENGTH OF IVSI PIPES.
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Startup FORM 102.20-N1 (1109) FOR REFERENCE ONLY Connect Signal Generator here for test and start up Jumper may be required here for test and start up LD13315 FIG.
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FORM 102.20-N1 (1109) Table 3-4 – BURNER TEPERATURE RISE CFM Temperature Rise (°F) DF15 DF20 DF25 INTERNAL PRESSURE DROP “ WC CFM Temperature Rise (°F) DF60 DF75 INTERNAL PRESSURE DROP “ WC 1,500 91 -- -- 0.17 6,000 91 -- 0.44 2,000 68 91 -- 0.29 6,500 84 -- 0.52 2,500 55 73 91 0.46 7,000 78 -- 0.6 3,000 46 61 76 0.65 7,500 73 91 0.68 3,500 40 52 65 0.89 8,000 68 85 0.78 4,000 35 46 57 1.17 9,000 61 76 0.98 4,500 31 41 51 1.
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Startup FORM 102.20-N1 (1109) Table 3-4 - BURNER TEPERATURE RISE (CONT) CFM Temperature Rise (°F) INTERNAL PRESSURE DROP “ WC CFM Temperature Rise (°F) DF125 DF150 DF275 DF300 13,000 89 -- 0.48 24,000 87 14,000 83 -- 0.56 27,000 77 -- -- -- 0.337 86 92.5 -- 0.427 15,000 77 93 0.65 30,000 69 77 83.3 90.8 0.527 16,000 72 87 0.73 33,000 17,000 68 82 0.82 36,000 63 70 75.8 82.5 0.637 58 64 69.5 75.7 0.758 18,000 64 77 0.
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FORM 102.20-N1 (1109) Electric Heat Startup Rotating parts and electrical shock hazards exist. Lock out and tag out the fan motor(s) and heat power disconnects before servicing. FOLLOW THE LATEST “LOCKOUT TAGOUT” PROCEDURE. Failure to follow proper safety precautions may result in serious injury or death All electrical connections in the heater, including both field and factory made connections, should be checked for tightness before operating the heater.
PAGE 132
Startup FORM 102.20-N1 (1109) TOP VIEW OF UNIT POSITIVE PRESSURE / AIR BLOWN THROUGH HEATER BLOWER HEATER AIRFLOW PICK UP TUBE TOWARDS BLOWER ATTACHED TO “HIGH” PORT OF AIRFLOW SWITCH NEGATIVE PRESSURE / AIR DRAWN THROUGH HEATER BLOWER HEATER AIRFLOW PICK UP TUBE TOWARDS BLOWER ATTACHED TO “LOW” PORT OF AIRFLOW SWITCH LD14268 FIG. 3-26 – PRESSURE PROBE DIRECTION MOUNTING BRACKET HIGH PORT C NO NC LOW PORT LD14270 FIG.
PAGE 133
FORM 102.20-N1 (1109) 3 FIG. 3-28 – AIR handler start-up checklist, FORM 100.
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Startup FORM 102.20-N1 (1109) TABLE 3-5 – INSPECTION REQUIREMENTS ITEM YORK Solution Instruction Location Pre Start-up Equipment received as ordered. Section 1, Inspection Unit checked for damage interior and exterior. Section 1, Inspection Verify unit installed on flat and level surface. Outdoor unit mounted within roof slope limitations where applicable. Section 2, Site Preparation Terminal screws and wiring connections tightened in control, electric and Air Modulator panels.
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FORM 102.20-N1 (1109) TABLE 3-5 - INSPECTION REQUIREMENTS (CONT.) ITEM YORK Solution Instructions Check fan base isolators and thrust restraints for proper adjustment. Section 3, Isolators IOM Section 5, Isolator Adjustment IOM Section 5, Thrust Restraint Replacement & Adjustment Fan bearings properly lubricated. IOM Section 4, Fan Bearing Lubrication Start-up Energize power to the unit disconnect switch. Section 3, Start-up Verify correct voltage, phase and cycles.
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©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 www.johnsoncontrols.com Printed in USA 102.20-N1 (1109) Replaces 102.
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literature supplement Form No.: 102.20-N1 (LS01) Supersedes: New Release File with: 102.20-N1 (1108) 102.20-NOM1(105) 509 Subject: Installation, Operating and Maintenance Instructions for Electric Heat Applications in Air Handling Products. (Listed or Certified to UL 1995.) Rotating parts and electrical shock hazards exist. Lock out and tag out the fan motor(s) and heat power disconnects before servicing. FOLLOW THE LATEST “LOCKOUT TAGOUT” PROCEDURE.
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FORM 102.20-N1 (509) 5. Supply conductors for heaters rated less than 50 KW, must be sized at 125% of rated load. On heaters rated 50 KW and more, the supply conductors may be sized at 100% of rated load, if indicated on the wiring diagram. The line current for either a single or three phase load is calculated as follows: Single Phase Line Current = KW x 1000 Voltage Three Phase Line Current = KW x 1000 Voltage x 1.73 6.
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FORM 102.20-N1 (509) AIR FLOW REQUIREMENTS 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 let A ir 24 6 4 FINNED TUBULAR CONSTRUCTION 2 Ai r 80 nle t Be °I -1 00 81 16 nl et -9 0° I 18 14 91 8 low 20 KW PER SQ. FT. DUCT AREA KW PER SQ. FT.