Manual Unidades Manejadoras

YORK Solution
Air handling units

Installation, operation & maintenance Supersedes 102.20-NOM1 (105) Form 102.20-NOM1 (909)
YORK Solution Indoor and outdoor models

27X27 through 132X138
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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:
DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation, which if not could lead to damage to the machine,
avoided, will result in death or seri- damage to other equipment and/or
ous injury. environmental pollution. Usually an
instruction will be given, together with
WARNING indicates a potentially a brief explanation.
hazardous situation, which if not
NOTE is used to highlight additional
avoided, could result in death or seri-
information that may be helpful to
ous injury.
you.
Consider for IAQ compliance per
ASHRAE STANDARD 62-2001
IAQ
External wiring, unless specified as an optional connection in the manufacturer’s product

line, is not to be connected inside the control panel cabinet. Devices such as relays, switches,
transducers and controls may not be installed inside the control panel. No external wiring
is allowed to run through the control panel. All wiring must be in accordance with John-
son Controls published specifications and must be performed only by qualified Johnson
Controls personnel. Johnson Controls will not be responsible for damages/problems result-
ing from improper connections to the controls or application of improper control signals.
Failure to follow this will void the manufacturer’s warranty and cause serious damage to
property or injury to persons.
FORM 102.20-NOM1 (909)
NOTICE TO CUSTOMER/CON- – Controls are complete.

TRACTOR – Shipping splits completely re-assembled,
PROTECT YOUR WARRANTY PRI- sealed and wired.
OR TO STARTUP.
– Filters are installed and secured.
• Read and follow the Installation & Start-up – All shipping materials have been removed.
Instructions provided with this equipment. METAL TAB USED TO SECURE DOOR IS
• Storage of this equipment MUST be on a flat A SAFETY DEVICE. DO NOT DISCARD
surface and protected from the weather. IT.
• Protect this equipment from damage, construction – Start-up will be performed according to that
dirt, debris and water. outlined in Section 3 of the Installation and
Start-up Instructions provided.
DO NOT OPERATE DOORS WHEN
UNIT IS NOT ON A FLAT SURFACE. • Temporary use of air handler requires startup
performed according to that outlined in Section
• Isolate this equipment from pressure testing of 3 of the Installation and Start-up Instructions
water, steam, gas and air piping. provided.
• Do not test, clean and flush piping through coils • A qualified startup technician must complete
in this equipment. the “AIR HANDLING UNITS START-UP
• Isolate this equipment from temporary building CHECK LIST” Form 100.00-CL1 and file a
power. copy at the local YORK Service Office. ► This
form is provided in the information package with
• Contact local Johnson Controls Service for each air handler.
purchase of Startup Service with two weeks
advance notice. Provide current job site • Rotate fans every four (4) weeks beginning upon
contact. arrival.
• To perform a careful and thorough startup, verify

the following:
– Reliable power will be available for
startup.
– Ductwork is complete.
CHANGEABILITY OF THIS DOCUMENT

In complying with Johnson Controls policy for continuous product improvement, the information contained in this
document is subject to change without notice. While Johnson Controls makes no commitment to update or provide
current information automatically to the manual owner, that information, if applicable, can be obtained by contacting
the nearest Johnson Controls Service office.
It is the responsibility of operating/service personnel to verify the applicability of these documents to the equipment
in question. If there is any question in the mind of operating/service personnel as to the applicability of these
documents, then prior to working on the equipment, they should verify with the owner whether the equipment has
been modified and if current literature is available.
johnson controls 3
FORM 102.20-NOM1 (909)
Table of contents
GENERAL SAFETY GUIDELINES.......................................................................................................................2
CHANGEABILITY OF THIS DOCUMENT............................................................................................................3
Table of contents........................................................................................................................................4
list of figures..............................................................................................................................................16
list of TABLES................................................................................................................................................25
service task reference...........................................................................................................................26
introduction.................................................................................................................................................29
GENERAL....................................................................................................................................................29
TYPICAL YORK SOLUTION OPERATION IN “HVAC” SYSTEM...............................................................29
VENTILATION SYSTEM...........................................................................................................................29
ECONOMIZER SYSTEM - TYPICAL.......................................................................................................30
HEATING OPERATION............................................................................................................................30
COOLING OPERATION...........................................................................................................................30
HAND IDENTIFICATION..............................................................................................................................30
SEGMENT IDENTIFICATION.......................................................................................................................31
UNIT IDENTIFICATION............................................................................................................................33
UNIT ID LABEL...................................................................................................................................33
SKID ID LABEL...................................................................................................................................33
SEGMENT IDENTIFICATION BOX.....................................................................................................33
FILTER ID LABEL...............................................................................................................................34
LOOSE COMPONENT ID LABEL......................................................................................................34
DIRECTION OF AIRFLOW.......................................................................................................................34
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
4 johnson controls
FORM 102.20-NOM1 (909)
Table of contents (Cont.)

2.0 INSTALLATION............................................................................................................................................2-1
SITE PREPARATION..................................................................................................................................2-1
OUTDOOR UNITS (SITE PREP).............................................................................................................2-1
MOUNTING...................................................................................................................................2-2
CURB............................................................................................................................................2-2
Curb Assembly & Installation Instructions..........................................................................2-3
STEEL FRAME.............................................................................................................................2-3
INDOOR UNITS (SITE PREP).................................................................................................................2-5
CLEARANCE.....................................................................................................................................2-5
MOUNTING........................................................................................................................................2-5
FLOOR..........................................................................................................................................2-5
HOUSEKEEPING PAD.................................................................................................................2-5
CEILING SUSPENDED UNITS.....................................................................................................2-6
General Requirements...........................................................................................................2-6
Structure Positioned Perpendicular to Airflow...............................................................2-6
Structure Positioned In the Direction of Airflow............................................................2-6
UNIT INSTALLATION..................................................................................................................................2-7
TOOLS NEEDED.....................................................................................................................................2-7
SHIP LOOSE PARTS..............................................................................................................................2-8
ASSEMBLY OF OUTDOOR UNIT.........................................................................................................2-13
INSTALLING SINGLE PIECE OUTDOOR UNIT..............................................................................2-13
INSTALLING MULTIPLE PIECE OUTDOOR UNIT ........................................................................2-13
ASSEMBLY OF INDOOR UNIT.............................................................................................................2-17
INSTALLING MULTIPLE PIECE INDOOR UNIT ............................................................................2-17
INSTALLATION OF TIERED UNIT..................................................................................................2-21
ASSEMBLY OF END CHANNEL SHIPPING SPLIT........................................................................2-23
HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS.............................................................2-24
OUTDOOR AIR TEMPERATURE AND/OR HUMIDITY SENSORS.........................................................2-24
ACTUATOR INSTALLATION....................................................................................................................2-25
INSTALLATION OF MULTIZONE (MZ) DAMPERS..................................................................................2-26
DAMPER INSTALLATION.....................................................................................................................2-26
ACTUATOR INSTALLATION MUTLIZONE (MZ) - FIELD SUPPLIED.................................................2-27
INERTIA FAN BASE FILL INSTRUCTION...............................................................................................2-27
HUMIDIFIERS............................................................................................................................................2-27
UVC EMITTER LIGHTS............................................................................................................................2-28
AIR MEASURING DEVICE CONNECTIONS (when provided)..........................................................2-29
AIR MEASURING AT THE FAN INLETS..............................................................................................2-29
AIR MEASURING AT UNIT INLETS.....................................................................................................2-29
PIPE CHASE INSTALLATION..................................................................................................................2-30
TOOLS REQUIRED...............................................................................................................................2-30
MATERIALS REQUIRED......................................................................................................................2-30
PROCEDURE........................................................................................................................................2-30
CONDENSATE DRAIN ARRANGEMENT.......................................................................................2-35
johnson controls 5
FORM 102.20-NOM1 (909)

ELECTRICAL - GENERAL........................................................................................................................2-36
POWER CONNECTIONS..........................................................................................................................2-37
SINGLE POINT POWER.......................................................................................................................2-37
MOTORS FOR SUPPLY FAN, RETURN FAN, EXHAUST FAN...........................................................2-37
ENERGY RECOVERY WHEEL OPTION..............................................................................................2-37
GAS HEAT OPTION..............................................................................................................................2-38
ELECTRIC HEAT OPTION....................................................................................................................2-39
AVAILABLE POWER OPTIONS......................................................................................................2-39
ELECTRIC HEAT DISCONNECT SWITCH OPTIONS....................................................................2-39
AVAILABLE CONTROL OPTIONS..................................................................................................2-40
INSTALLATION................................................................................................................................2-40
HUMIDIFIER OPTION (ELECTRIC)......................................................................................................2-43
HUMIDIFIER OPTION...........................................................................................................................2-43
PIPING CONNECTIONS...........................................................................................................................2-44
COIL PIPING.........................................................................................................................................2-45
STAGGERED COILS.............................................................................................................................2-45
WATER.............................................................................................................................................2-46
WATER COILS - HOT WATER & CHILLED WATER..................................................................2-46
HOT AND CHILLED WATER COIL PERFORMANCE...............................................................2-46
WATER TREATMENT.................................................................................................................2-48
Freeze Protection.................................................................................................................2-48
STEAM.............................................................................................................................................2-48
STEAM COILS............................................................................................................................2-48
STEAM DISTRIBUTING COILS..................................................................................................2-48
STEAM CONTROL.....................................................................................................................2-48
STEAM TRAPS...........................................................................................................................2-49
VIFB & IFB..................................................................................................................................2-50
Shipping Bolts (VIFB Only)..................................................................................................2-51
Piping Suggestions (VIFB & IFB)........................................................................................2-51
Flexible Connectors (VIFB Only).........................................................................................2-51
Freezing Conditions.............................................................................................................2-51
REFRIGERATION............................................................................................................................2-54
DIRECT EXPANSION COILS (DX).............................................................................................2-54
DX COIL TYPES.........................................................................................................................2-55
Interlaced...............................................................................................................................2-55
Row Split...............................................................................................................................2-55
Face Split...............................................................................................................................2-55
COMBINED COIL TYPES...........................................................................................................2-55
DX COIL CIRCUITING................................................................................................................2-55
DX COIL CIRCUITING AND STAGING......................................................................................2-57
THERMOSTATIC EXPANSION VALVES (TXV)..........................................................................2-59
6 johnson controls
FORM 102.20-NOM1 (909)

HOT GAS BYPASS..........................................................................................................................2-59
MAINTAINING ADEQUATE AIRFLOW ....................................................................................2-59
VAV SYSTEMS............................................................................................................................2-59
DRAINS AND TRAPS...........................................................................................................................2-61
CONDENSATE DRAIN PIPING.......................................................................................................2-61
CONDENSATE DRAIN TRAP..........................................................................................................2-61
ELEVATING UNIT FOR GRAVITY FLOOR DRAIN CONNECTIONS........................................2-62
DUCT CONNECTIONS.............................................................................................................................2-62
DUCT CONNECTION GUIDELINES.....................................................................................................2-62
SOUND AND VIBRATION TRANSMISSION........................................................................................2-64
FRONT AND REAR DISCHARGE OUTDOOR UNIT DUCT INSTALLATION......................................2-64
AIR FILTERS.............................................................................................................................................2-65
FILTER TYPES......................................................................................................................................2-65
MAINTENANCE AND REPLACEMENT...............................................................................................2-65
FILTER LATCHES.................................................................................................................................2-66
INSTALLATION OF 2" PERFECTPLEAT, PREMIUM OR PREMIUM HM............................................2-68
INSTALLATION OF 4" AMAIR 300X PLEATED FILTER......................................................................2-69
INSTALLATION OF SH SINGLE HEADERED FILTERS......................................................................2-70
INSTALLATION OF A 2" PREFILTER IN COMBINATION WITH A SINGLE HEADER
FINAL FILTER.......................................................................................................................................2-70
INSTALLATION OF A VARICEL DH DOUBLE HEADERED FILTER...................................................2-71
INSTALLATION OF A 2" & 4" PREFILTER IN COMBINATION WITH A DOUBLE
HEADER FINAL FILTER.......................................................................................................................2-72
HEPA FILTERS......................................................................................................................................2-74
WELDED BEVEL SEAL FRAME.....................................................................................................2-74
Extruded Aluminum Frames for Gasketed HEPA Filter Installations...................................2-74
Two Stage Gasket Compression Prevents Leakage...............................................................2-74
VISUAL CONTROL FILTER CLAMPS.............................................................................................2-74
HEPA Filter Applications...........................................................................................................2-74
Easy Clamp Installation............................................................................................................2-74
3.0 STARTUP.....................................................................................................................................................3-1
PRE START-UP...........................................................................................................................................3-2
PRE START UP FAN ASSEMBLY INSPECTION.......................................................................................3-3
MOTORS - ODP VS. TEFC ....................................................................................................................3-3
ISOLATORS............................................................................................................................................3-4
START-UP...................................................................................................................................................3-5
CHECK OPERATION OF FANS..............................................................................................................3-5
CHECK OPERATION OF DAMPERS.....................................................................................................3-5
AIRFLOW CONTROL DAMPERS.....................................................................................................3-5
TYPICAL ACTUATORS LOCATIONS................................................................................................3-6
johnson controls 7
FORM 102.20-NOM1 (909)

BASIC ACTUATORS INSTALLATION...............................................................................................3-6
DAMPER BLADE ORIENTATION.................................................................................................3-6
Return Air and Mixing Dampers with Power Off..................................................................3-6
Outside Air and Exhaust Air Dampers..................................................................................3-6
ENERGIZE FAN MOTOR(S)...................................................................................................................3-7
VARIABLE SPEED DRIVE (VSD)...........................................................................................................3-7
SET UP OF A NON- FACTORY MOUNTED VFD.........................................................................3-7
CHECK DOORS AND LATCHES FOR PROPER ADJUSTMENT.........................................................3-8
SHEAVES................................................................................................................................................3-8
ENERGY RECOVERY WHEEL...............................................................................................................3-9
UNIT CONFIGURATION....................................................................................................................3-9
START-UP PROCEDURE FOR ENERGY RECOVERY WHEEL.......................................................3-9
INDIRECT FIRED GAS HEAT START UP - ECLIPSE GAS BURNER START UP
10:1 - 25:1 TURNDOWN & POWERFLAME GAS BURNER START UP 3:1 - 10:1 TURNDOWN.....3-11
INTRODUCTION..............................................................................................................................3-11
IDENTIFY THE UNIT TYPE..............................................................................................................3-11
PRELIMINARY COORDINATION....................................................................................................3-12
TOOLS RECOMMENDED................................................................................................................3-12
AIR HANDLER PRE START CHECKS............................................................................................3-12
BURNER PRE START CHECKS.....................................................................................................3-12
BURNER START-UP PROCEDURE................................................................................................3-14
CONDENSATE DRAIN ARRANGEMENT.......................................................................................3-15
ELECTRIC HEAT STARTUP.................................................................................................................3-25
AIRFLOW REQUIREMENTS................................................................................................................3-25
4.0 OPERATION & maintenance.................................................................................................................4-1
OPERATION................................................................................................................................................4-1
TEST AND BALANCE.............................................................................................................................4-1
AIR BALANCE...................................................................................................................................4-1
DYNAMIC BALANCE.........................................................................................................................4-1
TEMPERATURE LIMITS.........................................................................................................................4-3
STATIC PRESSURE LIMITS...................................................................................................................4-3
MOTORS.................................................................................................................................................4-3
BELTS......................................................................................................................................................4-3
SHEAVES................................................................................................................................................4-3
MAINTENANCE..........................................................................................................................................4-3
INTRODUCTION......................................................................................................................................4-3
AIR HANDLER CABINET.......................................................................................................................4-3
HARDWARE CHECK.........................................................................................................................4-3
GASKETS...........................................................................................................................................4-3
PANELS..............................................................................................................................................4-3
HOODS AND LOUVERS....................................................................................................................4-4
BIRD SCREENS.................................................................................................................................4-4
8 johnson controls
FORM 102.20-NOM1 (909)

MIST ELIMINATORS..........................................................................................................................4-4
CLEANING/REPLACEMENT........................................................................................................4-4
FAN SEGMENT (SUPPLY, RETURN, EXHAUST) - FAN ASSEMBLY...................................................4-4
ADJUSTABLE MOTOR BASE OPERATION (Standard).............................................................4-5
ADJUSTABLE MOTOR BASE OPERATION.....................................................................................4-5
(Top Mount)....................................................................................................................................4-5
BELTS................................................................................................................................................4-7
SHEAVES ALIGNMENT.....................................................................................................................4-7
ALIGNMENT USING A STRAIGHTEDGE....................................................................................4-8
ALIGNMENT USING A STRING...................................................................................................4-8
LUBRICATION.................................................................................................................................4-10
VERIFY TYPES OF BEARINGS.................................................................................................4-10
Sealed (not to be re-lubricated in the field)........................................................................4-10
Standard Pillow Block..........................................................................................................4-10
Split Pillow Block..................................................................................................................4-10
FAN BEARING LUBRICATION..................................................................................................4-11
CHECK CONDITION OF EXTENDED LUBRICATION LINES WHEN PRESENT.....................4-11
RECOMMENDED LUBRICANT FOR FAN BEARINGS.............................................................4-11
PROPER INTERVAL AND QUANTITY.......................................................................................4-11
FAN SEGMENT-FAN MOTOR...............................................................................................................4-12
MOTOR CONDITION (VISUAL).......................................................................................................4-12
ELECTRICAL CHECKS...................................................................................................................4-12
LUBRICATION.................................................................................................................................4-13
MOTOR BEARING LUBRICANT................................................................................................4-13
FILTER SEGMENTS (PRE FILTER AND FINAL FILTER)....................................................................4-15
FILTER TYPES.................................................................................................................................4-15
MAINTENANCE AND REPLACEMENT..........................................................................................4-15
INSERTING FILTERS INTO SIDE LOAD FILTER TRACKS FOR ANGLE
AND FLAT FILTER SEGMENTS......................................................................................................4-15
INSTALLATION OF 2" PERFECTPLEAT, PREMIUM OR PREMIUM HM......................................4-18
INSTALLATION OF 4" AMAIR 300X PLEATED FILTER................................................................4-19
INSTALLATION OF SH SINGLE HEADERED FILTERS.................................................................4-20
INSTALLATION OF A 2" PREFILTER IN COMBINATION WITH A SINGLE HEADER
FINAL FILTER..................................................................................................................................4-21
INSTALLATION OF A VARICEL DH DOUBLE HEADERED FILTER.............................................4-22
INSTALLATION OF A 2" & 4" PREFILTER IN COMBINATION WITH A
DOUBLE HEADER FINAL FILTER..................................................................................................4-23
HEPA FILTERS......................................................................................................................................4-26
WELDED BEVEL SEAL FRAME.....................................................................................................4-26
EXTRUDED ALUMINUM FRAMES FOR GASKETED HEPA FILTER INSTALLATIONS..........4-26
TWO STAGE GASKET COMPRESSION PREVENTS LEAKAGE............................................4-26
johnson controls 9
FORM 102.20-NOM1 (909)

VISUAL CONTROL FILTER CLAMPS.............................................................................................4-26
HEPA FILTER APPLICATIONS..................................................................................................4-26
EASY CLAMP INSTALLATION..................................................................................................4-26
ECONOMIZER SEGMENT (DAMPERS)...............................................................................................4-28
CLEANING OF DAMPERS..............................................................................................................4-28
HARDWARE CHECK.......................................................................................................................4-28
COIL SEGMENT....................................................................................................................................4-28
COIL CLEANING PROCEDURE......................................................................................................4-28
SUGGESTED TOOLS, EQUIPMENT & MATERIALS LIST.......................................................4-28
CLEANING PROCEDURE..........................................................................................................4-28
CONDENSATE DRAIN PAN, TRAP AND DRAIN LINE CLEANING PROCEDURE.......................4-29
TOOLS AND MATERIALS..........................................................................................................4-29
CLEANING PROCEDURE..........................................................................................................4-30
FREEZE PROTECTION...................................................................................................................4-30
WINTERIZING DRAIN TRAPS.........................................................................................................4-30
ENERGY RECOVERY WHEEL.............................................................................................................4-31
TOOLS . ...........................................................................................................................................4-31
MATERIALS.....................................................................................................................................4-31
CLEANING ......................................................................................................................................4-31
WHEEL . .....................................................................................................................................4-31
ADJUSTMENT OF AIR SEALS.......................................................................................................4-31
WHEEL DRIVE COMPONENTS......................................................................................................4-32
5.0 service and Repair...............................................................................................................................5-1
SERVICE TOOLS AND EQUIPMENT.........................................................................................................5-1
SERVICE INFORMATION...........................................................................................................................5-2
TROUBLESHOOTING................................................................................................................................5-2
PITOT TUBE............................................................................................................................................5-3
INCLINED MANOMETER........................................................................................................................5-3
MINIHELIC FILTER GAUGE...................................................................................................................5-3
“U” TUBE MANOMETER........................................................................................................................5-4
DUCT PRESSURES AND HOW THEY WORK.......................................................................................5-5
VELOCITY..........................................................................................................................................5-5
STATIC PRESSURE...........................................................................................................................5-5
TOTAL PRESSURE............................................................................................................................5-5
TROUBLE SHOOTING TIPS...................................................................................................................5-6
REQUESTING ASSISTANCE.....................................................................................................................5-6
COMPONENT REPLACEMENT, ADJUSTMENT & REPAIR.....................................................................5-6
FAN REPLACEMENT & ADJUSTMENT................................................................................................5-6
TOOLS REQUIRED............................................................................................................................5-6
MATERIALS REQUIRED...................................................................................................................5-6
PROCEDURE.....................................................................................................................................5-6
10 johnson controls
FORM 102.20-NOM1 (909)

FAN REPAIR............................................................................................................................................5-7
TOOLS REQUIRED............................................................................................................................5-7
MATERIALS REQUIRED...................................................................................................................5-7
FORWARD CURVED FAN WHEEL REPLACEMENT.......................................................................5-7
AIRFOIL FAN WHEEL REPLACEMENT...........................................................................................5-8
FAN BEARING REPLACEMENT............................................................................................................5-9
SEALED BEARINGS.........................................................................................................................5-9
TOOLS REQUIRED......................................................................................................................5-9
MATERIAL REQUIRED.................................................................................................................5-9
PROCEDURE................................................................................................................................5-9
STANDARD PILLOW BLOCK BEARINGS.....................................................................................5-10
TOOLS REQUIRED....................................................................................................................5-10
MATERIAL REQUIRED...............................................................................................................5-10
ABOUT THIS DEVICE................................................................................................................5-10
PROCEDURE..............................................................................................................................5-11
PILLOW BLOCK BEARINGS WITH ECCENTRIC LOCKING COLLAR........................................5-12
TOOLS REQUIRED....................................................................................................................5-12
PROCEDURE..............................................................................................................................5-12
SPLIT PILLOW BLOCK BEARINGS...............................................................................................5-14
TOOLS REQUIRED....................................................................................................................5-14
PROCEDURE..............................................................................................................................5-15
SHEAVE REPLACEMENT AND ADJUSTMENT..................................................................................5-18
FIXED PITCH SHEAVES . ...............................................................................................................5-18
TOOLS REQUIRED....................................................................................................................5-18
SHEAVE REMOVAL....................................................................................................................5-18
SHEAVE INSTALLATION...........................................................................................................5-18
Standard Mounting...............................................................................................................5-18
Reverse Mounting................................................................................................................5-19
SHEAVE ADJUSTMENT.............................................................................................................5-20
ADJUSTABLE PITCH SHEAVES....................................................................................................5-20
T.B. WOODS MODEL JVS..........................................................................................................5-20
Tools Required......................................................................................................................5-20
Material Required.................................................................................................................5-20
Sheave Removal...................................................................................................................5-20
Sheave Installation...............................................................................................................5-20
Sheave Adjustment..............................................................................................................5-21
johnson controls 11
FORM 102.20-NOM1 (909)

T.B. WOODS MODEL FHP..........................................................................................................5-21
Tools Required......................................................................................................................5-21
Material Required.................................................................................................................5-21
Sheave Removal...................................................................................................................5-21
Sheave Installation...............................................................................................................5-22
Sheave Adjustment..............................................................................................................5-22
MOTOR REPLACEMENT.....................................................................................................................5-23
FAN MOTOR....................................................................................................................................5-23
TOOLS REQUIRED....................................................................................................................5-23
PROCEDURE..............................................................................................................................5-23
MOTOR REPAIR ..................................................................................................................................5-24
TOOLS REQUIRED..........................................................................................................................5-24
MATERIALS REQUIRED.................................................................................................................5-24
COIL REPLACEMENT..........................................................................................................................5-25
TOOLS REQUIRED..........................................................................................................................5-25
PROCEDURE...................................................................................................................................5-26
DOOR REPLACEMENT........................................................................................................................5-28
TOOLS REQUIRED..........................................................................................................................5-28
PROCEDURE...................................................................................................................................5-28
DOOR GASKET REPLACEMENT........................................................................................................5-29
TOOLS REQUIRED..........................................................................................................................5-29
PROCEDURE...................................................................................................................................5-29
REMOVE OLD GASKET.............................................................................................................5-29
REMOVE SEALANT...................................................................................................................5-29
INSTALL NEW MITERED GASKET (BEFORE JAN 2006)........................................................5-29
INSTALL NEW GASKET ON DOOR PRODUCED JAN 2006 THROUGH OCTOBER 2008)...5-34
INSTALL NEW GASKET ON DOOR PRODUCED AFTER OCT 2008.....................................5-40
PREPARATION......................................................................................................................5-40
GASKET INSTALLATION......................................................................................................5-40
Examples of a Good Gasket Corner..............................................................................5-41
Examples of Unacceptable Corners..............................................................................5-42
Examples of Unacceptable Gasket Fit..........................................................................5-42
Examples of Good Finished Joints...............................................................................5-44
Examples of Unacceptable Joints.................................................................................5-44
SPLICING...............................................................................................................................5-45
DOOR HANDLE/LATCH REPLACEMENT AND ADJUSTMENT.........................................................5-46
STANDARD OUT SWING DOOR....................................................................................................5-46
TOOLS REQUIRED....................................................................................................................5-46
MATERIALS REQUIRED............................................................................................................5-46
PROCEDURE..............................................................................................................................5-46
12 johnson controls
FORM 102.20-NOM1 (909)

STANDARD OUT SWING DOOR WITH MULTI-POINT LATCH.....................................................5-46
TOOLS REQUIRED....................................................................................................................5-46
PROCEDURE..............................................................................................................................5-46
STANDARD IN SWING DOOR........................................................................................................5-48
TOOLS REQUIRED....................................................................................................................5-48
PROCEDURE..............................................................................................................................5-48
STANDARD IN SWING DOOR WITH MULTI-POINT LATCH.........................................................5-48
TOOLS REQUIRED....................................................................................................................5-48
PROCEDURE..............................................................................................................................5-48
ISOLATOR SPRING REPLACEMENT AND ADJUSTMENT................................................................5-49
TOOLS REQUIRED..........................................................................................................................5-49
MATERIAL REQUIRED....................................................................................................................5-49
PROCEDURE...................................................................................................................................5-49
ISOLATOR SPRING REPLACEMENT ......................................................................................5-49
ISOLATOR ADJUSTMENT (LEVEL WITH PROPER CLEARANCES)......................................5-49
THRUST RESTRAINT REPLACEMENT AND ADJUSTMENT............................................................5-50
REAR DISCHARGE ORIENTATION................................................................................................5-50
TOOLS REQUIRED..........................................................................................................................5-50
PROCEDURE...................................................................................................................................5-50
THRUST RESTRAINT REPLACEMENT....................................................................................5-50
THRUST RESTRAINT ADJUSTMENT.......................................................................................5-51
FIELD CUT OPENINGS FOR DUCTS, DAMPERS AND SPECIAL ACCESS FOR
YORK SOLUTION DOUBLE WALL 2" PANELS..................................................................................5-52
TOOLS REQUIRED..........................................................................................................................5-52
PROCEDURE...................................................................................................................................5-52
PANEL REPLACEMENT.......................................................................................................................5-53
TOOLS REQUIRED..........................................................................................................................5-53
PROCEDURE...................................................................................................................................5-54
PRESSURE TAPE REMOVAL AND INSTALLATION INSTRUCTIONS ON XTO ROOF PANELS.....5-54
TOOLS REQUIRED..........................................................................................................................5-54
SEAM SEALING STRIP ORDERING INFORMATION...............................................................5-55
PROCEDURE...................................................................................................................................5-55
FIELD PENETRATIONS FOR PIPING & ELECTRICAL CONNECTIONS...........................................5-56
TOOLS REQUIRED..........................................................................................................................5-56
PROCEDURE...................................................................................................................................5-56
johnson controls 13
FORM 102.20-NOM1 (909)

FIELD MODIFICATION TO ADD DOORS.............................................................................................5-58
TOOLS REQUIRED..........................................................................................................................5-58
PROCEDURE...................................................................................................................................5-58
LIGHT BULB REPLACEMENT.............................................................................................................5-60
TOOLS REQUIRED..........................................................................................................................5-60
PROCEDURE...................................................................................................................................5-60
LIGHT ASSEMBLY REPLACEMENT...................................................................................................5-60
TOOLS REQUIRED..........................................................................................................................5-60
PROCEDURE...................................................................................................................................5-60
FILTER GAGE REPLACEMENT...........................................................................................................5-61
TOOLS REQUIRED..........................................................................................................................5-61
PROCEDURE...................................................................................................................................5-61
FILTER GAGE INSTALLATION (FIELD CUT)......................................................................................5-62
TOOLS REQUIRED..........................................................................................................................5-62
INSTALLATION CONSIDERATIONS...............................................................................................5-62
PROCEDURE...................................................................................................................................5-62
ENERGY RECOVERY WHEEL.............................................................................................................5-64
TOOLS REQUIRED..........................................................................................................................5-64
REPLACING WHEEL SEGMENTS..................................................................................................5-64
REMOVAL OF SEGMENTS........................................................................................................5-64
INSTALLATION OF SEGMENTS................................................................................................5-65
WHEEL DRIVE MOTOR & PULLEY REPLACEMENT....................................................................5-65
BELT REPLACEMENT....................................................................................................................5-66
INSTALLING DOOR SAFETY CHAIN..................................................................................................5-70
TOOLS REQUIRED..........................................................................................................................5-70
PROCEDURE...................................................................................................................................5-70
DIRECT COUPLED DAMPER ACTUATOR REPLACEMENT AND ADJUSTMENT...........................5-71
TOOLS REQUIRED..........................................................................................................................5-71
PROCEDURE...................................................................................................................................5-71
DAMPER BLADE ORIENTATION...............................................................................................5-71
Return Air and Mixing Dampers:.........................................................................................5-71
Outside Air and Exhaust Air Dampers:..............................................................................5-71
ACTUATOR REMOVAL..............................................................................................................5-72
ACTUATOR REPLACEMENT.....................................................................................................5-72
14 johnson controls
FORM 102.20-NOM1 (909)

MIXING DAMPER WALL REPAIR........................................................................................................5-72
TOOLS REQUIRED..........................................................................................................................5-72
PROCEDURE...................................................................................................................................5-73
POWER FLAME / ECLIPSE INDUCER FAN GASKET REPLACEMENT............................................5-75
TOOLS REQUIRED..........................................................................................................................5-75
PROCEDURE...................................................................................................................................5-75
6.0 WIRING SCHEMATICS...............................................................................................................................6-1
johnson controls 15
FORM 102.20-NOM1 (909)
list of figures
FIG. 1 – CUTAWAY OF YORK Solution SHOWING VARIOUS SEGMENTS.........................................29
FIG. 2 – UNIT AND COIL HAND IDENTIFICATION.....................................................................................30
FIG. 3 – UNIT ID LABEL..............................................................................................................................33
FIG. 4 – SKID ID LABEL..............................................................................................................................33
FIG. 5 – SEGMENT ID BOX EXAMPLE......................................................................................................33
FIG. 6 – LOOSE COMPONENT ID LABELS...............................................................................................34
FIG. 7 – filter LABELS............................................................................................................................34
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. 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 – BOTTOM 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 & 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
FIG. 2-28 – installing bolts after pulling units tight together...................................2-20
FIG. 2-29 – TIERED UNIT.........................................................................................................................2-21
FIG. 2-30 – TIERED UNIT SECURED WITH BRACKETS.......................................................................2-21
16 johnson controls
FORM 102.20-NOM1 (909)
list of figures (cont.)

FIG. 2-31 – APPLY GASKETS TO TOP PANEL BOTTOM TIER.............................................................2-21
FIG. 2-32 – GUIDING BRACKETS TOGETHER......................................................................................2-22
FIG. 2-33 – ASSEMBLY OF END CHANNEL SHIPPING SPLIT..............................................................2-23
FIG. 2-34 – HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS.........................................2-24
FIG. 2-35 – DIRECT COUPLED ON JACKSHAFT...................................................................................2-25
FIG. 2-36 – MZ DAMPER/ACTUATOR ASSEMBLY.................................................................................2-26
FIG. 2-37 – DAMPER SHAFT EXTENSION KIT.......................................................................................2-27
FIG. 2-38 – V-MOD INSTALLATION.........................................................................................................2-28
FIG. 2-39 – V-RAY INSTALLATION..........................................................................................................2-28
FIG. 2-40 – V-FLEX INSTALLATION........................................................................................................2-28
FIG. 2-41 – INSTALL GASKET UNDER ROOF OVERHANG..................................................................2-30
FIG. 2-42 – APPLY GASKET TO PIPE CHASE........................................................................................2-31
FIG. 2-43 – P
IPE CHASE BASERAIL TO UNIT BASERAIL INSTALLATION ........................................2-31
FIG. 2-44 – S
CREW PIPE CHASE TOP AND BOTTOM INTERNAL FLANGES TO AIR HANDLER ...... 2-31
FIG. 2-45 – BASERAIL CAULK APPLICATION...........................................................................................2-32
FIG. 2-46 – P
IPE CHASE TO ROOF INSTALLATION..............................................................................2-32
FIG. 2-47 – P
IPE CHASE TO AIR HANDLER CAULK APPLICATION.......................................................2-32
FIG. 2-48 – INSTALL COVER ANGLE......................................................................................................2-32
FIG. 2-49 – P
ROPER POSITIONING OF COVER ANGLE WITH NOTCH ON AIR HANDLER SIDE....... 2-33
FIG. 2-50 – PROPER PATTERN FOR INSTALLING SELF-DRILLING SCREWS TO COVER ANGLE.........2-33
FIG. 2-51 – BASERAIL COVER APPLICATION.......................................................................................2-33
FIG. 2-52 – GAS FURNACE FUEL VENTING SYSTEM..........................................................................2-34
FIG. 2-53 – GAS FURNACE Condensate drain trap....................................................................2-35
FIG. 2-54 – TYPICAL MOTOR DATA / NAMEPLATE...............................................................................2-37
FIG. 2-55 – TYPICAL POWER WIRING OF ENERGY RECOVERY WHEEL..........................................2-37
FIG. 2-56 – GAS BURNER COMPONENT LOCATIONS.........................................................................2-38
FIG. 2-57 – MAIN POWER AND CONTROL PANEL W/ COVER OPEN.................................................2-38
FIG. 2-58 – TYPICAL ELECTRIC HEAT CONTROL PANEL INTERIOR WIRING AND COMPONENTS.......2-39
FIG. 2-59 – TYPICAL FIELD CONTROL AND POWER CONNECTIONS................................................2-39
FIG. 2-60 – P
RESSURE PROBE DIRECTION.........................................................................................2-41
FIG. 2-61 – AIRFLOW SWITCH CONNECTIONS....................................................................................2-41
FIG. 2-62 – TYPICAL HUMIDIFIER PANEL LAYOUT..............................................................................2-43
FIG. 2-63 – SUPPLY POWER KNOCKOUTS...........................................................................................2-43
FIG. 2-64 – HUMIDIFIER POINTS............................................................................................................2-43
FIG. 2-65 – PIPE CHASE ENCLOSURE .................................................................................................2-44
FIG. 2-66 – FACTORY COIL CONNECTIONS..........................................................................................2-44
FIG. 2-67 – STAGGERED COIL CONFIGURATIONS..............................................................................2-45
FIG. 2-68 – CHILLED WATER COIL CONNECTIONS.............................................................................2-46
FIG. 2-69 – HOT WATER PIPING - 2 WAY VALVE...................................................................................2-47
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 & BYPASS COIL (HORIZONTAL; TUBES, STEAM SHOWN)................2-50
FIG. 2-73 – VERTICAL INTEGRAL FACE & BYPASS COIL...................................................................2-50
johnson controls 17
FORM 102.20-NOM1 (909)
FIG. 2-74 – HOT WATER PIPING FOR 2 ROW COIL VIFB.....................................................................2-52

FIG. 2-75 – HOT WATER PIPING FOR IFB..............................................................................................2-52
FIG. 2-76 – STEAM PIPING FOR VIFB COIL...........................................................................................2-53
FIG. 2-77 – TYPICAL PIPING AND SUNDRIES AT THE DX COIL..........................................................2-54
FIG. 2-78 – DX COIL CIRCUITING TYPES .............................................................................................2-55
FIG. 2-79 – NON-STACKED COIL DESIGN - SQ SPECIAL....................................................................2-56
FIG. 2-80 – NON-STACKED COIL DESIGN - STANDARD......................................................................2-56
FIG. 2-81 – STACKED COIL DESIGN - STANDARD...............................................................................2-57
FIG. 2-82 – STACKED COIL DESIGNS - SQ SPECIAL...........................................................................2-57
FIG. 2-83 – STACKED COIL CIRCUITING...............................................................................................2-57
FIG. 2-84 – O
NE COIL CIRCUIT PERREFRIGERANT CIRCUIT.............................................................2-58
FIG. 2-85 – TWO COIL CIRCUITS PERREFRIGERANT CIRCUIT..........................................................2-58
FIG. 2-86 – DO NOT USE THE ABOVE CONFIGURATION....................................................................2-58
FIG. 2-87 – THREE COMPRESSOR YCUL..............................................................................................2-58
FIG. 2-88 – DO NOT USE THE ABOVE CONFIGURATION....................................................................2-58
FIG. 2-89 – SIX COMPRESSOR YCUL....................................................................................................2-59
FIG. 2-90 – DRAIN TRAP SHOWING WATER LOCATION DURING DRAW
THROUGH OPERATION STAGES........................................................................................2-61
FIG. 2-91 – TRAP DETAIL FOR DRAW THROUGH APPLICATION........................................................2-61
FIG. 2-92 – TRAP DETAIL FOR BLOW THROUGH APPLICATION........................................................2-61
FIG. 2-93 – COMBINING DRAIN LINES...................................................................................................2-62
FIG. 2-94 – R
ECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS
ARE REQUIRED.....................................................................................................................2-62
FIG. 2-95 – R
ECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS
ARE REQUIRED.....................................................................................................................2-63
FIG. 2-96 – DUCT PENETRATION OF ROOF..........................................................................................2-64
FIG. 2-97 – R
OOF TO DUCT INSTALLATION - HORIZONTAL DISCHARGE.........................................2-64
FIG. 2-97A – TYPICAL FILTERS..............................................................................................................2-65
Fig. 2-98 – Filter Latches..................................................................................................................2-66
Fig. 2-99 – C
orrectly installed latch P/N 026-35778-000........................................................2-68
Fig. 2-100 – Fully installed filter................................................................................................2-68
orrectly installed latch P/N 026-35778-007......................................................2-69
Fig. 2-101 – C
Fig. 2-102 – Place the end of the latch over the filter frame,
securing the filter to the frame..........................................................................2-69
Fig. 2-103 – installed CARTRIDGE filter......................................................................................2-70
Fig. 2-104 – install latch p//n 026-35778-007.................................................................................2-70
Fig. 2-105 – installed CARTRIGE W/PLEATS...................................................................................2-70
Fig. 2-106 – CORRECT USE OF KNOCKOUTS.....................................................................................2-71
Fig. 2-107 – C
orrect latch/knockout configuration. ........................................................2-71
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
18 johnson controls
FORM 102.20-NOM1 (909)

Fig. 2-111 – Frame with 4 latches installed ............................................................................2-72
Fig. 2-112 – Prefilter latch after Installation onto filter header.............................2-72
Fig. 2-113 – Position prefilter in front of the final filter.
(2" w/026-36339-000 latch shown)...............................................................................2-73
Fig. 2-114 – Spring the end of the latch so that it fits over the edge of
the Prefilter. (4" w/026-36339-000 latch shown)................................................2-73
Fig. 2-115 – Completed assembly...................................................................................................2-73
FIG. 2-116 – HEPA FILTER FRAME CROSS SECTION VIEW................................................................2-74
FIG. 2-117 – VISUAL CONTROL FILTER CLAMPS.................................................................................2-74
FIG. 2-118 – HEPA FILTER INSTALLATION............................................................................................2-75
FIG. 2-119 – WELDED BEVEL SEAL FILTER INSTALLATION...............................................................2-75
FIG. 3-1 – TERMINATION CHART INSIDE ENCLOSURE DOOR.............................................................3-2
FIG. 3-2 – F
AN AND MOTOR ISOLATOR SUPPORT FRAME..................................................................3-3
FIG. 3-3 – ODP (OPEN DRIP PROOF).......................................................................................................3-3
FIG. 3-4 – TEFC (TOTALLY ENCLOSED FAN COOLED)..........................................................................3-4
FIG. 3-5 – SPRING ISOLATOR...................................................................................................................3-4
FIG. 3-6 – SEISMIC SNUBBER..................................................................................................................3-4
FIG. 3-7 – EXAMPLE OF SWEEP BALANCE RESULTS..........................................................................3-7
FIG. 3-8 – TYPICAL DRIVE KIT DATA TAG...............................................................................................3-8
FIG. 3-9 – INDOOR UNIT - VERTICAL WHEEL.........................................................................................3-9
FIG. 3-10 – OUTDOOR UNIT - HORIZONTAL WHEEL..............................................................................3-9
FIG. 3-11 – ENERGY RECOVERY WHEEL - PULLEY SIDE...................................................................3-10
FIG. 3-12 – SEGMENT RETAINER...........................................................................................................3-10
FIG. 3-13 – DIAMETER SEAL ADJUSTMENT.........................................................................................3-10
FIG. 3-14 – OPEN FUSE DISCONNECTS................................................................................................3-12
FIG. 3-15 – sET ID FAN DAMPER...........................................................................................................3-13
FIG. 3-16 – C
HECK MAIN GAS SUPPLY PRESSURE............................................................................3-13
FIG. 3-17 – DRAFT OVER FIRE test port..........................................................................................3-14
FIG. 3-18 – FLUE (STACK) combustion tEMPERATURE and efficiency test port.............3-14
FIG. 3-19 – DAMPER ACTUATOR...........................................................................................................3-15
FIG. 3-20 – CONDENSATE DRAIN .........................................................................................................3-15
FIG. 3-21 – GAS FURNACE Condensate drain trap....................................................................3-16
FIG. 3-24 – typical wiring diagram................................................................................................3-22
fIG. 3-25 – MINIMUM AIR VELOCITY REQUIRED FOR SAFE OPERATION........................................3-25
FIG. 3-26 – PRESSURE PROBE DIRECTION.........................................................................................3-26
FIG. 3-27 – AIRFLOW SWITCH CONNECTIONS....................................................................................3-26
FIG. 4-1 – MIST ELIMINATOR REMOVAL.................................................................................................4-4
FIG. 4-2 – TYPICAL DRIVE KIT DATA TAG...............................................................................................4-4
FIG. 4-3 – ADJUSTABLE MOTOR BASE (STANDARD)...........................................................................4-5
FIG. 4-4 – ADJUSTABLE MOTOR BASE (TOP MOUNT)..........................................................................4-6
FIG. 4-5 – BELT TENSIONING...................................................................................................................4-7
johnson controls 19
FORM 102.20-NOM1 (909)

FIG. 4-6 – BELT TENSIONING GAUGE.....................................................................................................4-7
FIG. 4-7 – SHEAVE ALIGNMENT...............................................................................................................4-8
FIG. 4-8 – belt replacement tensioning and alignment (TOP MOUNT)...............................4-9
FIG. 4-9 – SEALED BEARING..................................................................................................................4-10
FIG. 4-10 – B
EARING WITH SETSCREW TYPE LOCKING DEVICE.....................................................4-10
FIG. 4-11 – BEARING WITH ECCENTRIC CAM......................................................................................4-10
FIG. 4-12 – SPLIT BEARING....................................................................................................................4-10
FIG. 4-13 – LUBRICATION LINES (Optional)......................................................................................4-11
FIG. 4-14 – ODP (OPEN DRIP PROOF)...................................................................................................4-13
FIG. 4-15 – TEFC (TOTALLY ENCLOSED FAN COOLED)......................................................................4-13
FIG. 4-16 – GREASE FITTINGS ..............................................................................................................4-14
FIG. 4-17 – TYPICAL FILTERS.................................................................................................................4-15
FIG. 4-18 – ANGLE FILTER INSTALLATION...........................................................................................4-15
FIG. 4-19 – SIDE LOAD FILTER INSTALLATION....................................................................................4-15
Fig. 4-20 – Filter Latches..................................................................................................................4-16
Fig. 4-21 – Correctly installed latch P/N 315-004-003............................................................4-18
Fig. 4-22 – Fully installed filter..................................................................................................4-18
Fig. 4-23 – C
orrectly installed latch P/N 315-004-000............................................................4-19
Fig. 4-24 – P
lace the end of the latch over the filter frame, securing the
filter to the frame........................................................................................................4-19
Fig. 4-25 – Fully installed filter..................................................................................................4-20
Fig. 4-26 – install latch p//n 315-004-000.......................................................................................4-21
Fig. 4-27 – Fully installed filters................................................................................................4-21
Fig. 4-28 – CORRECT USE OF KNOCKOUTS.......................................................................................4-22
Fig. 4-29 – C
orrect latch/knockout configuration. ..........................................................4-22
Fig. 4-30 – Frame with 4 latches installed. .............................................................................4-22
Fig. 4-31 – S
pring latch should be pulled and fastened in hole in the
header of the filter.....................................................................................................4-23
Fig. 4-32 – C
orrect latch/knockout configuration. P/N 315-004-001 . ............................4-23
Fig. 4-33 – Frame with 4 latches installed ..............................................................................4-24
Fig. 4-34 – P
refilter latch after Installation onto filter header...............................4-24
Fig. 4-35 – P
osition prefilter in front of the final filter.
(2" w/315-003-002 latch shown)....................................................................................4-24
Fig. 4-36 – S
pring the end of the latch so that it fits over the edge of
the Prefilter. (4" w/315-003-004 latch shown)......................................................4-25
Fig. 4-37 – Completed assembly.....................................................................................................4-25
FIG. 4-38 – HEPA FILTER FRAME CROSS SECTION VIEW..................................................................4-26
FIG. 4-39 – VISUAL CONTROL FILTER CLAMPS..................................................................................4-26
FIG. 4-40 – HEPA FILTER INSTALLATION..............................................................................................4-27
FIG. 4-42 – R
INSE SEGMENTS WITH CLEAN WATER..........................................................................4-31
FIG. 4-43 – DIAMETER SEAL ADJUSTMENT.........................................................................................4-31
FIG. 4-44 – ENERGY RECOVERY WHEEL, BEARING SUPPORT BEAM SIDE . .................................4-32
FIG. 4-45 – MAINTENANCE REQUIREMENTS FOR YORK SOLUTION HANDLER.............................4-33
20 johnson controls
FORM 102.20-NOM1 (909)

FIG. 5-1 – CONSTRUCTION OF PITOT TUBE..........................................................................................5-2
FIG. 5-2 – PITOT TUBE..............................................................................................................................5-3
FIG. 5-3 – INCLINED MANOMETER..........................................................................................................5-3
FIG. 5-4 – MINIHELIC FILTER GAUGE......................................................................................................5-3
FIG. 5-5 – “U” TUBE MANOMETERS........................................................................................................5-4
FIG. 5-6 – SLACK-TUBE MANOMETER....................................................................................................5-4
FIG. 5-7 – STATIC PRESSURE - AIR SYSTEM.........................................................................................5-5
FIG. 5-8 – TYPES OF CENTRIFUGAL FAN IMPELLERS.........................................................................5-7
FIG. 5-9 – FC FAN SHAFT AND WHEEL MARKING ................................................................................5-7
FIG. 5-10 – AIRFOIL WITH CONE ASSEMBLY..........................................................................................5-8
FIG. 5-11 – SEALED BEARING..................................................................................................................5-9
FIG. 5-12 – B
EARING WITH SETSCREW TYPE LOCKING DEVICE.....................................................5-10
FIG. 5-13 – BEARING WITH ECCENTRIC CAM......................................................................................5-12
FIG. 5-14 – B
EARING INSTALLATION – ECCENTRIC LOCKING COLLAR..........................................5-12
FIG. 5-15 – SPLIT BEARING....................................................................................................................5-14
FIG. 5-16 – SPLIT BEARING ASSEMBLY................................................................................................5-15
FIG. 5-17 – INSERTION OF CAPSCREWS..............................................................................................5-18
FIG. 5-18 – S
TANDARD MOUNTING.......................................................................................................5-18
FIG. 5-19 – R
EVERSE MOUNTING..........................................................................................................5-18
FIG. 5-20 – ADJUSTABLE PITCH SHEAVE (JVS)..................................................................................5-20
FIG. 5-21 – ADJUSTABLE PITCH SHEAVE (FHP)..................................................................................5-21
FIG. 5-22 – ASSEMBLY OF CONNECTORS............................................................................................5-23
FIG. 5-23 – MOTOR WIRE CONNECTIONS............................................................................................5-23
FIG. 5-24 – DETERMINING LEFT - OR RIGHT-HAND COIL CONNECTION / DRIVE SIDE..................5-25
FIG. 5-25 – DOOR REPLACEMENT.........................................................................................................5-28
FIG. 5-26 – O
LD STYLE DOOR WITH MITERED CORNER GASKET....................................................5-29
FIG. 5-27 – CUTTING END OF GASKET.................................................................................................5-29
FIG. 5-28 – MARKING GASKET FOR FIRST CUT..................................................................................5-30
FIG. 5-29 – MAKING FIRST CUT ON GASKET ......................................................................................5-30
FIG. 5-30 – MAKING SECOND CUT ON GASKET .................................................................................5-30
FIG. 5-31 – CUT BACK STEM .................................................................................................................5-30
FIG. 5-32 – APPLY SEALANT TO OVERLAPPING SPLICE AREA........................................................5-30
FIG. 5-33 – APPLY SEALANT TO CORNER............................................................................................5-31
LACE ANGLE CUT IN CORNER AND APPLY SEALANT TO NOTCHED AREA..............5-31
FIG. 5-34 – P
FIG. 5-35 – MARK LOCATION FOR CUTTING NEXT CORNER.............................................................5-31
FIG. 5-36 – MARK GASKET FOR OVERLAP LOCATION.......................................................................5-32
FIG. 5-37 – APPLY SEALANT TO EDGE AND AROUND “IN PLACE” GASKET..................................5-32
FIG. 5-38 – O
VERLAP CUT PIECE WITH “IN PLACE” GASKET...........................................................5-32
FIG. 5-39 – APPLY SEALANT TO SPLICE BASE...................................................................................5-32
FIG. 5-40 – ENSURE ALL CORNERS HAVE ADEQUATE SEALANT....................................................5-33
FIG. 5-41 – C
ORRECT MITERED FOAM GASKET CORNER.................................................................5-33
FIG. 5-42 – INCORRECT MITERED FOAM GASKET CORNER.............................................................5-33
johnson controls 21
FORM 102.20-NOM1 (909)

FIG. 5-43 – NEW STYLE DOOR WITH BUT CORNER JOINT GASKET
(Units Produced Jan 2006 through oct 2008).......................................................5-34
FIG. 5-44 – C
UT IN 1/8" UNDER HARD PORTION OF GASKET............................................................5-34
FIG. 5-45 – S
NIP OFF HARD PORTION OF GASKET.............................................................................5-34
FIG. 5-46 – FINISHED CUT.......................................................................................................................5-34
FIG. 5-47 – APPLY FIRST PIECE OF HORIZONTAL GASKET...............................................................5-35
FIG. 5-48 – APPLY SEALANT IN CORNERS...........................................................................................5-35
FIG. 5-49 – ATTACH GASKET TO ONE CORNER..................................................................................5-35
FIG. 5-50 – ROLL GASKET TO OTHER CORNER..................................................................................5-35
FIG. 5-51 – APPLY SEALANT FOR FIRST VERTICAL GASKET...........................................................5-36
FIG. 5-52 – APPLY SEALANT END OF FIRST VERTICAL GASKET.....................................................5-36
FIG. 5-53 – POSITION FIRST VERTICAL GASKET................................................................................5-36
FIG. 5-54 – GOOD VERTICAL TO HORIZONTAL BUT JOINT................................................................5-36
FIG. 5-55 – R
OLL GASKET TO WITHIN 5 TO 6" OF OPPOSITE END...................................................5-37
FIG. 5-56 – TRIM GASKET END..............................................................................................................5-37
FIG. 5-57 – MARK VERTICAL GASKET .................................................................................................5-37
FIG. 5-58 – POSITION VERTICAL GASKET . .........................................................................................5-38
FIG. 5-59 – P
ROPER PLACEMENT OF VERTICAL TO HORIZONTAL GASKET .................................5-38
FIG. 5-60 – R
OLL VERTICAL GASKET INTO PLACE AND SECURE....................................................5-38
FIG. 5-61 – R
OLL TOWARDS OPPOSITE END OF VERTICAL GASKET..............................................5-38
FIG. 5-62 – WIPE OFF EXCESS SEALANT.............................................................................................5-38
FIG. 5-63 – APPLY CLAMP TO CORNER AS NECESSARY...................................................................5-39
FIG. 5-64 – UNACCEPTABLE BUT JOINT, STEP-OFF BETWEEN GASKET SURFACES...................5-39
FIG. 5-65 – UNACCEPTABLE BUT JOINT, VERTICAL GASKET NOT PUSHED IN FAR ENOUGH ...5-39
FIG. 5-66 – S
TEEL FRAME DOOR WITH BUT CORNER JOINT GASKET
(Units Produced AFTER oct 2008)...............................................................................5-40
FIG. 5-67 – C
UT GASKET AND PEEL BACKER ....................................................................................5-40
FIG. 5-68 – P
LACE GASKET ON LATCH SIDE OF FRAME...................................................................5-41
FIG. 5-69 – apply gasket to corner..............................................................................................5-41
FIG. 5-70 – start corner...................................................................................................................5-41
FIG. 5-71 – EXAMPLE OF A GOOD GASKET CORNER........................................................................5-41
FIG. 5-72 – UNACCEPTABLE CORNER - TOO TIGHT...........................................................................5-42
FIG. 5-73 – UNACCEPTABLE CORNER - GASKET EDGE NOT TOUCHING CORNER OF
ANTICOMPRESSION LEG....................................................................................................5-42
FIG. 5-74 – LAY GASKET ON GASKET LEG..........................................................................................5-42
FIG. 5-75 – UNACCEPTABLE gasket fit - gap too big.................................................................5-42
FIG. 5-76 – UNACCEPTABLE gasket fit - GASKET OVERHANGS ANTICOMPRESSION LEG.....5-43
FIG. 5-77 – cut gasket at starting point....................................................................................5-43
FIG. 5-78 – P
OSITION GASKET FOR SECURING..................................................................................5-43
FIG. 5-79 – push gasket into secured position.......................................................................5-43
FIG. 5-80 – F
INAL POSITIONING.............................................................................................................5-44
FIG. 5-81 – EXAMPLE OF A GOOD FINISHED JOINT............................................................................5-44
FIG. 5-82 – EXAMPLE OF An unacceptable joint - open joint...............................................5-44
22 johnson controls
FORM 102.20-NOM1 (909)

FIG. 5-83 – EXAMPLE OF An unacceptable joint - less obvious open joint...................5-44
FIG. 5-84 – EXAMPLE OF An unacceptable joint - offset joint...........................................5-44
FIG. 5-85 – EXAMPLE OF An unacceptable joint - poor joint...............................................5-45
FIG. 5-86 – GASKET SPLICE REQUIREMENTS.....................................................................................5-45
FIG. 5-87 – STANDARD DOOR LATCHES, IN SWING, OUT SWING & MULTI PT. LATCH..................5-47
FIG. 5-88 – ISOLATOR MOUNTING.........................................................................................................5-49
FIG. 5-89 – SUPPLY FAN RESTRAINT....................................................................................................5-50
FIG. 5-90 – THRUST RESTRAINT ASSEMBLY.......................................................................................5-51
FIG. 5-91 – C-CHANNEL..........................................................................................................................5-52
EMOVE COMPONENTS PRIOR TO REMOVING PANELS...............................................5-54
FIG. 5-92 – R
FIG. 5-93 – INSTALL PANELS..................................................................................................................5-54
FIG. 5-94 – APPLY CENTERED OVER SEAM.........................................................................................5-55
FIG. 5-95 – UNDER DRIP AND OVERHANG...........................................................................................5-55
FIG. 5-96 – DO NOT STRETCH................................................................................................................5-55
FIG. 5-97 – APPLY PRESSURE - ROLLER RECCOMENDED................................................................5-56
FIG. 5-98 – PENETRATIONS AND GROMMET DETAILS.......................................................................5-57
FIG. 5-99 – C-CHANNEL..........................................................................................................................5-58
FIG. 5-100 – INSTALL PANELS................................................................................................................5-59
FIG. 5-101 – DOOR REPLACEMENT.......................................................................................................5-59
FIG. 5-102 – LIGHT ASSEMBLY PULL SWITCH SHOWN).....................................................................5-60
FIG. 5-103 – R
EMOVE ELECTRICAL CONNECTORS............................................................................5-60
FIG. 5-104 – MINIHELIC GAGE................................................................................................................5-61
FIG. 5-105 – ASSEMBLY OF GAGE TO LINER COVER PLATE.............................................................5-61
FIG. 5-106 – FILTER GAGE DIAGRAMS.................................................................................................5-63
FIG. 5-107 – ENERGY RECOVERY WHEEL, PULLEY SIDE..................................................................5-64
FIG. 5-108 – SEGMENT RETAINER.........................................................................................................5-64
FIG. 5-109 – SEGMENT INSTALLATION.................................................................................................5-65
FIG. 5-110 – PULLEY LOCATION............................................................................................................5-65
FIG. 5-111 – ATTACHING THE HOOK END OF BELT TO WHEEL RIM WITH TAPE.............................5-66
FIG. 5-112 – CROSS SECTIONAL VIEW OF HOOK END OF BELT ATTACHED TO
WHEEL RIM WITH TAPE.....................................................................................................5-66
FIG. 5-113 – LINK BELT ENDS TOGETHER............................................................................................5-66
FIG. 5-114 – INSERT RIGHT ANGLE BELT RETAINING CLIP...............................................................5-67
ETAINING CLIP WITHIN A FEW INCHES OF THE BEARING SUPPORT BEAM...........5-67
FIG. 5-115 – R
FIG. 5-116 – STRETCHING BELT OVER PULLEY..................................................................................5-68
FIG. 5-117 – SECURING DOOR CHAIN ASSEMBLY..............................................................................5-70
FIG. 5-118 – DIRECT COUPLED ACTUATOR ON JACKSHAFT............................................................5-71
FIG. 5-119 – MIXING DAMPER WALL PUSHED OUT OF PLACE..........................................................5-72
Fig. 5-120 – SECURE MIXING DAMPER WALL TO SIDE PANEL.........................................................5-73
FIG. 5-121 – INSTALL BRACING TO MIXING DAMPER WALL ON EITHER SIDE OF DAMPERS.......5-73
FIG. 5-122 – C
ENTER AND INSTALL BRACING BETWEEN DAMPERS...............................................5-74
FIG. 5-123 – INSTALL ANGLE BRACKETS............................................................................................5-74
johnson controls 23
FORM 102.20-NOM1 (909)

FIG. 5-124 – ID FAN ASSEMBLY COMPONENT CALL OUT..................................................................5-75
FIG. 5-125 – O
PEN FUSE DISCONNECTS..............................................................................................5-75
FIG. 5-126 – R
EMOVE ID FAN WIRES AND ID AIRFLOW SWITCH WIRES..........................................5-75
FIG. 5-127 – R
EMOVE WIRING AND CONDUIT FROM CONTROL PANEL...........................................5-76
FIG. 5-128 – R
EMOVE EXHAUST VENT LOCKING COLLAR COVER AND LOCKING COLLAr........5-76
FIG. 5-129 – REMOVE CONDENSATE DRAIN TRAP.............................................................................5-76
FIG. 5-130 – R
EMOVE ID FAN FLANGE FROM HEAT EXCHANGER...................................................5-76
FIG. 5-131 – R
EMOVE ID FAN HOUSING FROM HEAT EXCHANGER.................................................5-77
FIG. 5-132 – R
EMOVE OLD GASKET......................................................................................................5-77
FIG. 5-133 – TRIM GASKET.....................................................................................................................5-77
FIG. 5-134 - C
AULK BETWEEN HEAT EXCHANGER AND SHEET METAL COVER SPANEL . ..........5-77
FIG. 5-135 – INSTALL NEW GASKET AND CAULK GASKET INNER EDGE........................................5-78
FIG. 5-136 – INSTALL ID FAN FLANGE ONTO HEAT EXCHANGER....................................................5-78
FIG. 5-137 – APPLY SEALANT TO LOCKING COLLAR GROOVES......................................................5-78
FIG. 6-1 – FULL VOLTAGE STARTER (204194)........................................................................................6-2
FIG. 6-2 – FULL VOLTAGE STARTER WITH SINGLE POINT POWER CONNECTION (204195)...........6-4
FIG. 6-3 – OUTSIDE AIR DAMPER KIT - RELAY INSTALLATION............................................................6-6
FIG. 6-4 – TERMINATION CHART INSIDE ENCLOSURE DOOR.............................................................6-7
FIG. 6-5 – YORK SOLUTION FPC WIRING (204197)................................................................................6-8
FIG. 6-6 – TRANSFORMER ENCLOSURE WIRING DETAIL SHOWN OPEN..........................................6-9
FIG. 6-7 – TRANSFORMER WIRING DIAGRAM.....................................................................................6-10
FIG. 6-8 – UV CONTROL PANEL WIRING - 8A.......................................................................................6-11
FIG. 6-9 – UV CONTROL PANEL WIRING - >8A.....................................................................................6-12
FIG. 6-10 – GAS HEAT, SINGLE PHASE, 1500VA TRANSFORMER, WIRING DIAGRAM....................6-14
FIG. 6-11 – GAS HEAT, (1) THREE PHASE MOTOR, 1000VA TRANSFORMER,
WIRING DIAGRAM................................................................................................................6-15
FIG. 6-12 – GAS HEAT, (2) THREE PHASE MOTORS, 500VA TRANSFORMER,
WIRING DIAGRAM...............................................................................................................6-16
24 johnson controls
FORM 102.20-NOM1 (909)
list of TABLES
TABLE 1 – SEGMENT IDENTIFICATION....................................................................................................31
TABLE 2 – UNIT NOMENCLATURE............................................................................................................32
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
TABLE 4-1 – MINIMUM MAINTENANCE ACTIVITY AND FREQUENCY
(ASHRAE STANDARD 62-2001 FOR INDOOR AIR QUALITY)...........................................4-2
TABLE 4-2 – FAN BEARING – LUBRICATION INTERVALS - BALL BEARING PILLOW BLOCKS.....4-12
TABLE 4-3 – F
AN BEARING – LUBRICATION INTERVALS - SPHERICAL ROLLER BEARING
SOLID PILLOW BLOCKS....................................................................................................4-12
TABLE 4-4 – F
AN BEARING – LUBRICATION INTERVALS - SPHERICAL ROLLER
BEARING-SPLIT PILLOW BLOCKS..................................................................................4-12
TABLE 4-5 – MOTOR BEARING – LUBRICATION INTERVALS.............................................................4-14
TABLE 4-6 – MOTOR BEARING – SERVICE CONDITIONS...................................................................4-14
TABLE 4-7 – MOTOR BEARING – LUBRICATION INTERVAL MULTIPLIER.........................................4-14
TABLE 5-1 – TORQUE FOR TIGHTENING SET SCREWS.......................................................................5-8
TABLE 5-2 – RECOMMENDED CLEARANCE REDUCTION VALUES OF SKF TAPERED
BORE BEARINGS (IN INCHES).........................................................................................5-17
TABLE 5-3 – RECOMMENDED CAP BOLT TORQUE VALUES FOR SPLIT PILLOW BLOCK.............5-17
TABLE 5-4 – C
APSCREW TORQUE VALUES FOR FIXED PITCH SHEAVES......................................5-19
TABLE 5-5 – CONNECTORS & SLEEVES WITH STRIP LENGTHS......................................................5-24
TABLE 5-6 – TORQUE CHART - TIGHTENING TORQUE IN INCH POUNDS........................................5-24
TABLE 5-7 – CROSS REFERENCE; CONTINUOUS TO SINGLE LINK BELT/BELT PULLEY KITS....5-69
TABLE 5-8 – TROUBLESHOOTING TIPS...............................................................................................5-79
johnson controls 25
FORM 102.20-NOM1 (909)
service task reference

Adjustable Motor Base Doors
Operation 4-5 Start-up Inspection 3-8
Air Hood, Outside and/or Relief Air Door Replacement 5-28
Installation 2-24 Gasket Replacement 5-29
Orientation 2-24 Handle / Latch Replacement & Adjustment 5-46
Inspection 2-24 Field Modification to Add Doors 5-58
Add Door Safety Chain 5-70
Air Louvers
Inspection 4-4 Drain Lines
Combining 2-62
Air Modulator
Cleaning 4-29
Start-up 3-7
Freeze Protection 4-30
Belts
Drain Pan
Checking Tension 4-7
Cleaning 2-61
Bird Screen Field Testing 4-29
Installation 2-24 Freeze Protection 4-30
Inspection 4-4
Drain Trap
Cabinet Maintenance Installation 2-61
Cleaning 4-3 Cleaning 4-29
Clearance Freeze Protection 4-30
Outdoor Unit 2-1 Drive Kit
Indoor Unit 2-5 Inspection 4-4
Coils Duct Connections
Piping 2-45 Effective Duct Length 2-62
Water 2-46 Turns 2-62
Freeze Protection 2-48 Front Discharge Outdoor Duct Installation 2-64
Steam 2-49 Sound & Vibration 2-64
Vertical Interface & Bypass (VIFB) 2-50
Electrical Connections 2-36
Horizontal Interface & Bypass (IFB) 2-50
Reqirements 2-36
Direct Expansion (DX) 2-54
Penetrations 5-56
Cleaning 4-28
Power Connections
Replacement 5-25
Energy Recovery Wheel 2-37
Controls Gas Heat 2-38
Control Wiring 3-2 Electric Heat 2-39
Humidifier 2-43 Humidifier 2-43
Curb Electric Heat
Assembly & Installation 2-3 Power Connections 2-39
Dampers Control Wiring 3-2
Installation of Multizone Dampers 2-26 Energy Recovery Wheel
Checking Operation 3-5 Power Connections 2-37
Blade Orientation 3-6 Control Wiring 3-2
Cleaning 4-28 Start-up 3-9
Hardware Check 4-28 Replacing Wheel Segments 5-64
Mixing Damper Wall Repair 5-72 Wheel Drive Motor & Pulley Replacement 5-65
Damper Actuator Belt Replacement 5-56
Installation External Lube Lines 4-11
Multizone Actuators 2-26
Fan Assembly
Direct Coupled Mounting 3-6
Pre Start-up Inspection 3-3
Maintenance
Cleaning 4-4
Multizone Actuators 2-27
Maintenance Inspection 4-4
Direct Coupled Replacement & Adjustment 5-71
26 johnson controls
FORM 102.20-NOM1 (909)
service task reference (Cont.)
Fan Bearing Motors

Types 4-10 Check Amperage after Air Balancing 4-3
Lubrication 4-11 Repair 5-24
Replacement 5-9 Replacement 5-23
Fan Motor Mounting
Energizing at Start-up 3-7 Ceiling Suspended Unit 2-26
Inspection & Maintenance 4-12 Outdoor Unit 2-5
Bearing Lubrication 4-13 Indoor Unit 2-5
Replacement 5-23 Pipe Chase
Fan Installation 2-30
Cleaning 4-4 Caulking Pipe Chase to Air Handler 2-32
Inspection 4-4 Caulking & Installation of Cover Angle 2-32
Replacement & Adjustment 5-6 Caulking & Installation of Baserail Covers 2-33
Repair 5-7 Panels
Gas Heat Field Cut Openings (Ducts, Dampers etc.) 5-52
Power Connections 2-38 Replacement 5-53
Control Wiring 3-2 Field Modification for Doors 5-58
Inducer Fan Gasket Replacement 5-75 Pressure Tape Removal and Installation
Wiring Diagrams 6-1 on XTO Roof Panels 5-54
UNIT INSTALLATION 2-7 Piping
Tools & Materials 2-7 Connections 2-45
Ship Loose Parts 2-8 Condensate Drain 2-61
Indoor Unit Drain Trap 2-61
Multiple Piece 2-7 Penetrations 5-57
Tiered or Stacked 2-21 Receiving Inspection 1-4
Outdoor Unit
Single Piece 2-13 Rigging
Multiple Piece 2-13 Indoor & Outdoor Units 1-1
Shipping Splits Spacing Requirements for Offloading Long Units 1-2
Examples 2-12 Sheaves
End Channel 2-23 Replacing after Air Balancing 3-8
Filters (AF, FF, RF) Alignment 4-7
Types 4-15 Replacement & Adjustment 5-18
Maintenance And Replacement 4-15 Short Term Storage 1-4
Inserting into Side Load Filter Tracks 4-15 Start-up 3-1
Filters (HEPA) Start-up Checklist 3-27
Installation 4-27 Steel Frame Assembly 2-3
Isolators Test & Balance
Preparing for operation 3-4 Air Balance 3-31
Isolator Spring Replacement and Adjustment 5-49 Dynamic Balance 3-31
Humidifiers Thrust Restraint
Power Connections 2-43 Replacement & Adjustment 5-51
Control Wiring 2-43 Tiered Unit
Latches (Door) Installation 2-21
Start-up Inspection 3-8 Variable Frequency Drive (VFD)
Replacement & Adjustment 5-46 Set Up of Non Factory Mounted VFD 3-7
Long Term Storage 1-5
Fan Check 1-5
Preventive Maintenance 1-5
Mist Eliminator
Installation 2-24
Inspection 2-24
johnson controls 27
FORM 102.20-NOM1 (909)
THIS PAGE INTENTIONALLY LEFT BLANK
28 johnson controls
FORM 102.20-NOM1 (909)
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,
operation and maintenance must be followed to realize 2. Economizer system (return air/mixing box
the full capacity and life of the units. section).
3. Heating system.
This instruction contains general recommendations,
but specific requirements may apply to the individual 4. Cooling system.
installation. Such requirements are outlined in federal,
state and local safety codes. Strict compliance with these VENTILATION SYSTEM
codes and strict adherence to these instructions are the
responsibility of the user. Particular attention should A ventilation system simply replaces the air in a given
be given to electrical wiring and other safety elements space. Usually the purpose is to remove air that is
such as design working pressures and requirements substandard to creature comfort or a process and replace
of the Government Clean Air Act Amendments as it it with suitable air. Depending on the application the
applies to refrigerant types and charges. General safety system will operate at various specified rates, volumes
practices are covered in AMCA Publication 410-90. and conditions. A ventilation system may employ an air
handler with a supply fan working in conjunction with
Read the entire instruction before installing or operating other remote exhaust fan(s). A more effective method
the air handler. Specific details and requirements apply would employ both a supply fan and an exhaust fan in
that require careful consideration to avoid damage to the air handler.
the equipment and injury to the installer or operator.
The YORK Solution features segmented construction

and is factory assembled. Segment arrangements will
vary to suit job application (see Fig. 1). Heavy gauge
galvanized steel is used on the exterior and interior of
the unit. Access doors are provided for accessibility
to the various sections. Removable access panels are
standard in lieu of doors on Commercial Performance
units. Panels and doors are double wall construction.
Panels, doors and structural frame are insulated with
spray-injected foam.
LD13764
FIG. 1 – CUTAWAY OF YORK Solution SHOWING VARIOUS SEGMENTS
johnson controls 29
FORM 102.20-NOM1 (909)
ECONOMIZER SYSTEM - TYPICAL HEATING OPERATION

The Economizer system could typically consist of: Various types of heating may be applied. Hot water
• Outdoor and return air dampers. or steam coils maybe specified typically. Electric heat
and fuel burner heat are available.
• Damper actuator.
• Enthalpy control. COOLING OPERATION
Various types of cooling may be utilized. Factory
• Minimum outdoor air adjustment.
mounted chilled water coils or direct expansion
• Exhaust air control. refrigerant coils may be specified for the YORK
Solution unit.
The Economizer system provides the first stage of
cooling whenever the outdoor air is cool and dry HAND IDENTIFICATION
enough to satisfy the internal cooling demand. The
outdoor and the return air dampers are operated by Coil connections and other components are located and
individual actuators. As the outdoor air dampers are described as left or right hand. The proper orientation
opened by the damper actuator, the return air dampers to describe the proper hand is when airflow is at your
are closed. back, as shown in Fig. 2.
If the economizer operation cannot satisfy the space

demand for cooling, stages can be energized as
needed.
FAN SEctION
Right
ReAR
rIGht hAND (rh)
cOIL cONNEctION
LEFt hAND (Lh)

cOIL cONNEctION
rEtUrN AIr
OUtSIDE AIr
leFt
INLEt SEctION
DrIVE hAND AND cOIL hAND DEtErMINED
By FAcING thE INLEt SEctION
FROnt
LD08004
FIG. 2 – UNIT AND COIL HAND IDENTIFICATION
30 johnson controls
FORM 102.20-NOM1 (909)
SEGMENT IDENTIFICATION
Refer to Tables 1 and 2 for segment identification and nomenclature.
TABLE 1 – SEGMENT IDENTIFICATION FILTER SEGMENTS

• FF – Flat Filter (2" or 4")
FAN SEGMENTS • AF – Angle Filter (2" & 4")
• FS – Supply • RF – High Efficiency Filter
• Forward Curved • Rigid Filter (12")
• Airfoil • Bag Filter (21")
• Industrial Airfoil • Mini-Pleat Filter (4")
• SWSI Plenum • HF – HEPA Filter
(Belt and Direct Drive) INLET SEGMENTS
• FR – Return • MB – Mixing Box
• Forward Curved • FM – Filter/Mixing Box
• Airfoil • EF – Filter/Economizer
• Industrial Airfoil • EE – Economizer
• SWSI Plenum • IP – Inlet Plenum
(Belt and Direct Drive) • VE – Vertical Economizer
• FE – Exhaust • VF – Vertical Filter/Economizer
• Forward Curved ACCESSORY SEGMENTS
• Airfoil • VP – Vertical Plenum
• Industrial Airfoil • DP – Discharge Plenum
• SWSI Plenum • TN – Turning Plenum
(Belt and Direct Drive) • DI – Diffuser
COIL SEGMENTS • XA – Access segment
• CC – Cooling Coil • AB- Air Blender
• HC – Heating Coil • EB – External Bypass
• VC – Vertical Coil • IB – Internal Bypass
• MZ - Multizone • FD – Face Damper
HEAT SEGMENTS • AT – Attenuator
• IC – Integral Face & Bypass Coil • HM - Humidifier
• IG – Indirect Gas Fired Furnace • UV - UVC Lamps
• EH – Electric Heater
ENERGY RECOVERY
• ER – Energy Recovery
johnson controls 31
32
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
FACTORY MOUNT END DEVICES.

0 NO
1 YES
H WIDTH FAN OPTIONS MOTOR HORSEPOWER

27 27,30,33,36,39,42,45,48,51,54,57 A NONE. A0
30 27,30,33,36,39,42,45,48,51,54,57,60 B DWDI FC FAN w/o MOTOR CONTROLLER. B 1/2
33 30,33,36,39,42,45,48,51,54,57,60,63,66,69 C DWDI FC FAN w/SERVICE DISCONNECT ONLY. C 3/4
36 30,33,36,39,42,45,48,51,54,57,60,63,66,69,72 D DWDI FC FAN w/MOTOR STARTER. D1
39 33,36,39,42,45,48,51,54,57,60,63,66,69,72,75,78 E DWDI FC FAN w/VARIABLE FREQUENCY DRIVE. E 1 1/2
42 36,39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,84 F DWDI AF FAN w/o MOTOR CONTROLLER. F2
45 36,39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,84,87 G DWDI AF FAN w/SERVICE DISCONNECT ONLY. G3
48 39,42,45,48,51,54,57,60,63,66,69,72,75,78,81,87,90 H DWDI AF FAN w/MOTOR STARTER. H5
51 42,45,48,51,54,57,60,63,66,69,72,75,78,81,84,87,90,93,96,99 J DWDI AF FAN w/VARIABLE FREQUENCY DRIVE. J 7 1/2
54 45,48,51,54,57,60,63,66,69,72,75,78,81,84,87,90,93,96,99,102 K SWSI PL FAN w/o MOTOR CONTROLLER. K 10
57 48,54,60,66,72,78,84,90,102,108 L SWSI PL FAN w/SERVICE DISCONNECT ONLY. L 15
60 48,54,60,66,72,78,81,84,90,96,102,108 M SWSI PL FAN w/MOTOR STARTER. M 20
63 51,57,63,69,75,81,87,90,93,99,105,111,117 N SWSI PL FAN w/VARIABLE FREQUENCY DRIVE. N 25
66 54,60,66,72,78,84,90,96,102,108,114,120 P SWSI PL FAN DIRECT DRIVE w/o MOTOR CONTROLLER. P 30
69 51,57,63,69,75,81,87,93,96,99,105,108,111,117,123 Q SWSI PL FAN DIRECT DRIVE w/SERVICE DISCONNECT ONLY. Q 40
72 54,60,66,72,78,84,90,96,102,108,114,120,126,132 R SWSI PL FAN DIRECT DRIVE w/MOTOR STARTER. R 50
75 57,63,69,75,81,87,93,99,105,111,117,120,123,129,135 S SWSI PL FAN DIRECT DRIVE w/VARIABLE FREQUENCY DRIVE. S 60
78 60,66,72,78,84,90,96,102,108,114,120,126,132,138,144 T 75
84 60,66,72,78,84,90,96,102,108,114,120,126,132,138,144 U 100
90 66,72,78,84,90,96,102,108,114,120,126,132,138,144 V 125
96 72,78,84,90,96,102,108,114,120,126,132,138,144
102 72,78,84,90,96,102,108,114,120,126,132,138,144
108 78,84,90,96,102,108,114,120,126,132,138,144
114 84,90,96,102,108,114,120,126,132,138,144
120 90,96,102,108,114,120,126,132,138,144
126 90,96,102,108,114,120,126,132,138,144
132 96,102,108,114,120,126,132,138 003-001.xls Rev New
Notes: 1.The height and width numbers only correspond to each other in the same row.
2. The height and width numbers will always be (3) characters long in the model number.
LD13350
johnson controls
FORM 102.20-NOM1 (909)
FORM 102.20-NOM1 (909)
UNIT IDENTIFICATION UNIT ID LABEL

Both indoor and outdoor units are labeled with a Unit The Unit ID Label contains the Model #, Serial/Date
ID Label, Skid ID Labels and Loose Component ID Code, Job Identification #, Segment Identification, #
Labels. Indoor units are shrink wrapped with Skid ID of Skids, Unit Tag #, Electrical Ratings, Coil Data &
Labels on the outside of the wrapping as well as on Manufacturing Location (see Fig. 3).
each skid.
SKID ID LABEL
Each skid in a multi piece unit is marked with a Skid
ID Label, which indicates its order of assembly in the
UNIT ID. THIS PRODUCT MANUFACTURED FOR OUTDOOR USE direction of airflow (see Fig. 4).
MODEL # COM : 117817
XTO-108X120-JJRN046A
SERIAL # / DATE CODE JOB IDENTIFICATION #
CHTM XT0085 08-179121-01-01
(FS)(CC-HM)(XA-IC-XA-RF)(EE)(FR)
# OF SKIDS UNIT TAG # See Fig. 5 for MODEL # COM : 117817
5 AHU 9-10 Segment ID XTO-108X120-JJRN046A
explanation SERIAL # / DATE CODE JOB IDENTIFICATION #
ELECTRICAL RATINGS CHTM XT0085 08-179121-01-01
TOTAL RATINGS (COMBINED LOADS)
VOLTS / PH / HZ M.C.A. MAX. O.C. PROT. (FS)(CC-HM)(XA-IC-XA-RF)(EE)(FR)
460/3/60 _____ _____ UNIT TAG
SUPPLY FAN MOTOR RATING (INDIVIDUAL LOAD)

HP FLA M.C.A. MAX. O.C. PROT.
SKID 1
JOB NAME
of 5 AHU 9-10
SKID OVERALL SIZE
50 72 90 150 Owens Corning BLDG-21 116 H x 120 W x 59 L
RETURN FAN MOTOR RATING (INDIVIDUAL LOAD)
AHU 9-10
25 38 47.5 80
HEAT RECOVERY WHEEL MOTOR RATING (INDIVIDUAL LOAD)
N/A N/A N/A N/A
ELECTRIC HEAT RATINGS GAS HEAT RATINGS Estimated Weight:
4,100
N/A N/A
LIGHTS & OUTLETS
VOLTS / PH / HZ M.C.A. MAX. O.C. PROT.
120/1/60 20 20
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. 50 Fan and is placed first in the direction of airflow.
See Segment ID box example.
EVAPORATOR COIL DESIGN PRESSURE. 325 PSI LD11729A
FIG. 4 – SKID ID LABEL
EVAPORATOR COIL REFRIGERANT USED. _____
EVAPORATOR COIL REFRIGERANT OIL USED. _____ SEGMENT IDENTIFICATION BOX
SUITABLE FOR USE WITH REMOTE CONDENSER; AIR-COOLED, WATER-COOLED, OR
VAPORATIVE. THE DESIGN PRESSURE MARKED ABOVE SHALL NOT BE LESS THAN THE
DESIGN PRESSURE MARKED ON THE REMOTE CONDENSING UNIT. The Segment Identification box indicates the skids and
MANUFACTURING LOCATION segments* used on a multi piece unit. The contents of
YORK INTERNATIONAL - East York FACILITY
each skid are indicated by segment(s) surrounded by
1499 E PHILADELPHIA ST
parenthesis (see Fig. 5 below).
YORK PA 17403
USE COPPER WIRES ONLY. CLEARANCE FROM COMBUSTIBLE SURFACE: UNIT IS 0 INCHES,
DUCT IS 0 INCHES. MAXIMUM INLET TEMPERATURE; 100^ F / MAXIMUM OUTLET (Skid 5 of 5) (Skid 3 of 5) (Skid 1 of 5)
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 4 of 5) (Skid 2 of 5)
(FS)(CC-HM)(XA-IC-XA-RF)(EE)(FR)
9800071 Direction of Airflow

Order of Assembly
LD11728A
* See Table 1 for Segment Identification LD11752A
FIG. 3 – UNIT ID LABEL FIG. 5 – SEGMENT ID BOX EXAMPLE
johnson controls 33
FORM 102.20-NOM1 (909)
LOOSE COMPONENT ID LABEL FILTER ID LABEL

Each loose component has a label showing where it is Fig 7 shows a typical Filter Label with Filter Segment
to be installed on the unit. The segment identification and Filter List.
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).
CHTM XT0085 08-179121-01-01
  
(XA-IC-XA-RF)

Filter
UNIT TAG
 
 
AHU 9-10
JOB NAME SKID OVERALL SIZE


Owens Corning BLDG-21 116 H x 156 W x 76 L

 Filters

 
026-32406-001 FLTR,PERFPLT,30%EFF,12W_24H_2D Qty: 4
  026-32406-003 FLTR,PERFPLT,30%EFF,24W_24H_2D Qty: 16
026-32404-009 FLTR,VCL_SH,12W_24H_12D,80-85% Qty: 4
 026-32404-010 FLTR,VCL_SH,24W_24H_12D,80-85% Qty: 16
   
Spare Filters
OA Moisture Eliminator installed on (EE) skid/segment. 026-32404-009 FLTR,VCL_SH,12W_24H_12D,80-85% Qty: 4
LD11730 026-32404-010 FLTR,VCL_SH,24W_24H_12D,80-85% Qty: 16
LD13942
FIG. 7 – filter LABELS
Bird Screen
DIRECTION OF AIRFLOW
The direction of airflow is always read from right to
CHTM XT0085 08-179121-01-01 left.
SEGMENT IDENTIFICATION *Ship Loose*
Outside Air 386-60000-938 Hood - EE
UNIT TAG
Hood 1 of 6 AHU 9-10
JOB NAME SKID OVERALL SIZE
Owens Corning BLDG-21 116 H x 180 W x 85 L
AHU 9-10
One of six hoods installed on (EE) skid/segment.
LD11751A
FIG. 6 – LOOSE COMPONENT ID LABELS
34 johnson controls
FORM 102.20-NOM1 (909)
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 All lifting points must be used to avoid
are utilized to properly package the air handling units. personal injury or death and to avoid
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-
ceiver is solely responsible for noting
Bill of Lading and filing freight claims SHIPPED LOOSE DAMPERS. When
IMMEDIATLY. Refer to Shipping large units are ordered with MZ seg-
Damage Claims Form 50.15-NM ments in rear discharge location (on
available from Johnson Controls Sales the end of the unit), the units will
representative. ship with the top section (hot deck)
separated. In these cases, the com-
plete multizone damper assembly (hot
deck and cold deck together) will ship
loose.
SPREADER BARS MUST BE WIDER THAN THE

UNIT WIDTH TO PREVENT DAMAGE TO THE
HOUSING & ROOF EDGE.
LD13769
FIG. 1-1 – RECOMMENDED LIFTING WITH FOUR LIFTING POINTS
SPREADER BARS MUST BE

WIDER THAN THE UNIT WIDTH TO
PREVENT DAMAGE TO THE
HOUSING & ROOF EDGE.
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
FIG. 1-2 – RECOMMENDED LIFTING WITH MULTIPLE POINTS

johnson controls 1-1
Pre-installation
FORM 102.20-NOM1 (909)
OFF-LOADING All lifting lugs must be used to avoid

Proper rigging and handling of the equipment is damage to unit. If unit does not have
mandatory during unloading and setting it into position lifting lugs, use bottom corner connec-
to retain warranty status. tors and intermediate raceway lifting
lugs. Do not use top corner connec-
Care must be taken to keep the unit in the upright tors.
position during rigging and to prevent damage to the
air and watertight seams in the unit casing. Prevent Unit section weights are furnished on the job submittal.
unnecessary jarring or rough handling. Due to the variance in weight of each unit design, it is
not possible to list unit weights in this instruction. The
For lifting air handling units with lifting lugs or corner submittal must be referred to when selecting a crane
connectors; proper spreader bars and hoisting line must for rigging and figuring roof weight loads. Contact
be used when rigging to prevent damage to the unit your Johnson Controls Sales representative if you have
casing (see Fig. 1-1). When lifting long units a special any questions regarding unit weights.
system must be used to insure a minimum 60° angle
between lifting lug and spreader bar/frame (see Fig. 1-2
CRANE AND SPREADER BARS
& Table 1-1). It is also mandatory that an experienced
and reliable rigger be selected to handle unloading and See Fig's 1-1 and 1-2.
final placement of the equipment. The rigger must be
advised that the unit contains internal components and FORK LIFT
that it be handled in an upright position. Care must be
Forklifts should not be used to off-load air handlers
exercised to avoid twisting the equipment structure.
except in special circumstances. If moving air handling
equipment with a fork lift or similar means becomes
Refer to the submittal for the section necessary, always make sure the lifting forks are long
weights. enough to reach from the fork truck to the opposite side
and slightly beyond. It is helpful to leave the shipping
blocks attached to the bottom of the equipment until
in its final location. There is no structural support
under the equipment except what is visible from the
TABLE 1-1 - SPACING REQUIREMENTS FOR
perimeter.
OFFLOADING LONG UNITS
MAX. LIFTING MIN. LIFTING COME-A-LONGS OR POWER PULL
UNIT HT.
LUG SPACING STRAP LENGTH See Fig1-3.
≤ 72" 120" 120"
> 72" 192" 192"
LD09613
FIG. 1-3 – TYPICAL COME-A-LONG TYPES
1-2 johnson controls

FORM 102.20-NOM1 (909)
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.
Fig’s 1-4 and 1-5 show YORK Solution

unit without baserails. When baser- 1
ails are present, always use all lifting
lugs pre-mounted on baserails. Do
not lift by corners.
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

Pre-installation
FORM 102.20-NOM1 (909)
INSPECTION STORAGE
CHECK FOR DAMAGE SHORT-TERM STORAGE
RECEIVER RESPONSIBILITY Indoor Units:
Receiver is solely responsible for noting freight bill and Under no circumstances should out-
filling freight claims IMMEDIATLY (see “Receiving” door storage be used
in this section).
Outdoor Units:
Visible damage should be noted on the signed and
Be sure all shipping covers are re-
dated bill of lading with a request that the carrier
inspect the damage within 72 HRS. of notification. The
applied after inspection, or tarps are
shipping wrapper must be removed and replaced with used during storage.
a tarp or similar protective covering. Any concealed
damaged reported after 15 days will compromise a Short-term storage is considered six (6) months or less
claim settlement. Inspection requests may be done from date of shipment. Storage maintenance during
by telephone or in person, but should be confirmed in this time is usually limited to the following.
writing. If assistance is needed with the claim process,
contact your Johnson Controls Sales representative.
• Rotate fans every four (4) weeks beginning
INDOOR UNITS upon arrival to prevent moisture from damaging
bearing.
It is Johnson Controls intention that a shipping wrapper
be applied to unpainted indoor units for protection • If the units are to be stored out-of-doors, prior
from weather, road dirt, etc. during inland transit and to installation, special care must be taken to
that the wrapper be removed at the time of delivery to cover and protect the units from dust, rain, snow
allow for a thorough inspection, both inside and out. and rodents. The units must be protected from
constant exposure to rain and snow.
OUTDOOR UNITS • Store on a firm, flat surface to prevent distortion.
Outdoor units are not fully wrapped. Exposed openings Block the unit off the ground to protect
are covered for protection from weather, road dirt, etc. components from water.
during inland transit. A thorough inspection, both
inside and out, should be done at the time of delivery.
Protect all parts and porous materials
from rain and other sources of mois-
CHECKING FOR NON MOUNTED PARTS
ture. Decontaminate or replace as
• Check the packing list for non-mounted ship needed to ensure microbial growth is
loose parts. (Check inside all segments.) IAQ not introduced to the air handler.
• Packing list will note how many and type of
parts.
• The unit must also be protected from damage
• Shortages must be reported within 10 days after to the exterior of the cabinet or coil connections
receipt of order. by construction vehicles and personnel.
See Ship Loose Parts, Fig 2-8 thru 2-14

FORM 102.20-NOM1 (909)
LONG-TERM STORAGE Long-term storage is considered to be

Long-term storage is considered any period beyond any period beyond six (6) months from
six (6) months from date of shipment. If long-term date of shipment. If long-term storage
storage is anticipated, contact the Johnson Controls is anticipated, contact Johnson Con-
Sales representative for the proper instructions and trols Sales representative at time of
requirements for long-term storage. It is mandatory order entry for the proper instructions
that a detailed record be maintained during this long- and requirements for long-term stor- 1
term period, such as, but not limited to: proper sealing age. Refer to Form 50.20-NM3.
of the cabinet, rotation of the blowers and bearings,
and protection of all motors from moisture. Refer to
Form 50.20-NM3 “Long Term Storage Requirement - PERIODIC FAN CHECK
Field Preparation” and Form 50.20-CL3 “Long Term
On a monthly basis, the fan and motor should be
Storage Periodic Checklist and Logs”, copies of which
rotated several times to replenish the bearing surfaces
is included in this section.
with fresh grease.
PREVENTIVE MAINTENANCE PRIOR TO LONG
The fan impeller should be left at approximately 180
TERM STORAGE
degrees from that of the previous month to prevent the
The following precautions should be taken prior to belts from taking a set position.
extended storage:
• Fan and motor bearings are to be greased per
the manufacturer’s specifications. It will be the responsibility of the cus-
tomer to submit a monthly log sheet
• Motors and sheaves must be protected from (MS577) showing the condition of the
free moisture or high humidity. This may be
unit and noting any discrepancies. A
accomplished by 1) spraying components with
an anti-rust solution (P/N 026-37707-000) or
copy of the log sheet should be sent
2) disconnecting the belts and wrapping the to the Johnson Controls Office, attn.:
sheaves and motor and sealing them with plastic. Sales Representative.
Insert a desiccant to absorb moisture that may
Failure to perform the long-term stor-
penetrate the plastic protection.
age requirements will void the war-
• The fan motor windings should be megged at ranty.
this time and recorded for comparison prior to
placing in service.
• If the fan housing was supplied with a drain
connection, this plug should be removed to
prevent moisture from accumulating in this
portion of the fan during storage.

Pre-installation
FORM 102.20-NOM1 (909)
LONG-TERM STORAGE
requirement - field preparation
AIR HANDLING UNITS
SERVICE POLICY & PROCEDURES Supersedes 50.20-NM3 (307 ) Form 50.20-NM3 (909)
Failure to comply with these requirements will render

any written or implied YORK warranty null and void.
Upon completion of the long term storage period, the warranty commences:
- Solution - 18 months parts only. (not to exceed 36 months from ship date with
delayed start up).
- Custom - 18 months factory parts (not to exceed 18 months from ship date).
- Labor 12 months only w/ delayed start up.
I. Supplementary Documentation
The following documentation is required to FULLY COMPLY with the Long-Term Storage requirements.
A. Long-Term Storage Requirements – GENERAL (refer to Form 50.20-NM1)
B. Long-Term Storage – PERIODIC CHECKLIST AND LOGS,
AIR HANDLING UNITS (refer to Form 50.20-CL3).
II. Field Preparation for Long-Term Storage

A. GENERAL
1. Remove and dispose of shipping materials.
2. Perform a visual inspection of the equipment.
Indoor Units
It is Johnson Controls' intention that a shipping wrapper be applied to unpainted indoor units for protection
from weather, road dirt, etc. during inland transit and that the wrapper be removed at the time of delivery
to allow for a thorough inspection, both inside and out. 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.
The shipping wrapper must be removed and replaced with a tarp or similar protective covering. Any
concealed damaged reported after 15 days will compromise a claim settlement. Inspection requests
may be done by telephone or in person, but should be confirmed in writing. If assistance is needed with
the claim process, contact your Johnson Controls Sales person.
Outdoor Units
Outdoor units are not fully wrapped. Exposed openings are covered for protection from weather, road
dirt, etc. during inland transit. A thorough inspection, both inside and out, should be done at the time of
delivery. 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. Concealed damage must be reported within 15
days of delivery with a request that the carrier inspect the damage within 72 hrs of notification. Any
concealed damaged reported after 15 days will compromise a claim settlement. Inspection requests
may be done by telephone or in person, but should be confirmed in writing. If assistance is needed with
the claim process, contact your Johnson Controls Sales person.

FORM 102.20-NOM1 (909)
3. Touch up any paint that has worn or chipped off using paint supplied in ship loose items. Prepare the
surface as required using a wire brush.
4. Verify that all ship loose items are present. Note any missing items on the Periodic Check List and Log
Sheet (50.20-CL3).
5. Locate unit(s) so that passing traffic will not damage shafts, coil connections, damper linkages or unit 1
panels.
6. Refrigerant coils must be evacuated and pre-charged with 5 PSIG nitrogen holding charge. DO NOT
damage or disturb these coils and connections.
7. Water coils must have all inlet and outlet connections capped or closed tight to prevent foreign materials
and liquids from gaining entrance during the storage period.
B. ELECTRICAL EQUIPMENT AND COMPONENTS

(Control Panels, Power Panels, Option Panels, Motors, etc.)
1. Electrical Equipment and Components shall not be stored or left in an outdoor environment.
2. Electrical Equipment and Components shall not be stored or left in a wet or damp environment.
Components sealed in plastic shrink-wrap are not exempt from this requirement. Moisture will collect
inside the plastic, resulting in corrosion of the cabinet, the electronic components and/or copper bus
bars.
3. Cortec® spray (Part VpCL-248) shall be applied to all components in the motor terminal box. The
spray shall be applied to all exposed areas of concern.
4. YORK Vapor Emitter(s) shall be installed inside each electrical and electronic components cabinet(s)
to protect against corrosion. Openings in cabinets shall be taped closed to minimize air infiltration
during the storage period. The quantity of emitters is determined by measuring the gross volume of the
component space occupied. YORK Part Number 026-37705-000 will protect a volume up to 5 cubic
feet. YORK Part Number 026-37706-000 will protect a volume up to 11 cubic ft. Both emitters have a
service life of 12 months.
5. A Vapor Type Corrosion inhibitor must be installed in the following equipment and components:
a. Place one corrosion inhibitor, YORK part number 026-37706-000, inside the power panel.
b. Place one corrosion inhibitor, YORK part number 026-37705-000, inside the control panel.
c. Place one corrosion inhibitor, YORK part number 026-37705-000, inside each VFD panel.
C. MECHANICAL
1. Spray all exposed shafts and sheaves with anti-corrosion spray, YORK part number 026-37707-007.
2. Disconnect belts and wrap all motors and sheaves in plastic with a YORK vapor emitter, part number
026-37705-000.
©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 50.23-NM3 (909)
www.johnsoncontrols.com Supersedes 50.23-NM3 (307)

Pre-installation
FORM 102.20-NOM1 (909)
LONG-TERM STORAGE
periodic checklist and logs
AIR HANDLING UNITS
SERVICE POLICY & PROCEDURES Supersedes: 50.20-CL3 (507) Form 50.20-CL3 (909)
Contract No. ________________________ Date Delivered _ _____________________

Job Name ________________________ Date of Storage Prep. _ _____________________
Serial No ________________________ Condition of Unit Delivered __________________
Unit Model No ________________________ Explain: __________________________________
_ ______________________________________________________________________
_ ______________________________________________________________________
_ ______________________________________________________________________
Failure to comply with these requirements will render

any written or implied Johnson Controls warranty null and void.
I. Supplementary Documentation
The following documentation is required to FULLY COMPLY with the long term storage requirements.
A. Long-Term Storage Requirements - GENERAL (refer to Form 50.20-NM1).
B. Long-Term Storage Requirement - LONG -TERM STORAGE REQUIREMENT FIELD

PREPARATION, AIR HANDLING UNITS (refer to Form 50.20-NM3).
II. Checks
1.0 Monthly Checks

1.1 Visually inspect Air Handler for damage.
1.1.1 Motors/Drives - The motors and sheaves should be inspected externally for evidence of
damage to the protective covering. An inspection is necessary only if it is apparent that the
control protection has been disturbed. If this is found, the motor should be re-protected by
wrapping and tightly sealing the control with plastic and inserting a desiccant to absorb
moisture.
1.2 Refrigerant Coils - Check holding charge pressure monthly to be sure that the pressure has not
dropped. If pressure has dropped, the unit should be inspected for signs of visible damage which may
have caused the loss of pressure. If pressure drops more than 2 psi, the unit should be pressure tested to
locate the leak, the leak repaired, and the unit recharged with nitrogen to 5 psig pressure. Note this in the
comments section of the monthly log sheet (see page 2 of this document).
1.3 Rotate fan shaft several revolutions by hand every month.

FORM 102.20-NOM1 (909)
2.0 Quarterly Checks

2.1 Complete Assembly - The unit should be checked quarterly to see that no damage has occurred to the
protective covering. Any apparent damage to the covering or units should be noted in the comments
section of the quarterly log sheet (see page 3 of this document).
2.2 Grease bearings every three months. The greasing procedure is explained in the product service
manual. 1
3.0 Semi Annual Checks
3.1 None
4.0 Annual Checks

4.1 Unwrap all electrical cabinets and install new Vapor Emitters (YORK P/N 026-37705-000); reseal.
4.2 Re-spray all exposed shafts and sheaves with anti-corrosion spray, YORK P/N 026-37707-007.
1.0 Monthly
Motor Belts &
Rotate 5 PSI Coil
Drives Protected Comments
Shafts Pressure
and Dry
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial
Date
Initial

Pre-installation
FORM 102.20-NOM1 (909)
2.0 Quarterly
Grease Inspect Protective
Bearings Covering
Comments
Date
Initial
Date
Initial
Date
Initial
Date
Initial
4.0 Annual
Re-spray
Install New
Vapor Emitters
Exposed Shafts Comments
and Sheaves
Date
Initial

FORM 102.20-NOM1 (909)
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.
MIN. CLEARANCE DIMENSIONS
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)
H Coil Access Panel on Outdoor Unit (allow clearance = to unit width)
FIG. 2-1 – MINIMUM SERVICE CLEARANCES
LD6328-4

Installation
FORM 102.20-NOM1 (909)
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 & 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.
Be sure the supporting structures will

not obstruct the duct, piping or wiring
connections.

FORM 102.20-NOM1 (909)
Curb Assembly & 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- If bolts are tightened after anchoring,
ing channel curb will be pulled, twisted and torqued
Make certain that all curb walls ac- out of square.
2
cessories and flanges, which may
have been distorted in handling, are
straightened before assembly.
6. Pipe Chase Curb Assembly - once curb is square
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)
shows a gasket that is mounted between the curb
and the unit. This gasket is shipped with the curb STEEL FRAME
parts. Install the curb gasket before setting the
unit on the curb. The gasket forms an air seal When a steel frame is used to support the unit, it must
between the unit and the curb and serves as a be level, flat without uneven steel frame joints, and
dampener, preventing metal-to-metal contact support the unit around the full perimeter. As a general
between the unit and curb. However, the gasket rule, cross members should be placed every 96" in
should not be used as a vibration isolator where addition to every shipping split.
the prevention of noise and vibration transmis-
sion into the building is critical.

Installation
FORM 102.20-NOM1 (909)
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
Curb for Pipe Chase UNIT

ROOF LEFT HAND
"A" 2"
CURB PIPE CHASE
2"
PIPE CHASE SECTION VIEW

SECTION "A-A"
Screw flange of pipe chase CURB CALCULATION FOR OUTSIDE DIMENSIONS

curb to unit roof curb 2" x 4"
nailer. A = Total unit length from YORKworks minus 0.875"
B = Pipe chase location distance from unit discharge end.
Screw flange of pipe chase
Pipe chase Mtg. holes will not be included on the
curb to unit roof curb.
pipe chase curb. Mtg. will be field located.
C = Pipe chase length minus 0.875"
D = Total unit width from YORKworks minus 0.875"
DETAIL B
PIPE CHASE CURB CONNECTION
TO UNIT CURB
WALL PANEL
WALL PANEL STANDARD

RACEWAY
STANDARD
RACEWAY 1.25" 1.50"
STANDARD
3.5" BASE RAIL
CURB GASKET 0.438" Note 2
TYP.
CURB REST 1.5"
CURB GASKET
CURB REST
2" x 4" NAILER NOMINAL 1.875"
Note 1 TYP.
2" x 4" NAILER
ROOF CURB NOMINAL
Note 1
2.00"
TYP. ROOF CURB
TYPICAL CURB SECTION DIMENSIONS

FOR UNITS W/O BASE RAIL
TYPICAL CURB SECTION FOR
UNITS WITH BASE RAIL
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
FIG. 2-2 – TYPICAL CURB ASSEMBLY

FORM 102.20-NOM1 (909)
INDOOR UNITS (SITE PREP)

Concrete pads often are not as flat
as they should be. Shimming and/or
grouting may be necessary. This is to
ensure the unit base is on a perfectly
flat plane.
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 0 LD05373
2
the unit for removing the coil or fan
assembly. FIG. 2-4 – NO HOUSEKEEPING PAD – BASERAIL
REQUIRED TO ACCOMMODATE TRAP
HEIGHT
MOUNTING
FLOOR
Units must be installed in such a manner as to provide
enough elevation for properly designed condensate The floor must be flat and level.
traps.
HOUSEKEEPING PAD
See Section 2 “Piping Connections - Condensate The housekeeping pad must be flat and level (see Fig's
Drain Trap.” ► 2-3, 2-4 & 2-5).
LD05372
FIG. 2-3 – NO BASERAIL – HOUSEKEEPING PAD

LD05374
REQUIRED TO ACCOMMODATE TRAP
HEIGHT
FIG. 2-5 – W
ITH BASERAIL AND HOUSEKEEPING
PAD

Installation
FORM 102.20-NOM1 (909)
STRUCTURE PARALLEL TO AIRFLOW STRUCTURE PERPENDICULAR TO AIRFLOW

(Units under 5 ft. wide) (Units over 5 ft. wide)
BDW COOLING
BDW COOLING
FAN SECTION FS
AIR FLOW AIR FLOW

PLAN VIEW PLAN VIEW
MC RF CC RF
MB MB
FAN SECTION FS
LD09619a
ELEVATION VIEW ELEVATION VIEW
FIG. 2-6 – CEILING SUSPENDED UNIT
CEILING SUSPENDED UNITS
It is recommended that support is • Upstream and downstream of each cooling coil

structurally engineered to prevent segment.
flexing, sagging or twisting of air • Under heavy components like fans, attenuators,
handlers. & heating segment.
Do not obstruct door operation, filter
Refer to Fig. 2-6 “Ceiling Suspended Unit” for proper access, piping, electrical or control
support of unit in the direction of airflow and/or connections with suspension mem-
perpendicular to the direction of airflow. bers.
General Requirements
Johnson Controls recommends that ceiling suspen-
sion of units be accomplished in the field with the Structure Positioned In the Direction of Airflow
following: The unit base must be supported continuously, on both
sides of the unit.
Structure Positioned Perpendicular to Airflow
The units must be supported (at a minimum) in the

following locations:
• Both ends.
• At each shipping split.

FORM 102.20-NOM1 (909)
UNIT INSTALLATION
TOOLS NEEDED See Fig. 2-7.

• 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.
2
• Pry bar.
• Drift pins and awls.
• Common hand tools.
• Caulking gun.
LD09613
Material not provided by YORK.
FIG. 2-7 – TOOLS TYPICALLY USED FOR When unit is shipped in sections, the
ASSEMBLY OF SHIPPING SPLITS gasket provided with the curb is to
be replaced with caulk provided by
contractor. Gaskets on curbs can
pose a problem when sliding sections
together for the final connection of
each shipping split.

Installation
FORM 102.20-NOM1 (909)
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.
3/8" x 3/4" Button

Head Screw
3/16" Allen
Wrench
3/8" Nut
Baserail Lifting Lugs Assembled
1/2" x 4" Bolt
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)
Raceway Lifting Lug (at shipping split)

3/8" Nut
3/8" x 1-1/2" Bolt
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)
FORM 102.20-NOM1 (909)
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.
ROOF SEAM CAP
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 TRIM ANGLE

• 1/4"-14 x 1" Hex Head w/ Washer & Gasket Tek Screw
P/N 021-30530-052
Apply 2" Gasket

& Caulk
Apply Butyl
PIPE CHASE
P/N 021-30530-052
Apply Caulk
Apply Caulk
PIPE CHASE BASERAIL COVER HOOD
P/N 086-23998-001
• 3/16" x 3/4" Butyl Tape
LD13770A
FIG. 2-12 – PIPE CHASE, HOODS & SEAM CAPS

Installation
FORM 102.20-NOM1 (909)
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 & sundries are shipped
loose.
FLUE CAP
CONTAINMENT
BAND
42"L VSI PIPE

(not insulated)
CLOSURE
BAND
STORM COLLAR
UV
UV
LIGHT
LIGHT
TUBE
TUBE
GAS FURNACE FUEL VENTING PARTS

UV LIGHT TUBES to be installed by contractor.
DO NOT touch UV Lamps (tubes)

with bare hands or leather gloves as LD13788
oils will damage the tubes. Use clean

cotton rags, clean jersey or latex gloves
to handle the lamps (tubes).
FIG. 2-13 – Miscellaneous parts for Options

FORM 102.20-NOM1 (909)
POLYURETHANE CAULK 1/4” X 3-1/2” x 3-1/2” SHIPPING SPLIT

P/N 013-02966-011 GREY, CORNER GASKET
P/N 013-03317-040 CHAMPAGNE P/N 028-11883-010
Never use silicone caulk/seal- (Outdoor Only)
ant or caulk/sealant contain-
ing silicone in or on any air
handling equipment. [Only 2
exception is when provided
(high temperature) with gas
heat venting] 12 OZ. TOUCH-UP SPRAY
P/N 013-03322-000
1/4” X 3/4” X 35' NEOPRENE

GRAY GASKET
P/N 028-11873-010
1/4” X 2” X 25' NEOPRENE GASKET 3/16” X 3/4” X 40' BUTYL TAPE

P/N 028-15954-010 P/N 013E-03327-010
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
FIG. 2-14 – HARDWARE, GASKETING, CAULK, PAINT AND TAPE

Installation
FORM 102.20-NOM1 (909)
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
REMOVABLE LIFITING LUGS

WELDED CHANNEL FILLER
Remove lifting lugs before
assembling shipping splits.
Retain bolts,etc. and use to
secure assembled shipping split.
BASE CHANNEL
BASE CHANNEL
3/4" GR5 HEX BOLT

(use from Lifting Lug)
3/4" ZINC HEX NUT
(use from Lifting Lug)
(no flat or lock washers required)
LD14263
FIG. 2-16 – SHIPPING SPLIT EXAMPLES FOR EXPANDED CABINET

FORM 102.20-NOM1 (909)
ASSEMBLY OF OUTDOOR UNIT INSTALLING MULTIPLE PIECE OUTDOOR UNIT

See rigging suggestions and details in See Fig. 2-15 & 2-16 for Shipping Split Examples.
Section 1. ►
If applicable, remove metal bracket
screwed to the cross channel and wood
shipping blocks before assembling
shipping splits.
Do not damage factory installed pipe
chase, electrical cabinet, hoods, pipe
stubs, door handles or roof over- When unit is provided with shipping
hang. splits, use construction grade caulk
(not provided) in place of curb top
gasket. Apply the caulk on top of curb
See “Ship Loose Parts” to identify just before each section is placed on 2
gaskets and hardware items. the curb. Apply the caulk with a 1/2"
diameter bead to assure seal after sec-
tions are pulled together. Positive seal
must be achieved. Disregard this note
if shipping splits are assembled prior
INSTALLING SINGLE PIECE OUTDOOR UNIT to placing the unit on curb.
1. Units should not be moved on a roof surface but
should be lifted from the ground onto the curb or If assembly is done prior to setting
support framework. Remove the wood shipping unit sections on a curb, be sure to
material from bottom of unit. have units on a flat surface during
the assembly process. Do not remove
The curb gasket, which is provided,
shipping blocks from under unit until
must be installed before the unit is
assembled unit is ready to be lifted
lowered onto the curb. The gasket is
and placed.
shipped with the curb package.
Make sure top of curb is flat and shims
2. SEAL (to curbing): When setting the unit onto added where/if needed to ensure curb
the curb, the installer should ensure that a sealing will remain flat.
gasket is positioned between the unit and curb
to provide a continuous airtight and watertight
connection.
3. Installation should be in accordance with local 1. Before placing sections on the curb:
code requirements. a) Verify the correct sections and orientation of
each section.
When installing on steel or slab, elimi- b) Remove cross brace(s) (shipping supports)
nate seal unless specified. from each section’s shipping split.
c) Remove plastic shipping covers and their
supports.
d) Remove screws from curb rest to release wood
shipping blocks. Leave blocks under unit
sections until lifted. Be sure that no debris
clings to the bottom of each section when
lifted for placement.

Installation
FORM 102.20-NOM1 (909)
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 path the section already placed.
of the shipping split mating surfaces to prevent
7. At this time feed the electrical and control
damage.
connections from section to section and ensure
f) Apply 3.5" x 3.5" separate gasket squares, that they will be accessible after the sections
placing one square at each corner of the face are joined. Assemble the electrical connectors
of one section. Apply 1/4" x 2" foam gasket and/or pneumatic tubes each according to their
to face perimeter from 3.5" square to 3.5" labels. Do this before joining sections if access
square. Apply this gasket 1/4" from outside will be 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
Butt joints to raceway gasket.
Caulked at joints.
0.25 thk
neoprene at
raceway split.
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 LD13773A
base where it meets the curb. LD13372
FIG. 2-17 – APPLYING GASKET
g) Apply a ½" thick bead of caulk (not provided),

to curb top surface only where the first section
will be placed.
2. Place the first section on the curb while
positioning it so that the overhanging curb rest
is spaced evenly from the curb on each side and
end.
3. After the first section is placed in position, anchor
LD13374
or block it before setting the next section.
4. Attach power pulls or come-a-longs to the first FIG. 2-18 – ELECTRICAL CONNECTIONS
section. Use lifting lugs on the base rail (not at
the shipping split) or holes in the two outside All lighting and 3-phase wires must
corners. be hard wired when no plug-ins are
5. Apply a ½" thick bead of caulk to curb top provided.
surface only where the next section will be
placed, plus about 4".

FORM 102.20-NOM1 (909)
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).
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.
b) Guide the top raceways together by placing
rods or drift pins through the holes in the top
guide angles. When the raceways are close
enough, install the long bolts provided. 2
c) Guide the bottom raceways together using
rods or drift pins through the bolt holes in the
lifting lugs on opposite sections. Do this on
each side of the unit simultaneously.
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 or
Remove ShippingSplit
Remove Shipping SplitAngle
Angle close to the shipping split. Straps may be used
after completion of
after completion ofwiring
wiringand
and
tubing placement
tubing placement and
and across the unit roof.
reposition before
reposition before proceeding
proceeding
with assembly of
with assembly shipping
of shipping e) If any difficulty due to top and bottom not
splits.
splits. pulling together evenly or simultaneously, the
curb is probably not installed flat. Apply shims
under the curb or roof decking to compensate
for irregularities of the roof deck.
10. Complete pulling the sections together.
Use come-a-longs to pull the sections

LD14097
together. The bolts are to hold the
FIG. 2-19 – R
EMOVE AND REPOSITION SHIPPING sections tight after they are pulled
SPLIT ANGLE together.
8. Attach the power pulls or come-a-longs to the

11. Fasten bottom lifting lugs together using 1/2" x
far end of the next section.
4" bolts provided.
12. Fasten top raceway bracket using 1/2" x 5-1/2"
bolts.

Installation
FORM 102.20-NOM1 (909)
LD13775 LD13777
LD13776 LD13778
FIG. 2-20 – BRINGING SECTIONS TOGETHER
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. Only needed on units or sections with-
out baserails.

FORM 102.20-NOM1 (909)
ASSEMBLY OF INDOOR UNIT c) Remove plastic shipping covers and their

supports.
See rigging suggestions and details in
Section 1. ► 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.
e) Apply 1/4" x 2" neoprene gasket material TO
ONE SIDE ONLY of each shipping split. Be
Do not damage factory installed pipe
sure the entire perimeter is covered with gasket
chase, electrical cabinet, hoods, pipe material, including the foamed corners. Any
stubs, door handles or roof over- void, depression or protrusion will allow air
hang. or water leakage. Gasket must be continuous
through the corners. Make any splices on a
straight run. Refer to Fig. 2-21 & 2-22. 2
See “Ship Loose Parts” to identify
gaskets and hardware items.
If the unit or unit sections are too

large to fit through an opening, contact
the local Johnson Controls office for
assistance. Technical instruction is
available for Disassembly and Reas-
sembly. LD13779
FIG. 2-21 – APPLYING GASKET TO SHIPPING

INSTALLING MULTIPLE PIECE INDOOR UNIT SPLIT
See Fig. 2-15 & 2-16 for Shipping Split Examples.
If applicable, remove metal tab screwed

to the cross channel and wood ship-
ping blocks before assembling ship- Panel
ping splits. Flange Connectors out of
the way.
Door Frame
Flange
If assembly is done prior to placing
unit sections, be sure to have sections
1/4” x 3/4”
on a flat surface during the assembly Gasket Only
process. used when a
door frame is at
a shipping split. LD13780A
1. Before placing sections: FIG. 2-22 – APPLYING GASKET TO DOOR FRAME

WHEN AT SHIPPING SPLIT
a) Verify the correct sections and orientation of
each section.
b) Remove cross brace(s) (shipping supports) f) For expanded cabinet with end channel
from each section’s shipping split. shipping split see fig. 2-23

Installation
FORM 102.20-NOM1 (909)
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).
After wiring connections are made
and before proceeding with assembly,
the top shipping split angle will need
to be removed and repositioned (see
Fig. 2-24).
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
with assembly of shipping
of shipping
splits.
splits.
LD14097
FIG. 2-24 – R
EMOVE AND REPOSITION SHIPPING
SPLIT ANGLE

FORM 102.20-NOM1 (909)
3. Attach power pulls or come-a-longs to the first

section. Use the lifting lugs on base rail (not at
the shipping split) or holes in the two outside Connectors
corners (see Fig. 2-25).
LD13782
2
LD13773A
FIG. 2-25 – P
lacing & anchoring first
section and attaching come-a-
longs
3A. For expanded cabinet with structural steel base

remove lifting lugs within the shipping split.
retain bolts and. nuts (see Fig. 2-26)
WELDED CHANNEL FILLER
BASE CHANNEL
LD13374
FIG. 2-27 – ELECTRICAL CONNECTIONS
REMOVABLE LIFITING LUGS

Remove lifting lugs before
assembling shipping splits. LD14265 All lighting and 3-phase wires must
Retain bolts,etc. and use to
secure assembled shipping split. be hard wired when no plug-ins are
provided.
FIG. 2-26 – R
EMOVE LIFTING LUGS AND SAVE
HARDWARE
4. Place the next section about 8" from the

section(s) already placed. 6. Attach the power pulls or come-a-longs to the
far end of the next section.
connections from section to section and ensure
that they will be accessible after the sections are Ensure chain does not apply pressure
joined. If any will not be accessible, assemble to drain connection. Improper posi-
the electrical connectors and/or pneumatic tubes tioning of chain may cause damage
each according to their labels before joining of to unit.
sections is complete. Refer to Fig. 2-27.

Installation
FORM 102.20-NOM1 (909)
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 or 11. Apply 1/4" x 2" foam gasket to the underside of
tubes are clear. the seam caps and install them over the joints
using 1/4"-14 x 1" hex head screws provided.
b) Guide the top raceways together by placing
Seam caps are provided for sides, top and
rods or drift pins through the holes in the top
floors.
guide angles. When the raceways are together,
install the long bolts provided. 12. Repeat previous steps for each additional section
to be placed in making up the complete unit.
c) Guide the bottom raceway/baserails together
using rods or drift pins through the holes in the 13. Install 1-1/2" Corner Connector Plugs in bottom
lifting lugs on opposing sections. Do this on raceway corners.
each side of the unit simultaneously.
d) If any difficulty aligning due to racking of one Only needed on units or sections with-
section or the other, use another come-a-long
out baserails.
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
Use come-a-longs to pull the sections together. The bolts are to

hold the sections tight after they are pulled together.
FIG. 2-28 – installing bolts after pulling

units tight together

FORM 102.20-NOM1 (909)
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.
d) Make sure all wiring and/or control tubing
connection pigtails are secured out of the
path of the mating surfaces to prevent damage 2
LD09624 during rigging.
FIG. 2-29 – TIERED UNIT
e) Ensure 1/4" x 2" neoprene gasket properly
See complete rigging instructions ex- installed on bottom tier. If the top tier is shorter
in direction of airflow than the bottom tier,
plained in detail in Section 1.
apply gasket material on the top panel of the
bottom tier from raceway to raceway but not
on top of raceways (see Fig. 2-31).
See “Ship Loose Parts” in this section

TOP TIER
of the Manual to identify gaskets and
PLACE SECOND LAYER OF GASKET OVER FIRST LAYER
hardware items. AND OVER RACEWAYS
INSTALLATION OF TIERED UNIT TOP LEFT TOP RIGHT

RACEWAY
TOP PANEL RACEWAY
A Tiered Unit may not be factory assembled. Field
assembled units are shipped with the top-tier segment
skidded. This top-tier segment is equipped with PLACE FIRST LAYER OF GASKET FROM RACEWAY TO
brackets bolted to the bottom raceway (see Fig. 2-30). RACEWAY
The bottom-tier segment is equipped with brackets BOTTOM TIER LD09690
bolted to the top raceway.
3/8" x 3/4" Button FIG. 2-31 – APPLY GASKETS TO TOP PANEL
Head Screw BOTTOM TIER
3/16" Allen
Wrench
3/8" Nut f) Apply second layer of 1/4" x 2" gasket over
top of that applied in step (e) but include the
raceways. Steps (e) and (f) are necessary
because the top panel of the bottom tier is
slightly recessed below the height of its
raceways.
g) If top tier has shipping splits, refer to
LD09625
3/8" Flat “Installing Multiple Piece Indoor Unit” for
Washer correct assembly procedure.
Allen Wrench
LD11029A
FIG. 2-30 – TIERED UNIT SECURED WITH BRACKETS

Installation
FORM 102.20-NOM1 (909)
Be sure all of the electrical or control 7. Lower the top tier onto bottom tier so that
wires or tubes in both tiers are clear. 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. Lift top tier assembly with crane or overhead
lift.
connections from top tier to bottom tier and
ensure that they will be accessible after the
sections are joined. If any will not be accessible,
assemble the electrical connectors and/or
pneumatic tubes each according to their labels
before joining the top and bottom tier.
LD09626
FIG. 2-32 – GUIDING BRACKETS TOGETHER
8. Carefully place each section of the top tier

without disturbing the gaskets on the bottom
tier.
9. Secure the top tier to bottom tier with 3/8" x .75"
Allen head bolts.
10. Install 1-1/2" Corner Connector Plugs in bottom
raceway corners.
Only needed on units or sections with-

out baserail

FORM 102.20-NOM1 (909)
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,
drawing the base together. 2
Prior to pulling sections together:
3. Attach the sides of the sections. Beginning at the
1. Remove baserail support plate (large units).
bottom of the sections secure the end channel
2. Remove shipping brackets in corners. assembly brackets together using 3/8" x 3/4"
Allen head bolts, lock washers & hex nuts
3. Remove screws in raceway corners at ends of all
at each bracket . Continue securing the end
segments joining together (as shown in Detail A
channel assembly brackets together, working
of Fig. 2-33).
from bottom to top, pulling the sections tight.
4. Clean the metal surface where gasket is to
4. After the sides are secured, secure the brackets
be applied with mineral spirits or rubbing
on top of the unit with the same hardware
alcohol.
mentioned in step 3.
HEAT WHEEL (ER) SEGMENT
END SPLIT MOUNTING BRACKET
SECURE TOGETHER USING 3/8" X 3/4"

BOLT, LOCK WASHER & HEX NUT.
INCLUDE 2 GASKETS SIDE BY

SIDE ON INTERMEDIATE
RACEWAY SURFACES.
REMOVE SHIPPING
BRACKETS APPLY 1/4" x 2" NEOPRENE GASKET TO
A ALL RACEWAY MATING SURFACES OF
ONE MATING SEGMENT.
REMOVE BASERAIL SUPPORT PLATE

PRIOR TO SECURING LARGE UNITS
TOGETHER.
3/16" ALLEN HEAD SCREWS IN RACEWAY

CORNERS AT ENDS OF ALL SEGMENTS
JOINING TOGETHER; MUST BE REMOVED DETAIL A
PRIOR TO PULLING SECTIONS TOGETHER.
LD12357
FIG. 2-33 – ASSEMBLY OF END CHANNEL SHIPPING SPLIT (ENERGY RECOVERY WHEEL SHOWN)

Installation
FORM 102.20-NOM1 (909)
Apply Butyl
Apply Caulk
Clip
Mist Eliminator LD13783
or Filter
FIG. 2-34 – HOOD INSTALLATION WITH OPTIONAL MIST ELIMINATORS
HOOD INSTALLATION WITH OPTIONAL 7. Each hood is to be centered over the width
MIST ELIMINATORS of the opening. All hoods, especially those
containing barometric dampers, MUST be
See “Ship Loose Parts” for identifica- installed 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 bottom
1. Identify correct hood and respective location 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. • Remove the clip(s) from the leading edge of
the hood.
2. Correct orientation is with the tracks or bird
screens to the bottom. The mounting flanges • Insert the proper size mist eliminator or filter
are predrilled. into the tracks.
3. Each hood is fitted with a factory installed • Reinstall the clip(s) on the leading edge of the
bird screen unless mist eliminator option is hood.
selected.
OUTDOOR AIR TEMPERATURE AND/OR
4. Apply provided 3/16" x ¾" Butyl tape to the HUMIDITY SENSORS
predrilled hood flanges and back wall angle that
contact the unit panels. When Outside Air Hoods are shipped loose on units
that include Factory Packaged Controls, these sensors
5. Use ¼"-14 x 1" Hex Head Self Drilling Screws will be dismounted and pulled back into the air handler.
w/EPDM washer provided. The contractor is to find them secured with tape inside
6. Each damper opening in the unit panels should be and put them through their respective penetration to
completely covered by its respective hood. The the exterior and mount them to the bracket provided.
bottom of the hood should extend approximately
6" below the opening in the unit panel.

FORM 102.20-NOM1 (909)
ACTUATOR INSTALLATION 5. Tighten the actuator shaft clamp to the damper

jackshaft. Make sure at this point, the damper
See Fig. 2-35 shaft is completely rotated to its proper
position.
1. Remove the bearing plate from the damper frame
and jackshaft. 6. Manually operate the actuator to its fully
actuated position using the crank arm provided
2. Slide the damper actuator onto the open end
with the actuator. Then release the spring to
of the shaft making sure that the proper spring
allow the damper to go back to its original
return position on the face of the actuator
position. This will verify the actuators spring
matches the damper shafts rotation. If not, then
rotation and stroke.
reinstall the actuator with it flipped over.
7. Set the damper actuators rotation selector switch
to the proper rotation required to actuate the
3. Reinstall the bearing plate to the damper frame damper.
and jackshaft. Make sure spring hose clamps
hold the jackshaft securely. 2
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-
damper frame using self drilling screws. 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
FIG. 2-35 – DIRECT COUPLED ON JACKSHAFT

Installation
FORM 102.20-NOM1 (909)
INSTALLATION OF MULTIZONE (MZ) Distortion will result in unreliable

DAMPERS blade operation.
See Fig. 2-36
SHIPPED LOOSE MZ DAMPERS. If

the MZ segment has a shipping split, 2. Remove 16 gauge shipping plate from air
a rear discharge (end of unit), and a entering side ONLY. Plate is located between
multizone damper, then the multizone hot and cold decks.
damper will be shipped loose. 3. Apply provided 1/4" x 2" neoprene gasket to the
mounting flanges of the damper assembly.
See “Ship Loose Parts” to identify
gaskets and hardware items. 4. Center the damper assembly over the discharge
openings of the hot deck (top) and cold deck
(bottom).
5. Attach the damper assembly to the unit outer
perimeter mounting flange using 1/4"-14 x 1"
DAMPER INSTALLATION self-drilling screws provided.
1. After the unit top tier is assembled to the unit 6. Remove 16 gauge shipping plate from air leaving
bottom tier and sealed, install MZ damper side.
assembly. The assembly includes both hot deck
and cold deck damper banks, already connected 7. Install screws through mounting flanges found
at each blade. between hot and cold decks.
ACTUATOR
ACTUATOR EXTENSION PIN
025-39032-002
025-39032-002
SCREW, TEK, PLTD, MTG BKT

1/4"-14 x .75" LG. 086-03474-516
025-19515-000
MTG BKT SCREW,

AIR
086-03474-516 025-19515-000
FLOW
HOT DECK
DAMPER
SHAFT
EXTENSION
KIT SHIPPING
026-33715-002 SHIPPING
PLATE
PLATE
AIR ENTERING
AIR LEAVING
MOUNTING
FLANGES COLD DECK
DAMPER
HOT DECK MOUNTING

DAMPER FLANGES
FACTORY
ACTUATOR P/N TORQUE BRACKET
INSTALLED SMALL 025-39032-002 35 IN LBS 086-03474-516
COUPLER
086-03474-516 (Top Disch.)
LARGE 025-30958-008 133 IN LBS
086-03474-517 (Rear Disch.)
COLD DECK
DAMPER
LD12029A
FIG. 2-36 – MZ DAMPER/ACTUATOR ASSEMBLY

FORM 102.20-NOM1 (909)
ACTUATOR INSTALLATION MUTLIZONE • Actuators and actuator mounting brackets are

(MZ) - FIELD SUPPLIED to be supplied by the contractor. P/N's 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
• Torque required is 7 inch pounds per square foot upper (hot) deck.
of damper area up to 2500 FPM velocity. • Do not allow duct insulation to restrict damper
• Damper blades are 6" wide and vary in height. blades or external linkage.
• Calculate the torque by number and size of • Direct coupled actuators are recommended.
blades in each individual zone. Remember there • Duct connections are to be made at the zone
are hot deck blades directly connected to cold dividers without damper blade restriction.
deck blades.
• Blades per zone are to be determined by 2
system CFM and static pressure requirements INERTIA FAN BASE FILL INSTRUCTION
for each zone by the Engineer’s construction
Inertia fan bases are pre-engineered according to fan
documents.
& motor size. Each cavity having a pre-installed
• The blade linkage (flat rods) connecting corrugated bottom is to be filled to the top with wet
all blades of each deck are to be cut at the concrete. The contractor must take care not to get
appropriate places to divide the decks into concrete mix on the bolts and adjusting parts of the
correct size zones. These blade linkage rods are adjustable motor base, sheaves, belts or on the floor
mounted externally on the assembly. Be sure to under the edges of the isolated fan base. The amount
cut a section of the flat connecting rod out. This of concrete can be calculated by measuring the overall
is to prevent interference when zones modulate length and width of the fan base assembly cavities
in opposite directions. that have the corrugated metal bottoms. The standard
depth of the cavity is 4".
• One Damper Shaft Extension Kit is provided for
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 & 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 & wiring are the responsibility of
the installing contractor(s).

P/N 026-33715-002 LD13784
FIG. 2-37 – DAMPER SHAFT EXTENSION KIT

Installation
FORM 102.20-NOM1 (909)
UVC EMITTER LIGHTS V-Ray lamps (tubes) have all four contact prongs on
one end of the lamp (tube). The lamp fits into clamps
When UV Lights are provided, the contractor is mounted in the air handler UV segment where a pre-
responsible for installing UV Lamps (tubes) and wired pig tail is installed. Simply engage the plug on
connecting a 120 volt power supply. The YORK the pig tail with the prongs on the end of the lamp.
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. The UV Lamps (tubes)
are shipped loose, but in protective packaging for
installation by the contractor.
DO NOT touch UV Lamps (tubes)

with bare hands or leather gloves as
oils will damage the tubes. Use clean
cotton rags, clean jersey or latex gloves
to handle the lamps (tubes). FIG. 2-39 – V-RAY INSTALLATION
There three different types of lamps used in YORK

Solution Air Handlers: V-Mod, V-Ray and V-Flex. V-Flex lamps (tubes) fit inside the opening at a slight
angle (with the pins aligned with the lamp holder).
V-Mod lamps are installed in the same manner as You then “snap” the lamp base in by holding with
standard fluorescent lamps with 2 contact prongs on slight pressure the end of the lamp you have placed
each end. Engage the prongs into the slotted fixtures inside the module with one hand and straightening up
and rotate the lamp (tube) 90 degrees. the other end of the lamp with your other hand until
you hear the click.
FIG. 2-38 – V-MOD INSTALLATION

FIG. 2-40 – V-FLEX INSTALLATION

FORM 102.20-NOM1 (909)
AIR MEASURING DEVICE CONNECTIONS AIR MEASURING AT UNIT INLETS

(when provided) AMS-60 used on Indoor YORK Solution air handlers
usually to measure outside air. This can be provided
AIR MEASURING AT THE FAN INLETS with one or two pairs of positive (+) and negative (-)
COMETER is a probe attached to the fan bearing connections. Connect (+) & (-) ports respectively
support on Comefri Forward Curve fans from size 7 x to the (+) & (-) ports of the transducer(s). Wiring &
7 up to 18 x 18. The probe is located on the outboard transducer are not provided unless factory packaged
side of the DWDI fan assembly. The probe is piped to controls were selected.
the negative (-) port of a factory mounted transducer
on the fan wall. The positive (+) port is left open to the EAML used on Outdoor YORK Solution air handlers
fan section. Wiring is not provided to the transducer usually to measure outside air. This can be provided
unless factory packaged controls were selected. with one or two pairs of positive (+) and negative (-)
connections. Connect (+) & (-) ports respectively
PIEZORING (PIEZOMETER) is a series of fittings in to the (+) & (-) ports of the transducer(s). Wiring &
the inlet cone(s) of DWDI fans larger than 18 x 18 and transducer are not provided unless factory packaged 2
all sizes of Plenum fans that are combined into a single controls were selected.
connection piped to the negative (-) port of a factory
mounted transducer on the fan wall. The positive
(+) port is left open to the fan section. Wiring is not
provided to the transducer unless factory packaged
controls were selected.

Installation
FORM 102.20-NOM1 (909)
PIPE CHASE INSTALLATION 1. Preparation
See “Ship Loose Parts” to identify • Pinpoint the exact location to attach the pipe
gaskets and hardware items. chase.
• Ensure enough space will remain to apply
pipe fittings with insulation, inside the pipe
chase.
Pipe chase should be installed before • The pipe chase height should align with the
piping is connected. unit height.
2. Apply Gaskets
• Apply provided 1/4" x 2" neoprene gasket to
the underside of the air handler roof overhang
(see Fig. 2-41).
TOOLS REQUIRED
• Screw Gun
• Complete set of mechanics hand tools.
MATERIALS REQUIRED
• Shipped loose package containing 1/4"-14 x 1"
Self-drilling Screws w/gasket, Caulking, 1/4" x
2" Neoprene Gasket.
AIR HANDLER
AIR HANDLER
Apply gasket
Apply gasket
• When unit purchased with Baserail: Pipe Chase
Baserail Covers, 3/8"-16 x 1-1/2" Bolts and
Lock Washers.
LD11564
PROCEDURE
FIG. 2-41 – INSTALL GASKET UNDER ROOF
Never use silicone caulk/sealant or OVERHANG
caulk/sealant containing silicone in or
on any air handling equipment. [Only
• Apply gasket provided by curb vendor to top
exception is when provided (high tem-
of curb.
perature) with gas heat venting]
• 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).
Horizontal gaskets must completely

Before installing pipe chase, remove overlap vertical gaskets in all four
any self-drilling screws from the top corners (see Fig. 2-42).
& bottom raceway and side panel that
may interfere with the installation of
the pipe chase or trim angles.

FORM 102.20-NOM1 (909)
3/8"-16 X 1-1/2" BOLT,

3 (typ.6)
3
LOCK WASHER, UNIT BASERAIL

2 Install (typ.6)
Install horizontal
horizontal
gaskets second
gaskets second
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)
BASERAIL COVER PIPE CHASE

1 Install (installed later - BASERAIL
Install vertical
vertical gaskets
gaskets first
first
see
see Fig.2-44)
Fig. 2-51)
LD12034C
2
FIG. 2-43 – P
IPE CHASE BASERAIL TO UNIT
BASERAIL INSTALLATION (When Purchased)
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
flange. Typical for both top and bottom
flange. bottom
FIG. 2-42 – APPLY GASKET TO PIPE CHASE
flanges.
flanges.
3. Attach Pipe Chase

• Set the pipe chase on the pipe chase curb
three inches away from the air handler.
• Tilt the top of the pipe chase toward the air
handler. Work it under the air handler roof
LD12561A
overhang, being careful not to damage the
neoprene gaskets. Lift the pipe chase slightly FIG. 2-44 – S
CREW PIPE CHASE TOP AND
to clear the gasket on the curb and swing the BOTTOM INTERNAL FLANGES TO AIR
HANDLER
bottom against the air handler.
• If there is a baserail, attach the baserail of the Do not over tighten or strip self-drill-
pipe chase to the baserail of the air handler. ing screws. Screws in top and bottom
Use 3/8" bolts & lock washers provided; flanges go into heavier gauge metal
placing bolts through the pipe chase baserail than screws in cover angles.
brackets into the threaded holes in the air
handler baserail (see Fig. 2-43).
• Make sure the pipe chase is square and the • Check to be sure door closes and latches
door(s) close and open without rubbing or properly. If not, loosen self-drilling screws,
binding. re-align pipe chase and re-tighten screws.
• Secure the pipe chase to the top and bottom Occasionally the curb under the pipe chase
raceways (heavy gage metal) of the air may be uneven, depending on installation.
handler through the pre-punched holes of 4. Seal Pipe Chase to Air Handler.
the inside top and bottom flanges of the
pipe chase. Use 1/4"-14 x 1" hex head self- • Apply caulking to all exterior joints between
drilling screws (see Fig. 2-44). pipe chase and air handler baserails (when
purchased) (see Fig. 2-45).
Installation
FORM 102.20-NOM1 (909)
AIR HANDLER
AIR HANDLER
Caulk
Caulk as
as shown
shown byby PIPE CHASE
PIPE CHASE
dotted
dotted line
line (visible)
(visible)
and
and
dashed
dashed line
line (hidden).
(hidden).
Apply caulk between
Pipe Chase and 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
Line up self-drilling Cover angles must be installed before

screws with existing the caulk from step 4 dries.
screws on roof.
AIR HANDLER
5
3
1
2
4 Install self-drilling
screws starting in • Apply 1/4" x 2" neoprene gasket to contact
middle and working
towards ends.
side of cover angle.
PIPE CHASE
• Remove top and bottom self-drilling screws
FIG. 2-46 – P
IPE CHASE TO ROOF INSTALLATION from pipe chase and set aside for later use.
• Place cover angles in vertical corners of pipe
• Add a small bead of caulking to the exterior chase and unit wall.
vertical seam between the air handler and
the pipe chase to insure complete seal. Pay
special attention to the top & bottom corners,
raceway & baserail engagements and under
the roof overhang (see Fig.'s 2-45 & 2-47).
AIR HANDLER
• Starting at the center, and working toward PIPE CHASE
each end, run 1/4"-14 x 1" hex head self-
drilling screws down through the air handler
overhang into the top of the pipe chase
through the gasket. Use caution not to strip Install Cover
Angle between
the 20-gage housing with the screws. Line Cover Angle Air Handler and
up self-drilling screws with double row of shown with Pipe Chase
screws on top of unit raceway, plus one gasket side before caulk
out dries LD12564
spaced evenly between each (see Fig. 2-46)
(No caulking required here.) FIG. 2-48 – INSTALL COVER ANGLE
5. Install the Cover Angles

Notch on cover angle must be on the
(See Fig. 2-48) air handler side (see Fig. 2-48).

FORM 102.20-NOM1 (909)
Install (2) top and (2) bottom

AIR HANDLER
self-drilling screws first.
PIPE CHASE
PIPE CHASE
AIR HANDLER
Put notch on cover angle

on Air Handler side. LD12563
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.
• 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.
• 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
housing (see Fig.2-50). FIG. 2-50 – P

ROPER PATTERN FOR INSTALLING
6. Install the Pipe Chase Baserail Covers SELF-DRILLING SCREWS TO COVER
ANGLE
(See Fig. 2-51)
• On the perimeter of the cover, caulk the
underside as shown.
• Apply cover to exposed baserail seam
between pipe chase and air handler (both
sides) (no screws required).
UNIT Cover PIPECHASE BASERAIL
BASERAIL
All pipe chase floor penetrations must Installation
1) CAULK PERIMETER
APPLY CAULK AROUND
be flashed, sealed and insulated to PERIMETER OF PART OF COVER AS SHOWN
BEFORE APPLYING TO BELOW.
prevent condensation entering build- BASERAIL SEAM.
2) APPLY COVER TO
ing. BASERAIL SEAM.
PIPECHASE BASERAIL Caulk

COVER Application LD12032B
FIG. 2-51 – BASERAIL COVER APPLICATION

STEP 3
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 mount-
5.50 ing.
FIG. 2-52 – GAS FURNACE FUEL VENTING SYSTEM 3. On all outdoor Air Handling units the vent piping parts internal to the pipe chase will be factory mounted.
johnson controls
FORM 102.20-NOM1 (909)
FORM 102.20-NOM1 (909)
BURNER
ASSY
ID
MOTOR
FLOW 2
1
3
4
2
3 2
PITCH
4 Foot
LD12912
1
FIG. 2-53 – GAS FURNACE Condensate drain trap

CONDENSATE DRAIN ARRANGEMENT 3. Condensate drain line size must be the full line size
The YORK Solution Indirect Fired gas heat exchanger of the heat exchanger drain connection.
has the potential to create highly acidic condensation,
particularly during extended operation at low capacity 4. Drain lines, fittings and supports should conform
or low firing rate conditions. To insure proper drainage to local codes and be suitable for the application.
the following guidelines should be followed (See Fig.
2-53). 5. Condensate drain and trap discharge should be
pitched away from the equipment at a slope of 1/4"
When constructing the condensate trap per linear foot or as local code dictates.
for the heat exchanger drainage sys-
6. For outdoor or unconditioned space installations
tem, make sure the trap is tall enough
local climate may dictate the need to heat trace
to handle the Total Static Pressure of
and/or insulate the exposed drain lines and trap.
the ID Blower at Low Fire times 2. Frozen drain lines and/or trap will cause build up
of condensate inside the heat exchanger resulting
Example: TSP is 6" at Low Fire - in leakage and damage to the air handler and pos-
construct trap 12" tall (See Table in sibly to the facility.
Fig. 2-53). 7. Provide unions in drain lines to allow removal of
trap for periodic cleaning of drain lines as well
Failure to follow these guidelines may as the trap. When the burner is operated at low
cause excessive condensation build up capacity for extended periods, more condensate
resulting in water damage to the facil- is generated and with it deposits of solids in the
ity and/or a cracked heat exchanger. condensate drainage system.
8. Provide the ability to prime the trap. During initial
1. Observe local jurisdiction codes for gravity con- and seasonal start up, trap inspection and priming
densate drainage requirements. is required. Condensate in the trap will evaporate
during long periods of non-use.
2. Be sure the air handler is installed at an elevation
that enables proper condensate drainage and trap-
ping dimensions as provided in Fig.2-53. Mini-
mum trap dimensions MUST be accommodated.

Installation
FORM 102.20-NOM1 (909)
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.
Unit is E.T.L. Listed. Some compo- DO NOT PENETRATE WIREWAYS

nents are U.L. labeled. Any changes in any manner. These sheet metal
in the field may affect their validity. channels, which run along the top
panel, contain electrical wires and
connections. Electrical shock and/or
damage to the unit may result.
The current characteristics, phase, cycle and voltage
are stamped on the nameplate of each component.
Electrical drawings are provided in the information
packet on the inside of a unit access door. Major
Electrical conduit connections made to exposed boxes
optional components will have specific electrical and
on units should be made on the bottom of the box.
IOM information packed inside their control panels
Installation should comply with code requirements.
or attached. See IOM Section 6 for generic electrical
Outdoor installation must be made watertight.
drawings.
The installing contractor is responsible for electrical
conduit penetrations through the building roof.
Penetrations through panels must be sealed (see IOM

Section 5 “Penetrations and Grommet Details”). ►
Electrical conduits that penetrate the
exterior (walls, pipe chase or floors)
of the unit will need to be externally
and internally sealed so that uncon-
ditioned air will not be drawn into
the unit through and around conduit.
This unconditioned air will result in
condensation that will fail compo-
nents prematurely.
All accessible electrical connections

must be checked for tightness prior
to the actual startup. Many of the
connections contain several strands
of wire, and while they were tightened
at the time of assembly, they should be
checked and re-tightened if needed.
The danger of a poor connection is
overheating and component failure.

FORM 102.20-NOM1 (909)
POWER CONNECTIONS
SINGLE POINT POWER ENERGY RECOVERY WHEEL OPTION

Single Point Power when ordered provides the installer Wiring of this device is the responsibility of the
with a main disconnect switch. The line side of this installer if Single Point Power was not selected. Use
switch (top) is where the installer is to land his main of the attached plug and/or pigtail is optional. YORK
power wires. Devices included in the Single Point does not provide pre-wired mating cables.
Power option are Supply Fan, Return Fan, Exhaust
Fan, Energy Recovery Wheel, Gas Heat, Electric On wheels of 52" diameter and smaller the motor
Heat and Ultra-violet Lights. Special Quoted devices comes with a cord. Single Phase motors have a 3-pin
may be purchased with the air handler that are NOT standard AMP connector on the cord. Three Phase and
included in the Single Point Power option. These items VFD models have a 4-pin standard AMP connector on
will require separate, additional power wiring by the the cord.
installer. When Single Point Power is NOT purchased
the installer is responsible for wiring to each electrical On wheels of 54" diameter and larger the motor does 2
component. not come with a cord.
MOTORS FOR SUPPLY FAN, RETURN

FAN, EXHAUST FAN
A motor connection diagram may be found on the
inside of the motor terminal box or on a tag attached
to the motor. Be sure to make a flexible conduit
connection at the motor to permit fan belt adjustment
and movement of spring isolated fan assembly. Refer
to Motor Data Nameplate for all motor specifications
(see Fig. 2-54).
LD11591
FIG. 2-55 – TYPICAL POWER WIRING OF ENERGY

RECOVERY WHEEL
00495VIP
FIG. 2-54 – TYPICAL MOTOR DATA / NAMEPLATE

Installation
FORM 102.20-NOM1 (909)
GAS HEAT OPTION

Terminal Strip for Power
Wiring of this device is the responsibility of the installer and Controls.
if Single Point Power was not selected.
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 LD11597
or side wall panels. Any penetration will have to FIG. 2-57 – MAIN POWER AND CONTROL PANEL
be drilled and must be properly sealed to keep out W/ COVER OPEN
moisture. Refer to IOM Section 5 “Field Penetrations
for Piping & Electrical Connections”. ►
Make power connections per wiring diagrams,

provided inside burner control panel. Also see generic
diagrams in IOM Section 6. Refer to Fig. 2-56 and
Fig. 2-57 for Gas Burner component locations.
Main Power and Control

Termination Panel w/ Gas
Burner ID and Ratings
Plate (see
Plate (see Fig.
Fig 2-50
2-57for
for
internal view).
Flue Connection
Inside of XTO Gas

Burner Pipe Chase. Draft Damper
Adjustable Quadrant
Safety Limits
ID Fan
ID Fan Motor
Burner Control Panel

(contains Factory Test
Data Sheet,
Manufacturers IOM
and Burner Control
System.)
LD11596B
FIG. 2-56 – GAS BURNER COMPONENT LOCATIONS

FORM 102.20-NOM1 (909)
ELECTRIC HEAT OPTION Main Disconnect Switch

Field Control Wiring & Field Power Connections
Wiring of this device is the responsibility of the installer Interface Terminals
if Single Point Power was not selected.
AVAILABLE POWER OPTIONS

• 460V-3PH.
• 208/230V-3PH.
• 380V-3PH.
• 575V-3PH.
LD11595
ELECTRIC HEAT DISCONNECT SWITCH OPTIONS
• Fused Disconnect. LD11595
• Non-fused Disconnect. FIG. 2-59 – TYPICAL FIELD CONTROL AND 2

POWER CONNECTIONS
Knockouts are provided on the top and bottom of the Hook up power (see Fig. 2-59 for power terminals
enclosure for field penetrations. The YORK Solution and Fig. 2-58 for control panel component location).
foam panel will have to be drilled to utilize these Terminals shown are for a 2 stage 24 VAC control
knockout locations. Refer to IOM Section 5 “Field interface. Terminals may also require 120VAC
Penetrations for Piping & Electrical Connections”. control interface based upon options selected. See
► wiring diagram on inside cover of electric heat control
panel.
Main Disconnect
Switch & Field
Power Connections Electrical conduits that penetrate the
(see Fig. 2-52).
2-59)
exterior (walls, pipe chase or floors)
of the unit will need to be externally
and internally sealed so that uncon-
High ditioned air will not be drawn into
Temperature the unit through and around conduit.
Cutout
This unconditioned air will result in
Control
Airflow Voltage condensation that will fail components
Proving Transformer prematurely.
Switch
Staging
All accessible electrical connections
Contactors 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
the time of assembly, they should be
checked and re-tightened if needed.
Knockouts
The danger of a poor connection is
overheating and component failure.
DO NOT PENETRATE any main or

LD11594A auxiliary drain pan.
FIG. 2-58 – TYPICAL ELECTRIC HEAT CONTROL
PANEL INTERIOR WIRING AND
COMPONENTS

Installation
FORM 102.20-NOM1 (909)
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
contactor from external BMS source. 3. Sufficient working space must be provided per
paragraph 110-26 of the NEC.
• Step Controller - device to receive a 0- to 10 VDC
or 4 to 20 mA signal and step on heat stages. 4. This electric heater is not designed for or intended
Mechanical/electrical device. to be used for temporary heat prior to system
startup / balancing.
• Vernier SCR - completely electronically con-
trolled by varying signal and varying output
between stages. Increases power to a stage by MECHANICAL INSTALLATION
modulation until another stage is needed. Ener- 1. All heaters will contain an adjustable airflow
gizes another stage and modulates power until switch in the heater control panel. This switch
another stage is needed. 0 to 10 VDC or 4 TO will be preset to close at a differential pressure of
20 mA. Less expensive than Full SCR. This approximately 0.3" W.C. In all cases the switch
system utilizes a step controller and one SCR will be connected to a pressure probe positioned
that modulates and resets for each stage. in the airstream. This probe has an arrow stamped
• Full SCR - completely electronically controlled on it that is viewable from inside of the control
by varying signal and varying output of a control- panel. When the heater is located upstream of the
ler. Like a VFD for electric heat. 0 to 10 VDC or fan this arrow will point away from the fan. When
4 to 20 mA. The controller modulates a separate the heater is located on the downstream side of the
SCR for each stage. fan the arrow will again point away from the fan or
with airflow. If it is incorrectly installed, remove
the (2) screws holding the pressure probe in place
INSTALLATION
and rotate 180° and reinstall. The airflow switch
pressure port that is not connected to this pressure
Rotating parts and electrical shock probe will be run to the exterior of the air handling
hazards exist. Lock out and tag out unit to source a reference differential pressure. In
the fan motor(s) and heat power some situations it may be necessary to adjust this
disconnects before servicing. FOL- airflow switch setting to allow for proper operation.
Precautions must be made at this time to make sure
LOW THE LATEST “LOCKOUT
that the airflow switch does not provide a false indi-
TAGOUT” PROCEDURE. Failure to
cation of airflow. Failure to meet this requirement
follow proper safety precautions may may result in serious damage or nuisance thermal
result in serious injury or death cutout tripping (see Fig. 2-60 and 2-61).
2. A visual inspection of the heater elements should
APPLICATION INFORMATION
be made prior to use of the heater. If physical
1. Follow the procedure given in this instruction to damage is evident, a Megohm test should be used
find the minimum air velocity for safe operation to validate the heater elements are safe for use. If
(see Fig. 3-25) . At least this minimum velocity a minimum value of 10 megohms is not achieved
must be provided at all points over the heater face then any damaged elements or ceramic insulators
area. Failure to meet this requirement may result must be replaced prior to operation.
in serious damage or nuisance thermal cutout trip-
ping.

FORM 102.20-NOM1 (909)
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
2
NEGATIVE PRESSURE / AIR DRAWN THROUGH HEATER
BLOWER
HEATER
AIRFLOW

ATTACHED TO “LOW” PORT OF AIRFLOW SWITCH
LD14268
FIG. 2-60 – P
RESSURE PROBE DIRECTION
MOUNTING C
BRACKET
NO
NC
HIGH PORT LOW PORT
LD14270
FIG. 2-61 – AIRFLOW SWITCH CONNECTIONS

Installation
FORM 102.20-NOM1 (909)
ELECTRICAL INSTALLATION 7. When connecting heaters with more than one stage,
wire stage No. 1 so that it is the first stage on and
1. Follow the wiring diagram on the inside of the
the last stage off.
terminal box.
8. The heater must be wired so that it cannot operate
2. Supply connections must be made with copper
unless air is flowing over it. This can be accom-
wiring rated for 75° C minimum.
plished by using a built-in airflow switch and a
3. If supply connections are for 250 volts or greater, remote interlock. See the accompanying wiring
all wiring must be insulated for 600 volts. diagram for the method used with this heater and
4. When making line connections to heater element provide appropriate interlock wiring as illustrated.
terminals FOR FINNED TUBULAR HEATERS This diagram will be located inside of the electric
ONLY, apply a 1/4" wrench to flat section of termi- heater control panel.
nal immediately below threads. Otherwise damage 9. If not supplied as part of this heater, install a
to terminal may result. line disconnect switch or main circuit breaker in
5. Supply conductors for heaters rated less than 50 accordance with the National Electrical Code.
KW, must be sized at 125% of rated load. On heat- Depending upon the heater’s location and acces-
ers rated 50 KW and more, the supply conductors sibility, a built-in disconnect switch may meet this
may be sized at 100% of rated load, if indicated requirement.
on the wiring diagram. The line current for either 10. All electrical connections in the heater, including
a single or three phase load is calculated as fol- both field and factory made connections, should be
lows: checked for tightness before operating the heater.
In addition, after a short period of operation, all
KW x 1000
Single Phase Line Current = connections should again be checked for tight-
Voltage
ness.
11. If heater is wired to a heating / cooling thermostat,
KW x 1000
Three Phase Line Current = use a thermostat with isolating circuits to prevent
Voltage x 1.73
possible interconnection of Class 2 outputs.
6. The following table shows the maximum current 12. If the heating elements are divided into several
for 75 °C copper wire with not more than 3 con- sections with resistance wire between two or more
ductors in a raceway. It is based on the National sections, maximum KW per sq. ft. should be cal-
Electrical Code Table 310-16. The amperages culated as follows:
shown are for 125% and 100% wire sizing. If there
are more than 3 conductors in a raceway, derate Heater nameplate KW
these amperages per Table 310-15(b)(2)(a).
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

FORM 102.20-NOM1 (909)
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. All air handling unit penetrations
must be sealed to prevent air and water leakage (see
IOM Section 5 “Penetrations and Grommet Details”).
► Field provided disconnects must provide circuit
protection according to the humidifier nameplate. All
field wiring to the humidifier must be in accordance 2
with NEC and local codes and by laws. KNOCKOUTS LD11727
FIG. 2-63 – SUPPLY POWER KNOCKOUTS
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.
If humidifier IOM cannot be located inside humidifier,

call Airside Product Support for information on
electronic version.
LD11726
LD11725
FIG. 2-62 – TYPICAL HUMIDIFIER PANEL LAYOUT FIG. 2-64 – HUMIDIFIER POINTS

Installation
FORM 102.20-NOM1 (909)
PIPING CONNECTIONS • Penetrations through pipe chase floor must be

flashed and sealed.
Do not remove bottom panel in pipe
chase. • Penetrations through panels must be sealed
(see IOM Section 5 “Penetrations and Grommet
Details”). ►
• Where piping is insulated, insulation should
When extended piping to or from not be installed until after the flashing has been
coils, humidifiers, etc., is present in- completed.
side the air handler, field provided
and installed insulation is required. Pipe chase should be installed before
piping is connected.
• Whenever possible, piping should be brought
down through outdoor units within the pipe
chase (see Fig. 2-65).
OUTDOOR: DRAIN CONNECTION IS ALWAYS ON SIDE OPPOSITE PIPE CHASE.

LD09629A
Usable working clearance is approximately the depth of the pipe

chase minus 5".
All dimensions are approximate and not certified for construction.
FIG. 2-65 – PIPE CHASE ENCLOSURE
LD06340-1
FIG. 2-66 – FACTORY COIL CONNECTIONS

FORM 102.20-NOM1 (909)
COIL PIPING piping the torque is not transmitted to the coil header,
Do not test, clean and flush piping thus damaging the coil connection.
through this equipment.
Application Notes - All connections are male piping
thread except DX coils, which are solder. Drain and vent
Isolate this equipment from pressure taps on water coils are pipe thread shipped with plugs
testing of water, steam gas and air installed. These taps are installed approximately two
piping. inches back from the end of the threaded connections.
Pipe for balanced flow and assure even

Consult the job specifications and submittal drawings airflow.
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 2
installations (see Fig. 2-66 showing factory coil
connections).
STAGGERED COILS
Support all connecting piping independently of the Staggered Coils in Expanded Cabinet size units will
coils. Provide swing joints or flexible fittings in all have connections brought to the unit exterior for liquid
piping connections, particularly adjacent to heating or steam coils. DX coils not included.
coils, to absorb expansion and contraction strains. • The external connections are either threaded pipe
Rigid piping connections can cause coil damage. or grooved pipe for the contractor to make his
connections when the media is liquid.
The coil supply and the return pipe connections are • The external connections are threaded pipe for the
labeled. When attaching piping to the coil header, contractor to make his connections when the media
make the connection only tight enough to prevent is steam.
leaks. Excessive tightening may cause damage to the
• The installing contractor is responsible for insulat-
header. A backup wrench should be firmly held on the
ing piping extensions we provided inside the air
coil connection so that in tightening the connecting
handler.
Staggered Coil – Angle Wall Staggered Coil – Opposite

Side Connections
FIG. 2-67 – STAGGERED COIL CONFIGURATIONS

Installation
FORM 102.20-NOM1 (909)
WATER
WATER COILS - HOT WATER & 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 The temperature rise of the air (hot water coil) or
flow of water and air. The return pipe will be connected temperature fall of the air (chilled water coil) leaving
to the remaining coil connection. the coil is dependent on the airflow across the coil, the
gallons of water flow through the coil and the entering
Install an air vent in place of the top pipe plug on the water temperature into the coil. Consult the submittal
return header. In order to provide for drainage, install for each job for the specific information.
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 & 2-70 for typical piping diagrams.
VENT PT 3 WAY CONTROL VALVE GLOBE

PLUG VALVE
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
GATE VALVE W/ LD12939

HOSE BIB
FIG. 2-68 – CHILLED WATER COIL CONNECTIONS Example - NOT for construction

FORM 102.20-NOM1 (909)
VENT PT 2 WAY CONTROL VALVE GLOBE

PLUG VALVE
ECCENTRIC HOT
RETURN REDUCER WATER
RETURN
COIL
SUPPLY
STRAINER
HOT
DRAIN WATER
SUPPLY
GLOBE
UNION VALVE
RETURN 2
COIL
SUPPLY
PT GATE
PLUG VALVE
GATE VALVE W/ LD13791

HOSE BIB
FIG. 2-69 – HOT WATER PIPING - 2 WAY VALVE Example - NOT for construction
VENT PT REDUCING GLOBE

PLUG TEE VALVE
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

Installation
FORM 102.20-NOM1 (909)
WATER TREATMENT STEAM DISTRIBUTING COILS
Any copper tube coils may be attacked by acid Do not bush or reduce the coil return pipe size. Use a
condensate. The practice of boiler water treatment full size return pipe to the bottom of a dirt pocket. The
should include CO2 removal to assure longer tube supply pipe may be reduced at the coil connection if
life. necessary. Install the coil casing level with the return
down. A coil must be sufficiently elevated to allow a
Freeze Protection 12 inch minimum drop between the return connection
Chilled water, hot water and steam coils can be on the coil and the trap. A greater than 2 inch drop is
damaged during freezing weather. Precautionary required for protection from freezing. The return main
measures must be taken to prevent freezing such as: should be located below the trap. Refer to Fig. 2-71.
STEAM CONTROL
• Positive coil freeze protection must be used in
installations where any part of the water coil is Continuous steam supply ensures long coil life and
subjected to temperatures of 32 degrees or lower. minimizes potential trapping, venting and freezing
This may be accomplished by using a suitable problems. A rapid cycling of the modulating steam
antifreeze solution. If the coil is not in use, it is supply or a frequent on-off steam supply control
recommended that the coil be completely drained results in repeated thermal and piping stresses which
and the inside of the tubes blown dry with com- will shorten the coil life. Modulating steam control
pressed air. valves must not be oversized but must be carefully
• After draining, flush coils with an antifreeze so- selected. A substantial variation in the supply pressure
lution such as glycol. A solution of 50% glycol will require the installation of a pressure-reducing
and 50% water will protect from freezing to ap- valve ahead of the automatic control valve.
proximately 35 degrees F below zero at sea level.
Also refer to ASHRAE and ARI guidelines. Light load operation with a modulated steam supply
• During winter operation due to the possibility of can be improved by the installation of a vacuum breaker
check valve. An open relief line to the atmosphere
shutdowns such as power failure, night shutdown from the return line near the coil is desirable, except
and weekend shutdown, the controls should be on vacuum systems.
installed so the return air dampers will go to the
full open position, and all fresh air dampers go With a modulated steam supply, it is not practical to
to the full closed position. A source of auxiliary lift the condensate to an overhead return. Locate the
heat must be maintained inside the unit cabi- coil well above the return, or provide condensate unit,
net. or a boiler return trap below the coil.
• Other means of protection such as various
electro-mechanical switches and the full constant Individual control valves are required on each coil
flow of water can be used; however, Johnson installed in series with respect to airflow. When a
Controls will not be responsible for any coils modulating steam valve supplies two or more coils
damaged by freezing. in parallel, with respect to airflow, the piping must be
designed to provide for uniform steam distribution to
STEAM each of the coils.
Refer to Fig. 2-71 “Steam Coil Piping
Arrangements.”
STEAM COILS
The operation of steam coils is dependent on airflow

quantity and temperature. Consult the submittal issued
for each specific unit for above information.

FORM 102.20-NOM1 (909)
STEAM TRAPS
Float and Thermostatic (F. & 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. & 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.
SYMBOLS FOR "SS" STEAM

COIL PIPING ARRANGEMENTS
AIN VACUUM
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.)
VACUUM CONTROL VALVE

BREAKER (MODULATING OR
1/2" CHECK TWO POSITION)
VALVE
M AIN STEAM COIL (OPTIONAL)
LY
PP
SU
PITCHED IN
CASING 12" MIN. F&T
TRAP CHECK VALVE
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
FIG. 2-71 – STEAM COIL PIPING ARRANGEMENTS

Installation
FORM 102.20-NOM1 (909)
STEAM IN
ACTUATOR
FACE
DAMPERS
CLOSED
BYPASS
OPEN
STEAM OUT
LD09630
FIG. 2-72 – INTEGRAL FACE & BYPASS COIL (HORIZONTAL; TUBES, STEAM SHOWN)
VIFB & IFB
A complete IOM is provided with each Below 35°, the Vertical Tube Integral Face & Bypass
IFB or VIFB coil unit. (VIFB) or Integral Face & Bypass (IFB) operates with
full steam pressure or full water flow at all times. This
prevents freeze-up and temperature stratification.
VIFB lower header must be free to STEAM IN

float. After coil has been piped, re-
move yellow colored bolts to allow
header to float. Always “back up” on
the coil connections when installing
fittings.
ACTUATOR
VIFB Warranty will be voided should
return piping on lower header (inlet
and return on two-row header) not
include flexible connector(s) and if
lower header(s) bolts are not removed STEAM OUT
prior to use.
LD09631
See IFB/VIFB manufacturer's IOM

for additional piping details. FIG. 2-73 – VERTICAL INTEGRAL FACE &
Factory does NOT pipe connections to BYPASS COIL
(FACE MOUNTED ACTUATOR SHOWN)
unit exterior.

FORM 102.20-NOM1 (909)
Shipping Bolts (VIFB Only) Flexible Connectors (VIFB Only)

Return steam condensate headers or hot water supply Return steam condensate headers, hot water supply,
and return headers are securely bolted to lower and return headers must be free to float. A flexible
mounting brackets to prevent damage to header and connector MUST be installed as close as possible to
tubes during shipment and piping of the coils. These the coil to accommodate a minimum of 1/2” expansion
bolts MUST be removed before applying steam or hot movement of the headers.
water but after all piping connections are made.
Failure to install connectors will restrict expansion
Piping Suggestions (VIFB & IFB) of the headers. This can result in bowing of tubes,
See IOM Section 5, “Field Penetra- bending of fins, interference with damper operation, or
tions for Piping & Electrical Connec- eventually tube breakage.
tions”. ► Freezing Conditions
Anti-stratification baffles are standard
on all IFB and VIFB coils mounted in 2
Steam and hot water field piping must be supported YORK Solution units.
separately after the flexible connector to isolate piping
strains and additional expansion from the coils.
Internal steam manifolds and piping should be The outside air and return air must be thoroughly
insulated. mixed before passing over the coil. When freezing air
enters only part of the coil, it creates a greater hazard
Steam traps should be sized for three times the than when the airflow entering the coil is of a uniform
calculated condensate loading at the coil design temperature.
conditions, based on the pressure differential across
the trap, not the boiler pressure. Traps should be of Coils used in series with respect to the airflow must
types that pass condensate and air at saturated steam have individual controls with ample space between the
temperature. Inverted bucket traps should incorporate coils for sensing devices, when required. Coils with
thermostatic air vents. two or more rows are more sensitive to freezing than
single row coils.
Make return connection full size as required and
reduce only at trap. Do not use reducing bushing on On 100% O.A. capable applications, locate low limit
coil return connection. at least 24" downstream of leaving edge of VIFB/IFB
casing. Low limit element must cross both face and
bypass areas, parallel to headers.

Installation
FORM 102.20-NOM1 (909)
3/4" (19.1mm)
AUTOMATIC AIR
VENT IN TOP
HEADER
VIFB AIR
COIL FLOW
HOT WATER
SUPPLY
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. 2-75 – HOT WATER PIPING FOR IFB

FORM 102.20-NOM1 (909)
STEAM PRESSURE BELOW 15 PSIG OR 103.4 KPA
VACUUM BREAKER CHECK

VALVE 1/2" (12.7)-15°
STEAM MAIN STEAM

DRIP TRAP MAIN
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)
1/2" (12.7) 3/4" (19.1)

THERMOSTATIC TRAP AUTOMATIC
FOR AIR REMOVAL AIR VENT
CONDENSATE CONDENSATE
FLOW FLOW
NON-VENTING TRAP NON-VENTING TRAP
STEAM PRESSURE ABOVE 15 PSIG OR 103.4 KPA
VACUUM BREAKER CHECK

VALVE 1/2" (12.7)-15°
STEAM MAIN STEAM

DRIP TRAP MAIN
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
FIG. 2-76 – STEAM PIPING FOR VIFB COIL

Installation
FORM 102.20-NOM1 (909)
REFRIGERATION
DIRECT EXPANSION COILS (DX)
DX coils are divided into splits depending upon the Do not leave piping open to the atmosphere
unit size and coil circuiting. Each split requires its own unnecessarily. Water and water vapor are detrimental
distributor nozzle, expansion valve and suction piping. to the refrigerant system. Until the piping is complete,
Suction headers are on the air entering side with suction recap the system and charge with nitrogen at the end
connection at bottom end of headers when the coil is of each workday. Clean all piping connections before
properly installed. Matching distributor connections brazing joints.
for each coil refrigeration circuit are on the air leaving
side. See certified drawing and/or connection labeling The orientation of the refrigerant distributor is not
to ensure correct matching of suction and distributor critical but the distributor tubes must not be kinked
connections. or bent in a non-uniform configuration. For this and
other piping & sundry tips, refer to Fig. 2-77.
Direct-expansion coils are shipped
charged with nitrogen. The orientation of the refrigerant distributor is not
critical but the distributor tubes must not be kinked
or bent in a non-uniform configuration. For this and
other piping & sundry tips, refer to Fig. 2-77.
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
MUST RISE TO THE TOP OF THE COIL

AND BE HIGH ENOUGH TO SLOPE TO
THE COMPRESSORS TO FACILITATE
BALL VALVE
OIL RETURN TO THE COMPRESSORS.
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
THERMAL SUCTION LINE

SPORLAN
ASC HOT GAS EXPANSION
FITTING VALVE
SIGHT GLASS
TXV Equalizer
Line
SUCTION LINE
1-7/8"
45°
Mount thermal expansion valve bulb on side of Construct suction line

horizontal run of suction line as shown. Insulate P-trap from street fittings
bulb / line after clamping bulb to line. to maintain minimum
trap volume.
LD05171A
FIG. 2-77 – TYPICAL PIPING AND SUNDRIES AT THE DX COIL

FORM 102.20-NOM1 (909)
DX COIL TYPES Face Split

There are three basic types of coil arrangements used On a face split coil, the circuiting is divided between
in field erected split systems, interlaced, row split and two separate coils. In field-erected systems, this
face split. arrangement may suffer from TXV superheat control
problems and compressor reliability. At low airflow,
Interlaced low load situations, the TXV may have difficulty
Interlaced coils are the most desirable type of coil “field controlling system superheat.
erected” designs. Interlaced coils ensure the entire face
of the coil is active with any number of compressors Air stratification, poor humidity control and
operating. Interlaced circuitry interweaves coil tubing condensation on downstream components can also
in both circuits across the entire face of the coil assuring occur when using face split coils. One way to address
uniform cooling of the air by the refrigerant. This type TXV control at part load is to provide a face damper to
of coil also allows one circuit to operate while the other shutoff airflow when a coil face is inactive.
circuit is turned off. Interlaced coils provide excellent
temperature control at full and part loads as well as COMBINED COIL TYPES
good TXV superheat control. TXV control is essential Coil types may be combined in some systems. This
2
for compressor reliability. requires special care. Control sequences and piping
tying the multiple systems and coils together should
Row Split
be well thought out and advice from an experienced
Row split coils arrangements place coils back to back design engineer is necessary.
in the air stream. Air passes through one coil before
passing through the next. Generally, the last coil in DX COIL CIRCUITING
the air stream is activated first. Each circuit may be
controlled independently in this arrangement. When On many coil banks, two, or even all three of the
both coils are operating, the coil closest to the leaving methods of circuiting may be combined depending
air will operate at a lower temperature. This type of upon the cooling capacity and the level of control
coil may not permit lead lag of the circuits and it may required. However, coil sections must be married or
be difficult to balance the capacity between the coils combined so that they provide for full-face operation
(see Fig. 2-78).
There are numerous coil arrangements available from

the Coil Marketing group as either standard designs
or contract engineering SQ optional designs. The coil
designs fall into the two following categories.
FACE SPLIT ROW SPLIT INTERLACED
REFRIGERANT IN
LEGEND
REFRIGERANT OUT WARM AIR COLD AIR
LD13319B
FIG. 2-78 – DX COIL CIRCUITING TYPES
Installation
FORM 102.20-NOM1 (909)
Coil Design Fin Height

H2
Non-stacked 48" and less
Stacked Greater than 48" H1
D2
Figs. 2-79 through 2-83 illustrate the available coil
H1
arrangements. Contact Coil Marketing for other D1
arrangements not shown.
D1
Face-split DX coils must be config-

ured to provide full-face coverage
at all condensing unit load steps. 1 Distributor 2 Distributor
Johnson Controls assumes no re- Circuit Circuits 50 - 50%
Interlaced
sponsibility for compressor failure LD09143A
if full-face coverage is not applied. FIG. 2-80 – NON-STACKED COIL DESIGN -

Consult the factory, if application STANDARD
assistance is needed to convert split
face to full-face operation.
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
3 Distributor 4 Distributor 4 Distributor 8 Distributor

Circuits Row Split Circuits Face Split Circuits Row Split Circuits Row Split
66-33 Split 50-50% Interlaced Interlaced & Face Interlaced
SQ Required SQ Required SQ Required SQ Required
LD09144A
FIG. 2-79 – NON-STACKED COIL DESIGN - SQ SPECIAL

FORM 102.20-NOM1 (909)
D2 2
H2 H1 2
D1 4
D4 1
H4 H3 1
D3 3
Four Circuits Two Circuits

4 Distributor Recommended NOT Recommended
Circuits Face Split
LD09147A
50 - 50% Interlaced LD09145A
FIG. 2-81 – STACKED COIL DESIGN - STANDARD FIG. 2-83 – STACKED COIL CIRCUITING
DX COIL CIRCUITING AND STAGING 2

On stacked coils, a minimum of four coil circuits should If one coil circuit is used (Fig. 2-84), the LLSV and
be used to achieve full-face control (Fig. 2-83). Each TXV must be sized to handle the full capacity of the
coil distributor circuit requires its own Thermostatic refrigerant circuit. When two coil circuits are used per
Expansion Valve (TXV). Each condensing unit circuit refrigerant circuit (Fig. 2-85), each TXV should be
requires its own liquid line solenoid valve (LLSV). sized to handle half of the capacity of the refrigerant
When the condensing unit has two compressors per circuit and the LLSV should be sized to handle the full
refrigerant circuit, either one or two coil circuits may capacity of the refrigerant circuit.
be used for each refrigerant circuit depending upon the
cooling capacity.
H2
Single H2 Single
HDR H1
HDR H1 D2 H2 Body
Body D2
D1 H1 Single D1 D2
HDR
Body
D1 D1 H1

Circuit Circuits 50 - 50% Circuits Face Split Circuits Row Split
SQ Required Interlaced SQ Required SQ Required
SQ Required
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

Circuits Row Split Circuits Row Split Circuits Face Split Circuits Row Split
66-33 Split Interlaced Row Split & Interlaced & Face Interlaced
SQ Required SQ Required SQ Required SQ Required LD09146
FIG. 2-82 – STACKED COIL DESIGNS - SQ SPECIAL

Installation
FORM 102.20-NOM1 (909)
compressor #1
100% capacity
tXV LLSV
compressor #3
Feeds both circuits
condensing Unit tXV LLSV

DX coil compressor #2 condensing Unit
DX coil
LD09148 LD09152
FIG. 2-84 – O
NE COIL CIRCUIT PER FIG. 2-88 – DO NOT USE THE ABOVE
REFRIGERANT CIRCUIT CONFIGURATION.
compressor #1
When sizing TXV's, each TXV must
tXV be sized for the refrigerant circuit
LLSV
tonnage divided by the number of
DX coil liquid distributors. The TXV
tXV
compressor #2 condensing Unit
should be equal to or smaller than the
DX coil calculated value.
LD09149
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
FIG. 2-87 – THREE COMPRESSOR YCUL
In the case of a stacked coil with four coil circuits piped

to a condenser with six compressors, the coil circuits
would be face-split and interlaced with two interlaced
circuits on the lower coil section and two on the upper
(Fig. 2-89).

FORM 102.20-NOM1 (909)
Comp 1 - 3 The venturi type distributor furnished with YORK DX

coils may be ordered for field application of a hot gas
TXV1
bypass valve. The connection may be made through a
tee installed in the field between the expansion valve
TXV3 LLSV1
Comp 4 - 6
and distributor. The system balance point and control
adjustments must assure compressor cooling and avoid
Comp 1 - 3 LLSV2 excessive compressor cycling. Refer to Form 50.40-
Condensing Unit
ES3, Section 3. ►
TXV2
MAINTAINING ADEQUATE AIRFLOW

TXV4
Comp 4 - 6
LD09153
An electrical interlock between the air handler and
DX Coils the condenser must be included for permissive run
FIG. 2-89 – SIX COMPRESSOR YCUL of the condenser. In addition, a differential pressure
switch mounted across the supply fan must always be
included to ensure airflow across the coil before the 2
THERMOSTATIC EXPANSION VALVES (TXV)
condensing unit is energized. The condenser must
Each coil distributor circuit requires its own never be operated unless the air handler fan is operating
Thermostatic Expansion Valve (TXV). Each and air is flowing across the active coil. Insufficient
condensing unit circuit requires its own liquid line airflow will result in liquid refrigerant returning to the
solenoid valve (LLSV). TXV's are to be equipped with condensing unit, which could damage the compressors
external equalizer tubes that are field connected to the by liquid slugging or washing oil from the bearing
suction line. The valve should be sized in accordance surfaces.
with the valve manufacturer's recommendations,
allowing approximately 35 PSI pressure drop In variable volume systems, the mini-
throughout the coil and distributor at full load. Do not mum acceptable airflow for fixed speed
oversize the valve. Follow the valve manufacturer's or VAV systems is 350 FPM face ve-
instructions on the location of the thermostatic bulb. locity across each DX coil, as applied
Proper expansion valve operation is necessary in order
to split DX systems. This is critical to
to realize the rated coil capacity.
assure that the TXV does not overfeed,
When a DX type coil is operated with a suction causing compressor failure.
temperature below 32°F, a buildup of frost will occur
on the finned surface. It is, not recommended therefore,
to operate DX coils for air conditioning purposes at The air velocity flowing through chilled water and
below freezing suction temperatures. If the full load direct expansion coils must not exceed specific
operating point for the coil is selected at a “safe” recommended values, to prevent water carryover.
temperature, a system analysis is required to check for
the lowest probable suction temperature at light load
VAV SYSTEMS
conditions.
Overhead variable air volume systems have been the
HOT GAS BYPASS preferred method of air distribution since the early
When using discharge air temperature control or 1970 ’s. Overhead VAV systems offered greater energy
systems with outside air economizer cooling, always efficiency and better control of building diversity than
include hot gas bypass (HGBP). It is not as critical to constant volume systems. Unlike a constant volume
use HGBP with return duct air temperature control, or system, in which the leaving air temperature is adjusted
suction pressure control, but it provides better capacity to satisfy the cooling load, in a VAV system the air
control at low loads. temperature remains constant and the air volume is
varied to meet the cooling requirements.

Installation
FORM 102.20-NOM1 (909)
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
static pressure in the ductwork changes. When a box decreases more quickly than the
opens, the duct static pressure decreases, and when a compressor control can respond to
box closes, the duct static pressure increases. The duct
the load change. Therefore, airflow
static pressure sensor controls the air handling unit
should never change at a rate faster
supply fan. Since an increase in duct pressure relates
to a decrease in the zone airflow required, the supply than 3% 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.

FORM 102.20-NOM1 (909)
DRAINS AND TRAPS

Heat trace and insulate traps where "H" must be at least
there is a risk of freezing to prevent 1 inch plus fan total
blockage and/or damage due to freez- static pressure
ing of the liquid in the trap.
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 han- "X" = 1/2 "H"
dler. In such cases it is recommended
to cap the drain in a manner that al-
lows opening or closing of the drain
depending on its use. 2
LD05370-2
CONDENSATE DRAIN PIPING

The majority of cooling coils are located in the units so FIG. 2-91 – TRAP DETAIL FOR DRAW THROUGH
that the supply air is drawn through them. This results APPLICATION
in the condensate being subjected to negative (-) static
pressure. Unless some means of pressure equalization CONDENSATE DRAIN TRAP
is provided in the condensate drain, the air rushing For “Draw Through” applications install a trapped
back through the drainpipe will cause the condensate condensate drain line at unit drain connection (see Fig.
to build up in the drain pan. As the unit continues to 2-91) according to all governing codes. “H” dimension
operate, the accumulated water will be carried with the must be at least 1 inch greater than design Total Static
air stream, overfilling the drain pan causing possible Pressure (TSP) of fan. This ensures proper drainage
water leaks into the supply duct and/or causing water even if filters clog or dampers malfunction.
damage in the building. A trap must be installed to
prevent this condensate water build-up (see Figs 2-90 For “Blow Through” applications, the same principles
and 2-91). apply, but the leaving pipe must be as shown in Fig.
2-92 for proper trap design.
DRAIN
PAN TRAP
"H" must be at least
DRAIN
NIPPLE 1 inch plus fan total Drain
Connection
NO.1 - FAN OFF
static pressure
DRAIN
PAN
H
NO. 2 - TRAP CONDITION WHEN FAN STARTS
DRAIN
PAN
COOLING COIL
DRAIN PAN Top of trap must be equal to or
lower than bottom of unit drain
NO. 3 - FAN RUNNING AND CONDENSATE LD06342-1 connection. LD05371-2
FIG. 2-90 – DRAIN TRAP SHOWING WATER

FIG. 2-92 – TRAP DETAIL FOR BLOW THROUGH
LOCATION DURING DRAW THROUGH
APPLICATION
OPERATION STAGES

Installation
FORM 102.20-NOM1 (909)
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 & 201 as a minimum. Duct turns and
TRAPS transitions must be made carefully to hold friction loss
to a minimum. Avoid short turns. Duct elbows should
LD06345-1 contain splitters or turning vanes.
FIG. 2-93 – COMBINING DRAIN LINES The Effective Duct Length connected to the fan or
unit discharge should run in a straight line for at least
If distance from drain pan outlet to trap exceeds 10', 2.5 Equivalent Discharge Diameters* for up to 2500
install additional clean outs for each 10' segment FPM fan outlet velocity and one additional diameter
of horizontal drain line (min. 1/4 in. per foot fall for each additional 1000 FPM fan outlet velocity. This
required). ductwork should be no greater than 105.5% or no less
than 85.5% of the discharge area. In addition, the
On initial startup, it may be necessary to fill the trap slope of the transition elements should not be greater
manually. than 15% for converging elements, or greater than 7%
for diverging elements.
ELEVATING UNIT FOR GRAVITY FLOOR DRAIN
CONNECTIONS * To find the Equivalent Discharge Diameter:
On indoor units, the installer must provide a means of EDD = 4ab/�

pumping or draining coil condensate water away from The letters “a” and “b” represent the height and width
the unit. The installer may have to elevate the unit to of the discharge.
provide space below the condensate drain of the unit to
install properly designed drain trap(s) to permit gravity A duct turn should be in the same direction as the
flow of condensate water from the drain pan (see Figs fan rotation. Never deadhead the discharge into the
2-3, 2-4 & 2-5). flat surface of a plenum.
DUCT CONNECTIONS
Duct must have positive seal to unit
openings. Outdoor baserails are
available in 3", 6", 8" & 10" heights.
Contractor is responsible for providing
ductwork to include baserail height. Effective Duct Length
All ductwork should be supported in-

dependently from the unit.
LD06335-2
FIG. 2-94 – R
ECOMMENDED DISCHARGE DUCT
ARRANGEMENT WHEN TURNS ARE
REQUIRED

FORM 102.20-NOM1 (909)
DUCT CONNECTIONS
Ducts must have positive seal to unit openings.
Installer is responsible for providing ductwork to include base rail height for curb mounted
units.
All duct work is to be supported independent of the connection to the unit.
If the entire unit is mounted on isolation, the duct connection is to be flexible.
This instruction is suitable for bottom, end, side and top connections. Top connections on
Outdoor units are not recommended.
FLANGED DUCTS OR SLEEVES:

To use flanged duct or sleeve be sure there will be access on all four sides to fasten the flange completely.
Flanged ducts can be connected with self drilling screws directly to the unit with gasket or sealant between unit and
duct flange.
2
A flanged sleeve may be dropped through the opening, provided there is access to seal & fasten the flange to the
unit interior surface.
:
RAW OR STRAIGHT EDGE DUCTS OR SLEEVES
The duct opening on the unit is located in a panel that is approximately 2” thick. The inside of the opening (2”
surface) is suitable for attaching ducts.
If access is not available from inside the unit, access may have to be from inside the duct or sleeve.
Raw or straight edge ducts can be connected with self drilling screws directly to the unit with gasket or sealant
between unit and duct.
DETAIL A
SHEET METAL SCREW
GASKET OR
SEALANT
GASKET OR SEALANT
FLANGED DUCT
RAW EDGE DUCT
BOTTOM VIEW OF UNIT

LD14087
FIG. 2-95 – R
ECOMMENDED DISCHARGE DUCT ARRANGEMENT WHEN TURNS ARE REQUIRED

Installation
FORM 102.20-NOM1 (909)
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
entering duct must provide a smooth transition from

COUNTERFLASHING
any high velocity effects. Stratifications of outside and
CURB
return air, especially where below freezing outside air
enters, must be avoided to prevent coil freeze-up or BASE FLASHING
nuisance low limit trips. ROOFING PLIES
DECK
CANT STRIP
SOUND AND VIBRATION TRANSMISSION
All roof mounted air-handling units generate some
sound and vibration that may or may not require some LD06494A
special treatment of the air-conditioned space. The

FIG. 2-96 – DUCT PENETRATION OF ROOF
noise generated by the air-handling unit is dependent
on the speed of the fan, the amount of air the fan is
• Adequate clearances between ducts and roof
moving, the fan type and the static efficiency of
penetration openings should be provided.
the fan. In applications where sound and vibration
transmissions may be objectionable, good acoustical • Ducts should be supported to avoid transfer of
engineering practices must be incorporated in the duct weight across flexible connections (see Fig.
system design. 2-97).
• Horizontal ducts should be pitched and provided
On units with return fans, it is espe- with drainage outlets as illustrated (by the system
cially important to consider the effects designer).
of sound transmission into the condi- • Ducts should be installed at a height sufficient to
tioned space. install roofing and flashing.
• See Duct connection guidelines on previous
page.
When a unit is used with a ceiling plenum return
air system, sound may be transmitted from the unit
through the ceiling to the conditioned space. For MECHANICALLY FASTEN
such applications, there should be a sound absorption DUCT TO HVAC UNIT WITH
FLANGE AND WATER PROOF
chamber installed near the unit return air inlet. Various
reference sources are available regarding acoustic
design. WATERPROOF
ALL SEAMS AND
JOINTS IN DUCTS
ROOF
FRONT AND REAR DISCHARGE OUTDOOR UNIT CURB
DUCT INSTALLATION 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.

FORM 102.20-NOM1 (909)
AIR FILTERS A list of filter part numbers, sizes and

It is mandatory that filters be in place in the filter frames quantities are shown on a label lo-
of each unit before putting the unit into operation to cated on each filter segment of each
protect the coils and keep them clean. 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
frames, filter bulkheads and filter seg-
Be sure to install all filters in the cor- ment panels are factory sealed and
rect orientation with regard to airflow must remain sealed for NO air by-
and with pleats or pockets vertical pass.
wherever possible. See IOM Section
4, “Filter Segments”. ►
Bag Filter 12" Cartridge
Most YORK Solution air handling units will be 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 Cartridge
or commissioning agent to be in touch with Johnson

Controls regarding this issue. Various filter types will
4" High
have different lead times. Efficiency 2" Pleated
Varicel II Filter
Filter clips if required will be shipped with the first

filter shipment, except for HEPA filters, in which case
the filter clips will be attached to the filter racks inside
the unit. Filter clips are not required for side load filter Cleanable Filter
arrangements.
LD09650
FIG. 2-97A – TYPICAL FILTERS

Contractor is responsible for installation of filters.
Contractor is responsible for freight claim if filters
arrive damaged. Other issues such as size, type, spares, FILTER TYPES
replacements or quantity should be addressed with the Flat, angle, rigid, bag, HEPA & charcoal.
Johnson Controls Sales office or project manager.
MAINTENANCE AND REPLACEMENT
Every month, check the cleanliness of the filters and
replace . Filters should be replaced when the pressure
drop, measured by a manometer, reaches the prescribed
limits for the installation.

Installation
FORM 102.20-NOM1 (909)
FILTER LATCHES
NOTE: Typically when filters are by others, so are the filter clips.
P/N - 026-35778-000
Used with 2" Perfectpleat, Premium or Premium HM and

SH Single Headered Filters.
Used with 2" (C86) & 4" (C89)” Amair 300 X Pleated Prefilter
in combination with a Single Header Final Filter.
P/N - 026-35778.007
P/N - 026-35778-006
Used with 2” & 4" Prefilter in combination with a Double

Header Final Filter and Varicel DH Double Headered
Filter.
2-13/16"
Used with 2” Prefilter in combination with a Double Header

P/N - 026-36339-001 Final Filter.

4-11/16"
Final Filter.
P/N - 026-36339-000
SINGLE FILTER RED

CLAMPS Used to attach HEPA Filters to Holding Frame.
(PERIMETER)
DOUBLE SILVER Used to attach HEPA Filters to Holding Frame.

FILTER
CLAMPS
(T. SECTION)
LD13303C
Fig. 2-98 – Filter Latches

FORM 102.20-NOM1 (909)
YORK MATRIX: FILTERS AND FILTER FRAMES / LATCHES
Single Filter Application

2” PerfectPleat, VariCel SH
Premium or 4” AmAir 300X or VariCel DH
Premium HM DriPak 2000
FILTER FRAME
12x24 - 16 ga. Galvanized
P/N 026-35778-000 X X
P/N 026-35778-007 X
P/N 026-35778-006 X
FILTER FRAME
24X24 - 16 ga. Galvanized 2
P/N 026-35778-000 X X
P/N 026-35778-007 X
P/N 026-35778-006 X
Prefilter / Final Filter Application

PerfectPleat,
PerfectPleat, 4” AmAir
Premium 4” AmAir
Premium 300X AND
or HM AND 300X AND
or HM AND VariCel SH or
Varicel SH or VariCel DH
Varicel DH DriPak 2000
DriPak 2000
FILTER FRAME
P/N 026-35778-007 & 026-35778-000 X
P/N 026-35778-006 & 026-36339-001 X
P/N 026-35778-007, 026-35778-008 & 026-35778-000 X
P/N 026-35778-006 & 026-36339-000 X

FILTER FRAME
24X24 - 16 ga. Galvanized
P/N 026-35778-007 & 026-35778-000 X
P/N 026-35778-006 & 026-36339-001 X
P/N 026-35778-007, 026-35778-008 & 026-35778-000 X
P/N 026-35778-006 & 026-36339-000 X

Installation
FORM 102.20-NOM1 (909)
INSTALLATION OF 2” PERFECTPLEAT, PREMIUM

OR PREMIUM HM
These instructions are for installing a 2” filter (typically Repeat the installation process with the remaining
PerfectPleat) into 16 ga. galvanized holding frames. latches in the other three corners.
• Latches needed for these applications are four 4. Rotate all of the latches outward, and insert the
(4) P/N 026-35778-000, as shown in Fig.2-98. filter into the frame.
• A single latch should be installed at each of the 5. After the filter has been placed into the frame, grasp
four (4) corners of the frame. the circular end of the latch and rotate it across the
• The latch fits into the set of knockouts, which corner of the filter.
consists of two (2) rows of three (3) knockouts. Push the end of the latch towards the filter, until the
The row of knockouts closest to the gasketing latch catches beneath the knockout on the frame.
should be used for nominal 1” filters or filters Repeat for the remaining latches.
with a 13/16” single header. The second set of
6. The filter should now be securely installed into the
knockouts should be used for nominal 2” fil-
frame (see Fig.2-100).
ters.
Installation of Spring Latches
1. Insert the straight end of the latch between the two

(2) knockouts furthest from the corner.
2. Using a moderate amount of pressure, force the
latch over the third knockout.
3 The latch installation should now be complete. The
latch should now be “trapped” within the three (3)
knockouts, but should be able to freely rotate (see
Fig.2-99).
LD010174
Fig. 2-100 – Fully installed filter
LD010171
Fig. 2-99 – C
orrectly installed latch P/N
026-35778-000.

FORM 102.20-NOM1 (909)
INSTALLATION OF 4” AMAIR 300X PLEATED

FILTER
These instructions are for installing a four (4)” filter 4. Insert the filter into the frame.
(typically AmAir 300X pleated filter) into 16 ga. 5. After the filter has been placed into the frame,
galvanized holding frames. grasp the loose end of the latch and place it over
• Latches needed for these applications are four the filter frame, so that the latch secures the filter
(4) P/N 026-35778-007, as shown in Fig. 2-98. into the frame (see Fig.2-102).
• A single latch should be installed at each of the Repeat for the remaining latches.
four (4) corners of the frame.
• The latch fits into the set of knockouts, which
consists of two (2) rows of three (3) knockouts.
The row of knockouts closest to the gasketing
should be used for filters with a 13/16” single
header in combination with a nominal 2” prefilter.
2
The second set of knockouts should be used for
nominal 4” filters.
1. Insert the straight end of the latch between the two

(2) knockouts furthest from the corner.
3. The latch installation is now complete. The latch
should now be “trapped” within the three (3) LD010179
knockouts (see Fig.2-101).

Fig. 2-102 – Place the end of the latch
Repeat the installation process with the remaining over the filter frame,
latches. securing the filter to the
frame.
6. The filter should now be securely installed into the

frame.
LD010177
Fig. 2-101 – C
orrectly installed latch P/N
026-35778-007

Installation
FORM 102.20-NOM1 (909)
INSTALLATION OF SH SINGLE HEADERED INSTALLATION OF A 2” PREFILTER IN COMBINATION

FILTERS WITH A SINGLE HEADER FINAL FILTER
These instructions are for installing single header filter These instructions are for installing a 2” prefilter,
(typically VariCel SH or DriPak 2000 filter) into 16 ga. (typically PerfectPleat, Premium or Premium HM
galvanized holding frames. pleated filter) used in combination with a single header
• Latches needed for these applications are four final filter (typically VariCel SH or DriPak 2000) into
(4) P/N 026-35778-000, as shown in Fig.2-98. 16 ga. galvanized holding frames.
• A single latch should be installed at each of the • Latches needed for this application are four (4)
four (4) corners of the frame. P/N 026-35778-000 and four (4) 026-35778-007
as shown in Fig.2-98.
consists of two (2) rows of three (3) knockouts. Follow instructions for Single
Headered (SH) filters then proceed
should be used for nominal 1” filters or filters
with a 13/16” single header. The second set of
with this procedure for 2" Pre-filters.
knockouts should be used for nominal 2” fil-
ters.
Installation of Latches
1. Insert the straight end of the latch (P/N 026-35778-
1. Insert the straight end of the latch between the two 007) between the two (2) knockouts furthest from
(2) knockouts furthest from the corner. the corner.
3. The latch installation should now be complete. The
latch should now be “trapped” within the three (3)
knockouts, but should be able to freely rotate.
Repeat the installation process with the remaining
latches.
4. Rotate all of the latches outward, and insert the SH LD010496
filter into the frame. The bulk of the filter should
be inserted through the frame, protruding out the Fig. 2-104 – install latch p//n 026-35778-007
backside. Only the header of the filter should be
contacting the flange of the frame. 2. Using a moderate amount of pressure, force the
5. After the filter has been placed into the frame, grasp latch over the third knockout (See Fig. 2-104).
the circular end of the latch and rotate it across the 3. After both filters have been placed into the frame,
corner of the filter. grasp the loose end of the latch and place it over
Push the end of the latch towards the filter, until the the prefilter frame, so that the latch secures the
latch catches beneath the knockout on the frame. prefilter to the SH filter. Repeat for the remaining
Repeat for the remaining latches. latches.
6. The filter should now be securely installed into the 4. The filters should now be securely installed into
frame (see Fig.2-103). the frame, as shown in Fig.2-105.
LD010160
LD010148
Fig. 2-105 – installed CARTRIGE W/PLEATS
Fig. 2-103 – installed CARTRIDGE filter
FORM 102.20-NOM1 (909)
INSTALLATION OF A VARICEL DH DOUBLE 4. Repeat the latch installation with the remaining
HEADERED FILTER latches. Note the orientation of the latch to the
knockouts in Fig.2-107.
These instructions are for the installation of a VariCel
After the latches have been installed, the frame
DH filter (nominal 12” deep double header) into 16 ga.
should be configured like that shown in Fig.2-
galvanized holding frames.
108.
• 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. 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 2
latch to the filter. See Fig.2-106 for the sets of
knockouts that should be used for the latches.
LD010183
Fig. 2-108 – Frame with 4 latches

installed.
The frame contains 2 latches per side,

none on the top or bottom.
DO NOT USE
LD010150
Fig. 2-106 – CORRECT USE OF KNOCKOUTS
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
Fig. 2-109 – Spring latch should be pulled

LD010154
and fastened in hole in the
Fig. 2-107 – C
orrect latch/knockout header of the filter.
configuration.
Installation
FORM 102.20-NOM1 (909)
INSTALLATION OF A 2” & 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 holes in the filter frame, used to secure the
latch to the filter. LD010156
Fig. 2-111 – Frame with 4 latches installed

1. Insert the straight end of the latch between the Installation of Prefilter Latches
knockouts furthest from the corner.
6. To install the prefilter latches, slide the end of
2. Using a moderate amount of pressure, force the the latch with the 180 ° turn, over the edge of the
latch over the third knockout. header, as shown in Fig.2-112. The latch should be
3. The latch installation should now be complete. installed at the approximate midpoint of the filter
The latch should now be “trapped” within the 3 leg.
knockouts (see Fig.2-110). The prefilter latch should be slid over the header
as shown in Fig.2-112.
LD010163
Fig. 2-112 – Prefilter latch after

LD010154 Installation onto filter
header.
Fig. 2-110 – C
orrect latch/knockout
configuration. P/N 026-35778-006

FORM 102.20-NOM1 (909)
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.
LD010165
Fig. 2-113 – Position prefilter in front of LD010167

the final filter. (2" w/026-36339-
Fig. 2-115 – Completed assembly
000 latch shown)
9. Grasp the end of the prefilter latch and “spring” it
so that it fits over the edge of the prefilter. Repeat
with the remaining latches.
After all remaining prefilter latches have been
placed around the prefilter; the finished assembly
should look like that in Fig.2-115.
LD010190
Fig. 2-114 – Spring the end of the latch so

that it fits over the edge of
thePrefilter. (4" w/026-36339-000
latch shown)

Installation
FORM 102.20-NOM1 (909)
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)
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)
HEPA FILTERS VISUAL CONTROL FILTER CLAMPS

WELDED BEVEL SEAL FRAME (See Fig. 2-117.)
Extruded Aluminum Frames for Gasketed HEPA Filter
Installations HEPA Filter Applications
The Bevel Seal frame is a factory welded, extruded Visual Control clamps are designed for use with any
aluminum frame developed specifically for High conventional gasketed HEPA filter. Located at midpoint
Efficiency Particulate Air (HEPA) filter installations. of each filter edge, the calibrated spring-loaded clamps
Standard Bevel Seal frames accommodate multiple maintain up to 100 pounds pressure against the filter at
sizes of gasketed HEPA filters 11-1/2" deep. (See Fig. each clamping point. Four clamps are used per filter to
2-116, 2-118 & 2-119.) assure uniform pressure against the gasket. The clamps
have a 1-1/2" wide bearing surface.
Two Stage Gasket Compression Prevents Leakage
Easy Clamp Installation
The Bevel Seal frame features a two level sealing
surface connected by a bevel. This causes the filter No special tools are required for proper clamp
gasket to be compressed in two stages as clamping installation. Just tighten the bolt head until it is
pressure is applied. The outer edge of the gasket is flush with the clamp face to achieve the prescribed
compressed to a greater degree than the inner portion of compression. Proper clamping pressure is created
the gasket. (See Fig. 2-119.) indefinitely by the calibrated spring.
In the event excessive clamping pres- Single filter clamps are used around the perimeter of the
frame bank. Double clamps are used along main runners
sure is applied, the individual cells in
to secure a filter on either side of the T-section. (See
the gasket material can be fractured
Fig. 2-117, 2-118 & 2-119.)
causing the gasket to relax, allowing
leakage.
11-1/2"
ASTROCEL
MAIN RUNNER PERIMETER EXTRUSION HCX
SINGLE
FILTER RED
2"
CLAMPS
(PERIMETER)
2" 2"
T-SECTION PERIMETER SECTION -
TYPE H
LD06647A DOUBLE SILVER
FILTER
FIG. 2-116 – HEPA FILTER FRAME CROSS CLAMPS
SECTION VIEW (T. SECTION)
LD06648-1
FIG. 2-117 – VISUAL CONTROL FILTER CLAMPS

FORM 102.20-NOM1 (909)
DOUBLE T-SECTIONS
FILTER
CLAMP
2
DOUBLE PERIMETER
FILTER SECTION
CLAMPS
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
CELL SIDE
FRAME
(PERIMETER
EXTRUSION)
MEDIA PACK
BEVEL SEAL FRAME
GASKET BEVEL
RECESSED SEALING
CELL SIDE SURFACE
LD06646A
FIG. 2-119 – WELDED BEVEL SEAL FILTER INSTALLATION

FORM 102.20-NOM1 (909)

FORM 102.20-NOM1 (909)
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 manufacturer's 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
When internal safety catch is not used, 2406).
always replace metal tab on access 3
doors that provide access to pressur- If your unit has HEPA filters the filter
ized areas. This mechanical protection frames, filter bulkheads and filter seg-
is to prevent accidental release of ac- ment panels are factory sealed and
cess doors under positive pressure. must remain sealed for NO air by-
pass.
Serious damage to the AHU and/or
system is eminent if the AHU is oper-
ated under any of the following condi- Never use silicone caulk/sealant or
tions: caulk/sealant containing silicone in or
• Wi t h o u t p r o p e r c o n t r o l o f on any air handling equipment. [Only
dampers. exception is when provided (high tem-
perature) with gas heat venting].
• With smoke dampers closed.
• During a fire alarm or smoke
purge test.
• Any airflow restriction greater
than normal.
• Fluctuating or incorrect voltage
power supply

Startup
FORM 102.20-NOM1 (909)
PRE START-UP Do not remove functional bolts from

seismic isolators (see Fig. 3-6).
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. • Ensure damper linkage is tight and in correct
For VFD equipped air handlers, refer to the VFD “power off” position.
literature for additional start-up requirements.
Return air dampers may be closed for
shipping. Loosen actuator or crank
• Verify equipment received as ordered.
arm on jackshaft, open dampers, and
• Check for damage to the interior and exterior of retighten actuator or crank arm.
unit.
• Verify unit installed on flat and level surface.
• Ensure terminal screws and wiring connections • Verify controls installation complete.
secure in control, electric and Air Modulator – Contractor Furnished Controls - Controls con-
panels. tractor is responsible for safe and proper control
• Verify air hoods field installed properly. of air handler.
• Verify condensate drain properly trapped. – Factory Furnished Controls - See Factory Engi-
neered Controls/Factory Packaged Controls (FEC/
• Verify all wiring and tubing connections complete
FPC).
at shipping splits.
• The termination chart is attached to the inside of
• Verify all field-piping connections complete.
control enclosure door (see Fig. 3-1).
• Verify all shipped loose parts installed.
• Verify all ductwork is complete and available for
full airflow.
• Verify unit installed with proper clearances.
• Verify installer has removed all dirt,

debris, hardware, mold, etc. from
interior of air handler and ducts.
IAQ
• Visually inspect roof curb for tight seal around

unit.
• Ensure clean air filters installed properly and
secured (see IOM Section 4).
• Verify filter gauge set to zero.
• Inspect all field provided wiring for complete-
ness. FIG. 3-1 – TERMINATION CHART INSIDE
• Verify all shipping splits sealed and secured ENCLOSURE DOOR
properly.
• Verify pipe chase floor sealed at penetrations.
• Verify all shipping bolts and other materials have
been removed.

FORM 102.20-NOM1 (909)
PRE START UP FAN ASSEMBLY In small units the tie down bolts may
INSPECTION only be applied to three corners of
the fan base since one corner is not
When the unit is removed from long-
accessible.
term storage moisture laden bearing
grease should be purged and replen-
ished with fresh grease per lubrication
TIE DOWN BOLTS
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.
• Check the bearings and locking collars (refer to

Table 3-1, “Torque for Tightening Setscrews”).
TABLE 3-1 – TORQUE FOR TIGHTENING

SETSCREWS
SETSCREW HEX. SIZE MIN. RECOMMENDED
DIA. ACROSS TORQUE
FLATS INCH LBS. FOOT LBS.
LDO9638
1/4 1/8 66 - 85 5.5 - 7.08
5/16 5/32 126 - 164 10.5 - 13.7
FIG. 3-2 – F
AN AND MOTOR ISOLATOR SUPPORT 3
3/8 3/16 228 - 296 19.0 - 24.7
FRAME.
7/16 7/32 348 - 452 29.0 - 35.7
1/2 1/4 504 - 655 42.0 - 54.6 MOTORS - ODP VS. TEFC
5/8 5/16 1104 - 1435 92.0 - 119.6
See Fig. 3-3 for ODP.
• Verify fan wheel properly aligned, tight on shaft

and freely moving.
• Ensure fan bearings properly lubricated (see Fan
label or IOM Section 4, “Fan Bearing Lubrica-
tion”). ►
• Belts and Sheaves
1. Verify sheaves properly aligned and tight on shaft.
Improper sheave alignment and belt tension are
potential causes of excessive noise and vibration,
as well as shortened belt and bearing life (see
IOM Section 4, “Sheaves Alignment”). ►
2 Check belt tension. If not familiar with the pro-
cess (see IOM Section 4, “Belts” and “Adjustable
Motor Base Operation”). ►
LD09635
It is normal for belts to loosen after start up. The FIG. 3-3 – ODP (OPEN DRIP PROOF)
new belts will “run in” or “take a set” by seating
slightly deeper into the grooves of the sheaves.
Recheck tension after one day and three days.
3. Ensure motor mounting bolts and adjustable mo-
tor base bolts are tight.
• Verify tie down bolts removed from 4 corners of
fan base assembly.

Startup
FORM 102.20-NOM1 (909)
See Fig. 3-4 for TEFC. • Fig. 3-6 shows isolator with seismic snubber
restraint option.
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
Isolator Nut Lock, Hex,
Spring 3/8"-16
(4) Screw, Hex, 3/8-16"
(4) Nut Lock, Hex, 3/8"-16

Iso Rail
LDO9639 LDO9636
FIG. 3-4 – TEFC (TOTALLY ENCLOSED FAN COOLED) FIG. 3-6 – SEISMIC SNUBBER
ISOLATORS
Check fan base isolators and thrust restraints for proper Preparing Fan Isolators for operation:
adjustment. 1. After tie down bolts are removed from the inter-
nal fan assembly check blower/motor frame for
• Standard fan isolation consists of spring isolators correct height and that the frame is level.
(see Fig. 3-5) mounted under the internal fan as- 2. To adjust isolators (see Fig. 3-5): First loosen
sembly. cap screws on top of adjustment bolt. Then turn
adjusting bolt. Next, check operational height
Cap Screw and level of frame. Repeat this procedure until
operational height and frame is level. Finally,
Adjusting Bolt tighten cap screws. (See IOM Section 5, “Isolator
Adjustment” for additional instructions). ►
3. Verify the fan is aligned with unit discharge.
4. Re-adjust as necessary with isolators.
LDO9637
FIG. 3-5 – SPRING ISOLATOR
• For thrust restraint adjustment procedures, when

applied, (see IOM Section 5.0). ►

FORM 102.20-NOM1 (909)
START-UP CHECK OPERATION OF DAMPERS

Temporary Operation: This equip- Ensure unit will not operate with all dampers closed.
ment should not be operated until after
Linkage design and/or damper linkage may not be
complete Start-up as outlined in this
provided by YORK. Airflow control dampers may
guide. Do not allow the unit to run be operated with pneumatic or electric actuator/
on temporary power that is not reliable controllers.
and could be off/on periodically or
rapidly. Also, protect it from irregular Prior to occupancy, test ventilation sys-
voltages and surges. tem to ensure that outdoor air dampers
operate properly in accordance with
We strongly recommend the startup the system design.
technician use the checklist provided IAQ
and record the gathered information in
the appropriate fields. If there are any AIRFLOW CONTROL DAMPERS
specific questions refer to the document Many combinations of damper sizes are available to
list on the checklist. Also, at the end of control the flow, the mixing of return air and outside
Section 3 is located a list of references air in the air inlet section of the unit may be supplied
for various check points on the checklist as follows:
(Inspection Requirements). This is a • One hundred percent outside air, 100% return
guide to "How To" information in this air.
and other documents. • One hundred percent outside air, 0% return 3
air.
Filter media must be installed prior
to Start-up. Use media provided or • Zero percent outside air, 100% return air.
temporary media that will adequately • Economizer Section - 100% outside air, 100%
protect the components in the air return air, 100% exhaust air or mixed air.
stream and duct system.
On dampers with actuators, intercon-
necting damper linkage is only pro-
CHECK OPERATION OF FANS
vided when selected by Sales.
1. Energize power to the unit disconnect
switch.
2. Verify correct voltage, phase and cycles.
Dampers, actuators, controls and link-
3. Energize fan motor(s), briefly (bump) and
check for correct fan rotation.
age must be checked prior to applying
power to the operators making sure
If rotation is incorrect: nothing will obstruct the operation of
1. On three-phase equipment reverse any 2 the dampers. Do not overdrive damper
motor leads at the load side of last starter actuators as this may cause damage to
component. the dampers.
2. On single-phase equipment, follow wiring
diagram on motor housing or inside motor Return air dampers may be closed for
terminal box. shipping. Loosen actuator or crank
arm on jackshaft, open dampers, and
3. Re-check for correct fan rotation.
retighten actuator or crank arm. Field
is responsible for adjustments.

Startup
FORM 102.20-NOM1 (909)
TYPICAL ACTUATORS LOCATIONS With the actuator shaft clamp tightened to the damper
Johnson Controls standard actuators are direct coupled jackshaft, and the damper shaft is completely rotated
on damper jackshaft. to its proper position, manually operate the actuator to
its fully actuated position using the crank arm provided
BASIC ACTUATORS INSTALLATION
with the actuator. Then release the spring to allow the
damper to go back to its original position. This will
A basic procedure for installing Johnson Controls verify the actuators spring rotation and stroke.
actuators is included in Section 2"Installation". Set the damper actuators rotation selector switch to the
proper rotation required to actuate the damper.
DAMPER BLADE ORIENTATION
Return Air and Mixing Dampers with Power Off Damper actuator will always be op-
posite the spring return rotation.
Position the blades so that they will be open once the
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.

FORM 102.20-NOM1 (909)
ENERGIZE FAN MOTOR(S) SET UP OF A NON- FACTORY MOUNTED VFD
1. Observe fan(s) for smooth operation. Refer to manufacturer's Start Up Guide

2. Check motor nameplate Full Load Amp rating. The Variable Frequency Drive (VFD) that controls the
3. Immediately, check current draw of each leg of speed of a YORK Solution air handler fan needs to be
each motor. set up so the fan does not run at resonant frequencies.
Improper adjustment may damage the equipment. To
VARIABLE SPEED DRIVE (VSD) determine which speeds are detrimental to the YORK
YORK Air‑Modulator (Variable Frequency Drive) equipment, refer to the document (058-008-002)
supplied with the YORK Solution air handler. This
YORK Air Modulators are provided information can also be found on the label located
with Start-up service. See Installation on the blower housing (see Fig. 3-7). This document
and Start-up Guide provided with the lists any frequencies and the bandwidths that need
YORK Air Modulator. to be jumped (skipped) by the VFD. The installer
needs to program the jump (skip) frequencies and the
bandwidths referenced in document (058-008-002)
into the VFD. Failure to properly set the VFD before
applying power to the motor will void the fan and
motor warranty.
If the skip frequencies are not avail-

able to the installing contractor, the
contractor must have the fan analyzed 3
by a professional balancer before the
VFD can be set and power is supplied
to the fan.
FIG. 3-7 – EXAMPLE OF SWEEP BALANCE RESULTS

Startup
FORM 102.20-NOM1 (909)
CHECK DOORS AND LATCHES FOR SHEAVES

PROPER ADJUSTMENT If optional adjustable sheaves pro-
See IOM Section 5 “Door Handle/Latch Replacement vided, we strongly recommend they
and Adjustment”. ► be replaced with correctly sized fixed
sheave immediately after system air
Plastic spacers must be removed be- balance is performed. It is not unusual
tween doors and doorframes before for an adjustable sheave at some point
Start-up. in time to create damaging vibration
in the fan assembly.
General Guidelines for replacing an adjustable sheave

with a fixed sheave:
Measure the outside diameter of a belt while it is seated

into at least one half the circumference of an adjustable
sheave groove. Use this measurement as the sheave
"pitch diameter". Order a sheave or sheave and bushing
combination that matches pitch diameter, belt cross
section and bore size. Order a sheave of good quality
and require that it is pre- balanced.
Reference Airside Parts - phone (800) 545-7814 to

purchase new sheaves.
Provide the following information:

• Drive tag information (see Fig 3-8).
• New fan RPM
• Measurement of pitch diameter adjustable sheave
is set at.
• Job ID # from YORK Solution Unit ID Label.
A new driver (motor) sheave or sheave and bushing

are usually all that is required to directly replace the
present adjustable driver sheave.
FIG. 3-8 – TYPICAL DRIVE KIT DATA TAG

FORM 102.20-NOM1 (909)
ENERGY RECOVERY WHEEL Keep hands away from rotating wheel!

UNIT CONFIGURATION
Contact with rotating wheel can cause
physical injury.
• 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
All outdoor units will accommodate horizontal (as viewed from the pulley side), to verify wheel
Energy Recovery Wheel segments in a low- turns freely through 360° rotation (see Fig.
profile, single unit arrangement (see Fig. 3-11).
3-10).
FILTER
RETURN AIR MIXING BOX EXHAUST

FAN
SUPPLY ENERGY FILTER/MIXING

FAN COOLING
COIL
HEATING WHEEL
COIL
BOX 3
OUTSIDE AIR
FIG. 3-9 – INDOOR UNIT - VERTICAL WHEEL
ELEVATION VIEW
SUPPLY FAN OUTSIDE AIR EXHAUST FAN

(SIDE ENTRY) E/A
BYPASS
ACCESS
COOLING HEATING
COIL COIL
ENERGY R/A DAMPER
WHEEL
O/A
BYPASS
FILTER RETURN AIR
PLAN (TOP) VIEW

O/A DAMPER
SUPPLY FAN
EXHAUST FAN
ACCESS
COOLING HEATING ENERGY

COIL COIL WHEEL
FILTER O/A DAMPER RETURN AIR LD09641A
FIG. 3-10 – OUTDOOR UNIT - HORIZONTAL WHEEL

Startup
FORM 102.20-NOM1 (909)
WHEEL
ROTATION
BEARING SUPPORT
BEAM - PULLEY SIDE
BALL
BEARINGS (2)
BEARING ACCESS
COVER (2)
BEARING DIAMETER SEAL

SUPPORT BEAM ADJUSTING SCREWS
- MOTOR SIDE
DRIVE REMOVABLE ENERGY

MOTOR TRANSFER SEGMENT (8)
BELT
DRIVE PULLEY LD09642
FIG. 3-11 – ENERGY RECOVERY WHEEL - PULLEY SIDE
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 inspect for excessive interference between the
frame and segment retainers are completely wheel surface and each of the four (4) diameter
fastened (see Fig. 3-12). seals. To correct, loosen diameter seal adjusting
screws and back adjustable diameter seals away
3. With hands and objects away from moving
from surface of wheel. Apply power to confirm
parts, activate unit and confirm wheel rotation.
wheel is free to rotate, then re-adjust and tighten
Wheel rotates clockwise (as viewed from the
hub and diameter seals (see Fig. 3-13).
pulley side).
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
FIG. 3-12 – SEGMENT RETAINER FIG. 3-13 – DIAMETER SEAL ADJUSTMENT

FORM 102.20-NOM1 (909)
INDIRECT FIRED GAS HEAT START UP - ECLIPSE GAS BURNER START UP 10:1 - 25:1
TURNDOWN & POWERFLAME GAS BURNER START UP 3:1 - 10:1 TURNDOWN
For your safety and satisfaction, this Your gas burner has been carefully
product requires check, test and start- inspected and tested at the factory;
up adjustment by a qualified HVAC however, different conditions at the
technician. Do not use for temporary jobsite, including controls that have
heat prior to start-up. been added at time of installation,
require careful testing and final ad-
justment for satisfactory operation.
Review burner control literature, in- The Burner Test Report / Factory
cluding wiring, piping, cut sheets and Specification Sheet in each unit shows
drawings before attempting to start the general data recorded during the
this unit. operation and safety tests at the fac-
tory. This data should be used as a
general guide; with final data recorded
on the start-up form. Do not exceed
All factory test start up burner speci- 550°F flue temperature at the ID fan
fications are located on a laminated inlet. Do not exceed 200°F supply air
“Factory Specification Sheet" located temperature.
on the inside of the control panel
door”. 3
INTRODUCTION IDENTIFY THE UNIT TYPE
This guideline describes the basic steps a technician Two types of Indirect Fired gas burners are used on
would take in starting an Indirect Fired gas heat system YORK Solution Air Handlers: The Powerflame series
on a YORK Solution Air Handler for the first time. and the Eclipse series. The Powerflame series offers
a turndown (modulating ratio) of 3:1 or 10:1. The
Each gas burner has been test run and inspected at Powerflame is easily identifiable by the motorized gas
the factory. Adjustments to component settings are valve with external linkage connecting the air dampers
typically not required. However, measurements of on the burner air inlet.
system parameters should be taken and compared to the
measurements recorded on the “Burner Test Report” to The Eclipse series uses an air/gas ratio regulator with
ensure safe and reliable operation. The “Burner Test no external linkage, and has a turndown range of 10:1
Report” is laminated to the inside of the burner control to 25:1 (sometimes greater). A visible external plastic
door. tube is used to transmit gas pressure from the burner to
the regulator. No external linkage is used.
Both burners utilize a combustion air blower. YORK

Solution Air Handlers also use an exhaust blower, called
an induced draft (ID) blower. This exhaust blower keeps
the combustion chamber at a slight negative pressure.
Verification of this negative pressure and other system
parameters is part of a proper start up procedure.

Startup
FORM 102.20-NOM1 (909)
PRELIMINARY COORDINATION AIR HANDLER PRE START CHECKS

Contact contractor/customer who requested start-up. • Verify air handler has had proper start up and
• Verify air handler has had proper start-up. airflow is at design maximum for heating cycle
• Ensure air handler and system is capable of (refer to air balance report).
design airflow for gas heat start-up. • Set bypass damper if provided in air handler.
• Ensure reliable power is available. • Airflow proving switch for main supply fan
• Verify gas lines are purged of air to equipment installed and operational.
valve. • Check with Control Technician: two-minute
• Verify controls are complete. post-purge programmed in air handler controller.
Upon call for air handler unit stop, burner cycles
• Verify flue (stack) is correctly installed if parts off then air handler fan cycles off two minutes
were shipped loose (see Fig's 3-22 and 3-23). later.
BURNER PRE START CHECKS

TOOLS RECOMMENDED
1. Open fuse disconnects before working on burner
• Electrical Multimeter w/ Amprobe (see Fig. 3-14).
• Heating Unit Installation and Operation
Instruction. - One is provided with every
heating unit for technical information and
troubleshooting.
BURNER CONTROL
• Magnehelic Gauge 0” To .25” WC, Dwyer
PANEL
Series 2000 or Model 1227 Dual Range
Manometer. - For checking pressure over fire
7800
(draft). Series Open fuse disconnects be-
Relay fore working on burner.
• Control Signal Generator, 0 to 20 mA
(Altek-234 or 334A) - For 2 to 10 VDC signal
add 500 ohms in series with signal generator.
• Magnehelic Gauge 0” to 15” WC and 0 to
LD12903
3 lbs. (Dwyer series-2000) or Monometer
(Dwyer- 1227) Duel Range Monometer. - For FIG. 3-14 – OPEN FUSE DISCONNECTS
checking supply gas pressure and manifold gas
pressure or pilot gas pressure. 2. Check all wire terminations for tightness.
• Honeywell - S7800A Test Module - For use 3. Check that the incoming voltage(s) are correct.
on (Honeywell-7800) Series Relay Module. Compare measured voltages to burner motor and
(Available through Airside Parts - 800-545- ID motor nameplates and the “Burner Test Report”.
7814, Ext.12). Reset fuse disconnects.
• Flue Gas Analyzer (CO2 and O2) 4. Check for correct rotation of 3 phase burner motor
and ID motor.
• Stack Thermometer (0°F - 1000°F
approx.) 5. Verify that contractor has purged new gas lines of
• Digital Manometer (replaces Magnehelic air up to manual valve on gas train.
Gauge).
6. Valves which have been closed for shipping must
Digital Manometer
be opened accordingly. Check that all manual
Cat. #475-1 FM-AV
valves operate without leaks.
Series: 475-1 Mark III
Range: 0 to 19.99 In. W.C.
Dwyer Instruments, Inc.
FORM 102.20-NOM1 (909)
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.
Main On Eclipse burners, this test port is

Condensate
Connection LD12910 located on the backside of the burner,
just below the spark igniter. A small
FIG. 3-15 – sET ID FAN DAMPER valve is provided at this test port.
8. Inspect condensate drain trap to see that it is large 3

12. Connect a manometer or other suitable device to
enough, as described in this guideline (see Fig.
the Heat Exchanger Draft Port located on the side
3-21).
of the unit near the burner. The expected draft
should read slightly negative – about -.03" WC.
9. Measure the gas supply pressure coming into
The draft port is typically made of ¾" steel pipe
the gas train (see Fig. 3-16). Gas pressure can be
and may be plugged. Remove plug and add a small
greater than shown on the “Burner Test Report”,
stop valve and a nipple for a rubber tube (see Fig.
but it must be between the min/max values listed
3-15 & 3-17).
in Table 3-2.
13. Install the Honeywell S7800 Test Module (display),
if available.
14. Connect signal generator (0-20mA) to terminals

in place of modulation control signal (for 2-10
VDC signal add a 500 Ω resistor in series). See
Fig. 3-24.
15. Visually check that the flue (stack) is secure and

connected properly. Typical connections are shown
at the end of this guideline (see Fig.’s 3-22 &
Main Gas Supply 3-23).
Test Port
LD12905 16. Burner panel off/on switch should be “off”
FIG. 3-16 – C
HECK MAIN GAS SUPPLY
PRESSURE System is now ready for start up.

Startup
FORM 102.20-NOM1 (909)
BURNER START-UP PROCEDURE

Prior to starting burner, technician
Heat Exchanger
must verify incoming gas pressure. Draft Port
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 Tube to
for heat (see Fig. 3-24 for typical wiring dia- Draft Gage LD12908
gram).
3. Turn burner panel off-on switch to on. FIG. 3-17 – DRAFT OVER FIRE test port
Once there is a call for heat, a 30 5. Observe the gas manifold pressure and compare to
data on the “Burner Test Report” under both High
second pre-purge period is initiated
Fire and Low Fire conditions.
to remove any gases from the heat
exchanger. The burner will then go 6. Check the flue (stack) combustion temperature at
through a second purge before igni- the ID Blower Housing Test Port. Make sure the
tion. test probe is inserted half way into the ID Inlet Tube
(see Fig. 3-18). Compare results to the “Burner
4. The burner will automatically go to Low Fire Test Report”.
at start up. After proof of Low Fire, the burner
will modulate up to High Fire. This may take 15
seconds for a Powerflame burner and 90 to 180
seconds for the Eclipse burner. After the burner
operates at High Fire use the manometer connected
to the Heat Exchanger Draft Port (see Fig. 3-17),
observe the reading. A negative pressure of about
-.03" WC is expected for draft overfire. Read-
ings may differ slightly from those shown on the
ID Fan Housing Test
“Burner Test Report”. Port
For valid readings, before making any

adjustments, allow the burner to fire
LD12906
at least 20 minutes to allow the heat
exchanger to come up to operating
temperature. FIG. 3-18 – F
LUE (STACK) combustion
tEMPERATURE and efficiency
test port
Ignition transformer is intermittent.

Pilot continues to burn after ignition
transformer is de-energized.

FORM 102.20-NOM1 (909)
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
FIG. 3-19 – DAMPER ACTUATOR
8. Using the standard operating controls, cycle the

burner several times to assure proper sequencing
of start-up, firing, and capacity modulation, plus 3
operation of all safety and monitoring controls.
9. Test 180°F. high temp. safety by running burner

LD12911
with airflow off or diverted. Burner will shut down
at 180°F. Turn air handler on as quickly as possible FIG. 3-20 – CONDENSATE DRAIN
to remove heat from the heat exchanger.
CONDENSATE DRAIN ARRANGEMENT
10. Burner efficiency testing should be done last. The The YORK Solution Indirect Fired gas heat exchanger
burner should be running at High Fire rate for 30 has the potential to create highly acidic condensation,
minutes before efficiency testing is done. particularly during extended operation at low capacity
or low firing rate conditions. To insure proper drainage
11. Efficiency at High Fire is pre-determined, but may the following guidelines should be followed (See Fig.
be checked by flue gas analysis at the entrance to 3-21).
the ID Blower Housing Test Port. At High Fire
CO2 should be between 8-1/2 and 10 %; 02 should When constructing the condensate trap
be between 7-1/2 and 4%. With these ranges, effi-
for the heat exchanger drainage sys-
ciency is 80% plus or minus 2% (see Fig. 3-18).
12. Contact contractor, facilities manager or customer to handle the Total Static Pressure of
to inform successful start-up has been complet- the ID Blower at Low Fire times 2.
ed.
Example: TSP is 6” at Low Fire -
construct trap 12” tall (See Table in
In the unlikely event that adjustment Fig. 3-21).
is required; it is done at High Fire and
must NOT retard Low Fire light-off.

Startup
FORM 102.20-NOM1 (909)
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.
1. Observe local jurisdiction codes for gravity con-
densate drainage requirements.
Frozen drain lines and/or trap will cause build up
in leakage and damage to the air handler and pos-
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
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
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
GAS LP = 2,500 BTU/ CU FT.

GAS NATURAL = 1,000 BTU/ CU FT.
{ Output is approx. 80% of input BTU's
3-17
FORM 102.20-NOM1 (909)
3
3-18
Startup
TABLE 3-2 – NATURAL GAS PRESSURE REQUIREMENTS (INCHES WC)

MAXIMUM ALLOW INLET PRESSURE Minimum Inlet Pressure to Fire
Nomenclature A03 U03 F03 R03 A10 U10 F10 R10 A25 U25 F25 R25 A03 U03 F03 R03 A10 U10 F10 R10 A25 U25 F25 R25
FEATURE GASBTUS GAS BURNER PIPING/GAS BURNER TD GASBURNER PIPING/ GAS BURNER TD
ANSI FM IRI ANSI FM IRI ANSI ANSI UL FM ANSI UL FM IRI
OPTION ANSI 3 UL 3 FM 3 IRI 3 UL 10 UL 25 UL 3 FM 3 IRI 3 IRI 10
10 10 10 25 25 25 3 10 10 10 25 25 25 25
Furnace Furnace
ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI
Output Output
3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1 3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1
(X10K) (X10K)
015 14.00 NA NA NA 27.00 NA NA NA NA NA NA NA 015 4.00 NA NA NA 13.00 NA NA NA NA NA NA NA
035 NA 14.00 NA 27.00 NA 27.00 NA 27.00 NA NA NA NA 035 NA 5.00 NA 4.00 NA 4.00 NA 4.00 NA NA NA NA
040 NA 14.00 NA 27.00 NA 27.00 NA 27.00 NA 27.00 NA 27.00 040 NA 5.00 NA 5.00 NA 5.00 NA 5.00 NA 18.00 NA 18.00
225 NA NA 27.00 27.00 NA NA 27.00 27.00 NA NA 55.00 55.00 225 NA NA 8.00 11.00 NA NA 8.00 11.00 NA NA 34.00 34.00
Note: Gas pressure requirements at the inlet to the main manual shutoff cock of the gas train.
johnson controls
FORM 102.20-NOM1 (909)
FORM 102.20-NOM1 (909)
TABLE 3-3 – P
IPE SIZE REQUIRED
Inlet Size (NPT)

A03 U03 F03 R03 A10 U10 F10 R10 A25 U25 F25 R25
GAS BURNER PIPING/GAS BURNER TURN DOWN
ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI
3 3 3 3 10 10 10 10 25 25 25 25
Furnace
Output
3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1
(X10K)
015 0.75 NA NA NA 1.00 NA NA NA NA NA NA NA

035 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA NA NA NA
040 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
045 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
050 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
060 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
075 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.25 NA 1.25
085 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.25 NA 1.25
100 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.25 NA 1.25
125 NA 1.25 NA 1.25 NA 1.25 NA 1.25 NA 1.50 NA 1.50
150 NA 1.25 NA 1.25 NA 1.25 NA 1.25 NA 1.50 NA 1.50 3
175 NA 1.25 NA 1.25 NA 1.25 NA 1.25 NA 1.50 NA 1.50
200 NA 1.50 NA 1.50 NA 1.50 NA 1.50 NA 1.50 NA 1.50
225 NA NA 2.00 1.50 NA NA 2.00 1.50 NA NA 2.00 2.00
250 NA NA 2.00 1.50 NA NA 2.00 1.50 NA NA 2.00 2.00
275 NA NA 2.00 1.50 NA NA 2.00 2.00 NA NA 2.00 2.00
300 NA NA 2.00 1.50 NA NA 2.00 2.00 NA NA 2.00 2.00
325 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
350 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
375 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
400 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50

3-20
END OF FLUE PIPE FLUE CAP
Startup
42"L VSI PIPE

44.40 TYP. (NOT INSULATED)
(36.00 MIN)
STORM COLLAR
SUPPORT ASSEMBLY PIPE CHASE
1.60 CURB PIECE
ROOF PEAK
IVSI PIPE (INSULATED PIPE)

SEE NOTE 1
ROOF PANEL CONTAINMENT BAND SET &

RACEWAY GASKET, 1" THK X 3"W X LG,
INSULATION FIBER REQ. WHEN
IVSI IS IN 2 PIECES.
SIDE PANEL IVSI PIPE (INSULATED PIPE) H=UNIT HEIGHT

SEE NOTE 1 W=UNIT WIDTH
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-NOM1 (909)
STEP 3
STEP 1 FLUE CAP
STEP 2
johnson controls
PIPE CHASE
CURB PIECE
RACEWAY
IVSI PIPE
SIDE PANEL (INSULATED PIPE)
SEE NOTE 1
CONTAINMENT
BAND SET &
INSULATION FIBER STEP 4
6"L SLIP
JOINT
GAS FURNACE WITH CASING 7.75 0.43"

CLEARANCE
12" ID
EXT. FAN TRANSITION
PIECE
STORM COLLAR
HAT CHANNEL
5.50
NOTES:

DETERMINE LENGTH OF IVSI PIPES.
FIG. 3-23 – GAS FURNACE FUEL VENTING SYSTEM LD13305
3-21
FORM 102.20-NOM1 (909)
3
Startup
FORM 102.20-NOM1 (909)
FOR REFERENCE ONLY
Connect Signal
Generator here for test
and start up
Jumper may be
required here for test
and start up
LD13315
FIG. 3-24 – typical wiring diagram

FORM 102.20-NOM1 (909)
Table 3-4 – BURNER TEPERATURE RISE
INTERNAL INTERNAL
PRESSURE PRESSURE
CFM Temperature Rise (°F) CFM Temperature Rise (°F)
DROP “ DROP “
WC WC
DF- DF- DF- DF- DF-

15 20 25 60 75
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 1.47 10,000 55 68 1.2
5,248 26 35 44 2 11,000 50 62 1.4
DF- DF- DF- 12,000 46 57 1.7
30 35 40
12,900 43 53.8 2
3,000 95 -- -- 0.22
DF- DF-
3,500 82 91 -- 0.31 85 100
4,000 71 79 95 0.41 8,500 91 -- 0.47
4,500 63 70 85 0.54 9,000 86 -- 0.52 3
5,000 57 63 76 0.66 9,500 81 -- 0.58
5,500 52 57 69 0.84 10,000 77 91 0.64
6,000 47 53 63 1 10,500 74 87 0.7
6,500 43 47 58 1.2 11,000 70 83 0.76
7,000 40 46 54 1.45 12,000 64 76 0.9
8,440 32.9 38.4 43.9 2 13,000 59 70 1.05
DF- DF- 14,000 55 65 1.25
45 50
15,000 51 61 1.4
4,500 88 -- 0.39
16,000 49 57 1.6
5,000 80 90 0.47
17,000 46 54 1.75
5,500 72 82 0.55
17,825 44 52 2
6,000 66 75 0.65
6,500 61 69 0.75
7,000 57 64 0.86
7,500 53 60 0.98
8,000 50 56 1.1
8,500 47 53 1.23
9,000 46 50 1.38
10,725 38.8 43.2 2

Startup
FORM 102.20-NOM1 (909)
Table 3-4 - BURNER TEPERATURE RISE (CONT)
INTERNAL INTERNAL
PRESSURE PRESSURE
DROP “ DROP “
WC WC
DF- DF- DF- DF- DF- DF-

125 150 225 250 275 300
13,000 89 -- 0.48 24,000 87 -- -- -- 0.337
14,000 83 -- 0.56 27,000 77 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 63 70 75.8 82.5 0.637
17,000 68 82 0.82 36,000 58 64 69.5 75.7 0.758
18,000 64 77 0.92 39,000 53 59 64 70 0.89
19,000 61 73 1.03 42,000 50 55 59.5 65 1.035
20,000 58 69 1.13 45,000 46 51 55.6 60.6 1.185
21,000 55 66 1.25 48,000 43 48 52.1 55.8 1.35
22,000 52 63 1.35 51,000 41 45 50 53.5 1.525
23,000 50 60 1.5 54,000 39 43 47 50.5 1.71
24,000 48 58 1.3 58,475 35 39.5 43.5 47.5 2
25,000 46 55 1.75 DF- DF- DF- DF-
325 350 375 400
26,315 43.6 52 2
31,565 95 -- -- -- 0.4
DF- DF-
175 200 35,290 85 92 -- -- 0.5
17,000 95 -- 0.45 41,755 72 78 83 89 0.7
18,000 90 -- 0.52 47,345 64 68 73 78 0.9
19,000 85 -- 0.57 52,340 57 62 66 71 1.1
20,000 81 93 0.63 54,665 55 59 64 68 1.2
21,000 77 88 0.7 59,045 51 55 59 63 1.4
22,000 74 85 0.76 63,125 48 51 55 59 1.6
23,000 71 81 0.82 66,950 45 48 52 55 1.8
24,000 68 78 0.9 70,573 42.6 45.9 49.2 52.4 2
26,000 62 71 1.05
28,000 58 66 1.25
30,000 54 62 1.4
32,000 51 58 1.6
34,000 48 54 1.8
35,635 45.5 52 2

FORM 102.20-NOM1 (909)
ELECTRIC HEAT STARTUP A visual inspection of the heater elements should be

made prior to use of the heater. If physical damage is
evident, a Megohm test should be used to validate the
Rotating parts and electrical shock heater elements are safe for use. If a minimum value
hazards exist. Lock out and tag out the of 10 megohms is not achieved then any damaged
fan motor(s) and heat power discon- elements or ceramic insulators must be replaced prior
nects before servicing. FOLLOW THE to operation.
LATEST “LOCKOUT TAGOUT”
PROCEDURE. Failure to follow Ensure filters are clean and airflow is
proper safety precautions may result at minimum requirement or greater.
in serious injury or death Preferably 100 % for this start up
procedure.
All electrical connections in the heater, including both
field and factory made connections, should be checked
To operate this heater make sure all associated control
for tightness before operating the heater. In addition,
equipment is on, energize main supply disconnect and
after a short period of operation, all connections should
set controlling thermostat above ambient temperature.
again be checked for tightness.
This heater is equipped with automatic and manual
reset temperature limiting controls. If it fails to operate,
DO NOT operate electric heat below make sure manual resets are operative by pushing reset
the minimum airflow requirement. buttons.
3
AIRFLOW 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
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)
fIG. 3-25 – MINIMUM AIR VELOCITY REQUIRED FOR SAFE OPERATION

Startup
FORM 102.20-NOM1 (909)
TOP VIEW OF UNIT

POSITIVE PRESSURE / AIR BLOWN THROUGH HEATER
BLOWER HEATER
AIRFLOW

ATTACHED TO “HIGH” PORT OF AIRFLOW SWITCH
NEGATIVE PRESSURE / AIR DRAWN THROUGH HEATER
BLOWER
HEATER
AIRFLOW

ATTACHED TO “LOW” PORT OF AIRFLOW SWITCH
LD14268
FIG. 3-26 – PRESSURE PROBE DIRECTION
MOUNTING C
BRACKET
NO
NC
HIGH PORT LOW PORT
LD14270
FIG. 3-27 – AIRFLOW SWITCH CONNECTIONS

FORM 102.20-NOM1 (909)
AIR handling units
start-up checklist Supersedes: 100.00-CL1 (309) Form 100.00-CL1 (909)
Air handler start-up checklist

OFFICE LOCATION_______________________________________ unit tag #_________________________________
Qualified TECHNICIAN ____________________________________ unit model #_______________________________
JOB NAME______________________________________________ UNIT SERIAL #____________________________
york JOB ID or contract #_____________________________ start date_____________________________
Job site location________________________________________________________________________________
job site contact and phone #________________________________________________________________
IMPORTANT SAFETY REQUIREMENT: FOLLOW THE LATEST “LOCK OUT TAG OUT” PROCEDURE.
pre start-up
GENERAL UNIT INSPECTION
Identify and perform appropriate “lock out/tag out” and safety rules. For details on points below see appropriate
section of the Installation Instruction provided with each air handler.
For VFD equipped air handlers, refer to the VFD forms for additional requirements.
Serious damage to the AHU and/ • With smoke dampers closed.
or system is eminent if the AHU is • During a fire alarm or smoke purge test. 3
operated under any of the following • Any airflow restriction greater than normal.
conditions:
• Without proper control of dampers.
Solution AH Units Form 102.20-NOM1 Air Modulator VFD Form 100.41-NO1

Custom AH Units Form 100.31-NOM1
□ Equipment received as ordered. □ Verify all ductwork is complete and available for full air flow.
□ Unit checked for damage to interior and exterior. □ Unit installed with proper clearances.
□ Unit installed on flat and level surface. Outdoor unit □ Visually inspect roof curb for tight seal around unit.
mounted within roof slope limitations where applicable.
□ Terminal screws and wiring connections secure □ Clean air filters installed properly and secured.
in control, electric and Air Modulator panels.
□ Air hoods installed properly. □ Filter gauge set to zero.
□ Condensate drain properly trapped. □ All field wiring complete and inspected.
□ All wiring and tubing connections made at shipping splits. □ All shipping splits sealed and secured properly.
□ All field piping connections complete. □ Pipe chase floor sealed at penetrations.
□ All shipped loose parts installed. □ All shipping bolts and other material have been removed.
(Fan, VIFB, Energy Recovery Wheel, Damper).
□ Installer has cleaned out interior. □ Damper linkage is tight and in correct “power off” position.
□ Verify all plug-ins and wire connections are tight on UV □ Controls installation complete.
equipment.
□ Verify Energy Recovery Wheel turns freely and wheel □ Verify correct piping of split system. Reference Section 2 of
segments are fully engaged. Solution IOM & Split System Application Guide (050.40-ES3).
Fan INSPECTION
□ Check bearings and locking collars for properly tightened □ Fan wheel properly aligned, tight on shaft and freely
setscrews, bolts and nuts. moving.
□ Sheaves properly aligned and tight on shaft. □ Check fan base isolators and thrust restraints for proper
adjustment. Note: Do not remove functional bolts
□ Belt tension adjusted properly per drive pkg. label on fan. from seismic isolators.
□ Check fan alignment with unit discharge. Adjust with □ Fan bearings have been re-lubricated properly.
isolation.

Startup
FORM 102.20-NOM1 (909)
start-up
Perform the following steps in order:
Refer to safety standards. Ensure all door latches are secured before starting.
□ 1. With all Electric Power off, all disconnect switches open and □ 8. Immediately check current draw of each leg of each motor.
fuses removed, check each circuit with an Ohm meter to
ground observing no continuity. Reinstall fuses.
□ 2. Energize power to the unit disconnect switch. □ 9. VFD, refer to manufactures start up guide
□ 3. Verify correct voltage, phase and cycles. □ 10. Check doors and latches for air leaks.
□ 4. Energize fan motor(s) briefly (bump) and check for correct fan □ 11. Check for obvious audible leaks.
rotation.
□ 5. Check operation of dampers. Insure unit will not operate with □ 12. Apply steam to cold coils slowly to prevent damage.
all dampers closed.
□ 6. Energize fan motor(s). Observe fan(s) for smooth operation. □ 13. Observe energy recovery wheel rotation.
□ 7. Check motor nameplate Full Load Amp rating.
RECORD DATA
POWER SUPPLY: Unit Nameplate V___ PH___ CYC, ____ Verify V __________/ _ _________ / ___________
DATA
SUPPLY FAN MOTOR EXHAUST/RETURN FAN MOTOR
Nameplate Volts_ ____________ Amps________________ Volts_ _______________ Amps_ ____________
Run Amps ____________ / _____________/ ___________ _ ___________ / ____________ / _ ___________
Catalog Number ______________________________________ _ ______________________________________
Spec Number ______________________________________ _ ______________________________________
Horse Power ______________________________________ _ ______________________________________
RPM Nameplate_ __________ Actual_____________ Nameplate___________ Actual_____________
Frame size ______________________________________ _ ______________________________________
Service Factor __________________________________ _ _________________________________
Jump (Skip) Frequencies ____________ / _____________/ ___________ _ ___________ / ____________ / _ ___________
SUPPLY FAN EXHAUST/RETURN FAN

Manufacture Name ______________________________________ _ ______________________________________
Type or Model Number ______________________________________ _ ______________________________________
Code or Shop Order Number ______________________________________
Serial Number ______________________________________ _ ______________________________________
SUPPLY FAN DRIVE KIT EXHAUST/RETURN FAN DRIVE KIT

Belts (Qty & ID #) ______________________________________ _ ______________________________________
Belt Tension Tag________________ Actual_ ____________ Tag________________ Actual______________
Fan RPM (DN) Tag________________ Actual_ ____________ Tag________________ Actual______________
other utilities
Steam Pressure Heating Coils _____PSI, Humidifier _____PSI

Hot Water Pressure/Temp. Supply _____PSI, _____°F, Return _____PSI, _____°F
Chilled Water Pressure/Temp. Supply _____PSI, _____°F, Return _____PSI, _____°F
Potable Water Pressure _____PSI, Pneumatic Air Pressure _____PSI
MAINTENANCE
Upon completion of start-up the customer assumes responsibility for periodic maintenance of this equipment in order to
continue warranty. Refer to the Installation Operation and Maintenance Manual (Form 102.20-NOM1).
Customer’s agent signature:_ __________________________________ Date: _____________________
©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 100.00-CL1 (909)
www.johnsoncontrols.com Supersedes 100.00-CL1 (309)

FORM 102.20-NOM1 (909)
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 Section 2, Site Preparation
within roof slope limitations where applicable.
Terminal screws and wiring connections tightened in control, electric Section 2, Electrical Connections ►
and Air Modulator panels. Section 3, Pre-Startup ►
Air hoods installed properly. Section 2, Hood Installation with Optional Mist Elimi-
nators ►
Condensate drain properly trapped. Section 2, Conden sate Drain Trap ►
All wiring and tubing connections made at shipping splits. Section 2, Assembly of Outdoor Units ► and
Assembly of Indoor Units ►
All field piping connections complete. Section 2, Coil Piping ►
All shipped loose parts installed. Section 1, Checking For Non Mounted Parts ►
Installer has cleaned out interior.
Make sure all ductwork is complete and available for full airflow. Section 2, Duct Connections ►
Section 3, Startup ►
Unit installed with proper clearances. Section 2, Outdoor Units Site Prep. ►
Section 2, Indoor Units Site Prep. ►
Visually inspect roof curb for tight seal around unit. Section 2, Curb; Assembly & Installation Instructions ►
3
Clean air filters installed properly and secured. Section 2, Air Filters ►
Filter gauge set to zero.
All field wiring complete and inspected. See Notes in General Safety Guidelines ►, Pre-
installation ► & Installation. ►
Section 2, Electrical Connections ►
IOM Section 6, Wiring Diagrams ►
All shipping splits sealed and secured properly. Section 2, Installing Multiple Piece Outdoor Unit ►
Installing Multiple Piece Indoor Unit ► and
Installation Of Tiered Unit ►
Pipe chase floor sealed at penetrations. Section 2, Pipe Chase Installation ►
All shipping bolts and other material have been removed. (Fan, Section 2, VIFB & IFB
VIFB, Energy Recovery Wheel, Damper). Note: Do not remove Section 3, Pre Start-up ►
functional bolts from seismic isolators.
Damper linkage is tight and in correct “power off” position. Section 3, Pre Start-up ►
Verify correct piping of split system. Section 2 & Split System Application Guide (050.40-
ES3).
Fan INSPECTION
Check bearings and locking collars. Section 3, Pre Start-up Fan Assembly Inspection ►
Sheaves properly aligned and tight on shaft. Section 3, Belts & Sheaves ►
IOM Section 4, Sheave Alignment ►
Belt tension adjusted properly per drive pkg. label on fan. IOM Section 4, Belts ►
Check fan alignment with unit discharge. Adjust with isolator. Section 3, Preparing Fan Isolators for Operation ►
Fan wheel properly aligned, tight on shaft and freely moving. IOM Section 5, Fan Repair ►

Startup
FORM 102.20-NOM1 (909)
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. Section 2, Electrical Connections ►
Energize fan motor(s) briefly (bump) and check for correct fan rotation. Section 3, Start-up ►
Check operation of dampers. Insure unit will not operate with all damp- Section 3, Start-up ►
ers closed.
Energize fan motor(s). Observe fan(s) for smooth operation. Section 3, Start-up-Energize Fan Motor ►
Check motor nameplate Full Load Amp rating. Section 3, Start-up-Energize Fan Motor ►
Immediately check current draw of each leg of each motor. Section 3, Start-up-Energize Fan Motor ►
VFD, refer to manufactures start engine guide. Section 3, Setup of Non-factory Mounted VFD ►
IOM Section 4, Dynamic Balance ►
Check damper operation. Section 3, Start-up-Check Operation of Dampers ►
IOM Section 4, Economizer Segment ►
Check doors and latches for proper adjustment. IOM Section 4, Air Handler Cabinet-Hardware
Check ►
IOM Section 5, Door Handle/latch Replacement
And Adjustment ►
Check doors for air leaks. IOM Section 5, Door Replacement ►
IOM Section 5, Door Gasket Replacement ►
Controls installation complete. Section 3, Pre Start-Up ►
Verify Energy Recovery Wheel turns freely and wheel segments are fully Section 3, Start-up Procedure For Energy Recov-
engaged. ery Wheel ►

FORM 102.20-NOM1 (909)
4.0 OPERATION & maintenance
Refer to ASHRAE 62-2001 for startup and maintenance practices related to achieving ac-
ceptable indoor air quality. ASHRAE standard 62-2001 is under continuous maintenance
by a Standing Standard Project Committee (SSPC) for which the Standards Committee has
established a documented program for regular publication of addenda or revisions, including
IAQ procedures for timely, documented, consensus action on requests for change to any part of
the standard (see Table 4-1).
DO NOT PENETRATE WIREWAYS Do not weld or use torches on the ex-

in any manner. These sheet metal terior or interior of the unit housing.
channels, which run along the top The housing contains polyurethane
panel, contain electrical wires and insulation, which when under combus-
connections. Electrical shock and/or tion will produce harmful, toxic gases
damage to the unit may result. resulting in personal injury or death.
Rotating parts and electrical shock Never use silicone caulk/sealant or

hazards exist. Lock out and tag out caulk/sealant containing silicone in or
the fan motor(s) and heat power on any air handling equipment. [Only
disconnects before servicing. FOL- exception is when provided (high tem-
LOW THE LATEST “LOCKOUT perature) with gas heat venting].
TAGOUT” PROCEDURE. Failure
to follow proper safety precautions OPERATION
may result in serious injury or death.
Refer to general safety guidelines and TEST AND BALANCE
safety symbols located at the front of AIR BALANCE
this Manual. ►
• System air balance should be performed as soon
as possible after air handler startup.
Always replace RED metal tab on 4
access doors that provide access to • Failure to perform air balance may result in
moving parts. This mechanical pro- damage to air handler, generate noise and
tection from moving parts is required vibration.
by UL-1995. • A qualified air balance technician should perform
Always replace RED metal tab on air balance.
access doors that provide access to
pressurized areas. This mechanical DYNAMIC BALANCE
protection is to prevent accidental • Dynamic balance has been performed at the
release of access doors under positive factory on the fan assemblies. If any changes
pressure. were made to the fan assembly (fan, motor,
sheaves, belts, isolators, support structure) a
Verify conformance with the total out- vibration analysis must be performed and the
door airflow and space supply air- fan assembly trim balanced if needed.
flow requirements of ASHRAE • Dynamic balance is affected by operation of
Standard 111, SMACNA’s HVAC Variable Frequency Drives. If VFD is applied,
IAQ Systems - Testing, Adjusting and see cautions in VFD Start-up literature. Be
Balancing, 2nd edition, or equiva- sure skip frequencies (jump frequencies) are
lent. installed prior to operation of motors for more
than 30 minutes. Refer to caution under Section
3 “Set-Up of a Non-Factory Mounted VFD” ►
or refer to IOM provided with the VSD.
Operation & Maintenance
FORM 102.20-NOM1 (909)
TABLE 4-1 – MINIMUM MAINTENANCE ACTIVITY AND FREQUENCY

(ASHRAE STANDARD 62-2001 FOR INDOOR AIR QUALITY).
IAQ
Refer to Fig. 4-32 - “Maintenance Requirements for YORK Solution Air Handler (includes suggested IAQ minimums
for ASHRAE STD. 62-2001 Compliance”.
Item Activity Minimum Frequency

Filters and air cleaning devices A According to O & M Manual
Outdoor air dampers and actuators B Every three months or in accordance with O & M
Manual
Humidifiers C Regularly when it is likely that dehumidification occurs
but no less than once per year or as specified in the O
& M Manual
Dehumidification coils D Once per year during cooling season or as specified in
the O & M Manual
Drain pans and other adjacent surfaces subject to wet- D Every six months or as specified in the O & M Manual
ting
Outdoor air intake louvers, bird screens, mist elimina- E Every six months or periodically specified in accordance
tors, and adjacent areas with the O & M Manual
Sensors used for dynamic minimum outdoor air control F Every six months or periodically in accordance with O &
M Manual
Air-handling systems except for units under 1000 L/s G Once every five years
(2000 CFM)
Cooling towers H In accordance with the O & M Manual or treatment
system provider
Floor drains located in plenums or rooms that serve as I Periodically according to O & M Manual
air plenums
Equipment / component accessibility J
Visible microbial contamination K
Water intrusion or accumulation K
ACTIVITY CODE:
A. Maintain according to O & M Manual.
B. Visually inspect or remotely monitor for proper function.
C. Clean and maintain to limit fouling and microbial growth.
D. Visually inspect for cleanliness and microbial growth and clean when fouling is observed.
E. Visually inspect for cleanliness and integrity and clean when necessary.
F. Verify accuracy and recalibrate or replace as necessary.
G. Measure the minimum quantity of outdoor air. If measured minimum airflow rates are less than 90% of the minimum
outdoor rate in the O & M Manual, they shall be adjusted or modified to bring them above 90% or shall be evaluated to
determine if the measured rates are in conformance with this standard.
H. Treat to limit the growth of microbial contaminates.
I. Maintain to prevent transport of contaminants from the floor drain to the plenum.
J. Keep clear the space provided for routine maintenance and inspection around ventilation equipment.
K. Investigate and rectify.
* Minimum frequencies may be increased or decreased if indicated in the O & M Manual.

FORM 102.20-NOM1 (909)
TEMPERATURE LIMITS SHEAVES

Cabinet Panels - 200° F. If optional adjustable sheaves pro-
Standard Motors with (Class B Insulation) - 104°F. vided, we strongly recommend they be
Motors with Class F. Insulation - 140°F. replaced with correctly sized fixed
Power Wiring - 140°F. sheave immediately after system air
Controls & Control Wiring - 140°F.
balance is performed. It is not un-
Prefilters - 150°F.
usual for an adjustable sheave at some
High Efficiency Filters - 200°F.
Variable Speed Drives - ABB Mfg. - 140°F. point in time to create damaging vibra-
Damper & Valve Actuators - 140° F. tion in the fan assembly.
STATIC PRESSURE LIMITS MAINTENANCE

• Maximum design cabinet pressure for YORK INTRODUCTION
Solution units is ± 8" W.C. A planned program of regularly scheduled maintenance
• Access doors are double wall. Doors provided will return dividends by averting possible costly and
with adjustable door latches and seals. unexpected periods of down time. It is the responsibility
of the owner to provide the necessary maintenance for
the air handling equipment and components.
MOTORS
Do not operate fan motors in overload Refer to Table 4-1 and ASHRAE Stan-
amperage condition. dard 62-2001 for Indoor Air Quality.
IAQ
Motor amperage should be checked again after the AIR HANDLER CABINET
connecting ductwork is installed and an air balance
performed on the air distribution system (see Section 4 Clean exterior with a mild, environ-
for Air Balancing Requirements). ► If motor operates mental safe detergent and high-pres-
at amperage levels above nameplate, discontinue sure water (2000 PSI max.).
operation and correct cause, or refer to Section 5.0, 4
“Service and Repair”. ► IAQ
BELTS HARDWARE CHECK

Belts should be checked for correct tension at startup Inspect doors, handles, latches and hinges for proper
and should be checked again after 24 hours of operation. operation. Secure any loose parts (see Section 5 for
On multiple belt adjustable pulleys, the pitch depth “Door Replacement” ► and “Door Handle/Latch
should be checked to insure identical belt travel, power Replacement” ► guides).
transfer and wear. Adjustable motor bases are provided
for belt adjustment. See procedure in this section of GASKETS
the IOM. ► Inspect door gaskets for damage and proper seal (see
Section 5 for “Door Gasket Replacement” guide). ►
PANELS
Inspect panels for damage. If panels show signs of
excessive pressure change, they will appear to bulge
inward or outward.
See Troubleshooting Guide regarding excessive
static pressure. ►
See Section 5 for “Panel Replacement” guide.
►
FORM 102.20-NOM1 (909)
HOODS AND LOUVERS FAN SEGMENT (SUPPLY, RETURN,

Inspect air hoods and air louvers for EXHAUST) - FAN ASSEMBLY
damage and debris. Remove debris as Fans can be removed for cleaning.
needed. Cleaning should be done using deter-
gent or solvent that is environmen-
IAQ
tally safe. If water pressure is used,
do not direct water stream onto bear-
BIRD SCREENS ing seals.
Forward Curved fan wheels are more
Inspect bird screens for damage and
susceptible to dirt accumulation than
debris. Remove debris as needed. Bird
others. Dirt and debris on fan wheels
screens are an integral part of hoods
and shafts may adversely affect the
and louvers. IAQ balance of the fan assembly.
IAQ
See Section 5 for replacement guides regarding fan

MIST ELIMINATORS
and fan assembly components. ►
Inspect mist eliminators for damage, • Check fan housing, wheel, shaft, frame and
dirt and debris. Mist eliminators are bearings: for damage, wear, loose parts, dirt and
optional equipment. Mist eliminators debris.
in air hoods are removable for clean-
IAQ • Check fan base, vibration isolators and thrust
ing (see Section 5 for mist eliminator restraints (optional) for damage, wear, loose
removal, cleaning and replacement). parts, dirt and debris.
CLEANING/REPLACEMENT • Check flex connector for damage and wear.

Make sure fan assembly does not rub flex
Cleaning or replacement (O.A. Hood) : material.
1. Remove clip(s) from leading edge of hood. • Check Drive Kit - Drive kit consists of belts,
2. Remove Mist Eliminator or Cleanable Filter. sheaves and sheave bushings if required. Check
3. Clean with Eco friendly solution. for damage, loose parts, wear, dirt, alignment
4. Install cleaner or new Mist Eliminator or Cleanable and belt tension.
Filter. (See Fig. 4-2, “Typical Drive Kit Data Tag” for example
5. Re-install the clips on the leading edge of the of data provided.) The unique/actual data required by
hood. design of each fan assembly is listed on the tag affixed
to the fan housing near the belts.
Clip
Mist Eliminator FIG. 4-2 – TYPICAL DRIVE KIT DATA TAG
FIG. 4-1 – MIST ELIMINATOR REMOVAL

FORM 102.20-NOM1 (909)
ADJUSTABLE MOTOR BASE OPERATION

(Standard)
1. Secure the nut with a wrench placed through
the service hole and loosen the bolt. Do this to
all four Hold Down Bolt Assemblies (See Fig.
4-3).
2. Insure the Drive Bolt Assembly threads are
lightly lubricated.
DRIVE BOLT
ASSEMBLY
3. Turn both Drive Bolt Assemblies in the same
direction to move motor for belt installation and
tensioning.
4. Turn Drive Bolt Assemblies independently to
move motor for sheave/belt alignment.
5. Tighten all four Hold Down Bolt Assemblies.
For belt tensioning instruction, see sub-topic “Belts”
in this section. ►
HOLD DOWN BOLT
ASSEMBLY
For alignment instruction, see sub-topic “Sheave
Alignment” in this section. ►
PLACE WRENCH ON NUT

ADJUSTABLE MOTOR BASE OPERATION THROUGH SERVICE HOLE
LD09645
(Top Mount)
See Fig.4-4 for procedure to adjust motor base. FIG. 4-3 – ADJUSTABLE MOTOR BASE
(STANDARD)

MOTOR BASE
ADJUSTMENT SCREWS STRAIGHT EDGE
NOTE 3
MOTOR'S NOTE 2
(DRIVE SIDE)
4-6
SHEAVE
MOTOR
MOTOR BASE
MOUNTING HARDWARE MOTOR
KEYWAY
NOTE 3
DRIVE SIDE
(FIG. 1) FAN'S SHEAVE
MOTOR BASE PLENUM

FAN
KEYWAY
FAN'S BEARING
PARALLEL MISALIGNMENT PARALLEL ALIGNMENT

(FIG. 4) (FIG. 5)
DRIVE SIDE
(FIG. 2)
MOTOR BASE
SUPPORT RAILS
MOTOR
MOUNTING/ADJUSTMENT
HARDWARE
MOTOR BASE
ADJUSTMENT SCREWS
(OPP-DRIVE SIDE)
NOTES:
1. THE SHEAVES SHOULD BE CENTERED ON THE SHAFT'S KEYWAY. SHEAVE CAN BE CLOSER TO THE BEARING,
AS LONG AS THE SHEAVES HUB IS ABLE TO FULLY ENGAGE WITH THE KEY.
2. CHECK FOR PARALLEL MISALIGNMENT BY PLACING A STRAIGHT EDGE ACROSS THE OUTER FACE OF THE
SHEAVES (FIG. 5). STRAIGHT EDGE IS TO BE LONG ENOUGH THAT IT EXTENDS PAST BOTH SHEAVES.
3. IF THE SHEAVES ARE MISALIGNED (FIG. 4), LOOSEN THE MOTOR'S MOUNTING HARDWARE AND SLIDE THE MOTOR
FORWARD (OR BACK) TO BRING THE SHEAVES INTO ALIGNMENT (FIG. 5), THEN RE-TIGHTEN HARDWARE.
MOTOR BASE
MOUNTING HARDWARE
FIG. 4-4 – ADJUSTABLE MOTOR BASE (TOP MOUNT)
johnson controls
FORM 102.20-NOM1 (909)
FORM 102.20-NOM1 (909)
BELTS Never use excessive tension as this

could result in damaging the bearing,
Check belt tension. It is normal for motor pulleys or motor base. See drive
belts to loosen after start up or replace- label on fan housing adjacent to drive
ment. The new belt will “run in” or for specific details on tension. Squeal-
“take a set” by seating slightly deeper ing belts during starting is caused by
into the grooves of the sheaves. Re- slipping belts that are not tensioned
check tension after one day, and again properly.
after three days.
Check belt tension (see Fig. 4-5, “Belt Tensioning” and

Fig. 4-6, “Belt Tensioning Gauge”).
1. Measure belt span (see Fig. 4-5).
2. Position bottom of the large “O” ring on the span
scale at the measured belt span (see Fig. 4-6).
3. Set the small “O” ring on the deflection force
scale to zero.
30
Deflection
Force
25
Scale
4. Place the tension gauge squarely on one belt at
20
15
the center of the belt span. Apply a force on the Small
“O”
Ring
plunger and perpendicular to the belt span until
the bottom of the large “O” ring is even with
the top of the next belt or with the bottom of a
straight edge laid across the sheaves.
5. Remove the tension gauge and read the force
applied from the bottom of the small “O” ring
on the deflection force scale.
150
6. Compare the force you have applied with the
value given on the Drive Kit Data Tag (see Fig. Span
4
100
SPAN
4-2). Large
“O”
Scale
Ring
of
50
INCHES
BELT SPAN
TI TH
EC NG
N
O
FL LE
DE AN
LD05628A
SP
FIG. 4-6 – BELT TENSIONING GAUGE
SHEAVES ALIGNMENT
An incorrectly aligned sheave can sub-

stantially shorten belt life or overload
LD05627A
blower and motor bearings, shortening
their life expectancy. A belt tensioned
too tightly can overload the motor elec-
FIG. 4-5 – BELT TENSIONING trically, causing nuisance tripping of
the motor overloads and/or motor fail-
ure and/or shaft failure.

FORM 102.20-NOM1 (909)
Sheave alignment and parallelism of shafts is very ALIGNMENT USING A STRAIGHTEDGE

important. Proper alignment helps equalize the load
(Preferred)
across the entire belt width, thereby reducing wear
Place a straightedge against the outer edge of the
and extending belt life. Fig. 4-7 shows how to align a
sheaves. Fig. 4-7(A) shows the four points where the
synchronous drive properly using a straightedge (A) or
straight edge should touch the sheaves. The straight
a piece of string (B).
edge should cross the sheaves at the widest possible
part of the sheave.
After aligning the sheaves, check the rigidity of
the supporting framework. Shafts should be well
supported to prevent distortion and a resulting change ALIGNMENT USING A STRING
in the center distance under load. Do not use spring- Tie a string around either shaft and pull it around and
loaded or weighted idlers. across the outer edge of both sheaves. Fig. 4-7(B)
shows how the string should touch four points when
the drive is properly aligned.
If alignment is other than described here, see Section 5,

“Sheave Replacement and Adjustment”. ►
Straightedge touching sheaves at

points indicated by arrows
(A) ALIGNMENT USING STRAIGHT EDGE
(B) ALIGNMENT USING STRING LD09646
FIG. 4-7 – SHEAVE ALIGNMENT

MOTOR'S STRAIGHT EDGE
SHEAVE NOTE 2
MOTOR BASE
MOTOR
johnson controls
BELT
PLENUM
FAN
FAN'S
SHEAVE
MOTOR BASE LOWERED ANGULAR MISALIGNMENT ANGULAR MISALIGNMENT ANGULAR ALIGNMENT

(FIG. 1) (FIG. 2) (FIG. 3) (FIG. 4)
NOTES:
1. TO REMOVE THE OLD BELT LOOSEN THE MOTOR BASE'S MOUNTING HARDWARE (DRIVE SIDE ONLY).
NOTE: THE DRIVE SIDE HAS 2 ADJ. SCREWS. TRY NOT TO INCREASE THE LEFT SIDE MORE THAN 1/2 AN INCH BEFORE INCREASING THE RIGHT SIDE.
2. LOWER DRIVE SIDE, USING THE ADJUSTMENT SCREWS (FIG. 3).
3. ONCE THE TENSION HAS BEEN REMOVED FROM THE BELT, THE MOTOR BASE'S (OPP-DRIVE SIDE) MOUNTING HARDWARE CAN BE LOOSENED.
4. CONTINUE LOWERING BOTH ENDS OF THE BASE UNTIL THE BELT(S) CAN BE REMOVED (FIG. 1).
5. ONCE THE SHEAVES HAVE BEEN CHECKED FOR PARALLEL ALIGNMENT (SEE SHEET 1), THE NEW BELT(S) CAN BE PLACED ON THE SHEAVES.
6. START RAISING THE BASE, TO TAKE THE SLACK OUT OF THE BELT(S), USING TH E ADJUSTMENT SCREWS ON BOTH ENDS. USE 1/2 INCH INCREMENTS.
7. AS THE BELT(S) START TO TIGHTEN, CHECK FOR PARALLEL MISALIGNMENT BY PLACING A STRAIGHT EDGE ACROSS THE OUTER FACE OF THE
SHEAVES (FIG. 4). STRAIGHT EDGE IS TO BE LONG ENOUGH THAT IT EXTENDS PAST BOTH SHEAVES.
8. IF THE SHEAVES ARE MISALIGNED AS SHOWN IN FIG. 2, THEN THE OPP-DRIVE SIDE NEEDS TO BE RAISED MORE.
9. IF THE SHEAVES ARE MISALIGNED AS SHOWN IN FIG. 3, THEN THE DRIVE SIDE NEEDS TO BE RAISED MORE.
***WARNING: AS THEN TENSION ON THE BELT INCREASES, IT IS LIKELY THAT THE OPP-DRIVE SIDE OF THE BASE WILL LIFT UP. IT IS ADVISABLE THAT
WHEN THE BELT STARTS TO GET TIGHT, THAT THE BASE'S OPP-DRIVE SIDE MOUNTING HARDWARE IS SECURED.
10. CONTINUE TIGHTENING THE BELT(S) US ING THE DRIVE SIDE ADJ. SCREWS ONLY.
11. IF THE SHEAVES ARE STILL ALIGNED (FIG 4), AFTER REACHING THE BELT'S SPECIFIED TENSION, SECURE THE BASE'S DRIVE SIDE MOUNTING
HARDWARE (YOU ARE FINISHED)..
12. IF THE SHEAVES ARE MISALIGNED (AS SHOWN IN FIG. 2 & 3), AFTER REACHI NG THE BELT(S) SPECIFIED TENSION, THEN LOWER THE DRIVE SIDE OF
THE BASE (TO REMOVE BELT TENSION). LOOSEN THE BASE'S (OPP-DRIVE SIDE) MOUNTING HARDWARE AND RAISE OR LOWER ACCORDINGLY A ND
REPEAT STEPS 6 THROUGH 11.
***NOTE: YOU MAY WANT TO MARK THE POSITION OF THE BASE'S OPP-DRIVE SIDE MOUNTING HARDWARE, BEFORE LOWER THE BASE. THIS MAY
HELP IN DETERMINING WHERE TO SECURE THE HARDWARE NEXT TIME AROUND.
FIG. 4-8 – belt replacement tensioning and alignment (TOP MOUNT)
4-9
FORM 102.20-NOM1 (909)
4
FORM 102.20-NOM1 (909)
LUBRICATION
SEAL ASSEMBLY
OUTER RING RECESSED CAM OR SELF-
VERIFY TYPES OF BEARINGS LOCKING COLLAR
Sealed (not to be re-lubricated in the field)
INNER RING
See Fig. 4-9
SELF LOCKING COLLAR
BALLS AND RACEWAY

CAM OR INNER RING
LD06357
FIG. 4-11 – BEARING WITH ECCENTRIC CAM
Split Pillow Block

See Fig. 4-12
8
1
LD09647
6
44
FIG. 4-9 – SEALED BEARING
5
9
Standard Pillow Block
See Fig. 4-10 & 4-11
Set
Screws
Lube
Fitting 7
Seal Lock
Ring
2 8
5
1
Pillow
Inner Block
Race 3 7
Outer 4 LD09648
00418VIP
Race
FIG. 4-12 – SPLIT BEARING
FIG. 4-10 – B
EARING WITH SETSCREW TYPE
1. Seal (4) 6. Lock Washer
LOCKING DEVICE
2. Housing Cap 7. Tapered Sleeve
3. Cap Bolts (2) 8. Bearing
4. Locating Ring (2) 9. Housing Base
5. Lock Nut

FORM 102.20-NOM1 (909)
FAN BEARING LUBRICATION
See Tables 4-2, 4-3 & 4-4
If fans will be down four (4) weeks or Re-lubrication is generally accompanied by a temporary
more, properly apply correct grease rise in operating temperature. Excess grease will be
and rotate monthly to prevent moisture purged at seals. Always wipe away purged grease
from damaging bearings. after several hours of operation.
CHECK CONDITION OF EXTENDED

Fan bearings on the YORK Solution units are equipped LUBRICATION LINES WHEN PRESENT
with standard lubrication fittings. Units under 42" See Fig. 4-13
tall cabinet size will have either extended lube lines,
enabling lubrication of both fan bearings from one side Check lube lines for:
of fan (see Fig. 4-13) or optional external lube lines.
– Cracks and brittleness (replace as needed).
For units of 42" tall cabinet size and above, extended
lube lines and external lube lines are optional. Some – Fittings tight and lube lines tight on fittings.
fans will have permanently lubricated bearings.
– Air bubbles in grease (disconnect and purge
as necessary).
Two lube fittings
accessible from
drive side. RECOMMENDED LUBRICANT FOR FAN
BEARINGS
A Lithium / Petroleum base grease conforming to an

NLGI Grade II consistency is normally used. Lubricant
must be free of any chemical impurities such as free acid
or free alkali, dust, rust, metal particles or abrasives.
This light viscosity, low torque grease is rust inhibited
and water resistant, has a temperature range of -30°F
to +200°F with intermittent highs of +250°F. Lubricate
bearings as required by the severity of required duty. 4
PROPER INTERVAL AND QUANTITY
LD09649 See Tables 4-2, 4-3 & 4-4
FIG. 4-13 – LUBRICATION LINES (Optional) Bearing on fan split pillow blocks is
For specific fan bearing lubrication, 1/3 full when only one side of bearing
check the instruction packet attached is completely full of grease.
to the fan housing. Some forward
curved fans are permanently lubri-
cated.
For best results, standard pillow block bearings should

be re-lubricated while in operation providing personal
safety is assured. Add grease slowly with shaft rotating
until a slight bead forms at the seals.
If necessary to re-lubricate while bearing is stationary,

refer to manufacturer’s data for maximum grease
capacity for the size bearing.

FORM 102.20-NOM1 (909)
TABLE 4-2 – FAN BEARING – LUBRICATION INTERVALS - BALL BEARING PILLOW BLOCKS
Re-lubrication schedule (months)
Speed (rpm) 500 1000 1500 2000 2500 3000 3500 4000 4500
Shaft dia.
1/2" thru 1-11/16" 6 6 5 3 3 2 2 2 1
1-15/16" thru 2-7/16" 6 5 4 2 2 1 1 1 1
2-11/16" thru 2-15/16" 5 4 3 2 1 1 1
3-7/16" thru 3-15/16" 4 3 2 1 1 1
TABLE 4-3 – FAN BEARING – LUBRICATION INTERVALS - SPHERICAL ROLLER BEARING SOLID
PILLOW BLOCKS
Re-lubrication schedule (months)
Speed (rpm) 500 1000 1500 2000 2500 3000 3500 4000 4500
Shaft dia
1-3/16" thru 1-7/16" 6 4 4 2 1 1 1 1 ½
1-11/16" thru 2-3/16" 4 2 1½ 1 ½ ½ ½ ½ ½
2-7/16" thru 3-7/16" 3 1½ 1 ½ ½ ½ ½
3-15/16" thru 4-15/16" 2½ 1 ½ ¼
TABLE 4-4 – FAN BEARING – LUBRICATION INTERVALS - SPHERICAL ROLLER BEARING- Grease to
SPLIT PILLOW BLOCKS be added

Re-lubrication schedule (months) at each
Speed (rpm) 500 750 1000 15000 2000 2500 3000 3500 4000 interval
Shaft dia
1-7/16" thru 1-15/16" 6 4½ 4 4 3½ 2½ 2½ 1 1 0.50 oz.
2-3/16" thru 2-11/16" 5 4½ 4 2½ 2½ 1½ ½ ¼ ¼ 0.75 oz.
2-15/16" thru 3-15/16" 4½ 4 3½ 2½ 1½ 1 ½ 2.00 oz.
4-7/16" thru 4-15/16" 4 4 2½ 1 ½ 4.00 oz.
5-7/16" thru 5-15/16" 4 2½ 1½ 1 7.00 oz.
FAN SEGMENT-FAN MOTOR MOTOR CONDITION (VISUAL)

See Section 5 “Fan Replacement & Adjustment” for • Check for leaky bearing seals.
motor replacement guide. ►
• Check for damage.
Keep the motor clean, dry and properly lubricated at • Check for dirt, dust & debris in air vents on
all times. On ODP (Open Drip Proof) type motors, motor housing.
blow dust and dirt out of windings periodically using
low-pressure (50 PSIG) air.
ELECTRICAL CHECKS
Mounting Hardware and Adjustable Motor Base
• Check all electrical terminations.
See Section 4 for motor base replacement and
adjustment guide. ► • Check conduit fittings and clamps for damage
or looseness.
• Check for loose parts. • Check operating amperage and compare to
• Check for damage. nameplate.

FORM 102.20-NOM1 (909)
– Shutdown temperature in case of a

malfunction = 115°C/175°F.
• Proper Interval
Lubrication Intervals – Recommended lubrication
intervals are shown in Table 4-5. It is important to
realize that the recommended intervals of Table
4-5 are based on average use. Refer to additional
information contained in Tables 4-6 & 4-7.
• Motor Lubrication Procedure

Be sure that the grease you are adding
to the motor is compatible with the
grease already in the motor. Consult
LD09635
your distributor or an authorized ser-
FIG. 4-14 – ODP (OPEN DRIP PROOF) vice center if grease other than the
recommended type is to be used.
To avoid damage to motor bearings,

grease must be kept free of dirt. For
an extremely dirty environment, con-
tact your distributor or an authorized
service center for additional informa-
tion.
– With Grease Relief Plug

1. Clean all grease fittings.
2. Remove grease relief plug.
3. If motor is stopped, add the recommended
4
LD09639
FIG. 4-15 – TEFC (TOTALLY ENCLOSED FAN

amount of grease.
COOLED) 4. If motor is to be greased while running, a
slightly greater quantity of grease will have
LUBRICATION to be added. Add grease slowly until new
grease appears at shaft hole in the end plate
MOTOR BEARING LUBRICANT or relief plug hole.
Bearing grease will lose its lubricating ability over 5. Clean off any grease from the grease
time, not suddenly. The lubricating ability of grease fitting.
(over time) depends primarily on the type of grease,
the size of the bearing, the speed at which the bearing 6. Run motor for 15 to 30 minutes with relief
operates and the severity of the operating conditions. plug out to warm up the grease.
Good results can be obtained if the following 7. Wipe off any grease that pushed out of the
recommendations are used in your maintenance relief plug.
program:
8. Re-install grease relief plug.
• A high-grade ball or roller bearing grease should
be used. Recommended grease for standard
service conditions is Polyrex EM (Exxon
Mobil).
– Maximum operating temperature for standard
motors = 110°C/166°F.
FORM 102.20-NOM1 (909)
TABLE 4-5 – MOTOR BEARING – LUBRICATION INTERVALS

RATED SPEED - RPM
NEMA / (iec) fram size
10000 6000 3600 1800 1200 900
Up to 210 incl. (132) ** 2700 HRS. 5500 HRS. 12000 HRS. 18000 HRS. 22000 HRS..
Over 210 to 280 incl. (180) 3600 HRS. 9500 HRS.. 15000 HRS. 18000
HRS...
Over 280 to 360 incl. (180) *2200 HRS. 7400 HRS.. 12000 HRS. 15000 HRS.
Over 360 to 5800 incl. (180) *2200 HRS.. 3500 HRS.. 7400 HRS.. 10500 HRS.
* Lubrication intervals are for ball bearings. For roller bearings, divide the listed lubrication interval by 2.
** For 6205 and 6806 bearings. For 6807 bearings, consult oil mist lubrication (MN410).
Re lubrication interval for 6205 bearing is 1550 HRS. (Using grease lubrication).
Re lubrication interval for 6806 bearing is 720 HRS. (Using grease lubrication).
TABLE 4-6 – MOTOR BEARING – SERVICE CONDITIONS

Severity of service Ambient temperature Atmospheric Type of bearing
Maximum Contamination
Standard 40°c Clean, Deep groove
Little corrosion Ball bearing
Severe 50°c Moderate dirt, Ball thrust, roller

Corrosion
>50°c* or Severe dirt,
Extreme All bearings
Class h insulation Abrasive dust
Low temperature <-30°c** Corrosion
* Special high temperature grease is recommended. Note that high temperature grease may not mix with other grease types. Thoroughly
clean bearing and cavity before adding grease.
** Special low temperature grease is recommended.
TABLE 4-7 – MOTOR BEARING – LUBRICATION

INTERVAL MULTIPLIER
SEVERITY OF SERVICE MULTIPLIER
Standard 1.0
Severe 0.5
Extreme 0.1
Low temperature 1.0 BEARINGS IN
BEARING
CAVITY
LD06352A
FIG. 4-16 – GREASE FITTINGS

FORM 102.20-NOM1 (909)
FILTER SEGMENTS (PRE FILTER AND INSERTING FILTERS INTO SIDE LOAD FILTER
FINAL FILTER) TRACKS FOR ANGLE AND FLAT FILTER
SEGMENTS.
A list of filter part numbers, sizes and
quantities are shown on a label lo- 1. Check filter sizes and quantities. See filter label
located on each filter segment.
cated on each filter segment of each
air handler. 2. Remove filter frame end cover (see Fig's 4-18
and 4-16).
3. Remove old filters if present.
If your unit has HEPA filters the filter
frames, filter bulkheads and filter seg- 4. Make sure gaskets at both ends of Side Load
filter tracks are in place. The gaskets are
ment panels are factory sealed and
normally found on inside of filter frame end
must remain sealed for NO air by- covers.
pass.
5. Slide the correct size new filters into tracks.
Bag Filter 12" Cartridge
6. On bag filters (in FF segments) leave banding
in place until filters are installed; then remove.
Install bag filters so that pocket dividers are
vertical if filters are over 12" high.
Cartridge 7. Airflow arrows must point downstream (in
direction of airflow).
4" High 8. All pleated filters must be installed with pleats
Efficiency 2" Pleated
Varicel II Filter vertical.
9. Re-install filter frame end cover.
Cleanable Filter
LD09650
FIG. 4-17 – TYPICAL FILTERS

FILTER
FILTER
FRAME
4
END
FILTER TYPES COVER
Flat, angle, rigid, bag, HEPA & charcoal.
MAINTENANCE AND REPLACEMENT

LD09651
Every month, check the cleanliness of the filters and
replace . Filters should be replaced when the pressure FIG. 4-18 – ANGLE FILTER INSTALLATION.
drop, measured by a manometer, reaches the prescribed
limits for the installation.
RIGID PRE-
FILTER FILTERS
FILTER
FRAME END
COVER
LD09652
LD09652
FIG. 4-19 – SIDE LOAD FILTER INSTALLATION.

FORM 102.20-NOM1 (909)
Filter LATCHES
AAF 315-004-003
YORK P/N - 026-35778-000
Used with 2" Perfectpleat, Premium or Premium HM and

SH Single Headered Filters.
AAF 315-004-000
Used with 2" (C86) & 4" (C89)” Amair 300 X Pleated Prefilter
in combination with a Single Header Final Filter.
YORK P/N - 026-35778.007
AAF 315-004-001
YORK P/N - 026-35778-006
Used with 2” & 4" Prefilter in combination with a Double

Header Final Filter and Varicel DH Double Headered
Filter.
AAF 315-003-002 VP2

2-13/16" Final Filter.
YORK P/N - 026-36339-001
AAF 315-003-004 VP4

4-11/16" Final Filter.
YORK P/N - 026-36339-000

WITH CLAMP)
SPRING
DUCTWORK
Used to attach HEPA Filters to Holding Frame.

AIRFLOW
BEVEL SEAL
CELL SIDE
FRAME
(PERIMETER
EXTRUSION)
MEDIA PACK
BEVEL SEAL FRAME
GASKET BEVEL
RECESSED SEALING
CELL SIDE SURFACE
LD13303A
Fig. 4-20 – Filter Latches

FORM 102.20-NOM1 (909)
YORK MATRIX: AAF FILTERS AND AAF FRAMES / LATCHES
Single Filter Application

2” AAF 4” AAF AmAir AAF VariCel SH AAF VariCel
PerfectPleat, 300X or DH
Premium or AAF DriPak
Premium HM 2000
AAF FRAME - 312-300-000
AAF 315-004-003 (C70) YORK 026-35778-000 X X
AAF 315-004-000 (C86) YORK 026-35778-007 X
AAF 315-004-001 (C80) YORK 026-35778-006 X
AAF FRAME - 312-300-006
24X24 - 16 ga. Galvanized
AAF 315-004-003 (C70) YORK 026-35778-000 X X
AAF 315-004-000 (C86) YORK 026-35778-007 X
AAF 315-004-001 (C80) YORK 026-35778-006 X
Prefilter / Final Filter Application

AAF AAF AAF 4” AmAir AAF 4” AmAir
PerfectPleat, PerfectPleat, 300X AND 300X AND
Premium or Premium or VariCel SH or VariCel DH
HM AND AAF HM AND AAF DriPak 2000
Varicel SH or Varicel DH
DriPak 2000
AAF FRAME - 312-300-000 12x24 -
16 ga. Galvanized 4
AAF 315-004-000 (C86) YORK 026-35778-007 & X
AAF 315-004-003 (C70) YORK 026-35778-000
AAF 315-004-001 (C80) YORK 026-35778-006 & X
AAF 315-003-002 VP2 - YORK 026-36339-001
AAF 315-004-000 (C86 & C89) YORK 026-35778-007 X
& 026-35778-008 &
AAF 315-004-003 (C70) YORK 026-35778-000
AAF 315-004-001 (C80) YORK 026-35778-006 & X
AAF 315-003-004 VP4 - YORK 026-36339-000
AAF FRAME - 312-300-006 24X24 -
16 ga. Galvanized
AAF 315-004-000 (C86) YORK 026-35778-007 & X
AAF 315-004-003 (C70) YORK 026-35778-000
AAF 315-004-001 (C80) YORK 026-35778-006 & X
AAF 315-003-002 VP2 - YORK 026-36339-001
AAF 315-004-000 (C86 & C89) YORK 026-35778-007 X
& 026-35778-008 &
AAF 315-004-003 (C70) YORK 026-35778-000
AAF 315-004-001 (C80) YORK 026-35778-006 & X
AAF 315-003-004 VP4 YORK 026-36339-000

FORM 102.20-NOM1 (909)
INSTALLATION OF 2" PERFECTPLEAT, PREMIUM

OR PREMIUM HM
These instructions are for installing a 2" filter (typically Repeat the installation process with the
AAF PerfectPleat) into AAF 16 ga. galvanized holding remaining latches in the other three corners.
frames.
4. Rotate all of the latches outward, and insert the
• Latches needed for these applications are four filter into the frame.
(4) AAF P/N 315-004-003, as shown in Fig.
4-20. 5. After the filter has been placed into the frame,
grasp the circular end of the latch and rotate it
• A single latch should be installed at each of the across the corner of the filter.
Push the end of the latch towards the filter, until
• The latch fits into the set of knockouts, which the latch catches beneath the knockout on the
consists of two (2) rows of three (3) knockouts. frame.
should be used for nominal 1" filters or filters Repeat for the remaining latches.
with a 13/16" single header. The second set 6. The filter should now be securely installed into
of knockouts should be used for nominal 2" the frame (see Fig 4-22).
filters.
1. Insert the straight end of the latch between the

two (2) knockouts furthest from the corner.
3 The latch installation should now be complete.
The latch should now be “trapped” within the
three (3) knockouts, but should be able to freely
rotate (see Fig. 4-21).
LD010174
LD010171
Fig. 4-21 – C
orrectly installed latch
P/N 315-004-003.

FORM 102.20-NOM1 (909)
INSTALLATION OF 4" AMAIR 300X PLEATED

FILTER
These instructions are for installing a four (4)" filter Repeat the installation process with the
(typically AAF AmAir 300X pleated filter) into AAF remaining latches.
16 ga. galvanized holding frames.
4. Insert the filter into the frame.
• Latches needed for these applications are four
(4) AAF P/N 315-004-000, as shown in Fig 5. After the filter has been placed into the frame,
4-20. grasp the loose end of the latch and place it over
the filter frame, so that the latch secures the filter
• A single latch should be installed at each of the into the frame (see Fig. 4-24).
Repeat for the remaining latches.
consists of two (2) rows of three (3) knockouts.
should be used for filters with a 13/16" single
header in combination with a nominal 2"
prefilter. The second set of knockouts should
be used for nominal 4" filters.

3. The latch installation is now complete. The
latch should now be “trapped” within the three
(3) knockouts (see Fig. 4-23).
LD010179
Fig. 4-24 – P
lace the end of the latch
over the filter frame, securing 4
the filter to the frame.
6. The filter should now be securely installed into

the frame.
LD010177
Fig. 4-23 – C
orrectly installed latch
P/N 315-004-000

FORM 102.20-NOM1 (909)
INSTALLATION OF SH SINGLE HEADERED

FILTERS
These instructions are for installing single header filter 4. Rotate all of the latches outward, and insert the
(typically AAF VariCel SH or DriPak 2000 filter) into SH filter into the frame. The bulk of the filter
AAF 16 ga. galvanized holding frames should be inserted through the frame, protruding
• Latches needed for these applications are four out the backside. Only the header of the filter
(4) AAF P/N 315-004-003, as shown in Fig. should be contacting the flange of the frame.
4--20. 5. After the filter has been placed into the frame,
• A single latch should be installed at each of the grasp the circular end of the latch and rotate it
four (4) corners of the frame. across the corner of the filter.
• The latch fits into the set of knockouts, which Push the end of the latch towards the filter, until
consists of two (2) rows of three (3) knockouts. the latch catches beneath the knockout on the
The row of knockouts closest to the gasketing frame.
should be used for nominal 1" filters or filters Repeat for the remaining latches.
with a 13/16" single header. The second set
of knockouts should be used for nominal 2" 6. The filter should now be securely installed into
filters. the frame (see Fig. 4-25).

3. The latch installation should now be complete.
three (3) knockouts, but should be able to freely
rotate.
Repeat the installation process with the
remaining latches.

FORM 102.20-NOM1 (909)
INSTALLATION OF A 2" PREFILTER IN COMBINATION

WITH A SINGLE HEADER FINAL FILTER
These instructions are for installing a 2" prefilter, 2. Using a moderate amount of pressure, force the
(typically AAF PerfectPleat, Premium or Premium HM latch over the third knockout (See Fig. 4-21).
pleated filter) used in combination with a single header
final filter (typically AAF VariCel SH or DriPak 2000) After both filters have been placed into the
into AAF 16 ga. galvanized holding frames. frame, grasp the loose end of the latch and
place it over the prefilter frame, so that the latch
• Latches needed for this application are four (4) secures the prefilter to the SH filter. Repeat for
AAF P/N 315-004-000 and four (4) 315-004-003 the remaining latches.
as shown in Fig. 4-20.
4. The filters should now be securely installed into
the frame, as shown in Fig. 4-27.
Follow instructions for Single
Headered (SH) filters then proceed
with this procedure for 2" Pre-fil-
ters.
1. Insert the straight end of the latch (P/N 315-004-

000) between the two (2) knockouts furthest
from the corner.
LD010160
4
Fig. 4-27 – Fully installed filters
LD010496
Fig. 4-26 – install latch p//n 315-004-000

FORM 102.20-NOM1 (909)
INSTALLATION OF A VARICEL DH DOUBLE

HEADERED FILTER
These instructions are for the installation of an AAF 4. Repeat the latch installation with the remaining
VariCel DH filter (nominal 12" deep double header) latches. Note the orientation of the latch to the
into AAF 16 ga. galvanized holding frames. knockouts in Fig. 4-29.
• The latches needed for this application are four
(4) spring latches, AAF P/N 315-004-001 (as
shown in Fig. 4-20).
• Two latches should be attached on each side of
the filter frame.
latch to the filter. See Fig. 4-28 for the sets of
knockouts that should be used for the latches.
LD010154
Fig. 4-29 – C
configuration.
After the latches have been installed, the frame

should be configured like that shown in Fig.
4-30.
DO NOT USE
LD010150
Fig. 4-28 – CORRECT USE OF KNOCKOUTS

3. The latch installation should now be complete.
three (3) knockouts.
LD010183
Fig. 4-30 – Frame with 4 latches installed.

FORM 102.20-NOM1 (909)
The frame contains 2 latches per side, INSTALLATION OF A 2" & 4" PREFILTER IN
none on the top or bottom. COMBINATION WITH A DOUBLE HEADER FINAL
FILTER
These instructions are for installing either a 2" or 4"
prefilter (typically AAF PerfectPleat, Premium or
Premium HM pleated filters) used in combination with
an AAF VariCel DH (nominal 12" deep) final filter into
5 Insert the VariCel DH filter into the frame. While AAF 16 ga. galvanized holding frames.
holding the filter in the frame, grasp the loop on • Two sets of latches are needed for these
the end of the latch and pull it until it stretches applications. Four (4) spring latches, AAF P/N
over the header and rests into the pre-drilled 315-004-001 are used to hold the VariCel DH
hole in the header of the filter (see Fig. 4-31). into the frame. In addition, four (4) prefilter
Repeat this with the remaining latches. latches, AAF P/N 315-003-002 are used to hold
the 2" and P/N 315-003-004 are used to hold
6. The filter should now be securely installed into
the 4" prefilter onto the face of the VariCel DH
the frame.
filter.
• For the spring latches, two (2) latches should be
attached on each side of the filter frame.
latch to the filter.

LD010184
4
Fig. 4-31 – S
pring latch should be pulled 3. The latch installation should now be complete.
and fastened in hole in the The latch should now be “trapped” within the 3
header of the filter. knockouts (see Fig. 4-32).
LD010154
Fig. 4-32 – C
configuration. P/N 315-004-001

FORM 102.20-NOM1 (909)
4. Repeat the latch installation with the remaining

latches; note the orientation of the latch to the
knockouts on Fig. 4-32.
5. Insert the VariCel DH filter into the frame. While
holding the filter in the frame, grasp the loop on
the end of the latch and pull it until it stretches
over the header and rests into the pre-drilled
hole in the header of the filter (see Fig. 4-33).
Repeat this with the remaining latches.
LD010163
Fig. 4-34 – P
refilter latch after
Installation onto filter
header.
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. 4-35, to allow the
LD010156
proper placement of the prefilter.
Fig. 4-33 – Frame with 4 latches installed
Installation of Prefilter Latches
6. To install the prefilter latches, slide the end of

the latch with the 180 ° turn, over the edge of the
header, as shown in Fig. 4-34. The latch should
be installed at the approximate midpoint of the
filter leg.
The prefilter latch should be slid over the header
as shown in Fig. 4-34.
LD010165
Fig. 4-35 – P
osition prefilter in front of
the final filter.
(2" w/315-003-002 latch shown)

FORM 102.20-NOM1 (909)
9. Grasp the end of the prefilter latch and “spring”

it so that it fits over the edge of the prefilter.
Repeat with the remaining latches.
After all remaining prefilter latches have been
placed around the prefilter, the finished assembly
should look like that in Fig. 4-37.
LD010190 LD010167
Fig. 4-36 – S
pring the end of the latch so Fig. 4-37 – Completed assembly
that it fits over the edge of
the Prefilter. (4" w/315-003-004
latch shown)

FORM 102.20-NOM1 (909)
VISUAL CONTROL FILTER CLAMPS FOR HEPA FILTERS

YORK 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. 4-26, 4-27 and 4-28 for application)
029-22082 Latch, HEPA Double 11-1/2"
Application: Holds one Astrocel I 11.5" D filter along frame middle. (See Fig. 4-39, 4-40 and 4-41 for application)
HEPA FILTERS VISUAL CONTROL FILTER CLAMPS

WELDED BEVEL SEAL FRAME (See Fig. 4-39.)
EXTRUDED ALUMINUM FRAMES FOR
GASKETED HEPA FILTER INSTALLATIONS HEPA FILTER APPLICATIONS
The Bevel Seal frame is a factory welded, extruded Visual Control clamps are designed for use with any
aluminum frame developed specifically for High conventional gasketed HEPA filter. Located at midpoint
Efficiency Particulate Air (HEPA) filter installations. of each filter edge, the calibrated spring-loaded clamps
Standard Bevel Seal frames accommodate multiple maintain up to 100 pounds pressure against the filter at
sizes of gasketed HEPA filters 11-1/2" deep. (See Fig. each clamping point. Four clamps are used per filter to
4-38, 4-40, & 4-41.) assure uniform pressure against the gasket. The clamps
have a 1-1/2" wide bearing surface.
TWO STAGE GASKET COMPRESSION
PREVENTS LEAKAGE EASY CLAMP INSTALLATION
The Bevel Seal frame features a two level sealing No special tools are required for proper clamp
surface connected by a bevel. This causes the filter installation. Just tighten the bolt head until it is
gasket to be compressed in two stages as clamping flush with the clamp face to achieve the prescribed
pressure is applied. The outer edge of the gasket is compression. Proper clamping pressure is created
compressed to a greater degree than the inner portion of indefinitely by the calibrated spring.
the gasket. (See Fig. 4-41.)
Single filter clamps are used around the perimeter of the
In the event excessive clamping pres- frame bank. Double clamps are used along main runners
to secure a filter on either side of the T-section. (See
sure is applied, the individual cells in
Fig. 4-38, 4-39 & 4-40.)
the gasket material can be fractured
causing the gasket to relax, allowing 11-1/2"
ASTROCEL
leakage. HCX
SINGLE
MAIN RUNNER PERIMETER EXTRUSION FILTER RED
CLAMPS
(PERIMETER)
2"
DOUBLE SILVER
FILTER
2" 2" CLAMPS
T-SECTION PERIMETER SECTION - (T. SECTION)
TYPE H LD06647A
FIG. 4-38 – HEPA FILTER FRAME LD06648-1
CROSS SECTION VIEW

FIG. 4-39 – VISUAL CONTROL FILTER CLAMPS

FORM 102.20-NOM1 (909)
DOUBLE T-SECTIONS
FILTER
CLAMP
DOUBLE PERIMETER
FILTER SECTION
CLAMPS
T-SECTION
SINGLE FILTER CLAMP
LD09657
FIG. 4-40 – HEPA FILTER INSTALLATION 4

WITH CLAMP)
SPRING
DUCTWORK
AIRFLOW
BEVEL SEAL
CELL SIDE
FRAME
(PERIMETER
EXTRUSION)
MEDIA PACK
BEVEL SEAL FRAME
GASKET BEVEL
RECESSED SEALING
CELL SIDE SURFACE
FIG. 4-41 – WELDED BEVEL SEAL FILTER INSTALLATION

FORM 102.20-NOM1 (909)
ECONOMIZER SEGMENT (DAMPERS) CLEANING PROCEDURE
Perform cleaning of dehumidification

Prior to occupancy, test ventilation coils at least once a year or when air
system to ensure that outdoor air pressure drop exceeds 125% of de-
dampers operate properly in accor- sign.
dance with the system design. IAQ
IAQ
1. Cover electrical components such as fan motors,

CLEANING OF DAMPERS
damper motors, compressors, thermostats, etc.
Cleaning of dampers should be performed before with plastic. Care should be taken on interior
operation is hindered in any way. Maintenance coil cleaning. Remove filters; cover fan bearings
personnel must determine when cleaning is necessary and any insulation to keep these items free of
based on observation and operation. water damage. Condensate drain piping should
be screened to allow coil-cleaning water to flow
Do not use lubricants. YORK suggests freely. Screening keeps traps and drain lines
from clogging with debris washed from the
cleaning with contact cleaner or 50/50
coils.
H²O/alcohol solution. Consult proper
building personnel to ensure above 2. Prior to any application of wet cleaning materials,
solution will not harm personnel or use a wide soft bristle paint brush to dust off any
equipment. heavy dust, leaves, bugs or other foreign matter
that may be on the coil fin surface.
HARDWARE CHECK
Make sure all linkage parts, actuators and, mounting Safety glasses should be worn when
brackets are secure. cleaning coils.
COIL SEGMENT
COIL CLEANING PROCEDURE
SUGGESTED TOOLS, EQUIPMENT & MATERIALS LIST
3. When possible, remove dirt lodged in the depth
• Pressure washer that does not exceed 2000 of the coil by using clean oil-free air under
PSI. pressure. Caution should be taken not to use
extreme high-pressure air as this may cause fin
• Sprayer (utility garden, etc.) applicator. surface damage. Direct the air straight at the
• Plastic sheeting. openings between the fins and never at an angle,
which may bend the fins against one another.
• Duct tape. Always apply the air from the air leaving side
• Screening. of the coil.
• Coil cleaner (safe, commercial grade, 4. On heavily soiled coils, use a safe commercial
disinfecting). grade coil cleaner.
• Garden hose.
Follow the safety and mixing instruc-
• Garden hose spray nozzle.
tions as noted on or with the cleaning
• Rags. agent.
• Pail.
• Trash bags.
• Power cords.
• Four inch paintbrush.
FORM 102.20-NOM1 (909)
5. Spray the cleaning agent on both sides of the CONDENSATE DRAIN PAN, TRAP AND DRAIN
coil to be cleaned. Allow the cleaning agent LINE CLEANING PROCEDURE
to remain in contact with the dirty surface for
about 5 minutes or as recommended by the agent Clean condensate drain pan, trap,
instructions. Then flush the coil with clean water drain line and adjacent wetted sur-
from a hose (with spray nozzle or from pressure faces at least once per year or as often
washer). Flush from the air leaving side of
as required to retard growth of micro-
the coil. Caution should be taken, as extreme IAQ bial substances.
water pressure may result in fin surface damage.
Direct the water straight at the openings between
Testing of Drain Pans - To minimize
the fins and never at an angle, which may bend
the fins against one another. This process will conditions of water stagnation that
wash away surface dirt on the air entering side may result in microbial growth, drain
of the coil, and prevent it from loading within pans shall be field-tested under normal
IAQ operating conditions to ensure proper
the depth of the coil.
drainage.
6. Most cleaners are concentrated detergents and
can be diluted with up to 10 parts of water.
Exception: Field testing of drain pans
Dilute as per cleaning agent instructions and coil is not required if units with factory-
condition. Re-spray both sides of the coil with installed drain pans have been certi-
cleaner. Allow to stand 5 minutes and flush as fied (attested in writing) by the manu-
described previously. Finish flushing from both facturer for proper drainage when
sides of the coil. installed as recommended.
TOOLS AND MATERIALS

Follow cleaning agent instructions.
Agent should meet environmental and • Toilet bowl brush or similar utility cleaning
OSHA standards. brush.
• Cleaning agent (safe, commercial grade,
disinfecting).
• Rags. 4
7 Some extreme oil and dirt conditions may
require steam cleaning. Most steam equipment • Trash bags.
can be adjusted to provide a mixture of water • Garden hose with spray nozzle or power
and steam at a moderate pressure. Steam alone washer.
without the presence of water does not work
well with most cleaning agents. Cleaning the • Scraper.
coils with steam should be done as described • Screening.
previously.
• Wet vacuum.
8. Comb out any bent or flattened areas of fin
surface.
9. Restore equipment to operational state.

FORM 102.20-NOM1 (909)
CLEANING PROCEDURE FREEZE PROTECTION

All chilled water, hot water and steam coils can be
1. Cover any nearby components such as motors,
damaged during freezing weather. Pre-cautionary
control devices or wiring.
measures must be taken to prevent freezing such as:
2. Sweep, gather and remove debris from drain • For all year operation, glycol and other antifreeze
pan, auxiliary pans and splash guards. solution must be circulated.
3. Scrape loose and remove any clinging • During winter operation and shutdowns such
substances. as power failure, night shutdown and weekend
4. Cover drain pan outlet with screening to prevent shutdown, the controls must be installed so
drain clogging. the valves will go to the full heat position,
and all fresh air dampers go to the full closed
5. Prepare cleaning agent per manufacturer’s position. The water circulation pumps must
instructions. keep circulating water through the coils and/
6. Apply cleaning agent with spray applicator or or auxiliary heat must be maintained inside the
brush. YORK Solution unit cabinet.
7. Apply cleaner to ALL surfaces including: • Draining each coil and related piping such as
underside of coil, header and return bends if in traps and making sure that all low areas also
air stream, coil supports, coil wall or bulkhead, drain.
auxiliary drain pans, splash guards, any other • After draining, flush coils with an antifreeze
surfaces subject to wetting by condensation solution such as propylene glycol. A solution
dripping or carried by normal airflow, drain pan of 50% glycol and 50% water will protect from
and outlet. freezing to approximately 35°F below zero at sea
8. Add ample amount of cleaning agent to drain level. Use adequate mixture for the geographic
line and trap. area of the installation.
9. Allow cleaner to stand for time required by

manufacturer’s instructions. WINTERIZING DRAIN TRAPS
During the winter months when the cooling system is
10. Flush with clean water from pressure washer or turned off and the unit is exposed to freezing conditions,
garden hose with spray nozzle. an antifreeze solution, which is environmentally
11. Apply as much water under pressure as possible friendly and safe for the roof can be poured in the
to drain outlet to clean trap and drain line. condensate drain trap to prevent freezing and possible
damage. The condensate drain trap may also be
12. Remove water from any puddle areas with wet removed as well as heat traced and insulated.
vacuum.
13. Wipe down if necessary to remove any stubborn
material.
14. Restore equipment to operational state.

FORM 102.20-NOM1 (909)
ENERGY RECOVERY WHEEL

TOOLS
• Brushes.
• Loctite.
• Screwdrivers.
MATERIALS
• Acti-Klean, Granger stock # 5W402. or alkaline
LD09659
detergent. FIG. 4-42 – R

INSE SEGMENTS WITH CLEAN
WATER
CLEANING
Some staining of the desiccant may
The need for periodic cleaning of the remain and is not harmful to perfor-
Energy Recovery Wheel will be a func- mance.
tion of operating schedule, climate and
contaminates in the indoor air being
IAQ exhausted and outdoor air being sup-
plied to the building. Do not use acid based cleaners, aro-
matic solvents, steam or temperatures
WHEEL in excess of 170°F: damage to wheel
• To clean, gain access to the Energy Recovery may occur!
Wheel and remove the segments (see Section 5
“Replacing Wheel Segments”). ►
ADJUSTMENT OF AIR SEALS
• Brush or vacuum foreign material from the face
off the wheel. Four adjustable diameter seals are provided on each
cassette to minimize transfer of air between the counter
• Wash the segments in a 5% solution of non-acid flowing airstreams (see Fig. 4-43).
based coil cleaner (see material list above) or 4
alkaline detergent and warm water.
• Allow segments to soak in solution until grease
and tar deposits are loosened. An overnight soak ROTATION
may be required to adequately loosen heavy
deposits of tar and oil based contaminants.
Before removing from solution, rapidly run
TO REMOVE
finger across surface of segment to separate DIAMETER
polymer strips for better cleaning action. Rinse SEAL
dirty solution from segment with clean water
(see Fig. 4-42) and allow excess water to drain
prior to remounting segments in the wheel (see
Section 5, “Replacing Wheel Segments”). ► A TO ADJUST
small amount of water remaining in the wheel
will be dried out by the airflow.
DIAMETER SEAL
ADJUSTING SCREWS FEELER
GAGE
LD09644
FIG. 4-43 – DIAMETER SEAL ADJUSTMENT

FORM 102.20-NOM1 (909)
WHEEL
ROTATION
BEARING SUPPORT
BEAM - PULLEY SIDE
BALL
BEARINGS (2)
BEARING ACCESS
COVER (2)

- MOTOR SIDE

BELT
FIG. 4-44 – ENERGY RECOVERY WHEEL, BEARING SUPPORT BEAM SIDE
• To adjust diameter seals, loosen diameter seal • The wheel drive pulley is secured to the drive
adjusting screws and move diameter seal away motor shaft by a combination of either a key or
from wheel surface. D slot and setscrew. The setscrew is secured
with removable locktite to prevent loosening.
• Rotate wheel clockwise until two opposing
Annually confirm setscrew is secure.
spokes are hidden behind the bearing support
beam (see Fig. 4-44). • The wheel drive belt is a urethane stretch belt
designed to provide constant tension through
• Using a folded piece of paper as a feeler gage,
the life of the belt. No adjustment is required.
position paper between the wheel surface and
Inspect the drive belt annually for proper
diameter seals. Adjust seals towards wheel
tracking and tension. A properly tensioned belt
surface until a slight friction on the feeler gage
will turn the wheel immediately after power is
(paper) is detected when gauge is moved along
applied with no visible slippage during start-
the length of the spoke.
up.
• Retighten adjusting screws and recheck
clearance with “feeler” gage.
If slippage is detected, replace wheel
drive belt as soon as possible. A non-
WHEEL DRIVE COMPONENTS rotating wheel in the active air stream
• The wheel drive motor bearings are pre- is likely to become clogged. Contact
lubricated and no further lubrication is local Johnson Controls Service to
necessary. order replacement belt. See Section 5
“Belt Replacement” for Energy Re-
covery Wheel drive belt replacement
procedure. ►

MAINTENANCE RECOMMENDATIONS FOR SOLUTION AIR HANDLER
(Includes suggested IAQ minimums for ASHRAE Std. 62-2001 Compliance)
PROCEDURE MONTHLY QUARTERLY YEARLY OTHER
johnson controls
Clean exterior of air handler cabinet. As Needed
Inspect doors, handles, latches and hinges for proper operation. X
Inspect door gaskets for damage and proper seal. X
Inspect panels for damage. X
Inspect air hoods and air louvers for damage and debris. 6 months
Inspect bird screens for damage and debris. 6 months
Inspect bird screens for damage, dirt and debris. 6 months
Clean fan segment and fan assembly (supply, return, exhaust). X
Check fan housing, wheel, shaft, frame, inlet vanes and bearings for damage, wear, loose parts, dirt and debris. X
Check fan base, vibration isolators and thrust restraints for damage, wear, loose parts, dirt and debris. X
Check flex connector for damage and wear. X
Check the cleanliness of the filters and replace or clean as required. X See IOM Tables
Check filter frames (filter tracks) for residual contaminates and clean as necessary. X
Verify filter gauge and/or switch function properly. X
Check drive kit for damage, loose parts, wear, dirt, alignment and belt tension. X
Check belt tension. X
Lubricate fan bearings. (Ball Bearing-Table 4-2, Roller Bearing-Table 4-3, Split Pillow Block-Table 4-4) See IOM Tables
Check condition of extended lubrication lines when present. X
Clean variable inlet vanes. X
Check adjustable fan motor base and mounting hardware for loose parts. X
Check adjustable fan motor base for damage. X
FIG. 4-45 – MAINTENANCE REQUIREMENTS FOR YORK SOLUTION HANDLER

Check fan motor for leaky bearing seals. X
Check fan for motor damage. X
Clean dampers. X
Check for dirt, dust & debris in air vents on fan motor housing. X
Clean dehumidification coils. X
Clean condensate drain pan, trap, drain line and adjacent wetted surfaces. X
Check, clean and calibrate controls. 6 months
Check Energy Recovery Wheel, clean media, adjust seals, replace belt As Needed
1.
For operating and maintenance requirements listed above, refer to appropriate service literature, or contact your local YORK Service Office.
2.
This procedure must be performed at the specified time interval by a Qualified Technician. A record must be maintained should proof of adequate maintenance be required for warranty validation.
3.
4-33
FORM 102.20-NOM1 (909)
More frequent maintenance may be required depending on actual operating conditions.

Form 102.20-MR1 (503)
4
FORM 102.20-NOM1 (909)

FORM 102.20-NOM1 (909)
5.0 service and Repair
Rotating parts and electrical shock SERVICE TOOLS AND EQUIPMENT

hazards exist. Lock out and tag out
• Complete set of mechanics hand tools.
the fan motor(s) and heat power
• Observation mirror.
disconnects before servicing. FOL- • Fin comb (straightener).
LOW THE LATEST “LOCKOUT • Heat gun.
TAGOUT” PROCEDURE. Failure • Straightedge.
to follow proper safety precautions • Tachometer.
may result in serious injury or death. • Manometers capable of .01" To 36" combined.
Refer to general safety guidelines and • Digital Manometer (replaces Magnehelic
safety symbols located at the front of Gauge).
this Manual. ► Digital Manometer
Cat. #475-1 FM-AV
Always replace RED metal tab on Series: 475-1 Mark III
access doors that provide access to Range: 0 to 19.99 In. W.C.
moving parts. This mechanical pro- Dwyer Instruments, Inc.
tection from moving parts is required • Pitot Tube.
by UL-1995. • Duct hood.
Always replace RED metal tab on • Velometer.
access doors that provide access to • Psychrometer.
pressurized areas. This mechanical • Combustion Efficiency Analyzer.
protection is to prevent accidental • Standard refrigeration gauges/manifold.
release of access doors under positive • Refrigerant re-claimer.
pressure. • Refrigerant leak detector.
• Vacuum pump.
• Gas torches (soldering and/or brazing).
Do not weld or use torches on the ex-
• Fire extinguisher.
terior or interior of the unit housing.
• Electronic Temperature Meter with a minimum
The housing contains polyurethane
of 3 Leads.
insulation, which when under com-
• Meg-ohm Meter.
bustion will produce harmful, toxic
• Phase Meter.
gases resulting in personal injury or • Capacitor Analyzer.
death. • Clamp on ammeter.
• Multi-meter or meters capable of reading the
DO NOT PENETRATE WIREWAYS following:
in any manner. These sheet metal – One thousand volts AC/DC.
channels, which run along the top
5
– Amperes.
panel, contain electrical wires and – Ohms.
connections. Electrical shock and/or – Millivolts.
damage to the unit may result. – Milliamps.
– Microfarad.
Never use silicone caulk/sealant or

Service & Repair
FORM 102.20-NOM1 (909)
SERVICE INFORMATION
All necessary tags and decals to aid in service or to While differences in temperature and humidity may
indicate caution areas are provided. Electrical wiring cause air movement, it may be considered very slight
diagrams are attached to the control panel access door. in comparison to the positive circulation required in
Installation, operation and maintenance manuals are an air conditioning system. To accomplish this air
supplied with each unit. movement, a fan has two functions to perform:
The YORK Solution offers unlimited unit access with • Produce sufficient pressure or head to accelerate
completely removable panels. All of the unit panels, the mass of air from a state of rest to the required
including the top panels can be completely removed. velocity.
The removal of top panels allows the use of overhead • Produce sufficient pressure to overcome any
cranes and gantries in removing and servicing of resistances to the flow of air.
components. Fan and filter segments come equipped
with doors as a standard feature. The determination of these pressures is a very important
part of troubleshooting an air conditioning system. The
TROUBLESHOOTING generally accepted standard instrument for measuring
these unit pressures is the Pitot Tube (see Fig's 5-1 &
An HVAC air system includes the air handling unit and 5-2). The Pitot Tube is used in conjunction with an
the entire air circuitry through which airflows. Included Inclined Manometer, Magnehelic Gauge, or a Tube
in the system are such components as ductwork, fittings, Manometer.
branch ducts, dampers, heat exchangers, filters, sound
traps, coils, elbows, diffusers, grilles, VAV's, MIT's When the Pitot Tube is used in conjunction with these
and other items through which airflows or which offer instruments, one is able to read velocity pressure (Vp),
obstruction to airflow. static pressure (SP), and total pressure (Tp) within the
system.
STATIC TUBE
0.02" DIAMETER HOLES
DRILLED THRU OUTSIDE IMPACT
TUBE INTO ANNULAR TUBE
SPACE.
8" x "D" 8" x "D"
D
LD06362-1
SOLDER
FIG. 5-1 – CONSTRUCTION OF PITOT TUBE

FORM 102.20-NOM1 (909)
27926B
FIG. 5-3 – INCLINED MANOMETER
MINIHELIC FILTER GAUGE

The Minihelic Filter Gauge is a diaphragm-operated
gage that has several advantages over a liquid
LD06363
manometer.
Unless extreme accuracy is required, this instrument

FIG. 5-2 – PITOT TUBE may replace the manometer for average air conditioning
work, and like the manometer, is available in a variety
of ranges. The dial is only 2 inches in diameter and
PITOT TUBE therefore has a limited scale; several instruments are
The Pitot consists of an impact tube within a larger required to cover the normal ranges encountered in
static tube. When the impact tube is pointed directly average air conditioning jobs (see Fig. 5-4).
into the air stream, the small static pressure holes are
perpendicular to the air stream and are not affected by The Minihelic Filter Gauge should be factory-installed
air velocity (see Fig. 5-2). level. Adjust indicator to zero with no airflow or press.
diff. across the sensors. Adjustment screw is located at
To read velocity pressure, the total pressure tap at the bottom behind of the plastic cover. When airflow
the end of the Pitot Tube is connected to one leg of a is initiated, the indicator should move to the right. If it
manometer and the static pressure tap at the other leg moves in the opposite direction, reverse the tubes.
of the manometer (see Fig. 5-3).
5
INCLINED MANOMETER
This instrument, is a simple, foolproof device, which
responds directly to the air pressure exerted against it
(transmitted from the Pitot Tube), and reads directly in
inches of water. Ranges for these instruments vary, and
the technician should have one or more instruments
to cover the range of 0 to 8 inches of water (see Fig.
5-3).
Before using the Inclined Manometer, ensure the

instrument is level and then adjust the meniscus to the LD11693
zero mark. The adjustment knob is located at the base
of the fluid reservoir. FIG. 5-4 – MINIHELIC FILTER GAUGE

Service & Repair
FORM 102.20-NOM1 (909)
“U” TUBE MANOMETER

Pressure is defined as force per unit area - and the best The U-tube Manometer is a primary standard because
way to measure air pressure is to balance a column of the difference in height between the two columns is
liquid of known weight against the air pressure and always a true indication of the pressure regardless of
measure the height of liquid columns so balanced. The variations in the internal diameter of the tubing.
units of measure commonly used are: inches of mercury
(in. Hg.), using mercury as the fluid; and inches of For use on all YORK air units, the manometers should
water (in. WG), using water or oil as the fluid. cover at least a 26 inch range (see Fig. 5-6).
Instruments employing this principle are called

manometers. The simplest form is the basic and well-
known U-tube Manometers (see Fig. 5-5). This device
indicates the difference between two pressures or
between a single pressure and atmosphere, when one
side is open to atmosphere.
If a U-tube is filled to the halfway point with water and

air pressure is exerted on one of the columns, the fluid
will be displaced. Thus, one leg of water column will
rise and the other falls. The difference in height “h”
which is the sum of the readings above and below the
halfway point indicated the pressure in inches of water
column.
27928B
FIG. 5-6 – SLACK-TUBE MANOMETER
PRESSURE VACUUM
4 4 4
3 3 3
2 2 2
1 1 1
0 0 0
1 1 h 1 h
2 2 2
3 3 3
4 4 4
LD06364-1
FIG. 5-5 – “U” TUBE MANOMETERS

FORM 102.20-NOM1 (909)
DUCT PRESSURES AND HOW THEY

WORK
VELOCITY
Velocity pressure and static pressure change in the
When air moves at a given velocity in a duct it creates a
ductwork with every change in the duct configuration,
pressure corresponding to the velocity; this is a measure
but the total pressure, on the other hand, remains
of the kinetic energy in the fluid and it is known as the
constant. Hence, as the velocity pressure decreases,
velocity pressure (Vp). Velocity pressure is always
the static pressure increases and vice versa, because
exerted in the direction of airflow. The relationship
the static pressure is always the difference between
between the velocity and the velocity pressure may be
total pressure and the velocity pressure. It should be
expressed by the following formulas:
remembered, however, that in an actual duct system, the
internal friction would cause a loss of total pressure.
( )
2
V
Vp =
4005
The static pressure in an exhaust system is always
V= 4005 Vp
below atmospheric pressure, and it is customary among
ventilation engineers to omit the minus sign affecting
the static (gage pressure). These men know, of course,
It is therefore a simple matter to determine the velocity
that the total pressure is higher than the static pressure
(FPM) of an air stream so the Vp can be measured. For
by the amount of the velocity pressure.
example, if a Pitot Tube Manometer hook-up reads
0.250 inches water, we substitute for the previous
When the unit is designed for connection to a duct
equation:
system and the installing contractor assembles ducts,
4005 0.250 = 2002 FPM elbows, registers, grilles, etc. to the outlet and/or
inlet of the unit, the static pressure drop through this
external ductwork is called external static pressure
STATIC PRESSURE
(see Fig. 5-7).
Independent of its velocity, air, when confined within
an enclosure such as a duct or tank, will exert itself Fans selected must be capable of moving the
perpendicularly to the walls of the enclosure. This desired airflow through the entire air moving system
is the compressive pressure existing in a fluid, and it including the unit (internal SP) and the duct system
is known as the static pressure (SP). Unlike velocity (external SP).
pressure, which is always positive, static pressure
when it is above atmospheric pressure will be positive
but when below atmospheric pressure it will be
negative. The discharge side of a fan in an air system
will read a positive pressure, the inlet side will read a
negative or minus pressure.
EXTERNAL
STATIC
TOTAL PRESSURE PRESSURE
5
Static pressure is exerted whether air is at rest or in
motion. The algebraic sum of static pressure and velocity
pressure gives the total pressure (Tp). Therefore:
Vp = TP – SP
The manometer does not sense the actual velocity INTERNAL STATIC
pressure directly but by using the Pitot Tube hook-up PRESSURE
with the static opening connected to the low pressure LD06365-1
side of the gauge, and the total pressure opening
connected to the high pressure side of the gauge, the
FIG. 5-7 – STATIC PRESSURE - AIR SYSTEM
manometer will read the difference between the two,
or the velocity pressure.

Service & Repair
FORM 102.20-NOM1 (909)
At a given flow rate the internal pressure losses plus • The most important item is to provide a detailed
the external static pressure losses equal the system explanation of the problem.
static pressure or the summation static pressure.
• An orifice is the best method of measuring flow
in piping. This is also true in an air system.
These pressures are of great importance when
troubleshooting for causes of reduced capacity,
vibration and noise. Changes in the cross sectional area
of a duct (contractions or enlargements) cause changes COMPONENT REPLACEMENT,
in the velocity of the air flowing through the duct. ADJUSTMENT & REPAIR
When the velocity decreases, the velocity pressure also

Disconnect or disable electric motor
decreases. Some of the velocity energy is lost because and lock out.
of the design of the duct where the area changes. Some
of the velocity energy is converted into static pressure
energy in the continuing ductwork. This conversion
of velocity energy to static pressure is called static
regain.
FAN REPLACEMENT & ADJUSTMENT
TROUBLE SHOOTING TIPS
TOOLS REQUIRED
For further assistance in troubleshooting the YORK
Solution unit, refer to “Troubleshooting Tips” Table • Standard mechanic’s and electricians hand
5-8. ► tools.
• Cordless screwdriver.
REQUESTING ASSISTANCE
• Hex head socket set.
When contacting Johnson Controls for assistance the
• Socket extension.
following information will be required:
• YORK Order No.
• Job name (not contractor). MATERIALS REQUIRED
Correct parts for the application (see Form 102.20-
• Unit Model No.
RP1). ►
• Customer’s Unit Identification.
PROCEDURE
• Design data and actual data.
– Fan RPM. 1. Remove unit side panel.
– Unit SP (across fan).– Unit CFM.

If unit is not high enough to work from
– Pressure drop of water across cooling coil side, remove top panel (see IOM Sec-
(PSIG). tion 5, “Panel Replacement”). ►
– Air pressure drop across cooling coil (inches
of water).
2. Remove flex connector parts.
– Temperature differential across cooling coil.
3. Remove belts.
– Motor voltage.
4. Remove sheave.
– Motor amperes.
5. Remove fan hold down bolts.
• For fan or motor RPM, use a tachometer,
stroboscope or revolution counter. 6. Remove fan from fan base.
• The voltage and amperes can be obtained by 7. Remove skid, crates and packaging material
using the appropriate multimeter test device. carefully from new fan.
• A sketch of the duct configuration would assist
us in trying to resolve the problem.
FORM 102.20-NOM1 (909)
8. Move the new fan to the final mounting FAN REPAIR

position.
TOOLS REQUIRED
9. Place the new fan on mounting structure.
• Standard mechanic’s and electricians hand
Carefully level fan using shims as required at all
tools.
mounting hole locations. Bolt down the fan.
• Allen torque wrenches.
10. Reinstall flex connector parts.
• Cordless screwdriver.
11. Reinstall sheave and belts.
• Emery cloth.
12. Perform sheave alignment (see Section 4 of this
IOM). ► • Rubber mallet or brass bar.
13. Check and adjust belt tension (see Section 4 • Flat file.
“Belts” of this IOM for checking belt tension
• Nail set.
► and Section 4 “Adjustable Motor Base
Operation” ► and “Sheave Alignment” for belt
tension adjustment). ► MATERIALS REQUIRED
14. Start up fan (see Section 3 “Start-Up” of this Correct parts for the application (see Form 102.20-
IOM). ► RP1). ►
15. Perform dynamic balance (see Section 4 of this
IOM). ► FORWARD CURVED FAN WHEEL REPLACEMENT
The forward curved fan wheel must be removed
through the fan discharge opening. The location of
Fan variations are shown in Fig. hubs, fan wheel, and shaft must be marked so each
5-8. of these components can be reassembled in the same
location (see Fig. 5-9). This will preserve the balance
of the rotating assembly. Proceed with the following
steps:
MARK ON
CLAMP AND FAN HUB
ROTATION
SHAFT
BACKWARD INCLINED BACKWARD

AIRFOIL (BIA) AIRFOIL (BAF)
SETSCREW
KEY
5
LD09661
FIG. 5-9 – FC FAN SHAFT AND WHEEL MARKING
BACKWARD FORWARD
1. Disconnect all ductwork or guards attached
CURVED CURVED to the blower housing to permit unobstructed
LD6350-2
access.
2. Remove the cut off plate attached at the discharge
FIG. 5-8 – TYPES OF CENTRIFUGAL FAN IMPELLERS
or blast area of the blower housing.

Service & Repair
FORM 102.20-NOM1 (909)
3. Thoroughly clean the shaft of all grease and c) Reassemble in reverse order, center the
rust inhibitor. Be careful not to contaminate the wheel between the edges of the inlet cones.
bearing grease. Use emery cloth to remove all If bearings were removed or replaced, be
rust or the wheel may become “locked” to the sure to reuse any shim stock found between
shaft. the mounting support/plate and bearing
housings.
4. Loosen and remove setscrews on both bearing
locking collars. Inspect and, if necessary, d) Torque all hardware (see table 5-1).
replace.
9. Dynamic rebalancing the fan assembly is
5. Loosen and remove setscrews from both sides recommended.
of the wheel hub. Inspect and, if necessary,
replace.
Refer to AMCA Publication 410-90
6. Using a rubber mallet or brass bar, slowly drive
“Recommended Safety Practices” for
the shaft in one direction until the setscrew
users and installers of industrial and
marks on the shaft are fully exposed. File the
marks completely smooth. Drive the shaft in the commercial fans.
opposite direction and file smooth the setscrew
marks. Continue to clean the shaft of all dirt and These procedures must be followed
residuals. to protect personnel and include
isolating the fan from any electrical
7. To remove the key, use a rubber mallet or brass
bar to drive the shaft and wheel in one direction. supply.
Drive the key in the opposite direction using a
nail set or smaller size key stock until the key is Service should only be performed by
completely free of the wheel. Be sure that key experienced and trained personnel.
does not get bent by allowing it to ride up the key
way edge. The slightest bend will prevent quick AIRFOIL FAN WHEEL REPLACEMENT
assembly. Should this occur, replace the key The airfoil wheels can be removed from the side of
stock with a key of the same size and length. the fan housing by removing one or both unit side
8. Remove the shaft, supporting the weight of the panels. It is possible to remove the fan wheel through
wheel, particularly for larger diameter wheels. the fan discharge opening.
Do not allow the weight of the shaft to be
supported by one bearing as you disassemble.
a) Remove the wheel through the discharge or
outlet area of the blower housing.
b) File the setscrew marks on the key until
smooth.
TABLE 5-1 – TORQUE FOR TIGHTENING SET

SCREWS
HEX MIN. RECOMMENDED
WRENCH TORQUE
SETSCREW
SIZE
DIA.
ACROSS INCH LBS. FOOT LBS.
FLATS
1/4 1/8 66 - 85 5.5 - 7.08
5/16 5/32 126 - 164 10.5 - 13.7
3/8 3/16 228 - 296 19.0 - 24.7
LD06356-1
7/16 7/32 348 - 452 29.0 - 35.7
1/2 1/4 504 - 655 42.0 - 54.6
FIG. 5-10 – AIRFOIL WITH CONE ASSEMBLY
5/8 5/16 1104 - 1435 92.0 - 119.6

FORM 102.20-NOM1 (909)
The first step in the removal of the fan wheel is to

remove the inlet cone from the side of the fan from
which the wheel is to be removed from the unit. If the BEARING SUPPORT
wheel is to be removed from the fan discharge, one of BRACKETS (3)
the inlet cones must be removed from the side of the SET SCREWS (2)
housing since the cones nest inside the blower wheel
NUTS (3 or 4)
(see Fig. 5-10). The remaining steps for removing
the assembly are the same as those provided in the
instructions for removing the forward curved fans. BOLTS
LOCKING (3 or 4)
COLLAR
Dynamic rebalancing the fan assembly is SEALED BEARING
recommended.
RUBBER
FAN BEARING REPLACEMENT MOUNTING
GROMMET
SEALED BEARINGS
LD09662
TOOLS REQUIRED FIG. 5-11 – SEALED BEARING
• Standard mechanic’s hand tools. 4. Clean shaft until it is shiny from bearings to ends
• Medium flat file. of shaft.
• Torque wrench, 0 to 250 in.-lb. range. 5. File any burrs or set screw impressions from
shaft.
• Hex (Allen) socket set for torque wrench.
6. Partially disassemble the bearing support
• Plastic or brass hammer. brackets by removing the bolts closest to the
• Brass bar or pipe of proper size. bearings on the bearing support brackets.
Depending on fan size, there are either 3 or 4
• Slings or jack to support larger wheels/shafts. bolts with nuts and “ Locktite”.
7. Remove the setscrews from the bearing locking
MATERIAL REQUIRED collars (two on one side of each bearing,
90 degrees apart). Inspect and, if necessary,
• Exact replacement bearings (always in pairs). replace.
• Steel wool, fine sanding cloth or fine emery 8. Pull each bearing with its rubber mounting
cloth. grommet, out of the bearing support brackets
• Blocking or temporary support for fan wheel/ as much as possible.
shaft. 9. Remove bearings. If a bearing will not move,
• Red “Locktite” or equivalent. shine the shaft behind the bearing and bump
the bearing toward the fan wheel. Use plastic 5
hammer, brass bar or brass pipe. Then de-burr
PROCEDURE and shine the shaft where the bearing was
previously located. Finally, pull the bearing
See Fig. 5-11 off.
1. Remove belts (see Section 4, “Adjustable Motor
10. If the bearing sticks while pulling it off, don’t
Base Operation”). ►
force it. Clean, shine and de-burr the shaft where
2. Remove sheave and key (see Section 5, “Sheave ever necessary.
Replacement and Adjustment”). ►
11. Make sure the shaft is straight and not worn at
3. Support fan wheel/shaft with cribbing, slings or the bearing location.
jacks.
12. With the shaft and bearings clean, slide the new
bearings onto the shaft with the setscrews facing
away from the fan wheel.

Service & Repair
FORM 102.20-NOM1 (909)
13. Reassemble the new bearings with rubber • Slings or jack to support larger wheels/shafts.
mounting grommets gently into the support
• Quarter inch drill bit.
brackets.
14. Remove any temporary supports or blocking of MATERIAL REQUIRED
fan wheel/shaft.
• Exact replacement bearings (always in pairs).
15. Apply red “Locktite” or similar product to bolts
and re-install them with nuts in the bearing • Steel wool, fine sanding cloth or fine emery
support brackets. Be sure the bearings are cloth.
seated in the brackets and not twisted. Tighten • Blocking or temporary support for fan wheel/
to appropriate torque rating. shaft.
16. Slide the shaft in or out of the new bearings to • Grease (see Section 4 or paperwork supplied
center the wheel between the inlet cones on both with new bearings). ►
sides of the fan. This is not critical, however
should be adjusted as close as possible by feeling • Quarter inch roll pins (1 on each small bearing,
the gaps with the fingertips. 2 on each large bearing).
17. Install the setscrews in the drive side bearing but Our standard is to use standard pil-
only tighten lightly. low block bearings with setscrew type
18. Spin the fan wheel by hand to insure no rubbing locking collars. If the fan bearings
will occur. Readjust if necessary. have separate eccentric type lock-
ing collars (see Fig. 5-13), refer to
19. Install setscrews in opposite side bearing and
tighten all setscrews to correct torque rating (see special instruction “FAN BEARING
Table 5-1). ► REPLACEMENT-ECCENTRIC
LOCKING COLLAR” elsewhere in
Alternate tightening of setscrews: this section. ►
Step 1. Tighten “A” to ½ recom-
mended torque value. ABOUT THIS DEVICE
Step 2. Tighten “B” to recom- These bearings can be found mounted in various
mended torque value. positions, over or under a horizontal support or on
Step 3. Tighten “A” to recom- either side of a vertical support.
mended torque value.
20. Re-install sheave and belts (see related Set
instructions in Sections 4 ► ► and 5 ► as Screws
Lube
needed). Fitting
21. Dynamically rebalancing the fan assembly is

recommended. Seal Lock
Ring
STANDARD PILLOW BLOCK BEARINGS
TOOLS REQUIRED
• Standard mechanic’s hand tools.

• Medium flat file.
Pillow
Inner
• Torque wrench, 0 to 250 in.-lb. range. Race
Block
Outer
• Hex (Allen) socket set for torque wrench. Race
00418AVIP
• Plastic or brass hammer. FIG. 5-12 – B

EARING WITH SETSCREW TYPE
LOCKING DEVICE
• Brass bar or pipe of proper size.

FORM 102.20-NOM1 (909)
PROCEDURE 16. Install the setscrews in the drive side bearing but
only tighten lightly.
See Fig. 5-12
1. Remove belts (see Section 4, “Adjustable Motor 17. Spin the fan wheel by hand to insure no rubbing
Base Operation”). ► will occur. Readjust if necessary. If the wheel
rubs even though it is centered between the inlet
2. Remove sheave and key. cones, adjust by sliding bearing housing(s) on
3. Support fan wheel/shaft with cribbing, slings or bearing support(s) until the wheel is spaced evenly
jacks. at both inlet cones all around its circumference.
4. Clean shaft until it is shiny from bearings to ends 18. Install setscrews in opposite side bearing and
of shaft. tighten all setscrews to correct torque rating (see
Table 5-1). ►
5. File any burrs or set screw impressions from
shaft. 19. Drill and pin the bearings to the bearing supports.
Use ¼" drill bit and ¼" roll pins. Apply in the area
6. Remove bolts holding bearings to bearing of the bolting flange on the housing base.
supports. Be sure to save any shims found
between bearing housing and bearing support for
re-use. Alternate tightening of setscrews:
7. Remove setscrews from bearing locking collars Step 1. Tighten “A” to ½ recom-
(two on one side of each bearing, 90 degrees mended torque value.
apart). Inspect and, if necessary, replace. Step 2. Tighten “B” to recommended
8. Remove bearings. If a bearing will not move, torque value.
shine the shaft behind the bearing and bump Step 3. Tighten “A” to recommended
the bearing toward the fan wheel. Use plastic torque value.
hammer, brass bar or brass pipe. Then de-burr and
shine the shaft where the bearing was previously
located. Finally, pull the bearing off. 20. Re-install sheave and belts (see related instructions
in Sections 4 ► ►and 5 ► as needed).
9. If the bearing sticks while pulling it off, don’t force
it. Clean, shine and de-burr the shaft where ever 21. Ensure bearings are properly lubricated (see
necessary. Section 4). ►
10. Make sure the shaft is straight and not worn at the 22. Dynamically rebalancing the fan assembly is
bearing location. recommended.
bearings onto the shaft with the setscrews facing A lock pin is inserted through the lubri-
away from the fan wheel. cation port on the “Sealmaster” brand
12. Reassemble bolts, flat washers, lock washers, bearing housing to prevent the bearing
nuts and any shims found exactly as they were from spinning inside the housing. If a 5
originally installed. There should be a flat washer grease fitting (lube fitting) must be
under the bolt head and under the lock washer. added or changed on bearings that
13. Lightly tighten each bolt so bearing position can utilize a lock pin under the fitting, it is
be adjusted at each bearing. important that the lock pin is in place
when the fitting is installed. If an
14. Remove any temporary supports or blocking of
adapter or grease fitting of improper
fan wheel/shaft.
style or length is used, the lock pin may
15. Slide the shaft in or out of the new bearings to be either too tight or loose and can af-
center the wheel between the inlet cones on both fect the alignment and re-lubrication
sides of the fan. This is not critical, however it of the bearing.
should be adjusted as close as possible by feeling
the gaps between the cones and the edge of the
wheel with the fingertips.
Service & Repair
FORM 102.20-NOM1 (909)
PILLOW BLOCK BEARINGS WITH ECCENTRIC

LOCKING COLLAR
See Fig. 5-13 and 5-14
SEAL ASSEMBLY
OUTER RING RECESSED CAM OR SELF-
LOCKING COLLAR
INNER RING
SELF LOCKING COLLAR
BALLS AND RACEWAY

CAM OR INNER RING
LD06357
FIG. 5-13 – BEARING WITH ECCENTRIC CAM

TOOLS REQUIRED
• Standard mechanic’s hand tools. Do not apply excessive force to the

bearing housing (pillow block or
• Medium flat file. flange) when installing the bearing on
• Torque wrench, 0 to 250 in.-lb. range. the shaft.
• Plastic or brass hammer.
• Slings or jack to support larger wheels/shafts.
• Center punch.
MATERIAL REQUIRED

• Steel wool, fine sanding cloth or fine emery
cloth.
• Blocking or temporary support for fan wheel/
shaft.
• Grease (see Section 4 or paperwork supplied
with new bearings). ►
LD06358
• Quarter inch roll pins (1 on each small bearing,
2 on each large bearing).
FIG. 5-14 – B
EARING INSTALLATION –
ECCENTRIC LOCKING COLLAR
ABOUT THIS DEVICE
An eccentric locking collar is engaged to a cam on the

PROCEDURE
bearing inner ring. Driven in the normal direction of
shaft rotation, it grips the shaft with a positive binding See Fig's 5-13 & 5-14.
action (see Fig. 5-14). 1. Remove belts (see Section 4, “Adjustable Motor
These bearings can be found mounted in various
positions, over or under a horizontal support or on 2. Remove sheave and key.
either side of a vertical support.
FORM 102.20-NOM1 (909)
3. Support fan wheel/shaft with cribbing, slings or 17. Slide the shaft in or out of the new bearings to
jacks. center the fan wheel between the inlet cones on
both sides of the fan housing. This is not critical,
4. Clean shaft until it is shiny from the bearings to
however should be adjusted as close as possible
ends of shaft.
by feeling the gaps between the cones and the
5. File any burrs or other impressions from the edge of the fan wheel with the fingertips.
shaft.
18. Spin the fan wheel by hand to insure no rubbing
6. Remove the setscrew from each eccentric locking will occur. Readjust if necessary. If the fan
collar. Inspect and, if necessary, replace. wheel rubs even though it is centered between
the inlet cones, adjust by sliding bearing
7. To remove the eccentric locking collars
housing(s) on bearing support(s) until the wheel
(self-locking collar). Hold a center punch in
is spaced evenly at both inlet cones all around
the drilled recess on the outer surface of the
its circumference.
eccentric locking collar. Position the punch to
drive the eccentric locking collar in the opposite 19. Tighten all bearing mounting bolts at this
direction of normal shaft rotation. time.
8. Give a sharp blow to the punch and the collar 20. Place each eccentric locking collar (self-locking
will release. Remove each eccentric locking collar) on the shaft with its cam adjacent to the
collar in the same manner. machined cam of the bearing inner ring. Rotate
the eccentric locking collar until it fits over
9. Remove bolts holding bearings to bearing
the machined cam of the inner ring (see Fig.
supports. Be sure to save any shims found
5-14).
between bearing housing and bearing support
for re-use. 21. Holding the eccentric locking collar against the
shoulder of the machined inner ring, rotate the
10. Remove old bearings. If a bearing will not
eccentric locking collar in the normal direction
move, shine the shaft behind the bearing and
of shaft rotation. The eccentric locking collar
bump the bearing toward the fan wheel. Use
will grip the shaft as the cams engage. Rotate
plastic hammer, brass bar or brass pipe. Then
until firmly hand tight.
de-burr and shine the shaft where the bearing
was previously located. Finally pull the bearing 22. Hold a center punch in the drilled recess on the
off. outer surface of the eccentric locking collar.
Position the punch to drive the eccentric locking
11. If a bearing sticks while pulling it off, don’t force
collar in the same direction as normal shaft
it. Clean, shine and de-burr the shaft where ever
rotation.
necessary.
23. Lightly tap the center punch to lock the eccentric
12. Make sure the shaft is straight and not worn at
locking collar in the same direction as shaft
the bearing location.
rotation.
24. Install the setscrew in each eccentric locking
bearings onto the shaft with the machined cam of
collar and tighten to the correct torque rating
5
the inner ring facing away from the fan wheel.
(see Table 5-1). ►
14. Reassemble bolts, flat washers, lock washers,
25. Drill and pin the bearings to the bearing supports.
nuts and any shims found exactly as they were
Use ¼" drill bit and ¼” roll pins. Apply in the
originally installed. There should be a flat
area of the bolting flange on the housing base
washer under the bolt head and under the lock
washer. Replace the lock washers if they have 26. Re-install sheave and belts (see related
taken a set making them nearly flat. instructions in Sections 4 ► ►and 5 ► as
needed).
15. Lightly tighten each bolt so bearing position can
be adjusted at each bearing. 27. Ensure bearings are properly lubricated (see
Section 4). ►
16. Remove any temporary supports or blocking of
fan wheel/shaft. 28 Dynamically rebalancing the fan assembly is
recommended.
Service & Repair
FORM 102.20-NOM1 (909)
A lock pin is inserted through the lubri- ABOUT THIS DEVICE

cation port on the “Sealmaster” brand This instruction is for the complete split pillow block
bearing housing to prevent the bearing bearing assembly replacement. If it is not necessary
from spinning inside the housing. If to replace the undamaged housing, eliminate the steps
a grease fitting (lube fitting) must be that follow for unbolting and bolting the base portion
added or changed on bearings that of the housing.
utilize a lock pin under the fitting, it is
important that the lock pin is in place The temporary supports for the fan wheel/shaft used
when the fitting is installed. If an during bearing replacement must be flexible, as the
assembly will have to be moved out of the base portion
adapter or grease fitting of improper
of the housing and back into it at some point during
style or length is used, the lock pin may this process.
be either too tight or loose and can af-
fect the alignment and re-lubrication These bearings can be found mounted in various
of the bearing. positions, over or under a horizontal support or on
either side of a vertical support.
SPLIT PILLOW BLOCK BEARINGS

8
TOOLS REQUIRED
1
6
• Medium flat file. 44
• Torque wrench, 20 to 300 ft.-lb. range. 5
9
• Plastic or brass hammer.
• Proper size spanner wrench.
• Slings or jack to support larger wheels/shafts.
7
1
MATERIAL REQUIRED
2 8
• Steel wool, fine sanding cloth or fine emery 6
cloth.
• Blocking or temporary support for fan wheel/ 1
5
shaft.
• Rags or paper shop towels. 3 7 LD09648
4
• Grease (see Section 4 or paperwork supplied
with new bearings). ► FIG. 5-15 – SPLIT BEARING
• Quarter inch roll pins (1 on each small bearing, 1. Seal (4) 6. Lock Washer
2. Housing Cap 7. Tapered Sleeve
2 on each large bearing).
3. Cap Bolts (2) 8. Bearing
4. Locating Ring (2) 9. Housing Base
5. Lock Nut

FORM 102.20-NOM1 (909)
PROCEDURE 3. Support fan wheel/shaft with cribbing, slings or

jacks.
See Fig. 5-15 & 5-16
1. Remove belts. (See Section 4, “Adjustable 4. Clean shaft until it is shiny from bearings to ends
Motor Base Operation”.) ► of shaft.
2. Remove sheave and key. 5. File any burrs or impressions from shaft.
Screw off the nut and remove the locking washer.
Turn the nut sufficiently to ensure that the shaft

makes proper contact (self-locking) with the
sleeve. Then turn the nut according to steps 34
and 35.
Wipe the preservative from the surfaces of the
sleeve and then oil the bore surface lightly. Use
a thin mineral oil.
NOTE: Then, reposition the spanner 180° and

tighten the nut a few degrees more by tapping
Open up the sleeve by inserting a screwdriver in the spanner handle lightly with a hammer.
the slit; then slide the sleeve along the shaft to
the correct position.
Wipe the preservative from the bearing and then Lock the nut by bending one of the locking
oil the surface lightly. Use a thin mineral oil. washer tabs down into one of the slots in the
nut. Do not bend it to the bottom of the slot.
5
Place the bearing on the sleeve. Place the

lockwasher and spacer (if provided) in position
and tighten the nut firmly. Check that the outer ring can be rotated easily
by hand.
LD09663
FIG. 5-16 – SPLIT BEARING ASSEMBLY

Service & Repair
FORM 102.20-NOM1 (909)
6. Remove the cap bolts from the split bearing Light oil applied to the sleeve out-
housing. side surface results in easier bearing
7. Remove bearing housing cap. Tapping side- mounting and removal.
ways with hammer may be necessary.
8. Move the supported wheel/shaft/bearing
assembly out of the housing base.
22. Mount the bearing on the tapered sleeve with
9. Remove bolts holding the housing base to the the large bore side first to match the taper of the
bearing support. Remove the housing. If the sleeve. Push the bearing on hand tight and as
housing is drilled and pinned to the support, pry straight as possible.
the pin from the support. Be sure to save any
shims found between the housing and bearing 23. With the bearing hanging freely on the shaft,
support for re-use. measure the UNMOUNTED, UNLOADED
radial clearance by inserting progressively larger
10. Install the new housing base to the bearing feeler blades the full length of the roller between
support with bolt, flat washers, new lock washer the bottom most unloaded roller and the outer
and nut. There should be a flat washer under the ring. RECORD THIS NUMBER.
bolt head and the lock washer. Make these hand
tight so bearing position can be adjusted at each 24. Apply the spacer, if provided, then the lock
bearing later in this process. washer as illustrated. Fit the tab on the inside
of the lock washer into a matching notch in the
11. Remove the bulk of the grease from the bearing tapered sleeve.
and parts remaining on the shaft.
25. Apply the locknut with the chamfered face
12. Find the bent lock washer tab inside one of the toward the lock washer. TIGHTEN BY HAND
slots in the lock nut. Bend it perpendicular to ONLY.
the shaft, in line with the other tabs of the lock
washer.
Apply lubricant on the face of the lock-
13. Hook proper size spanner wrench onto a slot in nut where it contacts the lock washer
the lock nut for counterclockwise rotation. for easier mounting and removal.
14. Strike the spanner handle sharply with a hammer
to break the nut free and remove the lock nut.
15. Remove the lock washer and spacer (if spacer
present). 26. Apply grease to the rubber seals and place one
in each new housing base already mounted.
16. Using a brass bar and hammer bump the bearing
off the tapered sleeve. 27. Insert the locating rings into the housing base
of the DRIVE SIDE BEARING HOUSING
17. Open the sleeve by inserting a screwdriver in ONLY. Leave these rings out of the opposite
the slit, and then slip it off the shaft. side bearing to allow for shaft thermal expansion
18. Make sure the shaft is straight and not worn at under load.
the bearing location. 28. At this time, bring the status of both inboard and
19. De-burr, shine and clean the shaft. outboard bearing assemblies to this same level
of completion.
20. Wipe preservative from tapered sleeve and
bearing bore. 29. Install the wheel/shaft/bearing assembly to the
new housing base. It may be necessary to slide
21. Place the tapered sleeve on the shaft with the bearing assemblies on the shaft to get both to
threaded end facing away from the fan wheel. line up with the proper cavity in the housings.
Position the tapered sleeve for approximate
location with respect to the required bearing 30. Center the wheel between the inlet cones on
centerline. both sides of the fan. This should be adjusted
as close as possible by feeling the gaps between
the cones and the edges of the wheel with your
fingertips.
FORM 102.20-NOM1 (909)
31. Spin the fan wheel slowly by hand to insure no 36. Lock the nut by bending one of the lock washer
rubbing will occur. Readjust if necessary. If the tabs downward into one of the slots in the
wheel rubs even though it is centered between locknut. Do not bend more than a 45° angle.
the inlet cones, adjust by sliding or shimming If one of the tabs does not line up with one of
bearing housing(s) on bearing support(s) until the slots, tighten the locknut until one does line
the wheel is spaced evenly at both inlet cones up. DO NOT LOOSEN THE LOCKNUT.
all around its circumference.
37. Using your fingers, pack each bearing with
32. Tighten the mounting bolts of the housing grease by pressing measures of grease into the
bases. rollers. Rotate the bearing and shaft to access
its entire circumference. Be sure to apply grease
33. Begin tightening the locknuts of each bearing
in this manner to both sides of each bearing so
assembly using spanner wrench and hammer.
that all of the rollers are embedded in grease
Stop to check that the wheel is still centered.
over their entire length.
34. While further tightening the locknuts, periodically
38. Insert the remaining, greased seals into the
stop to check the UNLOADED radial clearance.
groove in the housing caps and fill the space
Since the bearing is mounted and now resting
between the seal lips with grease.
in the housing, insert the feeler blades between
the TOP MOST UNLOADED ROLLER and 39. Install each housing cap onto its respective
the outer ring. Spin the wheel before each housing base. Apply cap bolts and tighten to
measurement to ensure the rollers are positioned correct torque value per Table 5-3.
properly. It may be necessary to lift the wheel/
TABLE 5-3 – RECOMMENDED CAP BOLT
shaft/bearing assembly off the housing to TORQUE VALUES FOR SPLIT
complete the tightening process. PILLOW BLOCK.
35. Continue tightening the lock nut until the CAP SCREW SIZE TORQUE VALUES
UNLOADED RADIAL CLEARANCE 10 mm 37
REDUCTION (difference between clearance 12 mm 59
measured in step #34 and step #23) is within 16 mm 110
the specifications listed in Table 5-2. 20 mm 148
TABLE 5-2 – RECOMMENDED CLEARANCE 24 mm 258
REDUCTION VALUES OF SKF
TAPERED BORE BEARINGS (IN
40. Drill and pin the bearings to the bearing supports.
INCHES)
Use ¼" drill bit and ¼" roll pins. Apply in the
REDUCTION IN RADIAL
BORE DIAMETER area of the bolting flange on the housing base.
INTERNAL CLEARANCE
D(MM)
(IN.) 41. Re-install sheave and belts (see related
Over Incl. Min. Max (1) instructions in Sections 4 ► ►and 5 ► as
24 30 0.0006 0.0008 needed).
30 40 0.0008 0.0010 42. Ensure bearings are properly lubricated (see 5
40 50 0.0010 0.0012 Section 4). ►
50 65 0.0012 0.0015
43. Dynamically rebalancing the fan assembly is
65 80 0.0015 0.0020 recommended.
80 100 0.0018 0.0025

Service & Repair
FORM 102.20-NOM1 (909)
SHEAVE REPLACEMENT AND • Reverse Mounted - Thread cap screws into

ADJUSTMENT threaded holes in bushing. Hand tighten
against sheave web.
FIXED PITCH SHEAVES
T.B. Woods with SURE GRIP ® bushings. 4. Tighten each cap screw gradually and evenly in
rotation to push the sheave off the taper of the
bushing. Light tapping with hammer may be
TOOLS REQUIRED
necessary.
• Standard mechanic’s hand tools. 5. Remove or loosen setscrew from flange of
• Medium flat file. bushing. Inspect and, if necessary, replace.
• Torque wrench, 0 to 250 in.-lb. range. 6. Pull bushing off shaft. If the bushing will not
come off, insert a screwdriver into the slit in the
• Hex (Allen) socket set for torque wrench. bushing.
• Torque wrench, 0 to 150 ft.-lb. range. 7. Remove key from keyway.
• Standard 3/8" or ½" socket set
SHEAVE INSTALLATION
• Hammer
See Fig. 5-17
MATERIAL REQUIRED
Do not use lubricants in this installa-
• Fine emery cloth. tion. Bushing and sheave mating
• Contact cleaner or mineral spirits surfaces must be clean and oil free.
FLANGE 1. Inspect the tapered bore of the sheave and the

GROOVE tapered surface of the bushing. Any paint, dirt,
KEYWAY SLIT
oil or grease MUST be removed.
WEB LOCKWASHERS
2. Select the type of mounting (Fig. 5-18 or 5-19)
TAPERED that best suits your application.
BORE
SETSCREW
(Not Shown) CAPSCREWS
TAPER
FLANGE
BUSHING SHEAVE
LD09664
LD05630 LD05631
FIG. 5-17 – INSERTION OF CAPSCREWS FIG. 5-18 – S

TANDARD FIG. 5-19 – R
EVERSE
MOUNTING MOUNTING
SHEAVE REMOVAL
Standard Mounting
See Fig. 5-17
1. Remove belts (see Section 4, “Adjustable Motor a) Install shaft key.
If key was furnished with bushing, you
2. Remove cap screws from bushing/sheave. must use that key.
3. Separate sheave from bushing.
• Standard Mounted - Thread cap screws into
threaded holes in sheave. Hand tighten against
bushing flange.

FORM 102.20-NOM1 (909)
b) Install bushing on clean shaft, flange end c) If using the setscrew, tighten it enough to
first. If bushing will not freely slide on the prevent the bushing from sliding on the
shaft, insert a screwdriver or similar object shaft.
into the flange sawcut to act as a wedge to
open bushings bore.
Do not tighten the setscrew to standard
torque values at this time.
Excessive wedging will split the bush-
ing.
d) Pull the sheave up on the bushing, aligning

c) If using the setscrew, tighten it just enough the drilled holes in the bushing flange with
to prevent the bushing from sliding on the the tapped holes in the sheave.
shaft.
e) Loosely thread the cap screws with lock
Do not tighten the setscrew to standard washers into the assembly. Do not use
torque values at this time. lubricant on the cap screws!
3. Using a torque wrench, tighten all cap screws

evenly and progressively in rotation to the
torque value in Table 5-4. There must be a gap
between the bushing flange and sheave hub when
d) Slide sheave into position on bushing, installation is complete. Do not over torque! Do
aligning the drill holes in the sheave with not attempt to close gap between bushing flange
the tapped holes in the bushing flange. and sheave hub!
e) Loosely thread the caps crews with lock TABLE 5-4 – CAPSCREW TORQUE VALUES
washers into the assembly. Do not use FOR FIXED PITCH SHEAVES.
lubricant on the cap screws! FT-LBS. TO APPLY
TAPERED SIZE & THREAD
WITH TORQUE
BUSHING OF CAPSCREW
WRENCH
Reverse Mounting
QT 1/4 X 1 9
a) With large end of the out, slide sheave onto JA No. 10-24 5
shaft as far as possible. Install shaft key. SH-SDS-SD 1/4-20 9
SK 5/16-18 15
If key was furnished with bushing, you SF 3/8-16 30
must use that key. E 1/2-13 60
F 9/16-12 110 5
J 5/8-11 135
The tightening force on the screws is

b) Install bushing onto shaft so tapered end will multiplied many times by the wedging
mate with sheave. action of the tapered surface. If ex-
treme tightening force is applied, or if
Excessive wedging will split the bush- a lubricant is used, bursting pressures
ing. will be created in the hub of the mating
part.
4. Tighten all setscrews per Table 5-1 “Torque for

Tightening Set Screws”. ►

Service & Repair
FORM 102.20-NOM1 (909)
SHEAVE ADJUSTMENT Material Required

Fine emery cloth.
1. Before belts are installed, check alignment as
described in Section 4.
Sheave Removal
2. If adjustment is required, measure the space See Fig. 5-20
between the straight edge and the sheave.
3. Follow steps 2 through 5 under “Sheave 1. Remove belts (see Section 4, “Adjustable Motor
Removal”. Base Operation”). ►
4. Move the bushing in the proper direction the 2. Loosen both clamp screws. (Allen wrench).
distance measured.
3. Clean and remove any burrs from shaft from
5. Proceed with “Sheave Installation” as listed sheave to end.
above.
4. Slide sheave off shaft. If tight, insert screwdriver
into slit in central sleeve.
ADJUSTABLE PITCH SHEAVES
T.B. WOODS MODEL JVS. Sheave Installation
Tools Required See Fig. 5-20
1. Loosen clamp screws on new sheave.
2. Slide the JVS sheave onto the shaft. The fan
• Medium flat file.
and motor sheaves should be placed on their
• Torque wrench, 0 to 250 in.-lb. range. respective shafts far enough to have shaft
exposed just past its chamfer is possible. This
is to facilitate proper alignment later in this
• Square. process.
• Straightedge.
The central sleeve of this sheave is split
STATIONARY FLANGE
at one end only. This end must be
CLAMP SCREW
installed first as the split allows the
sheave assembly to be secured to the
SLIP shaft.
KEYWAY
3. Adjust the sheave to the approximate pitch
diameter desired. One turn of the adjusting
screw will vary the pitch diameter .2 inches.
Seven turns are required to adjust the sheave
from minimum to maximum pitch diameter.
Slight finger pressure on the face of

CENTRAL the adjustable flanges near the split
SLEEVE
(180 ° from adjusting screw) may be
required to permit free and equal
movement of flanges during pitch
ADJUSTING SCREW adjustments. Tipping and binding
may otherwise occur.
ADJUSTABLE FLANGES
LD09665A
FIG. 5-20 – ADJUSTABLE PITCH SHEAVE (JVS)

FORM 102.20-NOM1 (909)
4. Align the sheave with the companion sheave T.B. WOODS MODEL FHP.
(see Section 4). ►
Tools Required
On adjustable sheaves of two or more • Standard mechanic’s hand tools.

grooves, if there is a difference of more • Medium flat file.
than 1/8" between the width of the
companion sheave and any adjustable • Torque wrench, 0 to 250 in.-lb. range.
pitch sheave, align per steps 5 through • Hex (Allen) socket set for torque wrench.
8.
• Square.
5. Alignment procedure for adjustable sheaves: • Straightedge.
• Use a square and straight edge to align the Material Required

center or stationary flange of the adjustable
sheave with the center flange of the companion Fine emery cloth.
sheave.
Sheave Removal
• Insure the shaft of the motor is parallel to the See Fig. 5-21
shaft of the fan.
1. Remove belts (see Section 4, “Adjustable Motor
6. Tighten the two clamp screws to the following 2. Loosen setscrews on adjustable flange(s) of
torque values: sheave. (Allen wrench)
a) JVS MODEL 130 - 160 in.-lbs. or 13 ft.-lbs. 3. Screw the adjustable flange(s) open to expose
b) All other JVS - 325 in.-lbs. or 27 ft.-lbs. and loosen the mounting setscrew in the central
sleeve over the key.
4. Clean and remove any burrs from shaft from
Be careful not to grasp flanges in such sheave to end.
a manner as to cock them while tight-
5. Slide sheave off shaft.
ening the clamp screws.
MOUNTING SETSCREW
ADJUSTABLE FLANGES
7. Install belts and properly tension (see Section

4). SETSCREW
8. Recheck alignment and speed.

KEYWAY
5
Sheave Adjustment
1. To adjust pitch diameter it is important to loosen
both clamp screws.
2. Remove belts.
3. Follow steps 3 through 8 in “Sheave
Installation”. CENTRAL
SLEEVE
STATIONARY FLANGE
LD09666
FIG. 5-21 – ADJUSTABLE PITCH SHEAVE (FHP)

Service & Repair
FORM 102.20-NOM1 (909)
Sheave Installation
See Fig. 5-21
1. Loosen setscrews on adjustable flange(s) of new 8. Secure the adjustable sheave to the shaft by
sheave (Allen wrench). tightening the setscrew over the key to the proper
torque value (see table 5-1). ►
2. Screw the adjustable flange(s) open to expose
and loosen the mounting setscrew in the central 9. Adjust the sheave flange(s) to the desired pitch
sleeve over the keyway. diameter. Each turn of the flange changes the
pitch diameter approximately .2 inches. Six turns
3. Inspect the shaft and key for any nicks and burrs.
are required to adjust the sheave from minimum
Remove same and clean shaft.
to maximum for “A” or “B” belts and seven turns
4. Insert key in keyway. for 5V belts.
5. Slide the new sheave onto the shaft with the
mounting setscrew over the key and toward the Both flanges of a 2-groove sheave
motor. MUST be adjusted evenly.
The fan and motor sheaves should be

placed on their respective shafts far
enough to have shaft exposed just past
10. Lock the adjustable flange(s) in position by
its chamfer if possible. This is to fa- tightening the setscrew(s) to the proper torque
cilitate ease of alignment later in this value (see Table 5-1). ►
process.
To prevent damage to central sleeve
6. Align the adjustable sheave’s stationary flange threads, the setscrews MUST be over
with the respective flange of the companion one of the flat areas of the central
sheave. (See Section 4 on sheave alignment.) sleeve. If the flange is not properly
►
locked, the sheave will fail rapidly.
On adjustable sheaves of two or more 11. Install belts and properly tension (see Section 4).
grooves, if there is a difference of more ►
than 1/8" between the width of the
12. Recheck alignment and speed.
companion sheave and any adjustable
pitch sheave, align per steps 7 through
10. Sheave Adjustment
1. Remove belts. (See Section 4, “Adjustable
7. Alignment procedure for multiple groove Motor Base Operation”.) ►
adjustable sheaves:
2. To adjust pitch diameter loosen setscrew(s) on
a) Use a square and straight edge to align the adjustable flange(s) of sheave.
center or stationary flange of the adjustable
sheave with the center flange of the companion 3. Follow steps 9 through 12 above.
sheave.
b) Insure the shaft of the motor is parallel to the
shaft of the fan.

FORM 102.20-NOM1 (909)
MOTOR REPLACEMENT 10. Check fan for proper rotation as described in

Start-Up Check List.
FAN MOTOR
TOOLS REQUIRED
• Motor Wire Connection Details
• Standard mechanic’s and electricians hand See Fig's 5-22 & 5-23
tools.
• Torque wrench, 0 to 250 in.-lb. range. All field wiring must conform to the
• Flat screwdriver socket for torque wrench. Use National Electrical Code (N.E.C.) and
with sizes 4, 6 & 8 connector. possible local codes that may be in
• Hex Allen sockets, 3/16" and 1/4" for torque addition to N.E.C.
wrench for larger size connectors.
MATERIAL REQUIRED
Wire insulation must be stripped in accordance with
• Correct size and quantity of insulated wire Table 5-5 for standard connectors. The wire insulation
connectors. on a properly installed wire must be inside the insulated
connector conductor port no less than 3/8". Apply the
• Correct size and quantity of flexible cable
flexible cable sleeves only to the motor wires and not
sleeves.
the power feed wires. Refer to Table 5-5 for sleeve
and connector part numbers and cable strip lengths.
PROCEDURE
Pressure screws must be secured at the torque value
1. Shut off motor power and lock out. corresponding to the wire size and connector size
shown in Table 5-6. The UL listing is for stranded
2. Disconnect and tag power wires at motor wire only, AL/CU 600V max.
terminals.
3. Loosen motor base-to-mounting-rail attaching
bolts.
4. Remove and set aside belts.
5. Remove motor bracket hold down bolts.
6. Remove motor pulley and set aside.
7. Remove motor.
LD13793
Connection box may have to be re-
moved from motor body in order to fit FIG. 5-22 – ASSEMBLY OF CONNECTORS
motor through doorway. Some ex- 5
treme cases may require removal of
door and frame as well (see Section 5,
“Door Replacement”). ►
8. Install new motor. Reassemble by reversing

steps 1 - 6. Be sure to reinstall multiple belts in
their original position. Use a complete new set
if required. Do not stretch belts over sheaves
(see Section 4 “Sheave Alignment” ► and belt
tensioning Section 4 “Belts”). ► LD09667
9. Reconnect motor leads and restore power. FIG. 5-23 – MOTOR WIRE CONNECTIONS

Service & Repair
FORM 102.20-NOM1 (909)
TABLE 5-5 – CONNECTORS & SLEEVES WITH STRIP LENGTHS

Wire Connector Flexible Cable Sleeve
Motor HP Strip
Voltage Part Number QTY Part Number QTY Length
200/208 1, 1.5, 2, 3 025-39042-001 3

200/208 5 025-39042-003 3
200/208 7.5 025-39043-001 4 025-39049-001 3 .689”
200/208 10 025-39043-001 4 025-39049-001 3 .689”
200/208 15 025-39043-001 3 025-39049-001 3 .689”
200/208 20 025-39043-001 3 025-39049-002 3 .875”
200/208 25 025-39044-002 3 025-39049-002 3 .875”
200/208 30 025-39044-002 3 025-39049-003 3 .875”
200/208 40 025-39044-002 3 025-39049-004 3 .875”
230/240 1, 1.5, 2, 3 025-39042-001 4
230/240 5, 7.5 025-39042-003 4
025-39042-003 1
230/240 10
025-39044-001 3 025-39049-001 3 .689”
230/240 15 025-39043-001 3 025-39049-001 3 .689”
230/240 20, 25 025-39043-001 3 025-39049-002 3 .875”
230/240 30, 40 025-39044-002 3 025-39049-003 3 .875”
230/240 50 025-39044-002 4 025-39049-004 3 .875”
460 1, 1.5, 2, 3, 5, 7.5 025-39042-001 6
460 10 025-39042-003 6
460 15 025-39042-003 6
460 20, 25, 30, 40 025-39043-001 6 025-39049-001 3 .689”
460 50 025-39043-001 6 025-39049-002 3 .875”
460 60, 75 025-39043-002 6 025-39049-003 3 .875”
460 100 025-39043-003 6 025-39049-004 3 .875”
TABLE 5-6 – TORQUE CHART - TIGHTENING MOTOR REPAIR

TORQUE IN INCH POUNDS TOOLS REQUIRED
WIRE CONNECTOR SIZE
Standard mechanic’s and electricians hand tools.
size 500 350 250 3/0 1/0 #4
4/0 250 250 250 MATERIALS REQUIRED
3/0 250 250 250 250
Correct parts for the application.
2/0 180 180 180 180 (See Form 102.20-RP1.) ►
1/0 180 180 180 180 180
#3-#1 150 150 150 150 150 Before replacing motor bearings, get
#4-#6 110 110 110 110 100 45 authorization of motor manufacturer's
#8 75 40 representative if within standard war-
#10-#14 35 35 ranty period or by Product Service if
within extended warranty period.

FORM 102.20-NOM1 (909)
COIL REPLACEMENT TOOLS REQUIRED

To determine if a coil has right or left connections, • Screw gun with #3 Phillips bit.
face the unit from the air inlet section (see Fig.
5-24). • Scraper.
• Broad, thin pry bar.
Always lightly flow dry nitrogen
• Power cords as required.
through tubing being brazed when in
refrigeration system. • Auxiliary lighting as required.
• Awl.
• Coil fin comb or fin straightener.
Inspect the coils for cleanliness. If necessary, hose the • Pipe wrenches of appropriate sizes.
coils down with a low pressure water hose or low-
pressure air. • Brazing/soldering equipment if DX coil.
• Refrigerant reclaim equipment if DX or
In no case should the piping joints be condenser coil.
heated for unsweating while refriger-
• Standard mechanics tool kit.
ant is within the coil. Dangerous pres-
sures and gases can result. • Lifting equipment (crane, fork lift, straps, dolly,
roof cart, etc.).
FAN SEctION
Right
ReAR
rIGht hAND (rh)
cOIL cONNEctION
LEFt hAND (Lh)

cOIL cONNEctION
rEtUrN AIr
OUtSIDE AIr
leFt
LD08004
INLEt SEctION
DrIVE hAND AND cOIL hAND DEtErMINED
By FAcING thE INLEt SEctION
FROnt LD08004
FIG. 5-24 – DETERMINING LEFT - OR RIGHT-HAND COIL CONNECTION / DRIVE SIDE

Service & Repair
FORM 102.20-NOM1 (909)
• Lifting lugs for large coils or difficult work 5. DO NOT STAND INSIDE DRAIN
locations. Lifting lugs can be ordered from PAN. IAQ EFFECTIVENESS WILL
Baltimore Parts. Contact BPC-Airside for part BE COMPROMISED.
number. Must provide number of rows deep in
order to obtain correct size lugs. IAQ
MATERIALS REQUIRED
6. Remove content of coil(s) safely in regard to
• Roof or floor protection materials. personnel and environment. Usually refrigerant
• Replacement gasket for coil mounting P/N 010- can be pumped into condenser, however if
02917-000. refrigerant remains in the coil being replaced,
reclaim it per procedures and licenses according
• Replacement screws for coil mounting P/N 021- to current, applicable laws.
12917-000.
7. Disconnect piping from coil(s).
• Replacement gasket for coil access panel P/N
028-11778-000. 8. Remove coil access panel.
• Replacement screws for coil access panel P/N • On outdoor units a removable panel is usually
021-17722-000. on opposite side of unit from pipe connections.
This panel is installed with a dry gasket in
• Replacement gasket for indoor coil panel P/N order to be removable. If other panels are to be
028-11960-000. removed, see Section 5 “Panel Replacement”
• Piping needs as required for specific for specific tools, material and procedures.
connections. ►
• Caulk, P/N 013-03317-050 or 013-03317-040 • On indoor units all panels are installed with a
for outdoor units with champagne paint. dry gasket in order to be removable.
• Heavy cardboard covering for coil fin surface. • If the panel on the piping side is to be removed
to access the coil, piping will have to be
• Duct tape. removed instead of just disconnected. The
reassembly procedure will also be slightly
different (see step 25 of this procedure).
•Cleaning materials including micro-
bial disinfectant. 9. Remove any components, devices or sensors
attached to coil, frame or intermediate drain pan.
This may include another coil.
IAQ
10. Remove any components, devices, sensors,
filters or frames as needed to access coil
mounting screws in bulkhead on air entering
PROCEDURE side of coil.
1. Shut down and lock out unit fan(s). 11. Remove coil mounting screws found securing
2. Shut off and lock out piping to coil(s). coil frame to bulkhead. Be sure coil will not tip
over.
3. For DX coils pump refrigerant into condenser,
valve off and lock out associated condenser 12. Remove and save rubber grommets from coil
components. connectors.
4. Lay down roof or floor protection material at 13. Remove any extended coil drain and vent piping
work areas. or fixtures.

FORM 102.20-NOM1 (909)
14. Large coils can be separated top and bottom by 27. Guide coil connectors through holes in panel
removing bolts from splice piece on coil end on piping side of unit. Stop short of the final
sheets and intermediate drain pan from coil air position.
leaving side.
28. Install rubber grommets onto coil connectors.
15. Large coils may be handled best with addition
29. Proceed to move coil guiding connectors and
of lifting lugs.
until coil is in final location.
16. Slide coil out of unit to cribbing, dolly, forklift,
30. Work the grommets into the holes around the
roof cart, etc.
coil connectors.
17. Install coil lifting lugs if applicable.
31. Make sure the coil is in the proper mounting
18. For crane lift use professionals who will rig coils position against the gasket on coil bulkhead.
without damage to coil frames or surfaces.
32. Reinstall screws to attach coil frame to
19. Take necessary precautions in moving heavy bulkhead.
objects across roof or flight over people and
33. Be sure coil and bulkhead will not allow air to
property.
bypass coil. Seal with caulk if necessary. This
20. Remove coil from workspace. material requires 3 hours to set.
34. Reinstall all components, sensors, frames, pans,
21. C
lean drain pan, all panels and filters, etc., which were removed previously
inside unit.
parts adjacent to coil area and
areas wetted by condensation. 35. Check alignment of coil connectors to existing
Use a microbial disinfectant and pipe connections. Coil connectors on copper
IAQ headers may be adjusted slightly by moving
cleaner or in combination (see
also Section 4 “Coil Cleaning carefully and gradually without causing damage
Procedure”). ► or leaks. This may be necessary because the
connectors may get bumped, pushed or pulled
slightly out of position.
22. Check gasket for coil mounting on coil bulkhead.
Replace if damaged. 36. Reconnect all piping, test for leaks and charge
systems.
23. Cover new coil fin surface on both sides of coil
with heavy cardboard or similar material to 37. Remove heavy cardboard or other material
protect from damage. previously installed on new coil as protection
for fins. Inspect fins for deformation and repair
24. Locate replacement coil at workspace. with a fin comb or fin straightener.
25. Slide coil into unit using caution not to damage 38. Check gasket for coil access panel, replaced if
coil supports, coil bulkhead, drain pan, etc. damaged.
26. If the panel on the piping side was removed to 39. Reinstall coil access panel. 5
access the coil, the procedure is the same except
reassembly will be in a slightly different order 40. Clean up inside and outside of unit. Especially
in regards to the panel. The coil will be placed check for screws or other sharp objects left on
in its final position and anchored; then the panel roof surface.
will be put on over the coil connectors. Before 41. Put unit back into operation per facility
fastening the panel in place, work the grommets requirements. Be sure if caulk was used, that
into the holes around the coil connectors. Then it has had time to set up to avoid creating air
fasten the panel in place. leaks.

Service & Repair
FORM 102.20-NOM1 (909)
DOOR REPLACEMENT
TOOLS REQUIRED 2. Before installing Door/Frame Assembly, remove
old gasket material from raceways and panels at
• Standard mechanic’s hand tools. mounting areas.
• Scraper. 3. Apply new gasket material to back of frame
• Spacers. along the outer edge. Use neoprene gasket, P/N
028-11873-010.
MATERIALS REQUIRED
• Correct parts for the application (see Form New door assemblies are provided with
102.20-RP1). ► plastic spacers to maintain proper
• Neoprene Gasket, P/N 028-11873-010 alignment.
PROCEDURE
See Fig. 5-25
1. To prevent damage during removal, close and
4. Install new door assembly with door closed and
latch doors. Remove as complete Door/Frame
latched with spacers in place.
Assemblies. On outdoor units, allow butyl tape
to properly release by removing Door/Frame 5 Then, install screws in hinge side of
Assembly slowly. Failure to do so may result doorframe.
in damage to frame.
6. Finally, install screws in top, bottom and latch
sides of doorframe. Once door assembly is
installed, remove plastic shipping spacers from
between door and doorframe.
7. Check operation of door with unit off.
8. Check for obvious air leakage with air unit in
operation.
LD14264
FIG. 5-25 – DOOR REPLACEMENT

FORM 102.20-NOM1 (909)
DOOR GASKET REPLACEMENT

This procedure tells how to replace foam gaskets onto
doors using a mitered corner (units mfg. before Jan.
2006) and a but corner joint (units mfg after door re-
design, Jan 2006).
TOOLS REQUIRED
• Scraper.
• Caulk gun.
MATERIALS REQUIRED
• Door gasket material (order by measuring exact
size of door panel height and width).
• One tube caulk (sealant), P/N 013-03317-050
aluminum gray or 013-03317-040 for outdoor
units with champagne paint.
LD09668
PROCEDURE GASKET
See Fig. 5-26 FIG. 5-26 – O

LD STYLE DOOR WITH MITERED
CORNER GASKET
REMOVE OLD GASKET
Using fingers or pliers, grasp the old gasket at a point INSTALL NEW MITERED GASKET (BEFORE JAN
near the center of any horizontal or vertical frame 2006)
component, and pull straight out of the frame, working 1. Cut the end of the gasket at an angle of 40°
from the center toward the corners. Repeat on each of through the top of foam to the stem (see Fig.
the four sides of the gasket. 5-27).
Do not start at a corner! Starting at a 2. Cut the stem back slightly so that the top of the
corner may cause a portion of the stem is flush with the base of the gasket, and the
gasket to tear away and remain inside barb end of the stem is cut back at a slight angle
(see Fig. 5-27).
the narrow groove in the aluminum
doorframe. Any such material must Cut the
the stem
stem back
backso so
be removed before the new gasket is that the
that the top
top of
of the
the stem
is flush
flush with
with the
the base
baseof of
installed. The old gasket MUST be the gasket, and and the
the barb
barb
COMPLETELY REMOVED. end ofof the
the stem
stem isiscut
cut 5
back at at aaslight
slightangle.
angle.
REMOVE SEALANT Gasket

Gasket
Flush
Flush
It is necessary to clean up any excess factory-applied Stem
corner sealant, which might prevent the new gasket
from laying flat on the doorframe. Use a flat, rigid
object such as a putty knife to scrape the surface of the Barb end
endisiscut
cutback
backatata aslight
slightangle
angle
frame where the new gasket will rest. Also, remove as baseof
from the base ofthe
thegasket.
gasket.
much sealant as possible from inside the groove so that LD12037A
the new gasket will seat properly.
FIG. 5-27 – CUTTING END OF GASKET

Service & Repair
FORM 102.20-NOM1 (909)
The first corner notching is done prior

Making the second
second cut
cut in
inthe
the gasket.
gasket.
to placement onto the door.
about 40
The cut should be about 40 degrees,
degrees, 2/3
2/3to
to3/4
3/4
of the
the way
way through
throughthethegasket.
gasket. The
The total
totalangle
angle
from
from the
the initial
initialcut
cutand
andthethesecond
secondcut
cutsould
souldbe
be
about 80 degrees +/-
about +/- 55degrees.
degrees.
• Measure in 6" (+/- 1.0") from the top of the

overlapping splice and mark the gasket where
the first cut is to be made (see Fig. 5-28).
LD12131A
FIG. 5-30 – MAKING SECOND CUT ON GASKET
6 inches
inches
• Turn the gasket over, open the notch, and cut
back the stem on both ends (see Fig. 5-31).
When starting,
starting, cut the end
end angle
anglefirst.
first.
Cut the
the first
first notch next.
next. TheThelength
lengthfrom
from
the top of the splice
splice to
to the
the first
first notch
notch
should be
be about
about6"
6"(+
(+/-/-1.0").
1.0").
LD12038A
FIG. 5-28 – MARKING GASKET FOR FIRST CUT Gasket stemcutback.
Gasket stem cutback.
Note: The
The stem
stemmust
must
be cut
cut back
backtotoallow
allow
• The first cut is about 2/3 to 3/4 of the way for a good
good corner
corner
through the gasket. The cut should be about
40 degrees (see Fig. 5-29).
LD12132A
Making the initial
initialcut
cutin
inthe
thegasket.
gasket.
location line
Using the location line as aa guide,
guide, FIG. 5-31 – CUT BACK STEM
cut about
about 2/3 to 3/4 of the way through
through the
the gasket.
gasket.
The cut should be
be about
about 4040 degrees.
degrees. 4. Apply the sealant to the area on the latch side
where the overlapping splice will be.
• The sealant must be in the groove and
surrounding area on the perimeter.
• The length of the sealant area is about 2" (see
Fig. 5-32).
LD12039A
FIG. 5-29 – MAKING FIRST CUT ON GASKET
• The second cut is about 2/3 to 3/4 of the way

through the gasket. The cut should be about
40 degrees. The total angle from the initial
and second cut should be about 80 degrees
+/- 5 degrees (see Fig. 5-30).
Sealant application in gasket joint
joint area.
area.
Sealant must be in in groove
groove and
andsurrounding
surrounding
area -- 2"
2" length.
length.
LD12133A
FIG. 5-32 – APPLY SEALANT TO OVERLAPPING

SPLICE AREA
FORM 102.20-NOM1 (909)
5. Apply sealant to the corner. 9. Fold the joint together and press the gasket into
place.
• Sealant needs to fill the gasket grooves 1 to
1-1/2" out from the corner.
• Sealant is also applied to the edge outside the Ensure that the mitered joint is com-
grooves. pletely closed, the two pieces are not
• A liberal amount is also applied on the inside offset, and it lays flat.
of the corner (see Fig. 5-33).
Note: DoDo not

not apply
apply sealant
sealanttotoall
all 10. Using a roller, press the gasket into the gasket
four corners
four corners at once. The
Thesealant
sealant
is to be applied
applied just
just prior
prior to placing groove within 6" of the next corner.
Corner application. the
sealantapplication.
Corner sealant gasket in
the gasket in the
the corner.
corner.
11. Using a pen, mark the location for cutting the
Note: fills
Note: Sealant fills next corner.
grooves 11to
to 111/2"
1/2"
out
out from
from the
the corner.
corner. • Line up the edge of the gasket with the edge
of the door.
is also
Sealant is alsoapplied
applied
to the
to the edge outside the • Mark the gasket (both on the inside and
A liberal amount is also
also
grooves.
applied on the
the inside
inside outside edge of the gasket material) where
of the corner.
the center of the miter joint on the aluminum
LD12134A doorframe perimeter is located (see Fig.
5-35).
FIG. 5-33 – APPLY SEALANT TO CORNER
Do not apply sealant to all four corners

at once. The sealant is to be applied
just prior to placing the gasket in the corner
Marking cut location for corner
corner.
up gasket
Line up gasketwith
with
edge of
of door,
door, mark
mark
gasket where
where center
centerof
of
6. Take the corner angle cut and place the end into miter
miter joint
joint is.
is.
the joint sealant.
(both on the inside
inside and
and
7. Press the gasket into the gasket groove, to the outside edge
edge of
of the
the
gasket material)
material)
corner, using a roller.
8. Insert sealant into the notched area (see Fig. LD12136A
5-34).
FIG. 5-35 – MARK LOCATION FOR CUTTING
NEXT CORNER 5
12. Notch gaskets, apply corner sealant and place
gaskets in remaining corners by repeating steps
3 through 10.
13. Roll the gasket to within six inches of the latch
side overlap.
Insert sealant
sealant into
into the
the notched
notched area.
area.
14. Lay the gasket next to the existing angle cut for
the overlap.
LD12135A
15. Using a pen, mark the top of the gasket about
1 to 2 mm longer than the top of the “in place”
FIG. 5-34 – P
LACE ANGLE CUT IN CORNER AND
APPLY SEALANT TO NOTCHED AREA
gasket.

Service & Repair
FORM 102.20-NOM1 (909)
16. Mark the bottom of the gasket about 1 to 2 mm Flush joints or gaps between pieces
longer than the base of the “in place” gasket (see are not acceptable (see Fig. 5-38 for
Fig. 5-36). correct overlap).
Gasket overlap --
Gasket must overlap
11 to
to 2 mm step
step
Marking cut location for Splice

Splice
LD12137A
FIG. 5-36 – MARK GASKET FOR OVERLAP

LOCATION LD12139A
FIG. 5-38 – O
VERLAP CUT PIECE WITH “IN
17. Cut the gasket at an angle using the two marks
PLACE” GASKET
as a guide.
18. Apply sealant to the splice area. 21. Apply sealant to the inside of the splice and
along the bottom of the gasket in the splice area
• Completely cover the cut edge of the “in (minimum of 1" to both sides of splice at the
place” gasket end. base). See Fig. 5-39.
• Fill the gasket groove on the perimeter and
surrounding area about 1" out from the base
of the “in place” gasket (see Fig. 5-37).
sure that
Make sure that sealant is
is applied
applied
to the
to the inside
inside of
of the
the splice and along
bottomof
bottom ofthe
thegasket
gasketin inthe
thesplice
splice area
area
(min of 1" to both
both sides splice at
sides of splice at base).
base).
Applying sealant
Applying sealant to
tosplice
splice area.
area. LD12140A
Note: Application
Note: Applicationtotosurface
surfacearea
area FIG. 5-39 – APPLY SEALANT TO SPLICE BASE
ofofgasket
gasketand
andextrusion.
extrusion.
LD12138A
FIG. 5-37 – APPLY SEALANT TO EDGE AND

AROUND “IN PLACE” GASKET
19. Assemble the joint by placing the cut piece onto

the “in place” gasket.
20. The cut piece of gasket must overlap by 1 to 2
mm.

FORM 102.20-NOM1 (909)
22. Inspect all corners for adequate sealant. The

inside of the corners must have sealant on the
gasket and door perimeter. Add sealant as Poor Corner - pulled
needed (see Fig. 5-40).
Note: rounded
appearance.
Corner of gasket
should be within
1/16" of the corner
of the door.
Gasket cannot overlap
the edge of the door.
cornermust
Inside corner must
have sealant
sealantshowing.
showing.
LD12141A
FIG. 5-40 – ENSURE ALL CORNERS HAVE

Poor corner - open.
ADEQUATE SEALANT
Angle cut too large.
23. Set door aside
In order to keep from creasing the gas-

kets, store the doors gasket to gasket.
LD12143A
FIG. 5-42 – INCORRECT MITERED FOAM

GASKET CORNER
24. Repeat steps to install gaskets on additional

doors. See Fig. 5-41 & 5-42 for examples of
correct and incorrect mitered foam gasket
corners.
Gasket Corner
Good Foam Gasket Corner
5
Gasket must
Gasket must not
not overlap
overlap
the edges of the
edges of the perimeter,
perimeter,
and point of gasket should
should extend
extend
out within
within 1/16"
1/16" (2mm) of point of
door perimeter.
LD12142A
FIG. 5-41 – C
ORRECT MITERED FOAM GASKET
CORNER

Service & Repair
FORM 102.20-NOM1 (909)
1/8”
Marking cut location for Splice

Splice
Cut in
in 1/8”
1/8” under
underthe
the
hard portion of the
gasket using
usingaashears.
shears. LD12247A
LD12137A
FIG. 5-43 – NEW STYLE DOOR WITH BUT FIG. 5-44 – C

UT IN 1/8" UNDER HARD PORTION
CORNER JOINT GASKET (Units OF GASKET.
Produced Jan 2006 through oct
2008)
INSTALL NEW GASKET ON DOOR PRODUCED

JAN 2006 THROUGH OCTOBER 2008)
1. Position the frame with the anti-compression leg

up.
2. Cut a piece of gasket that will fit between the
two verticals (+0, -2mm).
Turn the
the shears
shearsandand
snip off
off the
the hard
hard
portion of
portion of the
the gasket
At some point in time, the gasket may
LD12248A
come precut.
FIG. 5-45 – S
NIP OFF HARD PORTION OF
GASKET.
3. Remove 1/8" of the hard portion of the gasket,

on both ends (see Fig.’s 5-44 thru 5-46).
Turn the
the shears
shearsandand
snip off
off the
the hard
hard
portion of
portion of the
the gasket
LD12248A
FIG. 5-46 – FINISHED CUT

FORM 102.20-NOM1 (909)
4. Apply a continuous 1/8" diameter bead of sealant

along the gasket attachment leg from just inside Horizontal
(3/8 to 1/2") the vertical anti-compression leg in
one corner to the same location in the opposite
corner (see Fig. 5-47). 1/8” bead of
of sealant
sealant Vertical
The sealant can be applied to both Also apply

apply the
the
horizontals at the same time as long sealant about
about
Apply sealant
sealant from
from the
the edge
edgeofof 1/4” up the
the
as the gaskets are to be installed im- the vertical, out approx. 1-1/2”
1-1/2” vertical wall
mediately. onto the horizontal.
horizontal. Fill the
entire corner with
with sealant.
sealant.
LD12251A
FIG. 5-48 – APPLY SEALANT IN CORNERS

Apply a continuous
continuous
1/8”dia. bead
bead of
of sealant.
sealant.
6. Once the corner sealant is applied to both ends,
the gasket is attached to one corner (see Fig.
5-49), and rolled in place (see Fig. 5-50).
Vertical anti-compression
anti-compressionleg
leg Make sure that the gasket is completely
snapped in place or leakage will occur.
The horizontal gasket should extend
the entire width of the opening (+0,
LD12250A
-2 mm).
FIG. 5-47 – APPLY FIRST PIECE OF HORIZONTAL

GASKET
5. Apply sealant from the edge of the vertical, out

approximately 1-1/2" onto the horizontal. Make
sure to fill the entire corner with sealant. Also
apply sealant about 1/4" up the vertical wall (see
Fig. 5-48).
Apply sealant to the corners im-

mediately before the gasket is to be LD12252
installed. Do not apply sealant to all

FIG. 5-49 – ATTACH GASKET TO ONE CORNER
four corners at once. 5
LD12253
FIG. 5-50 – ROLL GASKET TO OTHER CORNER

Service & Repair
FORM 102.20-NOM1 (909)
7. Repeat steps 2 thru 6 for the other horizontal.

8. Vertical gaskets require cuts as close to 90
degrees as possible.
9. The hard portion of the vertical gasket does not
need to be cut back as in step 3.
At some point in time, the gasket may Apply sealant

sealant to
to
come precut. gasket end.
end.
LD12255A
10. Rough cut the gasket to approximately the same FIG. 5-52 – APPLY SEALANT END OF FIRST
length as the opening between the horizontal VERTICAL GASKET
frame pieces.
14. Place the vertical gasket about 1/4 to 1/2" from
11. Trim one end of the gasket to 90 degrees, per the horizontal gasket, align the attachment
step 8. pocket of the gasket over the gasket attachment
leg of the extrusion, and snap the last inch of
12. Apply sealant down the edge of the horizontal
the gasket into place. Push the vertical into the
gasket and fill the area out 1" between the anti-
side of the horizontal 1 to 2 mm. Sealant should
compression leg and the wall of the vertical (see
ooze from the joint (see Fig's 5-53 and 5-54).
Fig. 5-51).
1”
Apply
Apply sealant
down
down the
the edge
edge of
Fill area
areaout
out 1”
1”between
between Push the vertical
Push the verticalinto
into
the horizontal
the anti-compression
anti-compression leg
leg the side of
of the
the
gasket.
and the
the wall
wall of
of the
the horizontal 1 to
horizontal to 22 mm.
mm.
vertical
LD12256A
LD12254A
FIG. 5-53 – POSITION FIRST VERTICAL GASKET

FIG. 5-51 – APPLY SEALANT FOR FIRST
VERTICAL GASKET
13. Apply a modest amount of sealant to the gasket

end which was trimmed in step 11 (see Fig.
5-52).
Sealant should
shouldooze
ooze
from the joint.
joint.
LD12257A
FIG. 5-54 – GOOD VERTICAL TO HORIZONTAL

BUT JOINT
FORM 102.20-NOM1 (909)
15. Roll the gasket in place to within 5 to 6" from 16. Trim enough of the gasket off in order to allow
the opposite end. the tail end to fit inside the frame (see Fig.
5-56).
Make sure that the gasket is completely

snapped in place or leakage will occur
(see Fig. 5-55).
Trim enough
enough of of the
the
gasket end
endtoto allow
allow
the tail
tail end to fit
fit
inside the
the frame.
frame.
LD12259A
FIG. 5-56 – TRIM GASKET END
17. Lay the vertical gasket across the horizontal

gasket and place a mark 1 to 2 mm past the edge
of the horizontal gasket (see Fig. 5-57).
Roll the
the gasket
gasketininplace
placetoto
within 55 to 6”
within 6” of the opposite
end.
11 to
to 2 mm.
LD12260A
LD12258A
FIG. 5-57 – MARK VERTICAL GASKET
FIG. 5-55 – R
OLL GASKET TO WITHIN 5 TO 6" OF
OPPOSITE END 18. Trim the end of the gasket to 90 degrees, per 5
step 8.
19. Apply sealant down the edge of the horizontal
gasket and fill the area out 1" between the anti-
compression leg and the wall of the vertical (see
Fig. 5-51).

Service & Repair
FORM 102.20-NOM1 (909)
20. Place the vertical gasket about 1/4 to 1/2" from

the horizontal gasket, align the attachment
pocket of the gasket over the gasket attachment
leg of the extrusion, and snap the last inch of
the gasket into place. Push the vertical into the
side of the horizontal 1 to 2 mm. Sealant should
ooze from the joint (see Fig's 5-58 and 5-59).
Roll gasket
gasketinto
into place.
place.
LD12263A
FIG. 5-60 – R
OLL VERTICAL GASKET INTO
PLACE AND SECURE
Place thevertical
Place the verticalgasket
gasketabout
about1/4”
1/4”from
from the horizontal
the horizontal gasket.
gasket. Align Align
the the
attachment pocket of the gasket
attachment gasket over
over
the gasket attachment
attachment leg
leg of
of the
the
extrusion and snap
snapthe
thelast
lastinch
inchofofthe
the
gasket into
into place.
place.
LD12261A
FIG. 5-58 – POSITION VERTICAL GASKET
After securing
After cornerroll
securing corner roll
Sealant
Sealantshould
should ooze towards the opposite corner.
corner.
from the
from the joint.
joint.
LD12264A
FIG. 5-61 – R
OLL TOWARDS OPPOSITE END OF
VERTICAL GASKET
Push
Push the
the vertical gasket into
into 22. Using either a dry towel or one moistened in
the
the side of the horizontal mineral spirits; wipe the excess sealant from the
gasket
gasket11 to
to 2 mm. gasket and anti-compression leg area (see Fig.
LD12262A
5-62).
FIG. 5-59 – P
ROPER PLACEMENT OF VERTICAL
TO HORIZONTAL GASKET
21. Roll the gasket into place. Secure the corner first
as in Fig. 5-60 (roll into the corner). Once the
corner is secured, roll out towards the opposite
corner per Fig. 5-61.
Wipe away
away excess
excess
sealant from
from gasket.
gasket.
Wipe away
away excess
excesssealant
sealantfrom
from
anti-compression legarea.
anti-compression leg area.
LD12265A
FIG. 5-62 – WIPE OFF EXCESS SEALANT

FORM 102.20-NOM1 (909)
23. Repeat steps 8 thru 22 to place the gasket in the

other vertical.
24. In the event that the gasket will not lay flat, place Note step-off
step-off between
a clamp over the inside portion of the joint. The gasket surfaces.
surfaces.Joint
Joint
will leak.
will
clamp needs to rest on the anti-compression legs
(see Fig. 5-63).
LD12267A
FIG. 5-64 – UNACCEPTABLE BUT JOINT, STEP-

OFF BETWEEN GASKET SURFACES
When clamping
clampinggasket
gasketjoint,
joint,
the clamp must
must rest
reston
onthe
the
Note Step-off
Step-off is
is good.
good. Vertical
Vertical
anti-compression legs.
anti-compression legs. LD12266A needsto
gasket needs tobe
bepushed
pushed
farther into
farther into horizontal
horizontal gasket.
gasket.
FIG. 5-63 – APPLY CLAMP TO CORNER AS
NECESSARY
Clamps must stay in place for a mini-

mum of 10 minutes before removal.
LD12268A
25. See Fig's 5-64 and 5-65 for examples of
unacceptable gasket joints. FIG. 5-65 – UNACCEPTABLE BUT JOINT,
VERTICAL GASKET NOT PUSHED IN
FAR ENOUGH

Service & Repair
FORM 102.20-NOM1 (909)
3. Measure and cut the self-adhesive gasket to fit the

entire frame.
When cutting to size, cut the gasket 2"

to 3" longer than needed to allow room
for extra cutting and a proper fit.
GASKET INSTALLATION
1. Cut gasket and then peel red backer plastic back
12 to 18 inches (see Fig. 5-67).
Ensure that the cut is as close to 90

degrees as possible, both vertically and
horizontally, to ensure a proper fit.
FIG. 5-66 – S
TEEL FRAME DOOR WITH BUT
CORNER JOINT GASKET (Units
Produced AFTER oct 2008)
Cut gasket
and then peel
INSTALL NEW GASKET ON DOOR PRODUCED red backer
plastic back
AFTER OCT 2008 12 to 18
inches.
This procedure describes the method of installing the
self-adhesive gasket in frames to eliminate air/water
infiltration.
PREPARATION
1. Ensure that the frame has been cleaned and Ensure that cut is as close to 90 degrees as pos-
sible, both vertically and horizontally to ensure a
sealed. proper fit.
LD14271
Before starting, ensure that the gasket FIG. 5-67 – C

UT GASKET AND PEEL BACKER
leg has been cleaned with denatured
alcohol or rubbing alcohol. Also, 2. Starting on the latch side, 4 to 8 inches in from the
make sure it is dry to ensure that the horizontal, place the sticky side of the gasket down
gasket will adhere. onto the gasket leg (see Fig. 5-68).
Be extremely careful when handling The notch on the gasket is to the out-
frames as serious cuts may occur from side of the frame.
all exposed edges. Be extra careful
when sliding fingers down the gasket
to secure, as the exposed edges of the
anticompression leg are extremely
sharp.
2. Position the frame with the anti-compression leg

up.

FORM 102.20-NOM1 (909)
NOTE: The notch on

the gasket is to the
outside of the frame.
Start on the latch side, 4 to 8 inches Using the index

in from the horizontal finger, secure the
corner, and wrap
the unsecured
side around the
4T corner.
O8
IN.
LD14272
LD14274
FIG. 5-68 – P
LACE GASKET ON LATCH SIDE OF
FRAME FIG. 5-70 – start corner
3. Lay the gasket to the corner, lift the loose side of the Examples of a Good Gasket Corner
gasket up, and begin the corner (see Fig. 5-69).
Entire anticompression leg is visible
and the gasket is tight with it (see Fig.
5-71).
The entire
anticompression leg is
visible and the gasket is
tight with it.
Lay the gasket to the
corner, lift the loose
side of the gasket up
and begin the corner. LD14273
FIG. 5-69 – apply gasket to corner
4. Using the index finger, secure the corner, and wrap

the unsecured side around the corner (see Fig.
5-70). LD14275
FIG. 5-71 – EXAMPLE OF A GOOD GASKET

CORNER
5
Repeat these steps for other three
corners.

Service & Repair
FORM 102.20-NOM1 (909)
Examples of Unacceptable Corners It is best not to remove more than 12

See Fig. 5-72 and 5-73 for examples of unacceptable to 18 inches of the red plastic backer
corners. at once, because it will stick firmly to
itself if it comes in contact.
Do not stretch the corner tight (see
Fig. 5-72).
Lay the gasket on the gasket leg
next to the anticompression leg
and press into place. Ensure that
the gasket stays in contact with
the anticompression leg.
Gasket must be +0
/ -1mm from the
UNACCEPTABLE anticompression
leg.
LD14278
FIG. 5-74 – LAY GASKET ON GASKET LEG
Examples of Unacceptable Gasket Fit

LD14276
See Fig. 5-75 and 5-76 for examples of unacceptable
Gasket pulled too tight to corner.
gasket fit.
FIG. 5-72 – UNACCEPTABLE CORNER - TOO
TIGHT Gasket needs to be +0 / -1 mm from the
anticompression leg (see Fig. 5-75).
The edge of the gasket should be in
contact with the corner of the anti-
compression leg, +0/ -1 mm (see Fig.
5-73).
UNACCEPTABLE
UNACCEPTABLE
Gasket needs to be +0 / -1 mm
from the anticompression leg. This
gap is too big.
LD14279
The edge of the gasket should be in

contact with the corner of the
anticompression leg, +0/ -1 mm FIG. 5-75 – UNACCEPTABLE gasket fit - gap
LD14277 too big
FIG. 5-73 – UNACCEPTABLE CORNER - GASKET

EDGE NOT TOUCHING CORNER OF
ANTICOMPRESSION LEG.
5. Lay the gasket on the gasket leg next to the anti-

compression leg and press into place. Gasket must
be +0 / -1mm from edge of anticompression leg
(see Fig. 5-74).

FORM 102.20-NOM1 (909)
Gasket cannot overhang onto the anti-

compression leg (see Fig. 5-76).
UNACCEPTABLE
Hump the unattached gasket up

slightly and move it to the secured
portion. LD14282
FIG. 5-78 – P
OSITION GASKET FOR SECURING
Gasket cannot 8. Push the gasket into the secured portion (see Fig.
overhang onto the 5-79).
anticompression leg.
LD14280
FIG. 5-76 – UNACCEPTABLE gasket
fit - GASKET OVERHANGS
ANTICOMPRESSION LEG.
6. When you get to the starting point, overlap by 1/8"

to 1/4", and make a good 90 degree cut. (It is easier
to cut if the red backer plastic is still attached) (see Push the gasket into
Fig. 5-77). the secured portion.
1/8" to 1/4"
LD14283
FIG. 5-79 – push gasket into secured

position
When you get to the start-
ing point overlap by 1/8" to
1/4", and make a good 90
degree cut. (It is easier to
cut if the plastic backer is
still attached.)
LD14281
5
FIG. 5-77 – cut gasket at starting point
7. Hump the unattached gasket up slightly and move

it to the secured portion (see Fig. 5-78).

Service & Repair
FORM 102.20-NOM1 (909)
9. Push the gasket down onto the gasket leg (see Fig. Examples of Unacceptable Joints
5-80).
For examples of unacceptable joints see Fig 5-82
through 5-85.
Finished joint will not have any gaps;
it will be a perfect seal.
UNACCEPTABLE
Push the gasket

onto the gasket leg.
Open Joint
LD14286
FIG. 5-82 – EXAMPLE OF An unacceptable

joint - open joint
LD14284 UNACCEPTABLE
FIG. 5-80 – F
INAL POSITIONING
Examples of Good Finished Joints
Joint has a perfect seal (see Fig.

5-81).
Open Joint
LD14287

joint - less obvious open joint
Example of a
good finished joint
UNACCEPTABLE
LD14285
Offset Joint
FIG. 5-81 – EXAMPLE OF A GOOD FINISHED
JOINT
LD14288

joint - offset joint

FORM 102.20-NOM1 (909)
SPLICING
UNACCEPTABLE If the joint of the gasket is too short, and does not
make a perfect seal, a splice may be used rather than
replacing the entire gasket (see Fig. 5-86).
Requirements when splicing

Poor Joint
• Gasket splice must be at least 12" long.
• Gasket splice can be made on the latch side
only.
• Both joints where splice is made must have a
LD14289 perfect seal.

joint - poor joint
10. With fingers press entire gasket down flat onto the
gasket leg, ensuring it makes a seal all the way
around the frame.
Gasket splice must be at least 12" long.
Both joints must have a perfect seal
LD14291
FIG. 5-86 – GASKET SPLICE REQUIREMENTS

Service & Repair
FORM 102.20-NOM1 (909)
DOOR HANDLE/LATCH REPLACEMENT STANDARD OUT SWING DOOR WITH MULTI-POINT

AND ADJUSTMENT LATCH
STANDARD OUT SWING DOOR TOOLS REQUIRED
TOOLS REQUIRED Standard mechanics tool kit.
Standard mechanics tool kit.

MATERIALS REQUIRED
MATERIALS REQUIRED Correct parts for the application (see Form 102.20-
RP1). ►
Correct parts for the application (see Form 102.20-
RP1). ►
PROCEDURE
PROCEDURE See Fig. 5-87

1. Shut down and lock out unit fan(s).
See Fig. 5-87
1. Shut down and lock out unit fan(s). 2. Remove existing door latch assembly.
2. Remove existing door latch assembly. 3. Insert shafts of each of the individual latching
mechanisms through holes in door from outside
3. Insert shaft of latching mechanism through hole to inside.
in door from outside to inside.
4. Thread flanged retainers of latching mechanisms
4. Thread flanged retainer of latching mechanism onto each mechanism shaft until firmly against
onto mechanism shaft until firmly against inside inside of door.
of door.
5. Install one handle (without offset roller) to the
5. Thread 3/8" flat jam nut onto mechanism shaft mechanism designated to be the “operator” on
and tighten against retainer. outside of door using slotted screw to secure.
6. Install handle (without offset roller) to mechanism 6. Tighten slotted screw in handle and apply plastic
on outside of door using slotted screw to screw cover.
secure.
7. To the other mechanism(s), apply push on
7. Tighten slotted screw in handle and apply plastic cover(s) in place of handle(s).
screw cover.
8. Place the designated mechanism handle in a
8. Add two 3/8" flat washers. downward position.
9. Add cam roller (Detail B) so that roller will 9. Place the other mechanism(s) so the square
engage doorframe when handle is in the shaft(s) is/are positioned the same as that of the
downward position. designated mechanism shaft.
10. Add inside handle (if applicable) to mechanism 10. Apply a linkage adapter to each mechanism
shaft. shaft. Be sure the peg is downward and at an
11. Thread 3/8" lock nut w/nylon washer onto angle away from the edge of the door. Also, be
mechanism shaft and tighten. sure the smooth side of the linkage adapter is
toward the door.
12. Repeat these steps for each individual handle on
the door. 11. Install the connecting rod by engaging its
holes with the respective peg on each linkage
13. Check operation of door latch with unit off and adapter.
with unit in operation to check for leakage.
12. Secure the connecting rod by placing an “E” ring
14. If adjustment is required, add or take away 3/8" (snap ring) in the groove on each peg.
flat washers.
13. Add two 3/8" flat washers.

FORM 102.20-NOM1 (909)
3/8" Lock Nut Latching

w/Nylon Washer Mechanism 3/8" Flat Washer Cover
(3 Washers On
In Swing)
Latching
Mechanism Rod
Inside Handle (In Swing
Handle Handle (In Swing Offset Shown)
Offset Shown) (See Detail A)
Cam Roller, Snub (See Detail A) Cam Roller, Snub
Nose (Out Swing Nose (Out Swing
Only) (See Detail B) Only) (See Detail B)
Inside Handle
3/8" Flat Jam Nut

(Out Swing Only) Latching
Mechanism
3/8" Lock Nut

w/Nylon Washer Latching
3/8" Flat Washer
Mechanism
(Out Swing Only)
Linkage
Adapter
DETAIL A DETAIL B
HANDLE W/OFFSET ROLLER CAM ROLLER SNUB NOSE
(In Swing Only) (Out Swing Only) LD09669
FIG. 5-87 – STANDARD DOOR LATCHES, IN SWING, OUT SWING & MULTI PT. LATCH

Service & Repair
FORM 102.20-NOM1 (909)
14. Add cam rollers (Detail B) to each mechanism 11. Check operation of door latch with unit off and
shaft so that rollers will engage doorframe when with unit in operation to check for leakage. If
handle is in the downward position. leakage occurs, check door gasket (see “Door
Gasket Replacement” in this section). ►
15. Add one inside handle (if applicable) to the
mechanism shaft most convenient to operate 12. If adjustment is required, add or take away 3/8"
from inside unit. flat washers.
16. Thread 3/8" lock nuts w/nylon washer onto each
mechanism shaft and tighten. STANDARD IN SWING DOOR WITH MULTI-POINT
17. Check operation of multi-point latching LATCH
assembly with unit off and with unit in operation TOOLS REQUIRED
to check for leakage.
Standard mechanics tool kit.
If adjustment is required, add or take away 3/8"
flat washers. MATERIALS REQUIRED
STANDARD IN SWING DOOR Correct parts for the application (see Form 102.20-
RP1). ►
TOOLS REQUIRED
Standard mechanics tool kit. PROCEDURE
See Fig. 5-87

MATERIALS REQUIRED
Correct parts for the application (see Form 102.20- 2. Remove existing door latch assembly.
RP1). ►
3. Insert shafts of each of the individual latching
PROCEDURE mechanisms through holes in door from outside
to inside.
See Fig. 5-87
4. Thread flanged retainers of latching mechanisms
onto each mechanism shaft until firmly against
2. Remove existing door latch assembly. inside of door.
3. Insert shaft of latching mechanism through hole 5. Install one handle (with offset roller - Detail
in door from outside to inside. A) to the mechanism designated to be the
“operator” on outside of door using slotted screw
4. Thread flanged retainer of latching mechanism
to secure.
onto mechanism shaft until firmly against inside
of door. 6. Tighten slotted screw in handle and apply plastic
screw cover.
5. Install handle (with offset roller - Detail A) to
mechanism on outside of door using slotted 7. To the other mechanism(s), apply push on
screw to secure. cover(s) in place of handle(s).
6. Tighten slotted screw in handle and apply plastic 8. Place the designated mechanism handle in a
screw cover. downward position.
7. Add inside handle (if applicable) to mechanism 9. Place the other mechanism(s) so the square
shaft. shaft(s) is/are positioned the same as that of the
designated mechanism shaft.
8. Thread 3/8" lock nut w/nylon washer onto
mechanism shaft and tighten. 10. Apply a linkage adapter to each mechanism
shaft. Be sure the peg is downward and at an
9. Ensure offset on door handle engages doorframe
angle away from the edge of the door. Also, be
when handle is in the downward position.
sure the smooth side of the linkage adapter is
10. Repeat these steps for each individual handle toward the door.
on the door.
FORM 102.20-NOM1 (909)
11. Install the connecting rod by engaging its PROCEDURE

holes with the respective peg on each linkage ISOLATOR SPRING REPLACEMENT
adapter.
12. Secure the connecting rod by placing an “E” ring 1. Raise fan base assembly. Block or crib as
(snap ring) in the groove on each peg. necessary.
13. Add three 3/8" flat washers. 2. Remove isolator spring(s) being replaced.
14. Ensure offset on door handle engages door frame 3. Place replacement spring(s) in existing rubber
when handle is in the downward position. Isolator Cup.
15. Add one inside handle (if applicable) to the 4. Lower fan base assembly guiding the existing
mechanism shaft most convenient to operate Isolator Cap over the spring(s).
from inside unit. 5. Install washer and cap screw into top of
16. Thread 3/8" lock nuts w/nylon washer onto each adjustment bolt. Do not tighten cap screw at
mechanism shaft and tighten. this time.
ISOLATOR ADJUSTMENT (LEVEL WITH PROPER
17. Check operation of multi-point latching assembly
CLEARANCES)
with unit off and with unit in operation to check
for leakage (see “Door Gasket Replacement” in 1. With cap screw loose, turn adjustment bolts
this section). ► counter clockwise to raise or clockwise to lower
the fan base assembly.
ISOLATOR SPRING REPLACEMENT AND 2. Repeat the procedure one isolator at a time until
the required distance of 5/8" is reached between
ADJUSTMENT
the top of the isolator rail and the bottom of the
TOOLS REQUIRED spring rail.
• Mechanics tool kit 3. Make sure the spring is not collapsed. Minimum
• Pry bar (large fan base) and maximum tolerances shown in the table in
Fig. 5-88 should be followed.
• Lumber blocking/cribbing (large fan base)
4. Make sure the flex connector at the fan discharge
is not folded inward or pinched between the
MATERIAL REQUIRED floating fan assembly and the stationery segment
• Correctly sized replacement isolator spring(s) discharge.
5. Once the fan base assembly is adjusted, tighten
CAP SCREW the cap screws to lock the assembly in place.
ADJUSTMENT BOLT
A 5
ACCESS SLOT
SPRING TOLERANCE
ISOLATOR CAP
DEFLECTION LIMIT (A)
SPRING RAIL TYPE
1/2" TO 5/8" MIN MAX
1.00 1.50 2.75
2.00 1.00 3.00
ISO RAIL TABLE 1

CAGE NUT
NOTE:
ISOLATOR CUP 1. ALL VALUES ARE IN INCHES.
2. MINIMUM AND MAXIMUM DISTANCE ARE MEASURED FROM

THE TOP OF THE ADJUSTING BOLT, AS SHOWN IN FIGURE 1.
FIGURE 1
LD12559
FIG. 5-88 – ISOLATOR MOUNTING

Service & Repair
FORM 102.20-NOM1 (909)
THRUST RESTRAINT REPLACEMENT TOOLS REQUIRED

AND ADJUSTMENT Two 8" crescent wrenches.
Fan segments are cabinets containing a fan and motor.
They can develop extremely high thrusts. These MATERIAL REQUIRED
forces are horizontally opposite to the airflow. Thrust Appropriate Thrust Restraint Kit (see Form 102.20-
restraints are provided for all fans when the air thrust RP1). ►
exceeds 15% of the equipment weight when the
fan discharge is rear (see Fig. 5-89). Any other fan PROCEDURE
orientation does not require restraints due to one of
several reasons: See Fig's 5-89 & 5-90
• Top and Top Inverted - Isolators function as THRUST RESTRAINT REPLACEMENT
thrust restraints.
Supply fan is attached to bulkhead (or bulkhead clip),
• Bottom and Bottom Inverted - The weight of the one thrust restraint on each side near top of fan.
fan/motor exceed potential thrust. 1. Remove any existing thrust restraints.
• Rear Inverted - The horizontal thrust component 2. If fan wall will not support thrust or brackets,
is low with respect to the center of gravity of the install additional support from floor to roof and
fan/motor assembly. tie in at top, bottom and about 4’ intervals.
REAR DISCHARGE ORIENTATION 3. If fan structure angle is not present or doesn’t
line up, adjust thrust restraint mounting brackets
(or clips) furnished with thrust restraints. Attach
• On forward curved fans, the thrust to each side of fan housing nearest top and
is under 15% of the total weight. toward discharge.
Hence, the thrust restraints are not
required. 4. Lock two nuts together on one end of threaded
rod.
• On airfoil fans, it is required that
thrust restraints be used where the 5. Finally, add first flat steel washer, first flat rubber
TSP is greater than 6" washer, first steel cup retainer, spring, second
• On plenum fans, it is required that steel cup retainer, second flat rubber washer and
thrust restraints be used where the second flat steel washer.
TSP is greater than 3".
LD08592-1
FIG. 5-89 – SUPPLY FAN RESTRAINT

FORM 102.20-NOM1 (909)
FAN END DOUBLE NUTS LOCKED TOGETHER
STEEL WASHER STEEL WASHER

RUBBER WASHER
STEEL CUP
DOUBLE NUTS FOR NUT
ADJUSTMENT
STEEL WASHER
NUT
THREADED ROD
STEEL WASHER
RUBBER WASHER
STEEL WASHER
STEEL CUP
SPRING
THRUST RESTRAINT BULKHEAD OR
MOUNTING BRACKET BULKHEAD CLIP
(OR CLIP) LD09670
FIG. 5-90 – THRUST RESTRAINT ASSEMBLY
6. Slide threaded rod through thrust restraint 10. Push threaded rod through bulkhead (or bulkhead
mounting bracket on fan (or clip) toward clip) until spring parts are against thrust restraint
bulkhead (or bulkhead clip). mounting bracket on fan (or clip).
7. Add third flat steel washer and two nuts that will 11. Tighten nuts on both sides of bulkhead (or
lock together in a later step. bulkhead clip).
THRUST RESTRAINT ADJUSTMENT

The hardware thus far goes to the fan After installing thrust restraint, adjust as follows:
end of threaded rod.
1. Ensure nuts are tight on both sides of bulkhead
or bulkhead clip.
2. Adjust third flat steel washer and second set of 5
double nuts hand tight against thrust restraint
8. Next add one nut and flat one steel washer and mounting bracket on fan.
slide threaded rod through bulkhead (or bulkhead
clip). 3. Turn second set of double nuts four full turns
toward spring and lock in place.
9. Add flat steel washer and one nut on the other
side of bulkhead (or bulkhead clip). 4. Repeat this process for each thrust restraint.

Service & Repair
FORM 102.20-NOM1 (909)
FIELD CUT OPENINGS FOR DUCTS, .75"

DAMPERS AND SPECIAL ACCESS FOR
YORK SOLUTION DOUBLE WALL 2"
PANELS
A pre-manufactured replacement
panel with your specified opening size
and location may be available through
L
Baltimore Parts Center—Airside or
Local Johnson Controls Service. 1.938"

frames, filter bulkheads and filter seg-
ment panels are factory sealed and Notes:
1. Select the C-Channel that is nearest to the size of your
must remain sealed for NO air by- opening and cut to fit.
pass.
2. Available lengths (L) for stiffeners:
TOOLS REQUIRED PART NUMBER LENGTH (L)

087-40048-050 47.938”
• Screw gun with #3 Phillips bit.
087-40072-050 71.938”
• Gasket scraper. 087-40127-050 126.938” LD09671
• Broad, thin pry bar. FIG. 5-91 – C-CHANNEL

• Drill motor.
• 1/8" steel pop rivets for ¼" working thickness.
• One-eighth inch drills.
• Paint, cold galvanized.
• Pop rivet gun.
• Paint, touchup spray, champagne, P/N 013-
• Hole saw-approximately 1-1/2" diameter for 03322-000 (for outdoor unit exterior only).
starter holes.
• Caulk, P/N 013-02966-011 gray for indoor
• Power saw or power shear for metal cutting. units or 013-03317-040 for outdoor units with
• Power cords as required. champagne paint.
• Awl. • For door and panel flanges, use gasket, neoprene

.75"w x .25" thk, P/N 028-11873-010.
MATERIAL REQUIRED • Panel screws ¼" x ¾" pan head thread forming
• Two prefabricated pieces of “C” channel used sheet metal screw, P/N 021-17722-000.
for stiffeners and insulation covers equal to the • Clean up supplies.
height of the new opening. If this were a side
PROCEDURE
panel, this would be “vertical”. This channel is
20 gauge galvanized sheet metal, 1.938" wide 1. Cut the “C” Channel stiffeners to fit opening.
with .750" legs. Available through Baltimore Use for stiffening the cut panel and for sealing
Parts Center-Airside (see Fig. 5-91). of insulation and probable air leakage areas.
• Two prefabricated pieces of “C” channel used 2. Make sure any components; bulkheads or other
for stiffeners and insulation covers equal to the obstructions are disconnected from panel inside
width of the new opening. If this were a side and out.
panel, this would be “horizontal”. This channel
is 20 gauge galvanized sheet metal, 1.938" wide 3. When removing panel, to prevent damage of
with .750" legs, available through Baltimore outdoor unit remove panel slowly allowing butyl
Parts Center-Airside (see Fig. 5-91). tape to release.

FORM 102.20-NOM1 (909)
Panels can often be cut in place with- PANEL REPLACEMENT

out removing from the air handling If your unit has HEPA filters the filter
unit. frames, filter bulkheads and filter seg-
ment panels are factory sealed and
must remain sealed for NO air by-
pass.
4. Layout location and dimensions of opening to
be cut. Do this on both sides of double wall
panels. TOOLS REQUIRED
5. Cut desired opening in panel insuring cuts on • Screw gun with #3 Phillips bit.
both sides line up.
• Gasket scraper.
6. Insert stiffeners, legs first, by tapping into
panel until flush with new panel opening. • Broad, thin pry bar.
This simultaneously forces the legs of the “C” • Awl.
channels between the foam insulation and the
liner and between the foam insulation and MATERIAL REQUIRED
the outer sheet metal without damage to the
insulation. Be sure the broad sides of the “C” • Replacement panel, available through Airside
channels line up to form the desired opening Parts.
dimensions. This should be flush with edges • Caulk, P/N 013-02966-011 gray for indoor
of the new opening. units or 013-03317-040 for outdoor units with
7. Secure “C” channels with pop rivets at 3" champagne paint.
intervals on a line ¼” from the new opening • For door and panel flanges, use gasket, neoprene
edges. When fastening with pop rivets avoid .75"w x .25" thk, P/N 028-11873-010.
buckling or bulging of sheet metal by applying
rivets simultaneously on each side of opening, • Panel screws ¼" x ¾" pan head thread forming
working from center to corners. sheet metal screw, P/N 021-17722-000.
8. Apply gray sealant to corner seams and all seams • Paint, touch-up spray, champagne, P/N 013-
inside the new opening. 03322-000.
9. Paint rivets and raw edges of sheet metal with • Clean up supplies.
cold galvanized paint.
10. If the panel was removed, clean away damaged
or residual gasket or sealing compound and
replace with appropriate material (see material
list above).
11. Install panel on air handling unit carefully using 5
panel screws (see material list above).
12. All re-installed panels and alterations of
panels must provide integrity equal to original
equipment specifications.
13. Reconnect any components, bulkheads or other
fixtures that were disconnected from panel in
step # 2.
14. Thoroughly clean up inside and outside air
unit.

Service & Repair
FORM 102.20-NOM1 (909)
PROCEDURE
1. Make sure any components; bulkheads or other 5. All re-installed panels must provide integrity
obstructions are disconnected from panel inside equal to original equipment specifications.
and out (see Fig. 5-92).
6. Seal all penetrations with caulk.
fixtures that were disconnected from panel in
step # 1.
unit.
PRESSURE TAPE REMOVAL AND

INSTALLATION INSTRUCTIONS ON XTO
ROOF PANELS
This information details the proper procedure for field
LD09671
repair of factory roof seams on XTO air handlers using
new style seam sealing strip. Be sure to use applicable
FIG. 5-92 – R
EMOVE COMPONENTS PRIOR TO
safety equipment when performing these procedures.
REMOVING PANELS.
Gloves should be used when handling
2. When removing panel, to prevent damage of stainless steel tape; edges are very
outdoor unit remove panel slowly allowing butyl sharp and could cause injury.
tape to release.
Prior to panel removal on tiered or vertical units,
cut any gasket that crosses a seam. This will
prevent tearing gaskets. TOOLS REQUIRED
3. Clean away damaged or residual gasket or • Caulk gun.
sealing compound and replace with appropriate
new material (see material list above). • Spray bottle.
4. Install panel on air handling unit carefully using • Gloves.

panel screws (see Fig. 5-93). • Clean rags.
• Tape measure or ruler.
• Steel roofers roller or wallpaper roller.
MATERIAL REQUIRED
• MicroSealant seam strips, P/N 028-11888-010,
champagne, 4" w x 50 ft. roll.
• Caulk, Manus-Bond 75-AM, P/N 013-02966-
011.
• Paint, champagne, 12oz spray can, P/N 013-
03322-000.
• Isopropyl alcohol.
LD09672
FIG. 5-93 – INSTALL PANELS

FORM 102.20-NOM1 (909)
SEAM SEALING STRIP ORDERING INFORMATION

The new style seam sealing strip can be purchased
through Airside Parts in Johnstown, PA (800-545-7814)
or Baltimore Parts Center. The seam strips ship in 4 inch
x 50 foot rolls. To determine the amount needed use the
following equation:
(unit width + 12 inches) x # of factory seams = feet of sealing

12 strip needed
The +12 inches are to cover the drip edge on each side and
wrapping the tape under it as shown in Figs. 5-94 and 5-95.
Since all dimensions are in inches, the 12 indicated in the
equation converts inches to feet.
PROCEDURE FIG. 5-94 – APPLY CENTERED OVER SEAM
1. Score paint with utility knife along stainless

steel strip edge to reduce paint chipping and
flaking.
2. Remove existing stainless steel seam sealing
strip from seam.
3. Clean seam area by spraying the isopropyl
alcohol and wiping thoroughly with a clean rag.
It is not necessary to remove old glue left by
removal of the stainless steel sealing strip.
4. Inspect the existing caulk. If gaps are present or
the existing caulk is not applied over the black
gasket along the raceway, apply additional caulk.
Be sure to apply any additional caulking so the
new material lays flat along the seam. FIG. 5-95 – UNDER DRIP AND OVERHANG
Do not use silicone based caulk. Only
use urethane based factory approved
caulk listed above.
When applying the new seam sealing

strip, DO NOT stretch the material
across the seam. Doing so may cause 5
application issues.
5. When surface is dry, apply the sealing strip along

the seam as shown in Figs. 5-94 through 5-96,
making sure not to stretch the material. The FIG. 5-96 – DO NOT STRETCH
sealing strip should hang over the drip edge and
be wrapped back up under as shown.

Service & Repair
FORM 102.20-NOM1 (909)
6. Apply pressure to the sealing strip by using a MATERIAL REQUIRED

clean rag in a back and forth motion along the
• Neoprene grommet, 2-1/2", 3-1/4", 4-1/2" or
seam (Fig. 5-97). Pressure activates the adhesive,
5-1/2" as required (see Fig. 5-98).
so be sure to apply pressure along the entire
seam. A small hand roller is recommended. • Cold galvanized paint.
• Paint, touchup spray, champagne, P/N 013-
03322-000 (for outdoor unit exterior only).
• Caulk, P/N 013-02966-011 gray for indoor
units or 013-03317-040 for outdoor units with
champagne paint.
• Exacto knife.
• Clean up supplies.
PROCEDURE
See Fig. 5-98
1. Make sure any components; bulkheads or other
obstructions are disconnected from panel inside
FIG. 5-97 – APPLY PRESSURE - ROLLER and out.
RECCOMENDED
2. Layout location and dimensions of hole opening
to be cut. Do this on both sides of double wall
7. Once seams are repaired, check ALL of the roof panels.
screws and replace them if they are stripped out.
Apply caulking in the screw hole and install a 3. Carefully cut correct hole size for the application
1" X 17 screw, with rubber washer. (Fastenal # in panel, insuring cuts on both sides line up and
31917). a smooth clean cut is made.
4. Paint raw edges of sheet metal with cold
FIELD PENETRATIONS FOR PIPING & galvanized paint.
ELECTRICAL CONNECTIONS 5. Select appropriate grommet for new panel
For small sizes such as 1/2" iron pipe, hole and cut out appropriate hole diameter for
penetration with an Exacto knife.
1/2" conduit or 5/8" O.D. copper and
smaller; it is acceptable to use caulk 6. After paint dries, Install grommet into panel hole
instead of a grommet. opening.
7. Apply sealant all around new hole opening
behind lip of grommet, on both sides of panel.
Electrical conduits must be sealed
8. Run pipe or conduit through grommet and make
internally to prevent airflow and mois-
appropriate connections.
ture condensation.
9. All modified panels must provide integrity equal
to original equipment specifications.
TOOLS REQUIRED fixtures that were disconnected from panel in
step # 1.
• Drill motor.
• Pilot starter bit.
unit.
• Hole saws-approximately 2-1/2", 3-1/4" &
4-1/2" diameter for holes.
• Power cords as required.
FORM 102.20-NOM1 (909)
PANEL OUTER PANEL INNER

A SURFACE SURFACE
SEALANT** ALL
AROUND,
FOAM INSULATION BOTH SIDES OF
THE OPENING.
Ø E* NEOPRENE
ØB GROMMET***
PASSING ELEMENT
(CONDUIT, PIPE,
ØD ETC.)
3 OR 4 RINGS
SEALANT** ALL
AROUND,
ØC ØB BOTH SIDES OF
THE OPENING.
* HOLE SHALL BE CAREFULLY CUT WITH HOLE SAW OR

DRILL. LEAVING A SMOOTH, CLEAN CUT.
** RECCOMENDED SEALANT IS SIKAFLEX LD09673
DIMENSIONS
MARKED
GROMMET GROMMET GROMMET PANEL
IRON COPPER GROMMET
THIN WALL USE HOLE LIP HOLE HOLE CUT
PIPE SIZE PIPE SIZE DEPTH
CONDUIT GROMMET P/N DIAMETER DIAMETER DIAMETER DIAMETER
(nominal) (O.D.) (A)
(ØB) (ØC) (CUT OUT) (ØE)
(ØD)
3/4”, 1” 7/8”, 1-1/8” 3/4”, 1” 028-11872-000 2.375” 0.500” 3.125” 0.749 2.50”
1-1/4”, 1-1/2” 1-3/8”, 1-5/8” 1’1/4”, 1-1/2” 028-11871-000 2.375” 1.000” 3.875” 1.249 3.25”
1-1/4”, 1-1/2” 1-3/8”, 1-5/8” 1’1/4”, 1-1/2” 028-11872-000 2.375” 0.500” 3.125” 1.249 2.50”
1-1/4”, 1-1/2” 1-3/8”, 1-5/8” 1’1/4”, 1-1/2” 028-11861-000 2.375” 1.000” 5.125” 1.251 4.50”
2” 2-1/8” 2” 028-11871-000 2.375” 1.000” 3.875” 1.749 3.25”
2” 2-1/8” 2” 028-11861-000 2.375” 1.000” 5.125” 1.751 4.50”
2” 2-1/8” 2” 028-11872-000 2.375” 0.500” 3.125” 1.875 2.50”
2-1/2” 2-5/8” 2-1/2” 028-11861-000 2.375” 1.000” 5.125” 2.251 4.50”
2-1/2” 2-5/8” 2-1/2” 028-11871-000 2.375” 1.000” 3.875” 2.375 3.25”
3” 3-1/8” 3” 028-11861-000 2.375” 1.000” 5.125” 2.875 4.50”
4" 4-1/8" 4" 2.251" 1.250" 6.125" 3.875" 5.50"
028-11881-000
5
FIG. 5-98 – PENETRATIONS AND GROMMET DETAILS

Service & Repair
FORM 102.20-NOM1 (909)
FIELD MODIFICATION TO ADD DOORS .75"

This procedure instructs how to mod-
ify panels in order to install a door that
runs from the top to bottom raceway.
For doors that are smaller than the
height of the air handler see “Field
Cut Openings for Ducts, Dampers and
Special Access for YORK Solution L
Double Wall 2" Panels" ► and
“Door Replacement” ► procedures 1.938"
found in this IOM.
frames, filter bulkheads and filter seg- Notes:
ment panels are factory sealed and 1. Select the C-Channel that is nearest to the size of your
opening and cut to fit.
must remain sealed for NO air by-
pass. 2. Available lengths (L) for stiffeners:
PART NUMBER LENGTH (L)

TOOLS REQUIRED 087-40048-050 47.938”
087-40072-050 71.938”
LD09671 087-40127-050 126.938”
• Spacers, 1/8" thick approximately.
FIG. 5-99 – C-CHANNEL
• Screw gun with #3 Phillips bit.
• Awl. • Steel pop rivets, 1/8", for ¼" working
thickness.
• Gasket scraper.
• Self-drilling screws, 1/4"-14 x 3/4", P/N 021-
• Broad, thin pry bar. 19515-000.
• Drill motor. • Paint, cold galvanized.
• One-eighth inch drills. • Paint, touchup spray, champagne, P/N 013-
• Pop rivet gun. 03322-000 (for outdoor unit exterior only).
• Hole saw-approximately 1-1/2" diameter for • Caulk, P/N 013-02966-011 gray for indoor
starter holes. units or 013-03317-040 for outdoor units with
champagne paint.
• Power saw or power shear for metal cutting.
• Panel screws ¼" x ¾" pan head thread forming
• Power cords as required. sheet metal screw, P/N 021-17722-000.
MATERIAL REQUIRED • Clean up supplies.
• For door and panel flanges, use gasket, neoprene PROCEDURE
.75"w x .25" thk, P/N 028-11873-010.
1. Make sure any components; bulkheads or other
• Two prefabricated pieces of “C” channel (one obstructions are disconnected from panel inside
piece if door is to be mounted at a corner) used and out.
for stiffeners and insulation covers equal to the
height of the panel. This channel is 20 gauge 2. When removing panel, to prevent damage of
galvanized sheet metal, 1.938" wide with .750" outdoor unit remove panel slowly allowing butyl
legs. Available through Baltimore Parts Center- tape to release.
Airside (see Fig. 5-99).

FORM 102.20-NOM1 (909)
3. Clean away damaged or residual gasket or All re-installed panels and alterations
sealing compound and replace with appropriate of panels must provide integrity equal
new material (see material list above).
to original equipment specifications.
4. Cut “C” Channel stiffener(s) to fit. Use to
strengthen the cut panel(s) and for sealing of
insulation and probable air leakage areas.
5. Layout location of door for cutting. Do this on 12. Reconnect any components, bulkheads or other
both sides of double wall panel. fixtures that were disconnected from panel in
step # 1.
6. Cut panel from top to bottom at desired location
ensuring cuts on both sides line up. 13. Apply gasket material to back of doorframe
along the outer edge. Use compound sealing
7. Insert stiffeners, legs first, by tapping into (butyl tape), P/N 013-02976-000 for outdoor
panel until flush with cut edges of panel. This unit and neoprene gasket, P/N 028-11873-010
simultaneously forces the legs of the “C” for indoor unit.
channels between the foam insulation and the
liner and between the foam insulation and
the outer sheet metal without damage to the New door assemblies are provided with
insulation. plastic spacers to maintain proper
8. Secure “C” channels with pop rivets at 3" alignment.
intervals on a line ¼" from the edge of the
cut panel(s). When fastening with pop rivets
avoid buckling or bulging of sheet metal by
applying rivets simultaneously on each side of
14. Install new door assembly with door closed and
cut panel(s), working from center to top and
latched with spacers in place (see Fig. 5-101).
bottom.
9. Apply gray sealant to seal the “C” channel to
cut edges.
10. Paint rivets and raw edges of sheet metal with
cold galvanized paint.
11. Install panel(s) on air handling unit carefully
using panel screws (see Fig. 5-100).
LD14264
FIG. 5-101 – DOOR REPLACEMENT

LD09672
15. Then, install self-drilling screws in hinge side
FIG. 5-100 – INSTALL PANELS of doorframe.
16. Finally, install self-drilling screws in top, bottom
and latch sides of doorframe.
Service & Repair
FORM 102.20-NOM1 (909)
17. Check operation of door with unit off. LIGHT ASSEMBLY REPLACEMENT
18. Check for obvious air leakage with air unit in TOOLS REQUIRED
operation
• Phillips screwdriver, # 2.
• Nut setter or socket, 1/4".
unit.
20. Touch up paint as needed. MATERIALS REQUIRED
• Light Fixture w/ Cover (P/N 025-39013-001).
LIGHT BULB REPLACEMENT PROCEDURE
TOOLS REQUIRED See Fig. 5-102
• Phillips screwdriver, #2. 1. Disconnect power from light assembly.
2. Remove wireway from where it fastens to top
MATERIALS REQUIRED
panel by removing all self drilling screws.
• Lamp, Incandescent, 75W or Fluorescent,
3. Disconnect “stake-on” electrical connectors (see
20W.
Fig. 5-103).
PROCEDURE
See Fig. 5-102
1. Disconnect power from light assembly.
2. Remove two #2 Phillips screws connecting cover
to base.
3. Remove cover and replace bulb.
4. Fasten cover to base with two #2 Phillips
screws.
1/4"-20 PANEL NUTS

(4)
WIREWAY
LD09689
PRESS GROMMET
INTO WIREWAY STAKE-ON
CONNECTORS FIG. 5-103 – REMOVE ELECTRICAL
(3)
CONNECTORS
SELF DRILLING
SCREW
1/4"-20 x 3/4" LG 4. Remove two #2 Phillips screws connecting cover

PAN HEAD SCREW
(4) to base.
LIGHT FIXTURE 5. Separate light assembly from wireway by
W/COVER LIGHT BULB
removing four 1/4"-20 x 3/4" long pan head
#2 PHILLIPS
screws.
SCREWS
(2) 6. Remove grommet from wireway and light
LD09688 assembly; save for reuse.
FIG. 5-102 – LIGHT ASSEMBLY PULL SWITCH 7. Install new light assembly by reversing steps 1
SHOWN) through 6.

FORM 102.20-NOM1 (909)
FILTER ACCESS
DOOR OR UNIT
ADD SIDE PANEL
CAULK
MINIHELIC
GAGE
TOP VIEW
LD11693
FIG. 5-104 – MINIHELIC GAGE

# 4-40 THREADED
INSERT (2)
FILTER GAGE REPLACEMENT
LINER COVER PLATE
TOOLS REQUIRED # 4-40 HEX NUT (2)
• Four inch adjustable wrench or ignition wrench LD09674

set.
FIG. 5-105 – ASSEMBLY OF GAGE TO LINER
• Long, thin straight slot screwdriver. COVER PLATE
• Calking gun.
6. Insert two #4-40 threaded inserts into the
MATERIALS REQUIRED threaded holes located in the rear of the
replacement gage (see Fig. 5-105).
• Caulk, P/N 013-03317-050 aluminum gray
or 013-03317-040 for outdoor units with 7. Run a small bead of sealant around the exterior
champagne paint. perimeter of the gage where it will seal against
the filter access door or unit side panel.
PROCEDURE
8. Slide gage into opening on access panel.
1. Remove the 3/16" tubing from barbed fittings
on the back of the gage. Identify each tube as 9. Slide liner cover plate over two #4-40 threaded
“HIGH” or “LOW”. inserts.
2. Remove two #4-40 hex nuts and remove the liner 10 Secure gage by tightening two #4-40 hex nuts,
cover plate that holds the filter gage in place. making sure gage face is level.
3. Cut existing caulking from perimeter of gage. 11. Re-connect 3/16" tubing to barbed fittings on 5
the back of the gage.
4. Slide gage through front of filter access door or
unit side panel. 12. Remove lens by pressing finger tips firmly
against lens outer ring and turning CCW.
5. Clean old caulking from access panel.
13. Without any air applied, turn adjustment screw
until gage reads zero.
The replacement filter gage will be 14. Replace lens.
mounted to the liner cover plate by two
(2) #4-40 threaded inserts and hex
nuts that come with the gage.

Service & Repair
FORM 102.20-NOM1 (909)
FILTER GAGE INSTALLATION (FIELD CUT) The filter gage will require a 3" O.D.
TOOLS REQUIRED surface area on the door or panel for
mounting clearances and a minimum
• Adjustable wrench (4") or ignition wrench set. of 3" of depth behind the door panel,
• Drill. for proper tubing clearances.
• Punch.
2. Drill a 2-5/8" O.D. hole in the door or panel as
• Hole saw, 2-5/8" dia. close to the hinge side of the door as possible.
• Long, thin straight slot screwdriver. Center the hole as follows:
• Calking gun. • For units up to 72" the filter gage(s) should be

mounted 6" down from the top of the unit.
MATERIALS REQUIRED • For units taller than 72" the gage should
• Caulk, P/N 013-03317-050 aluminum gray be mounted up 60" from the bottom of the
or 013-03317-040 for outdoor units with unit.
champagne paint.
• Clean up supplies. If a view port is installed in the door,
the filter gage should be mounted
INSTALLATION CONSIDERATIONS above or below the view port to ensure
• Filter gage(s) can be installed in any filter best visibility.
segment. A filter gage can be installed across
one filter bank only, installed across each filter
bank in a segment, or one installed across all The filter gage will be mounted to the
filter banks in a segment. liner cover plate by two (2) #4-40
• If the unit is to have multiple filter gages then threaded inserts and hex nuts that
the preferred method of mounting the gages come with the gage.
is horizontally with the prefilter gage being
mounted first in airflow and the final filter gage
being mounted last in airflow. If room does not
allow for horizontal mounting then the gages can 3. Insert two #4-40 threaded inserts into the
be mounted vertically with the prefilter gage to threaded holes located in the rear of the
be mounted on the top. replacement gage (see Fig. 5-105).
• For all units with multiple filter gages, each gage 4. Run a small bead of sealant around the exterior
should be labeled with a polyester printed label. perimeter of the gage where it will seal against
The labels should read as follows: the filter access or unit side panel.
A. “Prefilter” 5. Slide gage into opening on access door or unit

side panel.
B. “Intermediate Filter”
6. Slide liner cover plate over two #4-40 threaded
C. “Final Filter” inserts.
D. “Total Filter” 7. Secure gage by tightening two #4-40 hex nuts,
making sure gage face is level.
PROCEDURE
8. Mount static pressure ports (eyelets) by drilling
1. The filter gages are to be mounted into the a 3/16" hole in the proper location(s) (see
filter access door or into unit side panel if space Fig. 5-106 for a general filter gage mounting
permits on filter segment. and tubing diagram) and inserting this eyelet
through the hole then installing the 3/16" push
nut retainer onto the backside of the eyelet to
hold it in place.

FORM 102.20-NOM1 (909)
The static pressure ports (eyelets) have filter track between the filters, that is tubed to
to be installed “out of the air stream” this tee. The remaining ports are treated just
to enable them to sense only static like above.
pressure and not velocity pressure. An • The prefilter is always the first filter bank in
“out of the air stream” location would the airstream and the final filters are always the
be above or beside the filters. Not last. There may also be an intermediate filter
mounted in the face of the filter. bank, which would be between the prefilters
and final filters. This configuration will require
9. Make Tubing Connections two filter segments in the same unit.
• The air entering side of the filter is always • When the gage is door mounted, clamp the
the high-pressure side. The downstream side tubing to the back of the door as you run it
is always the low-pressure side, of the filter along the hinge side. It will need to be looped
bank. so that there is enough tubing to flex around
the corner of the door when it is in its full
• If the filter gage is mounted on the upstream open position. The tubing will then need to
side of the filter bank then the “HI” port of the be clamped to the wall panel and neatly run to
gage is left as is to sense high-pressure and the the proper places.
“LO” port is tubed to the low-pressure side,
of the filter. 10. Re-connect 3/16" tubing to barbed fittings on
the back of the gage.
• If the filter gage is mounted on the downstream
side of the filter bank then the “LO” port is left 11. Remove lens by pressing finger tips firmly
as is, to sense low-pressure and the “HI” port against lens outer ring and turning CCW.
is tubed to the high-pressure side of the filter 12. Without any air applied, turn adjustment screw
bank. until gage reads zero.
• If the filter section is a combination filter 13. Replace lens.
assembly then the “LO” port of the prefilter
gage is always tee’d into the “HI” port of the
final filter gage and an eyelet is installed in the
2-5/8" DIA. MOUNTING HOLE

LOW PRESSURE SIDE HIGH PRESSURE SIDE MINIHELIC II 0-3"W.C.
LINER COVER PLATE
RETAINER
EYELET
3/16" DIA HOLE

LO
FILTER
HI
NOTE:
AIRFLOW IF FILTER GAGE IS MOUNTED
ON THE DOWNSTREAM SIDE
OF THE FILTER RACK, THEN
SIDE VIEW BACK VIEW THE LOW PRESSURE PORT IS
TO BE LEFT OPEN AND THE
HI PRESSURE PORT IS TO BE
TUBED THROUGH THE BULKHEAD
SINGLE / TOTAL FILTER GAGE ONLY
PRE AND FINAL FILTER GAGES
5
2-5/8" DIA. MOUNTING HOLE
LOW PRESSURE SIDE HIGH PRESSURE SIDE
MINIHELIC II 0-3"W.C.
RETAINER PREFILTER
EYELET
FRONT VIEW
3/16" DIA HOLE
POLYESTER GAGE LABEL
FINAL FILTER MINIHELIC II 0-3"W.C.
LINER COVER PLATE
PREFILTER
NOTE:
FILTER
FINAL
LO IF FILTER GAGES ARE MOUNTED

HI ON THE DOWNSTREAM SIDE
AIRFLOW OF THE FILTER RACK, THEN
1/4" BRASS TEE
THE HIGH PRESSURE PORT OF
THE PREFILTER GAGE IS TO BE
TUBED THROUGH THE BULKHEAD
PREFILTER BACK VIEW AND THE LOW PRESSURE PORT
IS TO BE TEE'D IN WITH HIGH
SIDE VIEW PRESSURE PORT OF THE FINAL
FILTER GAGE. THE LOW PRESSURE
PORT OF THE FINAL FILTER GAGE
IS TO BE LEFT OPEN.
LD09675
FIG. 5-106 – FILTER GAGE DIAGRAMS

Service & Repair
FORM 102.20-NOM1 (909)
ENERGY RECOVERY WHEEL Wheel segments are secured to the wheel frame by
a segment retainer, The retainer pivots on the wheel
TOOLS REQUIRED
rim and is held in place by a segment retainer catch
• Standard mechanic’s hand tools. (see Fig. 5-108).
• Metric Allen wrenches.
• Hammer. SEGMENT RETAINER
CATCH
• Drift. 2 ROTATE AWAY

FROM WHEEL RIM
• Metric socket wrench set w/ extension.

• Metric box wrench set.
MATERIALS REQUIRED SPOKE
• Replacement motor and hardware kit.

1 PUSH
• Replacement belts. TOWARD
CENTER
• Replacement segment.
WHEEL RIM
CENTER
REPLACING WHEEL SEGMENTS OF
WHEEL
Disconnect electrical power before LD09643

servicing Energy Recovery Wheel.
FIG. 5-108 – SEGMENT RETAINER
REMOVAL OF SEGMENTS
Always keep hands away from bear- See Fig. 5-109

ing support beam when installing or 1. Disengage segment retainer from segment
removing segments. Failure to do so retainer catch (usually two per retainer) by
pushing toward the center of the wheel.
could result in severe injury to fin-
gers or hand. 2. Rotate segment retainer away from wheel rim.
WHEEL
ROTATION
BEARING SUPPORT
BEAM - PULLEY SIDE
BALL
BEARINGS (2)
BEARING ACCESS
COVER (2)

- MOTOR SIDE

BELT
FIG. 5-107 – ENERGY RECOVERY WHEEL, PULLEY SIDE

FORM 102.20-NOM1 (909)
4. Close and latch each segment retainer under

segment retaining catch.
5 5. Slowly rotate the wheel 180°. Install the second

1 segment opposite the first for counterbalance.
Rotate the two installed segments 90° to balance
4 the wheel while the third segment is installed.
4 3 Rotate the wheel 180° again to install the fourth
segment opposite the third. Repeat this sequence
with the remaining four segments.
2
INSULATION
SEAL
PLATE
WHEEL
MOUNTING DRIVE
LD09676 BOLTS (4) MOTOR
FIG. 5-109 – SEGMENT INSTALLATION PULLEY
3. Pulling the segment by its two outer corners, A

SERIES DIM A
remove the segment. It may be necessary to use
36 1/4”
a flat blade screwdriver to nudge the segment
52 1/4”
from the wheel rim. Be careful not to damage
64 7/16”
the wheel rim.
74 7/16”
4. Rotate the segment retainer into the wheel rim 86 7/16”
LD09677
so that the wheel can be rotated to access other
segments. FIG. 5-110 – PULLEY LOCATION
5. It is advisable to rotate the wheel 180°. Remove
the second segment in the same manner as WHEEL DRIVE MOTOR & PULLEY REPLACEMENT
the first. Continue removing segments in this
See Fig. 5-110
manner until all are removed.
1. Disconnect power to wheel drive motor.
INSTALLATION OF SEGMENTS 2. Remove belt from pulley and position temporarily
See Fig. 5-109 around wheel rim.
3. Loosen set screw in wheel drive pulley using
1 Unlock two segments retainers (one on each side
Allen wrench and remove pulley from motor 5
drive shaft.
of the selected segment opening).
4. While supporting weight of drive motor in one
2. With the embedded stiffener facing the motor
hand, loosen and remove four (4) mounting
side, insert the nose of the segment between the
bolts.
hub plates.
5. Install replacement motor with hardware kit
3. Holding segment by the two outer corners, press
supplied.
the segment towards the center of the wheel
and inwards against the spoke flanges. If hand 6. Install pulley to dimension shown in Fig. 5-110
pressure does not fully seat the segment, insert and secure set screw to drive shaft.
the flat tip of a screwdriver between the wheel
7. Stretch belt over pulley and engage in groove.
rim and outer corners of the segment and apply
downward force while guiding the segment into 8. Follow start-up procedure in Section 3.
place.
Service & Repair
FORM 102.20-NOM1 (909)
BELT REPLACEMENT
BELT
Models ERC-36" Thru 110"
TAPE
Replacement consists of wrapping the belt around the
wheel rim, joining the ends by means of a single link
connector, and stretching the belt around the wheel
drive pulley.
1. Confirm the model number on the replacement
WHEEL
belt kit matches the model number on the energy
LD13356
recovery cassette label.
2. Remove any remnant of old belt from cassette. FIG. 5-112 – CROSS SECTIONAL VIEW OF HOOK
END OF BELT ATTACHED TO WHEEL
3. At location near pulley, attach the hook end of RIM WITH TAPE
belt to wheel rim with tape, making sure that
narrow side of “V” belt is positioned against rim 4. Rotate the wheel clockwise while feeding belt
and link is covered by the tape (see Fig. 5-111 & onto wheel rim (be careful not to twist belt) until
5-112). taped end returns to pulley location. Remove
tape from wheel.
5. Link belt ends together with belt wrapped
around wheel rim. (See Fig. 5-113).
LD09858
FIG. 5-111 – ATTACHING THE HOOK END OF BELT
TO WHEEL RIM WITH TAPE LD10016
FIG. 5-113 – LINK BELT ENDS TOGETHER

Later models of ERC-74 and larger
diameter wheels have a belt guide 6. Rotate wheel clockwise to position single link
channel on the outer surface of the connector approximately 180° from pulley
wheel rim into which the belt must be location.
positioned.

FORM 102.20-NOM1 (909)
7. At pulley location, insert the right angle belt- 8. Rotate wheel counterclockwise until belt
retaining clip between the rotatable segment retaining clip (red) is within a few inches of the
retainer latch and wheel rim at the left side of a bearing support beam (see Fig. 5-115).
spoke as shown in Fig. 5-114.
IMPORTANT: To avoid release of

segment retainer latch do not insert
retaining clip on other side of
spoke. Bearing Support Beam
Segment Retainer Latch
Belt Retaining Clip (Red)
Belt Retaining Clip

(Red)
LD10018A
LD10017A FIG. 5-115 – RETAINING CLIP WITHIN A FEW
FIG. 5-114 – INSERT RIGHT ANGLE BELT INCHES OF THE BEARING SUPPORT
RETAINING CLIP BEAM

Service & Repair
FORM 102.20-NOM1 (909)
9. Lift and remove the belt from the wheel rim

between a point opposite the pulley and belt
retaining clip and stretch over pulley (see Fig.
5-116).
LD13360
FIG. 5-116 – STRETCHING BELT OVER PULLEY
12. Apply power to cassette and observe belt

10. Rotate wheel clockwise until the belt is fully
tracking under power. If metallic “click” is heard
stretched onto pulley and wheel rim.
when link rotates past the bearing support beam
11. Remove belt retaining clip (red) and rotate wheel see note below.
clockwise a minimum of two full rotations (16
spokes) while verifying by observation and
touch that belt is not twisted on wheel rim as it Pile seal brackets are fixed with a
enters pulley, and is tracking midway between single screw to the cassette frame near
outer edge of rim and seal plate, or in belt guide the ends of the Bearing Support Beam.
channel where provided. Because the height of the belt link is
slightly higher than that of the ure-
thane belt, a rare interference may
occur when it passes the seal bracket.
If this occurs, remove the interfering
bracket (s). No measurable change of
performance will occur.

FORM 102.20-NOM1 (909)
TABLE 5-7 – CROSS REFERENCE; CONTINUOUS TO SINGLE LINK BELT/BELT PULLEY KITS
All Kits Includes V-belt, Belt Retaining Clip (Red) and Foil Tape. Contact local Johnson Controls Service to order parts.
SINGLE LINK BELT
MODEL WIDTH DESCRIPTION OLD NEW

NUMBER NUMBER
ERC-3615 1-1/2" Single Link V-Belt Type “3-L” 18160002 18160002B
ERC-3622 3" Single Link V-Belt Type “3-L” 18360006 18360006B
ERC-5230 1-1/2" Single Link V-Belt Type “3-L” 181770B 181770C
ERC-5245 1-1/2" Single Link V-Belt Type “3-L” 181770B 181770C
ERC-5248 3" Single Link V-Belt Type “3-L” 18520017 18520017C
ERC-5262 3" Single Link V-Belt Type “3-L” 18520017 18520017C
ERC-81110 3" Single Link V-Belt Type “A” 18810010 18810010B
ERC-104195 3" Single Link V-Belt Type “A” 18040010B 18040010C
5
ERC110220 3" Single Link V-Belt Type “A” 18100010B 18100010C
SINGLE LINK BELT AND PULLEY KITS
ERC-36 1-1/2" Belt/Pulley Kit Prior to 9813 NA 18360041A
ERC-36 1-1/2" Belt/Pulley Kit 9814-0032 NA 18360042A
ERC-52 1-1/2" Belt/Pulley “3-L”- Link V-Belt prior to 9806 18520031B 18520031C
ERC-52 1-1/2" V-Belt Link “3-L”/Pulley Kit 2.6 pitch 181769B 181769C
ERC-52 1-1/2" Motor Repl/ERC 52 w/2.0 pitch pulley and 3L Link Belt 18520009B 18520009C
ERC-64 3" Belt/Pulley Kit (2) 3/16” to (1 )”3L” Linked V-Belt 18640027B 18640027C
ERC-74 3" Belt/Pulley Kit (2 3/16” to (1 )”3L “Linked V-Belt 18740037B 18740037C
ERC-74 3" “3L” Linked Belt/Pulley Kit for ERC-7460/7490/74122 18740060 18740060B

Service & Repair
FORM 102.20-NOM1 (909)
INSTALLING DOOR SAFETY CHAIN PROCEDURE

This procedure instructs how to install 1. Attach chain to wall panel liner with a 1/4" x
a door safety chain in high pressure 3/4" self tapping screw and fender washers.
areas when an inward swinging door 2. Αttach chain, cold shut and eye snap as shown
is not possible. in Fig. 5-117.
3. Attach staple plate to door and liner with self-
tapping screw.
TOOLS REQUIRED
Door gap needs to be approximately
MATERIAL REQUIRED 4" wide to allow access to unclasp the
• Thread forming sheet metal screws, 1/4"-10 x snap.
3/4", P/N 021-17722-000.
• Steel security chain, P/N TAC2401012000.
• Bolt snaps, P/N TAC2401013000. Center the staple plate vertically in the
door. Do not interfere with the latch-
• Steel staple plate, P/N TAC2401014000. es.
• Cold shuts, P/N TAC2401015000.
• Fender washer, .313", P/N TAC3303006000.
SELF TAPPING SCREW

& FENDER WASHER STEEL SECURITY CHAIN
BOLT SNAPS
COLD SHUTS
STEEL STAPLE PLATE WALL PANEL
PURCHASED DOOR
LD10211
FIG. 5-117 – SECURING DOOR CHAIN ASSEMBLY

FORM 102.20-NOM1 (909)
DIRECT COUPLED DAMPER ACTUATOR PROCEDURE

REPLACEMENT AND ADJUSTMENT See Fig. 5-118
DAMPER BLADE ORIENTATION

Refer to Johnson Controls installation Return Air and Mixing Dampers:
manual for additional instructions and
Position the blades so that they will be open once
specifications.
the actuator is installed. This will be the dampers
spring return position. Note whether the damper
shaft is rotated fully clockwise or counter clock-
wise.
TOOLS REQUIRED
Standard mechanics tool kit. Outside Air and Exhaust Air Dampers:
Position the damper blades so that they will be
MATERIALS REQUIRED closed once the actuator is installed. This will be
• Actuator, locate part number on old actuator. the dampers spring return position. Note whether
the damper shaft is rotated fully clockwise or
counter clockwise.
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 5
MOUNTING BKT
JACKSHAFT
ACTUATOR
MANUAL
CRANK
SPRING HOSE
CLAMP(S)
LD12144
FIG. 5-118 – DIRECT COUPLED ACTUATOR ON JACKSHAFT

Service & Repair
FORM 102.20-NOM1 (909)
ACTUATOR REMOVAL MIXING DAMPER WALL REPAIR

1. Loosen the actuator shaft clamp to the damper Mixing damper walls on larger YORK Solution units
jackshaft. may become weakened in high CFM operation or
if dampers, and/or dirty filters cause a higher static
2. Remove the mounting bracket by first removing pressure (see Fig. 5-119). This instruction shows a
the self drilling screws from damper frame, then recommended method of fixing this problem.
back the bracket out of the mounting grooves on
the actuator. TOOLS REQUIRED
3. Remove the bearing plate from the damper frame Standard mechanic’s hand tools.
and jackshaft.
4. Slide the damper actuator off the open end of MATERIALS REQUIRED
the shaft. • Uni-strut bracing w/ associated hardware, or
equivalent.
ACTUATOR REPLACEMENT • Angle bracket or gussets w/ associated
hardware.
1. Slide the damper actuator onto the open end
• Screws, self tapping, 1/4".
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 All parts may be found at any electrical
reinstall the actuator with it flipped over. supply house or Home Depot / Lowes
2. Reinstall the bearing plate to the damper frame store.
and jackshaft. Make sure spring hose clamps
hold the jackshaft securely.
3. Slide the damper actuator mounting bracket into
the actuator mounting grooves and fasten to the
damper frame using self drilling screws.
4. Tighten the actuator shaft clamp to the damper
jackshaft. Make sure at this point, the damper
shaft is completely rotated to its proper
position.
5. Manually operate the actuator to its fully
actuated position using the crank arm provided
with the actuator. Then release the spring to
allow the damper to go back to its original
position. This will verify the actuators spring Mixing Damper Wall
rotation and stroke. shown oushed out of
place.
6. Set the damper actuators rotation selector switch
to the proper rotation required to actuate the
damper.
This will always be opposite the spring

return rotation. LD12715
FIG. 5-119 – MIXING DAMPER WALL PUSHED

OUT OF PLACE

FORM 102.20-NOM1 (909)
MIXING DAMPER WALL 2. Once mixing damper wall is correctly positioned,

(FLAT SIDE SHOWN) secure the wall by running 1/4" self tapping
screws through the wall flange into the side panel
Flange (see Fig. 5-120).
SIDE
PANEL A maximum spacing of 8" between
screws is recommended.
Install self tapping
screws through
flange on Mixing
Damper Wall into
Side Panel. Space
screws no more
than 8" apart
3. Once the mixing damper wall is properly
positioned and secured, install bracing (standard
Uni-strut or equivalent) vertically from ceiling
to floor (see Fig’s. 5-121 & 5-122).
LD12716
Fig. 5-120 – S
ECURE MIXING DAMPER WALL TO Install bracing on one side of the
SIDE PANEL mixing damper wall only. It is best
to install it on the flat side of the wall
PROCEDURE whenever possible.
1. Push mixing damper wall back into original
(vertical) position.
BACK SIDE OF MIXING

DAMPER WALL
3/8" or 1/2" bolt

and large washer
5
Install standard
Unistrut bracing
against ends of
dampers with damper
associated frame
hardware.
LD12717
LD12719
FIG. 5-121 – INSTALL BRACING TO MIXING DAMPER WALL ON EITHER SIDE OF DAMPERS

Service & Repair
FORM 102.20-NOM1 (909)
a. I nstall bracing on each end of the damper 4. Provide additional support by installing angle
and between dampers whenever possible brackets or gussets at the top and bottom of the
(see Fig’s. 5-121 & 5-124). bracing.
b. Center bracing between dampers and place
bracing up against each end of the damp-
ers.
Angle bracket installed
c. Secure all bracing to mixing damper wall between Uni-strut brac-
with associated hardware (3/8" or 1/2" bolts, ing and ceiling.
nuts and large washers).
Uni-strut bracing
centered between
dampers and installed
with associated
hardware.
Uni-strut bracing.
Angle bracket
installed between
Uni-strut bracing
and floor.
3/8" or 1/2" bolt & nuts.

LD12716
FIG. 5-123 – INSTALL ANGLE BRACKETS

LD12718
FIG. 5-122 – C
ENTER AND INSTALL BRACING
BETWEEN DAMPERS

FORM 102.20-NOM1 (909)
POWER FLAME / ECLIPSE INDUCER FAN

GASKET REPLACEMENT
This procedure tells how to replace gaskets on both
Jackson & Church Eclipse and Power Flame burners. BURNER CONTROL
PANEL
ID Fan Motor
Wiring & Conduit
7800
Series Open fuse
Relay disconnects
Lower before working
US FAN
G
Exhaust on burner.
IN
Vent
HO ID Pressure
Switch
LD12903
Condensate
Line
FIG. 5-125 – OPEN FUSE DISCONNECTS
ID Fan ID Fan
Flange Gasket
2. Remove ID fan wires from terminals M-1 and M-2.
Remove ID airflow switch wires from terminals
LD12915
FIG. 5-124 – ID FAN ASSEMBLY COMPONENT ID-1 and ID-2 (see Fig. 5-126).
CALL OUT
TOOLS REQUIRED
• Allen wrench, 3/16".
Remove ID fan
• Pipe wrenches. wires from terminals
M-1 and M-2
• Socket wrench with 7/16" socket.
• Metal putty knife or equivalent.
• Razor knife or equivalent.
• Caulk gun.
MATERIALS REQUIRED
• Gasket material - Call Product Service and
provide (H) # to obtain proper P/N. Remove ID
airflow switch
• Sealant, Fiber Frax LDS moldable high temp wires from
sealant, 2500˚F max temp to apply, 40˚F min
terminals ID-1
and ID-2
5
temp, available at Grainger (P/N KM87).
LD12732
PROCEDURE
1. Disconnect power to the burner and ID fan at fuse FIG. 5-126 – REMOVE ID FAN WIRES AND ID
disconnects located in the control panel of the main AIRFLOW SWITCH WIRES
burner (see Fig. 5-125).

Service & Repair
FORM 102.20-NOM1 (909)
3. Remove wires completely from the control panel 5. Disconnect the ID fan condensate drain from the
area. Remove Greenfield ID fan conduit from main condensate line by loosening the union with
control panel (See Fig. 5-127). a pipe wrench as shown in Fig. 5-129.
ID Fan
Condensate Trap
Loose union
coupling to
MAIN disconnect ID
Remove wiring COND fan condensate
ENSA
and conduit from TE LIN trap from the
E
control panel main condensate
area. line.
LD12733 LD12716
FIG. 5-127 – R
EMOVE WIRING AND CONDUIT FIG. 5-129 – REMOVE CONDENSATE DRAIN TRAP
FROM CONTROL PANEL
6. Using a 7 /16" socket wrench or nut driver, loosen
4. With a 3/16" Allen wrench, remove the exhaust the top nut on the ID fan flange where it fastens to
vent locking collar cover from the exhaust vent the heat exchanger (do not remove). After remov-
(see Fig. 5-128). Then remove two of the 3/16" ing the remaining nuts, remove the top nut while
Allen bolts from the locking collar (not shown). supporting the ID fan housing (see Fig. 5-130).
Loosen the other two 3/16" Allen bolts and remove
the locking collar. Remove any old sealant from
the groove on the locking collar and set the locking
collar aside.
1 Loosen top
REMOVE 2 PC. LOCKING 7/16” nut but do
COLLAR COVER not remove.
Using 3/16” Allen wrench
remove exhaust vent
Upper locking collar cover by 2 Remove top 7/16” nut
Exhaust removing 2 bolts and
Vent loosening the other 2 bolts.
while supporting ID
fan housing.
Exhaust
Vent Lock- REMOVE 2 PC. LOCKING Id fan
ing Collar COLLAR
flange 3 Remove remaining
Cover After removing the cover, Heat 7/16” nuts.
remove the locking collar
by removing all 4 bolts with exchanger LD12735
a 3/16” Allen wrench.

FIG. 5-130 – REMOVE ID FAN FLANGE FROM
Lower
Exhaust HEAT EXCHANGER
Vent LD12734
FIG. 5-128 – R
EMOVE EXHAUST VENT LOCKING
COLLAR COVER AND LOCKING
COLLAr

FORM 102.20-NOM1 (909)
7. Place your left hand under the extension tube be- 9. Before installing the ID fan housing, use a razor
tween ID fan and flange. Place the fingers of your knife or equivalent to trim the new gasket so that
right hand into the ID fan housing near the squirrel it will fit the heat exchanger opening (see Fig
cage fan. Lift and slide the ID fan housing from 5-133).
the threaded studs on the heat exchanger (see Fig
5-131).
Trim new gasket to fit

opening of heat
Place fingers of exchanger before
right hand into attaching the gasket.
fan housing near
squirrel cage.
Lift fan
housing
and slide
Place left off threaded
hand under studs.
extension LD12739
tube.
LD12736 FIG. 5-133 – TRIM GASKET
FIG. 5-131 – R
EMOVE ID FAN HOUSING FROM 10. Holding sheet metal cover panel 1/8" away from
HEAT EXCHANGER heat exchanger, apply moldable high temp sealant
(Fiber Frax LDS). See Fig 5-134.
8. Remove the old gasket from the ID fan flange.
Remove any remaining gasket material from the
ID fan flange and heat exchanger with a metal putty
knife or equivalent (see Fig 5-132).
HEAT
EXCHANGER
HEAT
EXCHANGER
COVER SHEET
METAL PANEL
Caulk with high temp
Remove all sealant between heat
old gasket exchanger and cover
material sheet metal panel. LD12740
from heat
exchanger
LD12737
FIG. 5-134 - C
AULK BETWEEN HEAT
5
EXCHANGER AND SHEET METAL
COVER SPANEL
ID FAN
FLANGE
Remove old
gasket from
ID fan flange.
LD12738
FIG. 5-132 – R
EMOVE OLD GASKET
Service & Repair
FORM 102.20-NOM1 (909)
11. Install new trimmed gasket over threaded studs 14. Apply moldable high temp sealant into both
on heat exchanger. Caulk the entire inner gasket grooves of the locking collar (see Fig. 5-137).
edge with moldable high temp sealant (see Fig.
5-135).
HEAT
EXCHANGER
Install new Caulk with high temp Apply moldable high temp
gasket over sealant around entire sealant to grooves in both
threaded edge of gasket. halves of locking collar.
studs on heat
exchanger. LD12741
FIG. 5-135 – INSTALL NEW GASKET AND CAULK

GASKET INNER EDGE
12. Install ID fan flange onto threaded studs on heat

exchanger. Install top 7/16" nut first to hold the ID
fan housing in place while installing the remainder
of the 7/16" nuts (see Fig. 5-136).
HEAT LD12914
EXCHANGER
ID FAN
FLANGE FIG. 5-137 – APPLY SEALANT TO LOCKING
COLLAR GROOVES
Install Top nut first to

Install remaining hold ID fan housing 15. Install the locking collar and tighten the four 3/16"
7/16” nuts.
Allen bolts.
16 Install the exhaust vent locking collar cover
ID FAN and tighten the four 3/16" Allen screws (see Fig
HOUSING 5-128).
LD12913
FIG. 5-136 – INSTALL ID FAN FLANGE ONTO

HEAT EXCHANGER
13. Install ID fan conduit and wiring into control

panel area. Attach wiring in the same positions as
removed in step 2. Refer to Figs 5-126 & 5-127.

FORM 102.20-NOM1 (909)
TABLE 5-8 – TROUBLESHOOTING TIPS
Sheave(s) not tight on shaft(s) (motor or fan). Tighten sheave(s). ►

Belts hitting belt guard. Adjust or tighten belt guard mounts. ►
Belts loose. Adjust to proper tension. Belts should be checked twice during first days
operation and periodically thereafter. ►
Belts too tight. Adjust to proper tension. ►
DRIVE NOISE Belts are wrong cross section to fit sheaves. Install proper belts. ►
Belts not matched in length on multi-belt drive. Install matched belts. ►
Misaligned sheaves. Align sheaves properly. ►

Belts worn. Replace belts. ►
Motor, base or fan not securely anchored. Anchor loose components as required. ►
Belts oily or dirty. Clean or replace belts. ►
Defective bearing. Repair or replace bearing. ►
Bearing needs lubrication. Lubricate bearing as required. ►
Bearing loose on bearing support. Tighten bearing support bolts. ►
Bearing loose on shaft. Tighten bearing to shaft. ►
BEARING NOISE Bearing misaligned (check alignment binding.) Align properly. ►
Foreign material inside bearing. Disassemble, inspect and clean or replace bearing
as required. ►
Fretting corrosion between bearing inner race and shaft. Clean or replace bearing as
required. ►
Ductwork too small. Increase duct sizes to obtain proper air velocity. ►
Fan running too fast. Check for proper fan RPM. ►
Static pressure lower than expected. Reduce fan speed to obtain desired flow rate. ►
HIGH VELOCITY AIR NOISE
Objects which are installed in a high velocity airstream can generate noise. This
includes flow sensors, turning vanes etc. ►
Registers and grilles too small. Install correct registers and grilles as required. ►
Dampers obstructed. Remove obstruction. ►
Diffusers obstructed. Remove obstruction. ►
Loose dampers or splitters. Tighten as required. ►
RATTLE OR WHISTLING NOISE
Loose grilles. Tighten grilles as required. ►
IN AIR STREAM
Sharp elbow(s). Install elbow(s) with larger turning radius. ►
Sudden expansion or contraction of ductwork. Install proper ductwork transitions. ►
Turning vanes loose or not properly installed. Tighten and / or reinstall as required. ► 5
Continued on next page

Service & Repair
FORM 102.20-NOM1 (909)
TABLE 5-8 – TROUBLESHOOTING TIPS (CONT.)
Fan wheel installed backwards. Install in correct position. ►

Fan wheel rotating backwards. Reverse any two power leads to fan, to change rota-
tion. ►
Fan wheel not centered in inlet cones. Realign fan to center of inlet cones. ►
Fan speed too slow. Check for proper fan RPM. ►
Actual duct system has more resistance to flow than originally designed. Enlarge
ductwork or remove restrictions to match design requirements. ►
Dampers closed and / or splitter rod disconnected. Open dampers and connect split-
ter rod. ►
Fire damper(s) closed. Open fire damper(s). ►
Registers closed. Open registers. ►
CFM LOWER THAN REQUIRED Insulating duct liner loose. Reattach loose duct liner. ►
Leaks in supply ducts caused by open seams or holes in ductwork. Repair seams
and / or leaks in duct system. ►
Air filters dirty or clogged. Remove clogging debris and / or clean filters. ►
Coils dirty or clogged. Remove clogging debris and / or clean coils. ►
System not balanced properly. Balance system per design specifications. Pay close
attention to external static pressure “design” vs. “actual”. ►
Not enough length of straight duct at fan outlet before turn or restriction. Increase
length of straight duct at fan outlet or increase fan RPM to offset performance loss.
Note: Observe fan RPM limits per manufacturer's guidelines. ►
Obstructions in fan discharge duct. Remove obstructions. ►
Oversized ductwork. Reduce duct sizes or decrease fan RPM to obtain desired flow.
►
Unit access door open. Close all unit access doors.
System not balanced properly. Balance system per design specifications. Pay close
CFM HIGHER THAN REQUIRED
attention to external static pressure “design” vs. “actual”. ►
Registers or grilles not installed. Install all registers and grilles per design specific-
ations. ►
Unit air filters not in place. Install air filters. ►

FORM 102.20-NOM1 (909)
Take ammeter readings on all three phases of motor to verify accuracy of ammeter.
►
High line voltage. Consult power company. Could possibly reduce voltage by using
lower transformer tap. ►
MOTOR-HIGH CURRENT DRAW Motor overloaded. Reduce load or use larger HP motor. ►
Low line voltage. Consult power company. Could possibly increase voltage by using
high transformer tap. ►
Re check air distribution system and air balance report for low static pressure or air
leaks in the unit or ductwork.
Unbalanced line voltage due to power supply, unbalanced electrical system loading
in building, high resistance connection or undersized power supply lines. Carefully
check voltage across each phase at the motor terminals with a quality, properly cali-
brated voltmeter. If the voltage per phase is more than 1 % out of balance, the current
will be out of balance by an even greater percentage. ►
MOTOR UNBALANCED If in doubt as to whether the problem is with the motor or incoming power supply lines
CURRENT DRAW perform the following test: Rotate all three input power lines to the motor by one posi-
tion - i.e., move line #1 to motor lead #2, line #2 to motor lead #3 and line #3 to motor
lead #1. If the unbalanced current draw pattern follows the input power lines the
problem is the power supply. Correct the voltage balance of the power supply. If the
unbalanced current draw pattern follows the motor leads the problem is a defective
motor. Replace motor. ►
Excessive starting or running load. Reduce load or install larger motor.
Inadequate power supply. Consult power company.
MOTOR-EXCESSIVE
VOLTAGE DROP Undersized power supply lines. Increase supply line sizes.
High resistance connections. Eliminate poor connections.
Motor overloaded. Reduce load or install larger motor. ►

Blocked ventilation. For ODP motors blow out internal ventilation passages with air
pressure and eliminate external interference to motor ventilation. For TEFC motors
clean external ventilation system and check motor ventilation fan.
MOTOR - RUNS High ambient temperature over 40°C or 105°C. Reduce ambient temperature or pro-
EXCESSIVELY HOT vide outside source or cooler air.
Unbalanced current draw. Balance supply voltage. Check motor leads for tightness.
►
Motor single phase condition. Eliminate single phasing problem. 5
Motor single phase condition. Shut power off. Eliminate single phasing condition.
Check motor leads for tightness. ►
Rotor or bearings locked or frozen. Shut power off. Check shaft for freeness of opera-
MOTOR -WILL NOT START
tion. Replace bearings. Check overload relay sizing and verify overload relays are in
each of the 3 phases of the starter. ►

Service & Repair
FORM 102.20-NOM1 (909)
Motor single phase condition. If motor cannot be restarted it is single phased. Elimi-
nate single phasing condition.
Motor single phase condition. Check overload relay sizing and verify overload relays
MOTOR -RUNS NOISY are in each of the 3 phases of the starter.
UNDER LOAD Motor shaft bearing damaged. Replace bearing. ►
Supply voltage high or inconsistent supply frequency. Adjustable frequency control-
lers can generate motor noise.
Motor overloaded. Reduce load or increase voltage.
Excessively low voltage. A reasonable overload or voltage drop will reduce motor
MOTOR – LOAD SPEED CONSID-
speed only 1 - 2%. A drop of any greater magnitude would be questionable.
ERABLY BELOW NAMEPLATE
SPEED Inaccurate method of measuring RPM. Check motor using another RPM measuring
device or method. ►
Motor mounting loose. Check motor mounting and be sure it is tight and solid.
Load unbalanced. Disconnect belt and restart motor. If vibration stops, the load is
unbalanced. Balance the load.
MOTOR - EXCESSIVE VIBRATION Remove drive sheave and tape 1/2 key in shaft keyway and restart motor. If vibration
stops the sheave is unbalanced. Replace sheave. ►
If after checking all other options above and motor still has excessive vibration, the
motor is unbalanced. Replace motor. ►
Bearing produces smooth mid-range hum. Normal fit, bearing is OK.
High whine. Internal fit of bearing too tight. Replace bearing and check it. ►
Low rumble. Internal fit of bearing too loose. Replace bearing, check fit. ►
MOTOR - NOISY BEARINGS
Rough clatter. Bearing destroyed. Replace bearing. ► Avoid mechanical damage,
excessive greasing, wrong grease, ► solid contaminants and water running into
motor.
Determine if noise is from motor or fan. Isolate motor from fan and check difference in
noise level.
Fan noise transmitted to motor through drive. Reduce fan noise or dampen noise
transmission to motor.
MOTOR - MECHANICAL NOISE
Be sure fan vibration isolator shipping brackets are removed. If still in place remove
shipping brackets to allow vibration isolation of fan and motor. ►
Manual reset thermal cutout in electric heater control circuit tripped. Check reason for
tripping and correct. Reset manual cutout switch.
Airflow switch interlock not closed. Check airflow sensing tube for proper location in
airstream and for possible damage. Repair or replace airflow switch and / or sensing
tube as required.
NO ELECTRIC HEAT
Broken electric heating element. Replace element.
Heat limiters blown. Replace heat limiters.
Electric heater circuit fuses blown. Replace fuses.
Defective electric heating circuit contactor. Repair or replace contactor as required.

FORM 102.20-NOM1 (909)
Defective hot water or steam valve actuator motor. Replace actuator motor. ►
Broken control linkage from actuator to valve assembly. Repair or replace actuator
NO HOT WATER OR STEAM HEAT
linkage. ►
Defective hot water or steam control valve. Replace valve. ►
Airflow too high – See “CFM HIGHER THAN REQUIRED” ►.
Drain pan full – See “DRAIN PAN NOT PROPERLY DRAINING”. ►

Water spraying out of drain pan – “DRAIN PAN NOT PROPERLY DRAINING”. ►
WATER CARRY-OVER FROM
WETCOOLING COIL ONTO Coil Bulkhead penetrations – Be sure any field penetrations are sealed. ►
FLOOR, MOTOR OR
FAN HOUSING If intermediate drain pans on the coil face are present – Be sure they drain properly,
checking for debris and damage. ►
Check auxiliary drain pans under coil headers – Be sure they drain properly into the
main drain pan, checking for debris or damage. ►
If unit shipped in more than one piece – Be sure these field reassembly joints are
properly sealed against rain water and air leaks. ► ►
If field piping or electrical conduits penetrate the unit – Be sure they are sealed prop-
WATER INSIDE UNIT
erly. The electrical conduits must be sealed internally to prevent airflow and moisture
condensation. ►
Be sure trap is installed and of correct size and construction. ►
Be sure unit is installed level on curb, steel or pad. ►

DRAIN PAN NOT PROPERLY Check the segment which houses the drain pan. Be sure it is under the correct pres-
DRAINING
sure (positive or negative) and that pressure does not exceed the design for that
segment per the design data sheet in the submittal.
If outside air hoods are shipped loose – Be sure they are properly installed and
sealed at top flange. Some hoods may be shipped with mist eliminators or prefilters to
PRE-FILTERS ARE WET be mounted in the hood openings when hoods are being installed. ►
If unit has outside air opening – Be sure airflow does not exceed the design for out-
side air per the design data sheet in the submittal.

Service & Repair
FORM 102.20-NOM1 (909)
Check for dirty filters. Filters may load much more rapidly if construction is on going
in the immediate area, if certain area vegetation releases airborne substances or if
insect swarms are present. ►
Check for wet filters or snow loading – See PRE-FILTERS ARE WET.
FILTERS OUT OF FILTER RACK Check for damage to the filter racks, filter frames, filter headers or filter tracks. ►
Check for missing filter clips or latches when required. ►

Be sure air pressure drop (APD) across the filters does not exceed design – See Engi-
neering Guide Form 100.10-EG2, “FILTER APD”.
Verify external safety circuit is wired in at correct terminals and it has continuity.
AIR MODULATOR (AIRMOD) WILL Verify control signal is wired in (or piped in if pneumatic) at correct terminals and is of
NOT OPERATE correct type.
Refer to Installation, Operation, Programming, Troubleshooting and Technical Support
information packed inside Airmod.
AIR LEAKS
UNIT SWEATING
DAMPERS NOT OPERATING
PROPERLY
Misalignment of drive components.
Loose foundations or mounting structure. (Resonance's).
Foreign material attached to rotating components.
Damaged rotating components. (Bearings, shaft, fan, wheel, sheaves).
Broken, loose or missing setscrews.
Loose belts.
Vibration may be coming from a source other than the fan. Stop the fan and deter-
FAN VIBRATION ►
mine if the vibration still exists. Disconnect the driver motor from the fan and operate
it by itself to determine if it produces vibration.
Water accumulating in airfoil blades.
Fan is operating in stall or unstable flow region (see fan curve).
Loose bolts on bearings, housing, hub or sheaves.
Loose locking device on bearing.
Finally, have the vibration professionally analyzed.
Check for obvious damage.
Check unit location for flat level surface of curb or housekeeping pad. Uneven sur-
face will rack unit causing door to bind.
DOOR BINDING Check door frame for bow or twist.
Measure corner to corner of door and frame independently. If frame is out of square,
remove and re-install door frame and door as an assembly. If door is out of square,
replace door frame assembly.

FORM 102.20-NOM1 (909)
6.0 WIRING SCHEMATICS
External wiring, unless specified as an optional connection in the manufacturer’s product

line, is not to be connected inside the control panel cabinet. Devices such as relays, switches,
transducers and controls may not be installed inside the control panel. No external wiring
is allowed to run through the control panel. All wiring must be in accordance with Johnson
Controls published specifications and must be performed only by qualified Johnson Controls
personnel. Johnson Controls will not be responsible for damages/problems resulting from
improper connections to the controls or application of improper control signals. Failure to
follow this will void the manufacturer’s warranty and cause serious damage to property or
injury to persons.
Rotating parts and electrical shock The purpose of drawings in this sec-
hazards exist. Lock out and tag out tion is to aid in installation, startup
the fan motor(s) and heat power and troubleshooting. Actual wiring
disconnects before servicing. FOL- configuration may deviate from these
LOW THE LATEST “LOCKOUT drawings and are subject to change
TAGOUT” PROCEDURE. Failure without notice.
to follow proper safety precautions
may result in serious injury or death. DO NOT PENETRATE WIREWAYS
Refer to general safety guidelines and in any manner. These sheet metal
safety symbols located at the front of channels, which run along the top
this Manual. ► panel, contain electrical wires and
connections. Electrical shock and/or
damage to the unit may result.


Wiring & Schematics
FORM 102.20-NOM1 (909)
PDTB
L1
208/230/380/460VAC
3 PHASE INPUT
L2
50/60 HZ
L3
1 2
NOTE: CUSTOMER SUPPLIED

DISCONNECT MUST MEET
LOCAL CODES. L2 L3
FU1 FU1
2L2 2L3
SEE TRANSFORMER 7
CONNECTION DIAGRAMS
1 2 FOR PROPER T1
FU2
2 1 X1 CONNECTIONS X2
A A
8 3
A
A,B OFF RUN/TIME 6
HAND AUTO CLOCK
OOX 5
SAFETIES
B A AB
1 3 A FIRESTAT FREEZESTAT
OL1 8 14 X2
2 XOO 6 7
M1
C C BC SS1 B A,B A,B
2 4
OPTIONAL B J J
REMOVE JUMPER WHEN
CONNECTING SAFETIES CONTROL
2 CONTROL POWER X2 POWER
C OPTION B 9 UP TO (4)
8 1 PANEL 2 100VA TRANS.
OR LOW TEMP.
RESET
20 M1 21 LTC
OPTION
PANEL
WIRED IN YELLOW
OPTION
DISC1 FU3
DISC1
L1 L1
208/230/380/460VAC
208/230/380/460VAC
3 PHASE INPUT
3 PHASE INPUT
L2
50/60 HZ
L2
50/60 HZ
L3 L3
OPTIONAL OPTIONAL
DISCONNECT FUSED DISCONNECT
NOTE: CUSTOMER SUPPLIED NOTE: CUSTOMER SUPPLIED
DISCONNECT MUST MEET DISCONNECT MUST MEET
LOCAL CODES. LOCAL CODES.
FIG. 6-1 – FULL VOLTAGE STARTER (204194)

FORM 102.20-NOM1 (909)
M1 OL1 T1
T2
3PH
MOTOR
T3
NOTES:
- TERMINAL POINT
- REMOTE DEVICE (BY OTHERS)
CT1 M1
CT2
3PH
MOTOR
CT3
OL1
ALTERNATE OL1 - USED WITH CT1,2,3 WHEN MOTOR
ALTERNATE OL1 FLA. IS GREATERTHAN 80 AMPS.
LD09683 6

Wiring & Schematics
FORM 102.20-NOM1 (909)
DISC
L1
208/230/380/460VAC
3 PHASE INPUT
L2
50/60 HZ
L3
NOTE: CUSTOMER SUPPLIED

DISCONNECT MUST MEET
LOCAL CODES. 1 2
L2 L3
FU1 2KVA FU1

TRANSFORMER
2L2 2L3
SEE TRANSFORMER E
CONNECTION DIAGRAMS T1 7
1 2 FU2 FOR PROPER 2KVA
2 1 X1 CONNECTIONS X2
A C AB ABD E
8 3 ABC
LINE X2
B B
GFI AC
LOAD
A A
SERVICE
LIGHT
SWITCH S
L N
B AB A A A C
6 A
A,B OFF RUN/TIME
HAND AUTO CLOCK
OOX 5
SAFETIES
B A AB
1 3 A FIRESTAT FREEZESTAT
OL1 8 14 X2
2 XOO 6 7 SUPPLY
M1
BC SS1 B A,B A,B FAN
4 A A,B
J J
OFF RUN/TIME REMOVE JUMPER WHEN
HAND AUTO CLOCK CONNECTING SAFETIES
OOX 9
CD A
5
OL2
2 XOO 10 RETURN
M2
E E DE SS1 B A,B B FAN
2 6
OPTIONAL B
CONTROL
2 CONTROL POWER X2 POWER
OPTION UP TO (4)
8 E 1 PANEL 2 B 9
100VA TRANS.
OR LOW TEMP.
RESET
20 M1 21 22 M2 23 LTC
OPTION
PANEL
WIRED IN YELLOW
OPTION
1 2
L2 150VA OR 500VA L3
TRANSFORMER
FU1 FU1
2L2 2L3
SEE TRANSFORMER
CONNECTION DIAGRAMS 7
FOR PROPER T1
FU2
1 X1 CONNECTIONS X2
3
FIG. 6-2 – FULL VOLTAGE STARTER WITH SINGLE POINT POWER CONNECTION (204195)

FORM 102.20-NOM1 (909)
DISC2
FU3 M1 OL1 2T1
2T2
3PH SUPPLY FAN
MOTOR
2T3
USED WHEN FUSES

ARE GREATER
THAN 60 AMP.
DISC3
FU4 M2 OL2 2T1
2T2
3PH RETURN FAN
MOTOR
2T3
CT1 M1
CT2
3PH
MOTOR
CT3
SUPPLY FAN
OL1
CT4 M1
CT5
3PH
MOTOR
CT6
SUPPLY FAN
OL2
NOTES:
- TERMINAL POINT
- REMOTE DEVICE (BY OTHERS)
LD09684 6

Wiring & Schematics
FORM 102.20-NOM1 (909)
Panel part # 025-39132-000 or 025-39133-000
1. This kit will be required for some of

the Johnson FEC control standards
(100% outside air).
2. install relay (025-39136-001) on din

rail provided in panel at the location
shown.
Components on din rail will need to be
shifted down to allow relay to fit.
3. Wire relay as shown on the diagram

below using the wire called for in kit.
Install Relay
LD12500
DAMPER INTERLOCK RELAY CIRCUIT

FROM FEC CONTROLLER OUTPUT
A1
IR-1 A2
LOCATED IN SUPPLY FAN MOTOR CONTROLLER.
R BLK
OUT1 BO SF-C
OCOM1 R BLK
N.O. C
11 14 RUN COMMAND
R
LOCATED IN MB/FM
21 24 BO OAD-C
R R R BLK
3C 6C
SIGNAL COM
FIG. 6-3 – OUTSIDE AIR DAMPER KIT - RELAY INSTALLATION

FORM 102.20-NOM1 (909)
FIG. 6-4 – TERMINATION CHART INSIDE ENCLOSURE DOOR

Wiring & Schematics
FORM 102.20-NOM1 (909)
DEVICE TERMINAL
IDENTIFICATION IDENTIFICATION
TB1-13 A1
A B
NODE
NUMBER
14
14A A,B,C,D SUFFIX
ex: COMPLETED LETTER
WIRE NUMBER A2
A1
C
CR2
115 VOLT SUPPLY
PLUG
1 2
2A X2A
TB2-1 TB2-2
BLK 2C X2C WHT
115V
A,C,D 2 T1 A,C,D X2
TB2-3 TB2-4 100VA TB2-5 TB2-6
J BLU 6D 2C YEL J
24V
5 6 7 8
B,C,D B,C,D B,C,D C,D
BLK 2D X2D WHT

115V
T2
TB2-7 100VA TB2-8
BLU 9D 10C YEL
24V
9 10
D C
TB2-9 TB2-9 SUPPLY FAN

A1 A2
6B C B A D 15D 7B START / STOP
CR1
CUSTOMER SUPPLIED
START / STOP CONTACT
TB2-10 TB2-10 A1 A2 RETURN/EXHAUST FAN
6C C B A D 16D 7D START / STOP
CR2
CUSTOMER SUPPLIED
START / STOP CONTACT
11 CR3 14 TB2-11 TB2-11 TB2-12 TB2-12 A1 A2

5C 17B J J 8D
B C D A LTC A D B C 18C
CR3
17 18 18
17
1 1B
5B 17C 17D
PB1 TR1
4 5 1
5D 8C
2 3
1 SECOND RESET LATCH

21 CR3 22
LOW TEMPERATURE CUTOUT STATUS
NOTES:
1. THIS DRAWING IS A TYPICAL AS WIRED DRAWING AND IS NOT CREATED ON A PER UNIT ORDER BASIS,
ONLY FACTORY PROVIDED OPTIONS ARE SHOWN.
2. THE LOW VOLTAGE TRANSFORMERS IN THE CONTROL ENCLOSURE ARE FOR
FACTORY PROVIDED END DEVICES ONLY.
LD09686A
FIG. 6-5 – YORK SOLUTION FPC WIRING (204197)

FORM 102.20-NOM1 (909)
X2(B) S
LINE 1(B)
WHITE HOT
L(A)
WHITE HOT
N
LOAD L(A) L(B)
X1
X2(B)
X2(A) TO TRANSFORMER
2L2
2L3
GND
X1
GRD
FU1 FU1 FU2
N L S 1 X2
GND
N L(B) S 1(A) X2(A) 2L2 2L3 1(A) 1(B)
LD09691
FIG. 6-6 – TRANSFORMER ENCLOSURE WIRING DETAIL SHOWN OPEN

Wiring & Schematics
FORM 102.20-NOM1 (909)
1 2
L2 L3
FU1 2KVA FU1

TRANSFORMER
7
2L2 2L3
SEE TRANSFORMER E
CONNECTION DIAGRAMS T1
FOR PROPER 2KVA
FU2 CONNECTIONS
1 X1 X2
C AB ABD E
ABC
3
LINE X2
B B
GFI AC
LOAD
A A
SERVICE
LIGHT
SWITCH S
L N
B AB A A A 6 C
LD09692
FIG. 6-7 – TRANSFORMER WIRING DIAGRAM

FORM 102.20-NOM1 (909)
085-013-001 NEW
FIG. 6-8 – UV CONTROL PANEL WIRING - 8A

Wiring & Schematics
FORM 102.20-NOM1 (909)
085-013-002 NEW
FIG. 6-9 – UV CONTROL PANEL WIRING - >8A

FORM 102.20-NOM1 (909)
FIG. 6-9 – UV CONTROL PANEL WIRING - >8A (CONT)

Wiring & Schematics
FORM 102.20-NOM1 (909)
LD11599
FIG. 6-10 – GAS HEAT, SINGLE PHASE, 1500VA TRANSFORMER, WIRING DIAGRAM

FORM 102.20-NOM1 (909)
LD11690
FIG. 6-11 – GAS HEAT, (1) THREE PHASE MOTOR, 1000VA TRANSFORMER, WIRING DIAGRAM

Wiring & Schematics
FORM 102.20-NOM1 (909)
LD11691
FIG. 6-12 – GAS HEAT, (2) THREE PHASE MOTORS, 500VA TRANSFORMER, WIRING DIAGRAM
©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 102.20-NOM1 (909)
www.johnsoncontrols.com Replaces 102.20-NOM1 (105)

Form Number: 102.20-NOM1 (LS01) 307
Supersedes: 102.20-NOM1 (LS01) (606)
LITERATURE SUPPLEMENT File with: 102.20-NOM1 (105)

Subject: Pipe Chase Installation Instructions for Solution Air Handler
PIPE CHASE INSTALLATION 1. Preparation

Pipe chase should be installed before • Pinpoint the exact location to attach the pipe
piping is connected. chase.
• Ensure enough space will remain to apply
pipe fittings with insulation, inside the pipe
chase.
• The pipe chase height should align with the
TOOLS REQUIRED unit height.
• Screw Gun 2. Apply Gaskets
• Complete set of mechanics hand tools. • Apply provided 2” x 3/16” neoprene gasket
MATERIALS REQUIRED
to the underside of the air handler roof
overhang (see Fig. 1).
• Shipped loose package containing 1/4"-14 x
1" Self-drilling Screws w/gasket (021-30530-
052), Caulking (013-03317-040), Gasket,
Neoprene, 2" x 3/16" (028-11880-010). When
unit purchased with Baserail: Pipe Chase
Baserail Covers (013-03317-010), 3/8"-16 x 1-
1/2" Bolts (021-01499-000) and Lock Washers
(021-01155-000).
AIR HANDLER
Apply gasket
PROCEDURE
caulk/sealant containing silicone in or LD11564
exception is when provided (high tem- FIG. 1 – INSTALL GASKET UNDER ROOF
OVERHANG
perature) with gas heat venting]
• Apply gasket provided by curb vendor to top
The top and bottom flanges are inside of curb.
pipe chase. Separate cover angles are • Apply 2” x 3/16” neoprene gasket to the pipe
used on external vertical seams. chase (vertical gaskets first, then horizontal
gaskets). Keep the gasket aligned with the
outside edges of the pipe chase housing (see
Fig. 2).
Before installing pipe chase, remove Horizontal gaskets must completely
any self-drilling screws from the top overlap vertical gaskets in all four
& bottom raceway that may interfere corners (see Fig. 2).
with the installation of the pipe chase
or trim angles.
FORM 102.20-NOM1 (LS01) (307)
3/8"-16 X 1-1/2" BOLT,

3 021-01499-000
3
(typ.6)
2 Install horizontal LOCK WASHER, UNIT BASERAIL

gaskets second 021-01155-000
(typ.6)
3 Horizontal gaskets
completely overlap
vertical gaskets in
PIPE CHASE all four corners
RIVET NUT
(installed by factory)
1 Install vertical gaskets first BASERAIL COVER PIPE CHASE

(installed later - BASERAIL
see Fig.11)
FIG. 3 – PIPE CHASE BASERAIL TO UNIT

BASERAIL INSTALLATION (When Purchased)
PIPE CHASE
3
IInstall
nstall with self drilling screws. Insert screws
into, and between, all pre-punched holes in
3 flange. Typical
Typical for
for both
both top
top and
and bottom
bottom
flanges.
FIG. 2 – APPLY GASKET TO PIPE CHASE
3. Attach Pipe Chase

• Set the pipe chase on the pipe chase curb
three inches away from the air handler.
• Tilt the top of the pipe chase toward the air
handler. Work it under the air handler roof
overhang, being careful not to damage the
neoprene gaskets. Lift the pipe chase slightly FIG. 4 – SCREW PIPE CHASE TO AIR HANDLER
to clear the gasket on the curb and swing the TOP AND BOTTOM INTERNAL FLANGES
bottom into the air handler.
• If there is a baserail, attach the baserail of the Do not over tighten or strip self-drill-
pipe chase to the baserail of the air handler. ing screws. Screws in top and bottom
Use 3/8" bolts & lock washers provided, flanges go into heavier gauge metal
placing bolts through the pipe chase baserail than screws in cover angles.
brackets into the threaded holes in the air
handler baserail (see Fig. 3).
• Make sure the pipe chase is square and the • Check to be sure door closes and latches
door(s) close and open without rubbing or properly. If not, loosen self-drilling screws,
binding. re-align pipe chase and re-tighten screws.
Occasionally the curb under the pipe chase
• Secure the pipe chase to the top and bottom may be uneven, depending on installation.
raceways (heavy gage metal) of the air
handler through the pre-punched holes of 4. Seal Pipe Chase to Air Handler.
the inside top and bottom flanges of the pipe • Apply caulking to all exterior joints between
chase. Use self-drilling screws (see Fig. pipe chase and air handler baserails (when
4). purchased) (see Fig. 5).
2 YORK INTERNATIONAL
FORM 102.20-NOM1 (LS01) (307)
AIR HANDLER
Caulk
Caulk as shown by PIPE CHASE
dotted line (visible)
and
dashed line (hidden).
A
Apply
pply caulk between
Pipe Chase and Air
Handler
AIR HANDLER
PIPE CHASE
FIG. 7 – PIPE CHASE TO AIR HANDLER CAULK

APPLICATION
FIG. 5 – BASERAIL CAULK APPLICATION
Cover angles must be installed before
Line up self-drilling
screws with existing the caulk from step 4 dries.
screws on roof.
AIR HANDLER
5
3
1
2
IInstall
nstall self-drilling
4
screws starting in
• Apply 2" x 3/16" neoprene gasket to contact
middle and working side of cover angle.
towards ends.
PIPE CHASE • Remove top and bottom self-drilling screws
from pipe chase and set aside for later use.
FIG. 6 – PIPE CHASE TO ROOF INSTALLATION
• Place cover angles in vertical corners of pipe
• Add a small bead of Sikaflex or Manus chase and unit wall.
champagne caulking to the exterior vertical
seam between the air handler and the pipe
chase to insure complete seal. Pay special
attention to the top & bottom corners,
raceway & baserail engagements and under
A
AIR
IR HANDLER
the roof overhang (see Fig.'s 5& 7). PIPE CHASE
• Starting at the center, and working toward
each end, run self-drilling screws down
through the air handler overhang into the top Install Cover
of the pipe chase through the gasket. Use Angle between
caution not to strip the 20-gage housing with Cover Angle Air Handler and
shown with Pipe Chase
the screws. Line up self-drilling screws with gasket side before caulk
double row of screws on top of unit raceway, out dries
plus one spaced evenly between each (see FIG. 8 – INSTALL COVER ANGLE
Fig. 6) (No caulking required here.)
5. Install the Cover Angles Notch on cover angle must be on the
air handler side (see Fig.9).
(See Fig. 8)
YORK INTERNATIONAL 3
Install (2) top and (2) bottom
AIR HANDLER
self-drilling screws first.
PIPE CHASE
PIPE CHASE
AIR HANDLER
Put
Put notch on cover angle
on Air Handler side.
FIG. 9 – PROPER POSITIONING OF COVER

A
Alternating
lternating between Air
ANGLE WITH NOTCH ON AIR HANDLER Handler and Pipe Chase,
SIDE install remaining self-drilling
screws starting at the top and
• Attach the cover angle to the air handler and working toward the bottom.
pipe chase panels. Install self drilling screws
removed earlier to top and bottom holes on
cover angle.
• 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 20-
gage housing with the (see Fig.10).
FIG. 10 – PROPER PATTERN FOR INSTALLING
6. Install the Baserail Covers SELF-DRILLING SCREWS.TO COVER ANGLE
(See Fig. 11)
• Caulk perimeter of cover as shown.
• Apply cover to baserail seam between pipe
chase and air handler (both sides) (no screws
required).
All pipe chase floor penetrations UNIT Cover PIPECHASE BASERAIL

BASERAIL
must be flashed, sealed and insulated Installation
APPLY CAULK (013- 1) CAULK PERIMETER
to prevent condensation entering 03317-010) AROUND OF COVER AS SHOWN
PERIMETER OF PART BELOW.
building. BEFORE APPLYING TO
BASERAIL SEAM. 2) APPLY COVER (086-
23998-001) TO
BASERAIL SEAM.
IF ANY QUESTIONS, CONTACT (800) 838-7219, EX- Caulk
TENSION 7448. PIPECHASE BASERAIL
COVER (086-23998-001) Application
FIG. 11 – BASERAIL COVER APPLICATION
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2007 ALL RIGHTS RESERVED
Form 102.20-NOM1 (LS01) (307)
Replaces 102.20-NOM1 (LSO1) (606)
Form Number: 102.20-NOM1 (Ls02) 1108
Supersedes: 102.20-NOM1 (LS02) (605)
Literature supplement File with: 102.20-NOM1 (105)

Subject: Ship Loose Parts for Solution Air Handler
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.
3/8" x 3/4" Button
Head Screw
3/16" Allen
Wrench
3/8" Nut
3/8" Flat
Washer
Allen Wrench Baserail Lifting Lugs Assembled
LD11029A
Bracket p/n 086-11146-001
FIG. 1 – SECOND TIER TIE-DOWN FASTENER PACK P/n 1/2" x 4" Bolt
386-03419-000 (4 each per pack)
1/2" Nut 1/2" Flat

Washer
1/2" Lock
Washer
LD11032A
FIG. 3 – B
ASERAIL SHIPPING SPLIT FASTENER PACK P/n
386-03417-000 (4 each per pack)
Raceway Lifting Lug (at shipping split)

3/8" Nut
3/8" x 1-1/2" Bolt
Raceway Lifting Lugs

(assembled) 3/8" Flat
Washer
3/8" Lock 1/2" x 5-1/2"
Washer LD11030A
Hex Cap
Screw (2)
FIG. 2 – B
OTTOM RACEWAY SHIPPING SPLIT
FASTENER PACK .56" ID x 1.38"
P/n 386-03418-000 (4 each per pack) 1/2" Hex OD Flat
Nut Lock Washer (2) Washer (2)
LD13349
FIG. 4 – TOP RACEWAY SPLIT FASTENER PACK

P/n 386-04747-000 (2 each per pack)
FORM 102.20-NOM1 (LS02)
Floor, Wall & Indoor Top Seam Cap
Roof Seam Cap (Outdoor)
SEAM CAP
• 1/4"-14 x 1" Phillips Pan Head Tek Screw, P/N 021-19560-000
P/N 021-30530-052 for Outdoor Wall.
ROOF SEAM CAP
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 TRIM ANGLE

P/N 021-30530-052
Apply 2" Gasket

& Caulk
Apply Butyl
PIPE CHASE
P/N 021-30530-052
Apply Caulk
Apply Caulk
PIPE CHASE BASERAIL COVER HOOD
P/N 086-23998-001
• 3/16" x 3/4" Butyl Tape
LD13770
FIG. 5 – PIPE CHASE, HOODS & SEAM CAPS
2 YORK INTERNATIONAL
FORM 102.20-NOM1 (LS02)
CORNER CONNECTOR HOLE PLUG

P/N 021-19568-000

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 & sundries are shipped
loose.
FLUE CAP
CONTAINMENT
BAND
42"L VSI PIPE

(not insulated)
CLOSURE
BAND
STORM COLLAR
UV
LIGHT
TUBE
GAS FURNACE FUEL VENTING PARTS

UV LIGHT TUBES to be installed by contractor.
DO NOT touch UV Lamps (tubes) with bare

hands or leather gloves as oils will damage LD13788
the tubes. Use clean cotton rags, clean jersey

or latex gloves to handle the lamps (tubes).
FIG. 6 – Miscellaneous parts for Options
YORK INTERNATIONAL 3
1/4” X 3-1/2” x 3-1/2” SHIPPING SPLIT
POLYURETHANE CAULK
CORNER GASKET
P/N 013-02966-011
P/N 028-11883-010
Never use silicone caulk/seal- (Outdoor Only)
ant or caulk/sealant contain-
ing silicone in or on any air
handling equipment. [Only
exception is when provided
(high temperature) with gas
heat venting] 12 OZ. TOUCH-UP SPRAY
P/N 013-03322-000
1/4” X 3/4” X 35' NEOPRENE

GRAY GASKET
P/N 028-11873-010
1/4” X 2” X 25' NEOPRENE GASKET 3/16” X 3/4” X 40' BUTYL TAPE

P/N 028-15954-010 P/N 013E-03327-010
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
FIG. 7 – HARDWARE, GASKETING, CAULK, PAINT AND TAPE
©2008 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 102.20-NOM2 (LS02) (1108)
www.johnsoncontrols.com Supersedes 102.20-NOM2 (LS02) (605)
Form No.: 102.20-NOM1 (LS03) 506
Supersedes: None
LITERATURE SUPPLEMENT File with: 102.20-NOM1 (105)
Subject: Installation of Multizone (MZ) Dampers
INSTALLATION OF MULTIZONE (MZ) DAMPERS Distortion will result in unreliable

blade operation.
See Figure 1
SHIPPED LOOSE DAMPERS. If

the MZ segment has a shipping split,
a rear discharge (end of unit), and a 2. Remove 16 gauge shipping plate from air
multizone damper, then the multizone entering side ONLY. Plate is located between
damper will be shipped loose. hot and cold decks.
3. Apply gasket provided (P/N 028-11778-010,
DAMPER INSTALLATION
Neoprene, 1-1/4" W x 1/4" Thk) to the mounting
1. After the unit top tier is assembled to the unit flanges of the damper assembly.
bottom tier and sealed, install MZ damper
4. Center the damper assembly over the discharge
assembly. The assembly includes both hot deck
openings of the hot deck (top) and cold deck
and cold deck damper banks, already connected
(bottom).
at each blade.
ACTUATOR
ACTUATOR EXTENSION PIN
025-39032-002
025-39032-002
SCREW, TEK, PLTD, MTG BKT

1/4"-14 x .75" LG. 086-03474-516
025-19515-000
MTG BKT SCREW,

AIR
086-03474-516 025-19515-000
FLOW
HOT DECK
DAMPER
SHAFT
EXTENSION
KIT SHIPPING
026-33715-001 SHIPPING
PLATE
PLATE
AIR ENTERING
AIR LEAVING
MOUNTING
FLANGES COLD DECK
DAMPER
HOT DECK MOUNTING

DAMPER FLANGES
FACTORY ACTUATOR P/N TORQUE BRACKET

INSTALLED
COUPLER SMALL 025-39032-002 35 IN LBS 086-03474-516
086-03474-516 (Top Disch.)
LARGE 025-30958-008 133 IN LBS
COLD DECK 086-03474-517 (Bottom Disch.)
DAMPER
LD12029
FIG. 1 – MZ DAMPER/ACTUATOR ASSEMBLY

5. Attach the damper assembly to the unit using • The blade linkage (flat rods) connecting
screws provided (P/N 021-19515-000 - screw, all blades of each deck are to be cut at the
hex, self-drilling, 1/4"-14 x 3/4"), through the appropriate places to divide the decks into
outer perimeter mounting flange. correct size zones. These blade linkage rods are
mounted externally on each deck.
6. Remove 16 gauge shipping plate from air leaving
side. • Shaft extensions, clips, hat channels, actuators
and actuator mounting brackets are to be
7. Install screws through mounting flanges found
supplied by the contractor. York P/N's available
between hot and cold decks.
upon request.
• On rear mount (discharge through end of unit),
ACTUATOR INSTALLATION - FIELD SUPPLIED always mount the actuators on the top of the
When actuators are field supplied on multizone damp- upper (hot) deck.
ers, the following information is intended to aid in • Do not allow duct insulation to restrict damper
sizing and selection: blades or external linkage.
• Torque required is 7 inch pounds per square foot
of damper area up to 2500 FPM velocity. • Direct coupled actuators are recommended.
• Damper blades are 6” wide and vary in height. • Duct connections are to be made at the zone
dividers without damper blade restriction.
• Calculate the torque by number and size of
blades in each individual zone. Remember there
are hot deck blades directly connected to cold MAINTENANCE
deck blades. Follow recommendation in IOM (see Section 4 of
• Blades per zone are to be determined by 102.20-NOM1 (105) “Economizer Segment (Damp-
system CFM and static pressure requirements ers)”.
for each zone by the Engineer’s construction
documents.
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Tele. 800-861-1001 Subject to change without notice. Printed in USA
Copyright © by Johnson Controls 2006 www.York.com ALL RIGHTS RESERVED
Form 102.20-NOM1 (LS03)
New Release
Form No.: 102.20-NOM1 (LS04) 109
Supersedes: 102.20-NOM1 (LS04) 208
literature supplement File with: 102.20-NOM1 (105)
Subject: Indirect Fired Gas Heat Start Up - Eclipse Gas Burner Start Up 10:1 - 25:1 Turndown
& Powerflame Gas Burner Start Up 3:1 - 10:1 Turndown
For your safety and satisfaction, this Your gas burner has been carefully
product requires check, test and start- inspected and tested at the factory;
up adjustment by a qualified HVAC however, different conditions at the
technician. Do not use for temporary jobsite, including controls that have
heat prior to start-up. been added at time of installation,
require careful testing and final ad-
justment for satisfactory operation.
Review burner control literature, The Burner Test Report / Factory
including wiring, piping, cut sheets Specification Sheet in each unit shows
and drawings before attempting to the general data recorded during the
start this unit. operation and safety tests at the fac-
tory. This data should be used as a
general guide; with final data recorded
on the start-up form. Do not exceed
All factory test start up burner speci- 550°F flue temperature at the ID fan
fications are located on a laminated inlet. Do not exceed 200°F supply air
“Factory Specification Sheet" located temperature.
on the inside of the control panel
door”.
INTRODUCTION IDENTIFY THE UNIT TYPE

This guideline describes the basic steps a technician Two types of Indirect Fired gas burners are used on
would take in starting an Indirect Fired gas heat system YORK Solution Air Handlers: The Powerflame series
on a YORK Solution Air Handler for the first time. and the Eclipse series. The Powerflame series offers
a turndown (modulating ratio) of 3:1 or 10:1. The
Each gas burner has been test run and inspected at Powerflame is easily identifiable by the motorized gas
the factory. Adjustments to component settings are valve with external linkage connecting the air dampers
typically not required. However, measurements of on the burner air inlet.
system parameters should be taken and compared to the
measurements recorded on the “Burner Test Report” to The Eclipse series uses an air/gas ratio regulator with
ensure safe and reliable operation. The “Burner Test no external linkage, and has a turndown range of 10:1
Report” is laminated to the inside of the burner control to 25:1 (sometimes greater). A visible external plastic
door. tube is used to transmit gas pressure from the burner to
the regulator. No external linkage is used.
Both burners utilize a combustion air blower. YORK

Solution Air Handlers also use an exhaust blower, called
an induced draft (ID) blower. This exhaust blower keeps
the combustion chamber at a slight negative pressure.
Verification of this negative pressure and other system
parameters is part of a proper start up procedure.
FORM 102.20-NOM1 (LS04) (109)
PRELIMINARY COORDINATION AIR HANDLER PRE START CHECKS

Contact contractor/customer who requested start-up. • Verify air handler has had proper start up and
• Verify air handler has had proper start-up. airflow is at design maximum for heating cycle
• Ensure air handler and system is capable of (refer to air balance report).
design airflow for gas heat start-up. • Set bypass damper if provided in air handler.
• Ensure reliable power is available. • Airflow proving switch for main supply fan
• Verify gas lines are purged of air to equipment installed and operational.
valve. • Check with Control Technician: two-minute
• Verify controls are complete. post-purge programmed in air handler controller.
Upon call for air handler unit stop, burner cycles
• Verify flue (stack) is correctly installed if parts off then air handler fan cycles off two minutes
were shipped loose (see Fig's 3-21 and 3-22). later.
BURNER PRE START CHECKS

TOOLS RECOMMENDED
1. Open fuse disconnects before working on burner
• Electrical Multimeter w/ Amprobe (see Fig. 3-13).
• Heating Unit Installation and Operation
Instruction. - One is provided with every
heating unit for technical information and
troubleshooting.
BURNER CONTROL
• Magnehelic Gauge 0” To .25” WC, Dwyer PANEL
Series 2000 or Model 1227 Dual Range
Manometer. - For checking pressure over fire
7800
(draft). Series Open fuse
Relay disconnects before
• Control Signal Generator, 0 to 20 mA working on burner.
(Altek-234 or 334A) - For 2 to 10 VDC signal
add 500 ohms in series with signal generator.
• Magnehelic Gauge 0” to 15” WC and 0 to
LD12903
3 lbs. (Dwyer series-2000) or Monometer
(Dwyer- 1227) Duel Range Monometer. - For FIG. 3-13 – OPEN FUSE DISCONNECTS
checking supply gas pressure and manifold gas
pressure or pilot gas pressure.
2. Check all wire terminations for tightness.
• Honeywell - S7800A Test Module - For use
on (Honeywell-7800) Series Relay Module.
3. Check that the incoming voltage(s) are correct.
(Available through Airside Parts - 800-545-
Compare measured voltages to burner motor and
7814, Ext.12).
ID motor nameplates and the “Burner Test Report”.
• Flue Gas Analyzer (CO2 and O2) Reset fuse disconnects.
4. Check for correct rotation of 3 phase burner motor
• Stack Thermometer (0°F - 1000°F
and ID motor.
approx.)
5. Verify that contractor has purged new gas lines of
air up to manual valve on gas train.
6. Valves which have been closed for shipping must

be opened accordingly. Check that all manual
valves operate without leaks.
2 johnson controls
FORM 102.20-NOM1 (LS04) (109)
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. 3-14).
11. Connect a 0-15" gas pressure gauge or other suit-
able instrument to the gas manifold port. The gas
Check Draft Test
ID fan Port
pressure will be measured when running (refer to
rotation step 4 of Burner Start-up Procedure).
Damper
Adjustment and On Powerflame burners this test port
Indicator Plate is downstream of the main regulator,
BURNER PANEL typically on a standard tee fitting in the
main gas line.
Main On Eclipse burners, this test port is

Condensate located on the backside of the burner,
Connection LD12910
just below the spark igniter. A small
FIG. 3-14 – sET ID FAN DAMPER valve is provided at this test port.
8. Inspect condensate drain trap to see that it is large 12. Connect a manometer or other suitable device to
enough, as described in this guideline (see Fig. the Heat Exchanger Draft Port located on the side
3-20). of the unit near the burner. The expected draft
should read slightly negative – about -.03" WC.
9. Measure the gas supply pressure coming into The draft port is typically made of ¾" steel pipe
the gas train (see Fig. 3-15). Gas pressure can be and may be plugged. Remove plug and add a small
greater than shown on the “Burner Test Report”, stop valve and a nipple for a rubber tube (see Fig.
but it must be between the min/max values listed 3-14 & 3-16).
in Table 3-2.
13. Install the Honeywell S7800 Test Module (display),
if available.
14. Connect signal generator (0-20mA) to terminals

in place of modulation control signal (for 2-10
VDC signal add a 500 Ω resistor in series). See
Fig. 3-23.
15. Visually check that the flue (stack) is secure and

connected properly. Typical connections are shown
at the end of this guideline (see Fig.’s 3-21 & 3-
Main Gas Supply 22).
Test Port
LD12905 16. Burner panel off/on switch should be “off”.
FIG. 3-15 – CHECK MAIN GAS SUPPLY PRESSURE System is now ready for start up.
johnson controls 3
FORM 102.20-NOM1 (LS04) (109)
BURNER START-UP PROCEDURE

Prior to starting burner, technician Heat Exchanger
Draft Port
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 Tube to
Tube to
for heat (see Fig. 3-23 for typical wiring dia- Draft Gage
Draft Gage
LD12900
gram).
FIG. 3-16 – DRAFT OVER FIRE test port
3. Turn burner panel off-on switch to on.
5. Observe the gas manifold pressure and compare to
data on the “Burner Test Report” under both High
Once there is a call for heat, a 30 Fire and Low Fire conditions.
second pre-purge period is initiated
to remove any gases from the heat 6. Check the flue (stack) combustion temperature at
exchanger. The burner will then go the ID Blower Housing Test Port. Make sure the
through a second purge before igni- test probe is inserted half way into the ID Inlet Tube
tion. (see Fig. 3-17). Compare results to the “Burner
Test Report”.
4. The burner will automatically go to Low Fire
at start up. After proof of Low Fire, the burner
will modulate up to High Fire. This may take 15
seconds for a Powerflame burner and 90 to 180
seconds for the Eclipse burner. After the burner
operates at High Fire use the manometer connected
to the Heat Exchanger Draft Port (see Fig. 3-16),
observe the reading. A negative pressure of about ID Fan Housing
-.03" WC is expected for draft overfire. Read- Test Port
ings may differ slightly from those shown on the
“Burner Test Report”.
For valid readings, before making any LD12906
adjustments, allow the burner to fire

at least 20 minutes to allow the heat FIG. 3-17 – F
LUE (STACK) combustion
tEMPERATURE and efficiency
exchanger to come up to operating
test port
temperature.
Ignition transformer is intermittent.
Pilot continues to burn after ignition
transformer is de-energized.
4 johnson controls
FORM 102.20-NOM1 (LS04) (109)
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
FIG. 3-18 – DAMPER ACTUATOR
8. Using the standard operating controls, cycle the

burner several times to assure proper sequencing
of start-up, firing, and capacity modulation, plus
operation of all safety and monitoring controls.
9. Test 180°F. high temp. safety by running burner

with airflow off or diverted. Burner will shut down LD12911
LD12911
at 180°F. Turn air handler on as quickly as possible

to remove heat from the heat exchanger. FIG. 3-19 – CONDENSATE DRAIN
CONDENSATE DRAIN ARRANGEMENT

10. Burner efficiency testing should be done last. The
burner should be running at High Fire rate for 30 The YORK Solution Indirect Fired gas heat exchanger
minutes before efficiency testing is done. has the potential to create highly acidic condensation,
particularly during extended operation at low capacity
11. Efficiency at High Fire is pre-determined, but may or low firing rate conditions. To insure proper drainage
be checked by flue gas analysis at the entrance to the following guidelines should be followed (See Fig.
the ID Blower Housing Test Port. At High Fire 3-20).
CO2 should be between 8-1/2 and 10 %; 02 should
be between 7-1/2 and 4%. With these ranges, effi- When constructing the condensate trap
ciency is 80% plus or minus 2% (see Fig. 3-17). for the heat exchanger drainage sys-
12. Contact contractor, facilities manager or customer to handle the Total Static Pressure of
to inform successful start-up has been complet- the ID Blower at Low Fire times 2.
ed.
Example: TSP is 6” at Low Fire - con-
In the unlikely event that adjustment struct trap 12” tall (See Table in Fig.
is required; it is done at High Fire and 3-20).
must NOT retard Low Fire light-off.
johnson controls 5
FORM 102.20-NOM1 (LS04) (109)
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.
1. Observe local jurisdiction codes for gravity con-
densate drainage requirements.
Frozen drain lines and/or trap will cause build up
in leakage and damage to the air handler and pos-
sibly to the facility.
ping dimensions as provided in Fig. 3-20. Mini-
mum trap dimensions MUST be accommodated. 7. Provide unions in drain lines to allow removal of
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
6 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
GAS LP = 2,500 BTU/ CU FT.

GAS NATURAL = 1,000 BTU/ CU FT.
{ Output is approx. 80% of input BTU's
7
FORM 102.20-NOM1 (LS04) (109)
8
TABLE 3-2 – NATURAL GAS PRESSURE REQUIREMENTS (INCHES WC)
MAXIMUM ALLOW INLET PRESSURE Minimum Inlet Pressure to Fire
Nomenclature A03 U03 F03 R03 A10 U10 F10 R10 A25 U25 F25 R25 A03 U03 F03 R03 A10 U10 F10 R10 A25 U25 F25 R25
FEATURE GASBTUS GAS BURNER PIPING/GAS BURNER TD GASBURNER PIPING/ GAS BURNER TD
ANSI FM IRI ANSI FM IRI ANSI ANSI UL FM ANSI UL FM IRI
OPTION ANSI 3 UL 3 FM 3 IRI 3 UL 10 UL 25 UL 3 FM 3 IRI 3 IRI 10
10 10 10 25 25 25 3 10 10 10 25 25 25 25
Furnace Furnace
ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI ANSI UL FM IRI
Output Output
3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1 3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1
(X10K) (X10K)
035 NA 14.00 NA 27.00 NA 27.00 NA 27.00 NA NA NA NA 035 NA 5.00 NA 4.00 NA 4.00 NA 4.00 NA NA NA NA
Note: Gas pressure requirements at the inlet to the main manual shutoff cock of the gas train.
johnson controls
FORM 102.20-NOM1 (LS04) (109)
FORM 102.20-NOM1 (LS04) (109)
TABLE 3-2A – 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
3 3 3 3 10 10 10 10 25 25 25 25
Furnace
Output
3:1 3:1 3:1 3:1 10:1 10:1 10:1 10:1 25:1 25:1 25:1 25:1
(X10K)

035 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA NA NA NA
040 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
045 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
050 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
060 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.00
075 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.25 NA 1.25
085 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.25 NA 1.25
100 NA 1.00 NA 1.00 NA 1.00 NA 1.00 NA 1.25 NA 1.25
125 NA 1.25 NA 1.25 NA 1.25 NA 1.25 NA 1.50 NA 1.50
150 NA 1.25 NA 1.25 NA 1.25 NA 1.25 NA 1.50 NA 1.50
175 NA 1.25 NA 1.25 NA 1.25 NA 1.25 NA 1.50 NA 1.50
200 NA 1.50 NA 1.50 NA 1.50 NA 1.50 NA 1.50 NA 1.50
225 NA NA 2.00 1.50 NA NA 2.00 1.50 NA NA 2.00 2.00
250 NA NA 2.00 1.50 NA NA 2.00 1.50 NA NA 2.00 2.00
275 NA NA 2.00 1.50 NA NA 2.00 2.00 NA NA 2.00 2.00
300 NA NA 2.00 1.50 NA NA 2.00 2.00 NA NA 2.00 2.00
325 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
350 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
375 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
400 NA NA 2.50 2.50 NA NA 2.50 2.50 NA NA 2.50 2.50
johnson controls 9
10
END OF FLUE PIPE FLUE CAP
42"L VSI PIPE

44.40 TYP. (NOT INSULATED)
(36.00 MIN)
STORM COLLAR
SUPPORT ASSEMBLY PIPE CHASE
1.60 CURB PIECE
ROOF PEAK
IVSI PIPE (INSULATED PIPE)

SEE NOTE 1
ROOF PANEL CONTAINMENT BAND SET &

RACEWAY GASKET, 1" THK X 3"W X LG,
INSULATION FIBER REQ. WHEN
IVSI IS IN 2 PIECES.
SIDE PANEL IVSI PIPE (INSULATED PIPE) H=UNIT HEIGHT

SEE NOTE 1 W=UNIT WIDTH
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:
5.50 DETERMINE LENGTH OF IVSI PIPES.
FLOOR PANEL
W
LD13304
FIG. 3-21 – GAS FURNACE FUEL VENTING SYSTEM
johnson controls
FORM 102.20-NOM1 (LS04) (109)
STEP 3
STEP 1 FLUE CAP
STEP 2
johnson controls
PIPE CHASE
CURB PIECE
RACEWAY
IVSI PIPE
SIDE PANEL (INSULATED PIPE)
SEE NOTE 1
CONTAINMENT
BAND SET &
INSULATION FIBER STEP 4
6"L SLIP
JOINT
GAS FURNACE WITH CASING 7.75 0.43"

CLEARANCE
12" ID
EXT. FAN TRANSITION
PIECE
STORM COLLAR
HAT CHANNEL
5.50
NOTES:

DETERMINE LENGTH OF IVSI PIPES.
FIG. 3-22 – GAS FURNACE FUEL VENTING SYSTEM LD13305
11
FORM 102.20-NOM1 (LS04) (109)
FORM 102.20-NOM1 (LS04) (109)
FOR REFERENCE ONLY
Connect Signal
Generator here for test
and start up
Jumper may be
required here for test
and start up
LD13315
FIG. 3-23 – typical wiring diagram
12 johnson controls
FORM 102.20-NOM1 (LS04) (109)
Table 3-3 – BURNER TEMPERATURE RISE
INTERNAL INTERNAL
PRESSURE PRESSURE
DROP “ DROP “
WC WC
DF- DF- DF- DF- DF-

15 20 25 60 75
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 1.47 10,000 55 68 1.2
5,248 26 35 44 2 11,000 50 62 1.4
DF- DF- DF- 12,000 46 57 1.7
30 35 40
12,900 43 53.8 2
3,000 95 -- -- 0.22
DF- DF-
3,500 82 91 -- 0.31 85 100
4,000 71 79 95 0.41 8,500 91 -- 0.47
4,500 63 70 85 0.54 9,000 86 -- 0.52
5,000 57 63 76 0.66 9,500 81 -- 0.58
5,500 52 57 69 0.84 10,000 77 91 0.64
6,000 47 53 63 1 10,500 74 87 0.7
6,500 43 47 58 1.2 11,000 70 83 0.76
7,000 40 46 54 1.45 12,000 64 76 0.9
8,440 32.9 38.4 43.9 2 13,000 59 70 1.05
DF- DF- 14,000 55 65 1.25
45 50
15,000 51 61 1.4
4,500 88 -- 0.39
16,000 49 57 1.6
5,000 80 90 0.47
17,000 46 54 1.75
5,500 72 82 0.55
17,825 44 52 2
6,000 66 75 0.65
6,500 61 69 0.75
7,000 57 64 0.86
7,500 53 60 0.98
8,000 50 56 1.1
8,500 47 53 1.23
9,000 46 50 1.38
10,725 38.8 43.2 2
johnson controls 13
Table 3-3 - BURNER TEMPERATURE RISE (CONT)
INTERNAL INTERNAL
PRESSURE PRESSURE
DROP “ DROP “
WC WC
DF- DF- DF- DF- DF- DF-

125 150 225 250 275 300
13,000 89 -- 0.48 24,000 87 -- -- -- 0.337
14,000 83 -- 0.56 27,000 77 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 63 70 75.8 82.5 0.637
17,000 68 82 0.82 36,000 58 64 69.5 75.7 0.758
18,000 64 77 0.92 39,000 53 59 64 70 0.89
19,000 61 73 1.03 42,000 50 55 59.5 65 1.035
20,000 58 69 1.13 45,000 46 51 55.6 60.6 1.185
21,000 55 66 1.25 48,000 43 48 52.1 55.8 1.35
22,000 52 63 1.35 51,000 41 45 50 53.5 1.525
23,000 50 60 1.5 54,000 39 43 47 50.5 1.71
24,000 48 58 1.3 58,475 35 39.5 43.5 47.5 2
25,000 46 55 1.75 DF- DF- DF- DF-
325 350 375 400
26,315 43.6 52 2
31,565 95 -- -- -- 0.4
DF- DF-
175 200 35,290 85 92 -- -- 0.5
17,000 95 -- 0.45 41,755 72 78 83 89 0.7
18,000 90 -- 0.52 47,345 64 68 73 78 0.9
19,000 85 -- 0.57 52,340 57 62 66 71 1.1
20,000 81 93 0.63 54,665 55 59 64 68 1.2
21,000 77 88 0.7 59,045 51 55 59 63 1.4
22,000 74 85 0.76 63,125 48 51 55 59 1.6
23,000 71 81 0.82 66,950 45 48 52 55 1.8
24,000 68 78 0.9 70,573 42.6 45.9 49.2 52.4 2
26,000 62 71 1.05
28,000 58 66 1.25
30,000 54 62 1.4
32,000 51 58 1.6
34,000 48 54 1.8
35,635 45.5 52 2
©2009 Johnson Controls, Inc. P.O. Box 423, Milwaukee, WI 53203 Printed in USA 102.20-NOM1 (LS04) (109)
www.johnsoncontrols.com Supersedes 102.20-NOM1 (LSO4) (208)

Manual Unidades Manejadoras

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YORK Solution

Air handling units

YORK Solution Indoor and outdoor models

DANGER indicates an imminently CAUTION identifies a hazard which

External wiring, unless specified as an optional connection in the manufacturer’s product

NOTICE TO CUSTOMER/CON- – Controls are complete.

• To perform a careful and thorough startup, verify

CHANGEABILITY OF THIS DOCUMENT

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

Table of contents (Cont.)

list of figures (cont.)

list of figures (cont.)

FIG. 2-74 – HOT WATER PIPING FOR 2 ROW COIL VIFB.....................................................................2-52

list of figures (cont.)

list of figures (cont.)

list of figures (cont.)

list of figures (cont.)

list of figures (cont.)

list of figures (cont.)

service task reference

service task reference (Cont.)

Fan Bearing Motors

THIS PAGE INTENTIONALLY LEFT BLANK

GENERAL TYPICAL YORK SOLUTION OPERATION

The YORK Solution features segmented construction

FIG. 1 – CUTAWAY OF YORK Solution SHOWING VARIOUS SEGMENTS

ECONOMIZER SYSTEM - TYPICAL HEATING OPERATION

If the economizer operation cannot satisfy the space

LEFt hAND (Lh)

FIG. 2 – UNIT AND COIL HAND IDENTIFICATION

TABLE 1 – SEGMENT IDENTIFICATION FILTER SEGMENTS

FACTORY MOUNT END DEVICES.

H WIDTH FAN OPTIONS MOTOR HORSEPOWER

UNIT IDENTIFICATION UNIT ID LABEL

SUPPLY FAN MOTOR RATING (INDIVIDUAL LOAD)

9800071 Direction of Airflow

FIG. 3 – UNIT ID LABEL FIG. 5 – SEGMENT ID BOX EXAMPLE

LOOSE COMPONENT ID LABEL FILTER ID LABEL

RECEIVING RIGGING OF INDOOR AND OUTDOOR

SPREADER BARS MUST BE WIDER THAN THE

FIG. 1-1 – RECOMMENDED LIFTING WITH FOUR LIFTING POINTS

SPREADER BARS MUST BE

FIG. 1-2 – RECOMMENDED LIFTING WITH MULTIPLE POINTS

OFF-LOADING All lifting lugs must be used to avoid

FIG. 1-3 – TYPICAL COME-A-LONG TYPES

1-2 johnson controls

Fig’s 1-4 and 1-5 show YORK Solution

johnson controls 1-3

1-4 johnson controls

LONG-TERM STORAGE Long-term storage is considered to be

johnson controls 1-5

FIG. 1-3 – TYPICAL COME-A-LONG TYPES

FIG. 2-3 – NO BASERAIL – HOUSEKEEPING PAD