York SOLUTION XTO Series

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JOHNSON CONTROLS

FORM 102.20-N1

ISSUE DATE: 7/06/2016

SECTION 1 - GENERAL INFORMATION AND SAFETY

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Table of Contents5
Section 1 - General Information and Safety13
- Introduction13
- Warranty13
- Responsibility for Safety13
Section 2 - Product Description15
- Typical Solution Operation15
- Cleaning16
- Hand Orientation16
- AHU Identification (ID)16
- Direction of Airflow19
- FIGURE 6 - Example of Moisture Eliminator Loose Component ID Label19
- FIGURE 7 - Example of Hood Loose Component ID Label19
- FIGURE 8 - Filter ID Label19
Section 3 - Handling, Storage, and Installation21
- Delivery and Storage21
  - Short Term21
  - Long Term22
- Inspection, Damage, and Shortage22
  - Check Solution XT Doors and Latches23
  - Indoor Ahus23
  - Outdoor Ahus23
  - Shipped Loose Parts23
- Lifting Weights23
- Moving the AHU23
- Rigging23
- FIGURE 9 - Metal Spacers on Solution XT Doors23
- Using Fork Lift in Special Circumstances24
- Come-A-Longs (Power Pulls)24
- Proper Lifting with Shackles24
- FIGURE 10 - Recommended Lifting with Multiple Points24
- FIGURE 11 - Typical Come-A-Longs24
- FIGURE 12 - Proper Lifting with Shackle with Corner Connector Corners24
- Preparing the Site25
  - Clearance for Outdoor Ahus25
  - FIGURE 13 - Proper Lifting with Shackle at Lifting Lug25
  - FIGURE 14 - Proper Lifting with Base Rail25
  - Assembling the Johnson Controls Provided Curb26
  - FIGURE 15 - Minimum Service Clearances26
  - FIGURE 16 - Typical Curb Assembly27
  - Clearance and Mounting for Indoor Ahus28
  - FIGURE 17 - Solution XT no Base Rail - Housekeeping Pad Required to Accomodate Trap Height28
  - FIGURE 18 - no Housekeeping Pad - Solution XT Base Rail Required to Accomodate Trap Height28
  - FIGURE 19 - with Base or Base Rail and Housekeeping Pad28
  - Installing Ceiling Suspended Ahus29
  - FIGURE 20 - Ceiling Suspended AHU on Structural Steel29
- Tools Required to Install AHU30
- Shipped Loose Parts30
  - FIGURE 21 - Tools Needed to Assemble Shipping Splits30
  - FIGURE 22 - Second Tier Tie-Down Fastener Pack (P/N 386-03419-000)30
  - FIGURE 23 - Bottom Raceway Shipping Split Fastener Pack (P/N 386-03418-000)31
  - FIGURE 24 - Base Rail Shipping Split Fastener Pack (P/N 386-03417-000)31
  - FIGURE 25 - Top Raceway Bracket Assembled (P/N 386-04747-000)31
  - FIGURE 26 - Neoprene Gasket - 1/4 In. X 2 In. X 25 Ft (P/N 028-11883-010)31
  - FIGURE 27 - Neoprene Gray Gasket - 1/4 in X 3/4 in X 35 Ft (P/N 028-11873-010) for Door31
  - FIGURE 28 - Phillips Hex Head Screw (P/N 021-32268-011) for Indoor Unit Seam Cap31
  - Pipe Chase, Hoods and Seam Caps31
  - FIGURE 29 - Hex Head Screw for Outdoor Roof Seam Cap, Pipe Chase, and Rain Hood - 1/4 In-14 X 1 in32
  - FIGURE 30 - Butyl Tape - 3/16 in X 3/4 in X 40 Ft (P/N 013E-03327-010)32
  - FIGURE 31 - Polyurethanecaulk (P/N 021-19568-000 - Grey; P/N 013-03317-040 - Champagne) for32
  - FIGURE 32 - Roof Seam Cap (Assembled)32
  - FIGURE 33 - Pipe Chase, Trim Angle, and Cover32
  - Additional Parts33
  - FIGURE 34 - Hood33
  - FIGURE 35 - Damper Shaft Extension Kit (P/N 026-33715-002)33
  - FIGURE 36 - Corner Connector Hole Plug (P/N 021-19568-000) (8)33
  - FIGURE 37 - Touch-Up Spray - 12 Oz. (P/N 013-03322-000)33
  - FIGURE 38 - Shipping Split Corner Gasket - 3.5 X 3. 5 (P/N 028-11883-010)33
  - FIGURE 39 - Spare Fan Belt33
  - FIGURE 40 - Conduit (P/N 025-39024-001) and SJO Cord (P/N 025-35746-001)33
- Installing Outdoor AHU34
  - Single Piece Outdoor AHU34
  - Multi-Piece Outdoor Solution XT AHU34
  - FIGURE 41 - Shipping Split Examples35
  - FIGURE 42 - Shipping Split Examples Using Structural Steel Baserails35
  - Setting up the Sections36
  - FIGURE 43 - Applying Gasket Square, Neoprene Gasket and Caulk to Raceway Split36
  - FIGURE 44 - Typical Come-A-Longs36
  - FIGURE 45 - Electrical Connector (Not Connected)36
  - Pulling the Solution XT Sections Together37
  - FIGURE 46 - Electrical Connectors (Connected)37
  - FIGURE 47 - Remove and Reposition Shipping Split Angle37
  - Figure 48 - Come-A-Long Attached to Asection37
  - FIGURE 49 - Bring Shipping Splits Together37
  - FIGURE 50 - Applying Caulk to Seams38
  - FIGURE 51 - Installing Gaskets38
  - FIGURE 52 - Solution XT Corner Connector Hole Plug (P/N 021-19568-000)38
- Installing Indoor Solution XT AHU39
- FIGURE 53 - Use Gasket (P/N 028-11883-010) at Shipping Split39
- FIGURE 54 - Use Gasket (P/N 028-11873-010) to Door Frame at Shipping Split39
- FIGURE 55 - Assembly of End Channel Shipping Split with a Solution XT Expanded Cabinet40
- Setting up and Pulling Solution XT Sections Together41
- Figure 56 - Come-A-Long Attached to Asection41
- FIGURE 57 - Remove Lifting Lugs in Expanded Cabinet41
- FIGURE 58 - Electrical Connector (Not Connected)41
- FIGURE 59 - Electrical Connectors (Connected)41
- FIGURE 60 - Remove and Reposition Shipping Split Angle42
- FIGURE 61 - Bring Shipping Splits Together42
- Installing a Tiered AHU43
- FIGURE 62 - Fasten Bottom Lifting Lugs43
- FIGURE 63 - Installing Gaskets43
- FIGURE 64 - Solution XT Corner Connector Hole Plug (P/N 021-19568-000)43
- FIGURE 65 - Tiered Solution XT AHU43
- FIGURE 66 - Second Tier Tie-Down Fastener Pack (P/N 386-03419-000)44
- FIGURE 67 - Apply Gaskets to Top Panel on Bottom Tier44
- FIGURE 68 - Guide Brackets Together44
- Assembling the Solution XT End Channel Shipping Split45
- FIGURE 69 - Solution XT Lights Tier Transition Drawing45
- FIGURE 70 - Assembling the End Channel Shipping Split with Energy Recovery Wheel46
- Installing Hood with Moisture Eliminators47
- Outdoor Air Temperature And/Or Humidity Sensors47
- FIGURE 71 - Installing Hood with Optional Moisture Eliminators47
- Installing Damper Actuator48
- FIGURE 72 - Installing the Direct Coupled Actuator48
- Installing Multi-Zone (MZ) Dampers49
- FIGURE 73 - Installing MZ Damper49
- Installing Field Supplied MZ Damper Actuators50
Back Draft Dampers for Dual Fans and Fan Arrays50
FIGURE 74 - Damper Shaft Extension Kit (P/N 026-33715-002)50
FIGURE 75 - Counterbalance Locked into Place for Shipping50
FIGURE 76 - Counterbalance Unlocked for Start-Up50
Filling Inertia Fan Base51
Steam Humidifier51
UVC Emitter Lamps51
- Two Types of Lamps51
- FIGURE 77 - V-Max Grid Lamps51
- FIGURE 78 - Installing V-Mod Lamp51
- FIGURE 79 - Installing V-Max Grid Lamps51
- FIGURE 80 - UV Control Panel Wiring (8 Amps)53
- FIGURE 81 - UV Control Panel Wiring (Greater than 8 Amps)54
Air Measuring Device Connections56
- Air Measuring at the Fan Inlets56
- Air Measuring at Unit Outside Air Inlets56
- FIGURE 82 - High and Low Connections for an in Fan Air Monitoring System56
- FIGURE 83 - High and Low Connections and Associated Tubing for Fan Mounted Air Monitoring System56
- FIGURE 84 - Port Locations for Fan Mounted Air Monitoring System56
Installing the Pipe Chase57
- Tools and Materials57
- Preparing Pipe Chase for Installation57
- Apply Gaskets57
- FIGURE 85 - Install Gasket under Roof Overhang57
- Attach Pipe Chase58
- FIGURE 86 - Apply Gasket to Pipe Chase58
- FIGURE 87 - Install Pipe Chase Base Rail to AHU Base Rail58
- FIGURE 88 - Install Flanges58
- Seal Pipe Chase to Solution XT AHU59
- Install Cover Angles59
- FIGURE 89 - Apply Caulk to Solution XT Base Rail59
- FIGURE 90 - Apply Caulk between Pipe Chase and Solution XT AHU59
- FIGURE 91 - Install Pipe Chase to Solution XT Roof59
- FIGURE 92 - Install Cover Angle59
- Install Base Rail Covers (if Applicable)60
- FIGURE 93 - Position Cover Angle Properly60
- FIGURE 94 - Properly Install Screws60
- FIGURE 95 - Apply Solution XT Base Rail Cover60
Installing External Vent Piping for Outdoor AHUS61
- Condensate Drain Arrangement61
- FIGURE 96 - Gas Furnace Fuel Venting System61
- FIGURE 97 - Gas Furnace Condensate Drain Trap62
- TABLE 2 - TSP and Drain Trap62
Field Penetrations for Piping and Electrical Connections63
- Tools Required63
- Material Required63
- Procedure63
- FIGURE 98 - Penetrations and Grommet Details64
General Electrical Information65
Power Connections65
- Single Point Power65
- FIGURE 99 - Single Point Power Connection65
- Motors for Supply, Return, and Exhaust Fans66
FIGURE 100 - Typical Motor Data/Name Plate66
FIGURE 101 - Another Typical Motor Data/Name Plate66
FIGURE 102 - Access Electrical Box66
Wiring the Energy Recovery Wheel66
FIGURE 103 - Typical Power Wiring of Energy Recovery Wheel67
FIGURE 104 - Gas Burner Component Locations67
FIGURE 105 - Main Power and Control Panel with Cover Open67
Wiring the Gas Heat Device67
Wiring the Electric Heat Device68
- Power Options68
- Disconnect Switch Options68
- FIGURE 106 - Typical Electrical Heat Control Panel Interior Wiring and Components68
- FIGURE 107 - Typical Field and Power Connections68
- Control Options69
- Installing Electrical Heat Option69
- FIGURE 108 - Pressure Probe Direction70
- FIGURE 109 - Air Flow Switch Connections70
- TABLE 3 - Maximum Current71
FIGURE 110 - Layout of Typical Humidifier Panel72
FIGURE 111 - Supply Power Knockouts72
FIGURE 112 - Humidifier Points72
Electric Humidifier72
Humidifier72
FIGURE 113 - Solution XT AHU with Lights Tier Transition Drawing73
FIGURE 114 - Solution XT Pipe Chase Enclosure73
Lights for Solution XT Ahus73
Piping Connections73
Coil Piping74
- Staggered Coils74
- FIGURE 115 - Factory Coil Connections74
- FIGURE 116 - Staggered Coil - Angled Wall74
- FIGURE 117 - Split Coil - Opposite Side Connections74
- Hot and Chilled Water Coils75
- FIGURE 118 - Chilled Water Coil Connections Example - (Not for Construction)75
- FIGURE 119 - Hot Water Piping with 2-Way Valve Example (Not for Construction)76
- FIGURE 120 - Hot Water Piping with Diverting Valve Example (Not for Construction)76
Water Treatment77
- FIGURE 121 - Steam Coil Piping Arrangements78
- Vertical Tube Integral Face and Bypass (VIFB) and Integral Face and Bypass (IFB)79
- Refrigeration83
- DX Coil Circuiting and Staging87
- Hot Gas Bypass (HGBP)87
- Thermostatic Expansion Valves (TXV)87
- FIGURE 136 - Three Compressor Unit88
- FIGURE 137 - Six Compressor Unit88
- Maintaining Adequate Airflow88
- Drains and Traps89
- VAV Systems89
- Duct Connections91
- Air Filters94
- Hepa Filters103
- Visual Control Filter Clamps104
- TABLE 9 - si Metric Conversion107
- Temperature107

York SOLUTION XTO Series - Page 14

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