Solution Air Handling Units 200 To 100,000 CFM (Indoor & Outdoor S), Engineering Guide, 102.20 QG1 060 Solutions Ahu

User Manual: 060

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FORM 102.20-QG1 (808)

SOLUTION AIR HANDLING UNITS

2000 TO 100,000 CFM

(Indoor & Outdoor Models)

ld08301

FPC

HFDP XA FS XA CC HCXA RF FEMB

Split

VC XA HC RF MB

VFD

FS DI RF XA DP

Split

ld08302

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

TABLE OF CONTENTS

GENERAL INFORMATION

Introduction ............................................................3

A Proud History of Experience & Qualiﬁ cations .....3

Assurance of Johnson Controls Backing ...............3

Computer Selection Programs ...............................4

Innovative Engineering & Design ...........................5

Flexibility of Design ................................................6

Superior Casing Performance ................................6

Pre-engineered Packaged Controls .......................7

Customized Variable Size Openings ......................7

Airﬂ ow Measurement Performance ........................8

State-of-the-Art Certiﬁ cation & Testing ...................8

New Sound Testing Laboratory ..............................8

Quality Construction Equals Improved IAQ ............9

Multi-Sloped Drain Pans ........................................9

Raceways ...............................................................9

Improve Cost Savings ............................................9

A Complete Line of Filters ....................................10

Energy Saving Fan Options .................................10

Energy Consumption ............................................11

Sound Attenuation ................................................13

Inertia Base ..........................................................13

Quick Selection ....................................................14

FAN APPLICATION REVIEW

Fan Laws .............................................................15

Variable Air Volume ..............................................16

Component Temperature Margins ........................17

Fan Motor Heat ....................................................17

COIL OPTIONS

Cooling Coils ........................................................18

Heating Coils ........................................................19

Typical Application of AH Coils .............................20

SOLUTION SEGMENT IDENTIFICATION

Segment Listing ...................................................21

Unit & Coil Hand Selection ...................................21

FAN SEGMENTS – FS, FR, FE

Fan Applications ...................................................22

Dual Fan Considerations ......................................22

Dual Fan Applications ..........................................22

Door and Discharge Locations .............................23

Single Fan DWDI Options ....................................24

Single Fan SWSI Options ....................................25

Dual Fan DWDI Options .......................................26

Dual Fan SWSI Options .......................................27

SWSI vs. DWDI ....................................................28

Fan Motor Control Methods .................................29

COIL SEGMENTS

Cooling (CC) ........................................................30

Heating (HC) ........................................................30

Vertical Coil (VC) ..................................................31

STAGGERED COIL OPTIONS

Angle Wall ............................................................32

Back-to-Back ........................................................32

Multizone (MC) .....................................................33

HEATING SEGMENTS

Integral Face & Bypass ........................................34

Indirect Gas-Fired ................................................35

Turndown Examples and Guidelines....................36

Electric Heat Options & Applications ....................37

ENERGY RECOVERY

Heat Wheel ..........................................................40

FILTER SEGMENTS

Applications & Options Table ...............................41

Mechanical Air Filters ...........................................42

MERV Analysis .....................................................43

MIXING SEGMENTS & ECONOMIZERS

Mixing Box /Economizers .....................................44

Mixing Box Optimization Chart .............................46

Typical Economizer Application ............................47

Building Pressurization .........................................47

Methods of Pressurization Control .......................48

Economizer Arrangements ...................................48

Face Damper .......................................................49

Inlet Plenum .........................................................49

ACCESSORY SEGMENTS

Diffuser Segment .................................................50

Access Segment ..................................................50

Vertical Plenum ...................................................51

Discharge Plenum ................................................51

Sound Attenuator .................................................52

Noise and Vibration ..............................................53

Air Blender - Mixers ..............................................54

Face & Bypass Damper Segment ........................55

Turning Segments ................................................56

Humidiﬁ er Segment ..............................................56

UV Segment .........................................................57

Pipe Chase Enclosure ..........................................58

Roof Curb .............................................................58

Special Curb Requests ........................................59

CONTROLS

F. P. Controls & Motor Control Centers ................60

Typical FPC Wiring ...............................................60

Software Process .................................................61

Field Equipment Controller ...................................61

Power Wiring Options ..........................................62

INDUSTRY FORMULAS

Miscellaneous Industry Formulas .........................63

GUIDE SPECIFICATIONS WITH TIPS

Part 1 - General ....................................................64

Part 2 - Products ..................................................67

Part 3 - Execution .................................................81

JOHNSON CONTROLS 3

FORM 102.20-QG1 (808)

GENERAL INFORMATION

Introduction

This Equipment Guide will provide engineers with

a summary of Solution air handling information in the

most convenient, time-saving manner possible. The

guide will direct you to various sources of data and infor-

mation helpful in solving questions concerning product

options, design application, as well as installation and

operation.

A Proud History of Experience & Qualiﬁ cations

Johnson Controls combined with YORK heating, ventila-

tion, air-conditioning, and refrigeration (HVAC&R) sys-

tems and solutions creates the largest global provider of

integrated products, systems and services for the $200

billion global building environment industry.

Johnson Controls/YORK is:

• A global leader in control systems and services

for heating, ventilating, air conditioning (HVAC),

lighting, security and ﬁ re management for non-

residential buildings, facility management and

consulting services.

• Represented in over 125 countries, including

North America, Asia, Europe, the Middle East,

Africa and Latin America and in all markets.

YORK® Solution® air-handling units (AHUs) from John-

son Controls–the only names you need to know for a line

that has no limits. Johnson Controls/YORK engineers

have developed an AHU line that is so ﬂ exible, and able

to deliver such high standards of performance, that it can

handle virtually any application. Whatever the air-han-

dling challenge–IAQ, acoustics, energy, controls, you

name it–Johnson Controls/YORK can build a Solution

AHU that will meet your needs.

Solution® AHU’s from Johnson Controls

comprise a complete AHU line to meet commercial,

institutional and industrial indoor and outdoor unit

applications. For more than 50 years, YORK air

handling units have been installed in every type of facility to

handle any type of requirement; manufacturing, education,

healthcare, life sciences and process manufacturing.

Solution® AHU’s come equipped with industry-leading

Metasys® controls that are installed and commissioned

at the factory. Factory installation assures superior

quality, saves time on the jobsite and delivers accurate

performance. Plus, you can count on seamless opera-

tion with a Metasys building management system.

Assurance of Johnson Controls Backing

With every Solution system, you get the support and

resources that come from dealing with a worldwide

manufacturer – JOHNSON CONTROLS. You are not

tied to the limitations of a regional supplier. Instead, you

get the ﬂ exibility being able to design in one part of the

country, and buy and install in another location.

Johnson Controls Factory Service

Turn to the experts at Johnson Controls/YORK.

Johnson Controls/York carries the burden of single-

source responsibility since Johnson Controls/YORK

packages the total system, including custom air han-

dlers, chillers, controls, and variable air-volume boxes

and building automation systems. For added peace

of mind, Johnson Controls/YORK offers Inspection

Only, Preventive Maintenance and Inspection, or Total

Service Contracts to meet your speciﬁ c ﬁ nancing and

management requirements. Johnson Controls service

can also provide certiﬁ ed technicians available locally

for factory start-up, drawing from over 700 factory-

trained service technicians in 100 strategically-located

ofﬁ ces nationwide – a capability not offered by indepen-

dent manufacturers.

Full Service Support

Because JOHNSON CONTROLS factory packaged

devices and motor controls are an integral part of the

equipment, who better to troubleshoot and service the

system than a professional Johnson Controls Service

Technician. The Johnson Controls Service technician

knows not only the equipment and the hardware, but

also has a working knowledge of equipment applica-

tion and operation. Every unit is backed by this kind of

professional support.

Development and Preparation of Service Literature

Johnson Controls/YORK produces quality product

literature to ensure proper installation, operation and

maintenance. Installation, Operation and Maintenance

manuals must be followed to realize the full capacity

and life of the units. In addition, literature supplements

of special characteristics and features are distributed as

required to support regular product enhancements.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

GENERAL INFORMATION

Computer Selection Programs

YORKworks™ software is the primary source for the

latest product design and performance data.

1. Includes the latest innovations, updates, and ef-

ﬁ ciencies of YORK® products

2. Includes general functionality used to select

equipment factory packaged controls.

3. Sound data for air-handling units

4. All screens are interconnected and are continually

updated according to conﬁ guration inputs.

This powerful software tool brings ﬂ exibility and com-

puting power to the desktop of designers. The software

allows you and the customer to make product decisions

and view performance data in a user-friendly, step-by-

step, screen-driven environment.

YORKworksCE™ software is a necessity for your

customer’s engineering toolbox. YORKworks revolution-

izes the way you specify HVAC equipment. Johnson

Controls/YORK can optimize the selection of any air

handling unit for a speciﬁ c job requirement with its

computer selection programs.

Literature Reference — see ‘Sales Guide – YORK works CE’ Form 70.02-SG1

Quick and Easy selection

• Save Time – choose components and

complete conﬁ gurations with a couple

of clicks.

• Reduce Errors – use pre-programmed

rules and guidelines for component

selection.

Just Click to

select and add

components

JOHNSON CONTROLS 5

FORM 102.20-QG1 (808)

Innovative Engineering & Design

Solution Air Handlers are not just ‘fans-in-a-box’!

1. Solution is a structure that withstands deﬂ ection

2. Solution is a sound/noise barrier

3. Solution is a container of clean and conditioned air

4. Solution is an integral part of a building’s ﬁ re and

safety plans

5. Solution’s Variable Aspect Ratio eliminates the

need for costly modiﬁ cations.

6. Solution ﬁ ts the speciﬁ cation and the space!

Innovative Engineering & Design allows you to choose

from a limitless variety of conﬁ gurations. See con-

ﬁ gurations below for some of the popular applications

designed to meet your particular need.

VC XA HC FM

XAFS

DPAT

EH MBRF

FS CC XA HC FF MB

FS CC

HF RF

FS CC XA HC

AF EE FR

FS CC AFHM IG

EE FE

Conﬁ guration 1 (Stacked Unit) –

Mechanical room favorite. Reduced footprint with tiered

supply fan

Conﬁ guration 2 (Stacked Unit) –

Ultra-quiet design with plenum fan and U-shaped

cabinet

Conﬁ guration 3 – Minimum frills. Maximum IAQ

Conﬁ guration 5 – Cooling-only lab design with HEPA ﬁ ltration

Conﬁ guration 6 – Classic hospital design with return fan economizer operation.

Conﬁ guration 4 – Exhaust air ﬂ exibility with gas-heat and humidiﬁ cation

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

GENERAL INFORMATION

Flexibility of Design

Solution AHUs offer the ultimate in dimensional, mate-

rial, and component ﬂ exibility. Solution AHUs have the

same appeal for both “standard” and “custom” markets.

How an air-handling unit is designed and built deter-

mines how well it performs.

Engineering Flexibility

• Variable cabinet dimensions

• Material and component ﬂ exibility

• Full line of factory packaged controls installed,

tested and commissioned by Johnson Controls

certiﬁ ed technicians

• Variable sized inlet and discharge openings

• Indoor and outdoor constructions

• Tiered (stacked) and custom conﬁ gurations

• Panels are individually removable without affect-

ing structural integrity.

Dimensional Flexibility

You can design Solution AHUs to ﬁ t the application and

the space. Length, height and width can all be varied

to match building constraints. With hundreds of cross-

sectional possibilities, you choose the best match for the

application. In addition, all Solution AHU components

have been designed with a variable-aspect ratio to meet

your space and air-velocity requirements.

Material Flexibility

A complete line of construction materials are available,

including galvanized steel, aluminum, painted steel,

stainless steel, and more. Solution AHUs can handle

a multitude of environments, from the most benign to

the most corrosive. NOTE: All units/unit segments are

shrink-wrapped to protect unit from contamination dur-

ing shipping

Component Flexibility

AHUs are responsible for providing

the environment with quality indoor

air, in an energy efﬁ cient and quiet

manner. Solution AHUs help meet

that responsibility by offering every

available component, from energy

wheels to air-monitoring stations

to specialty-purpose filters. As

technology creates new capabilities, Johnson Controls/

YORK will apply these to our Solution line.

Superior Casing Performance

The foam injected panels of our Solution air handling

units enhance performance, maximizing the indoor air

quality and help to create ASHRAE 62-2000 compliant

designs while reducing costs. The direct result of the

foam injection insulation is a rigid panel, low leakage,

high pressure air handler, with increased energy sav-

ings, and reduced initial cost.

Better IAQ

Deﬂ ection presents a potential in leaks that form over

time from the operational pressure. The foam injected

Solution panels are 20% more rigid (L/240 vs. L/200)

then the typical ﬁ berglass or foam board construction.

In addition the smaller deﬂ ections can be achieved using

lighter sheet metal gauges then required by ﬁ berglass

construction. The result is a lower initial cost unit with

greater performance.

Lower leakage reduces the inﬁ ltration of unﬁ ltered and

unconditioned air into the space. The inﬁ ltration of un-

conditioned air can lead to condensation in unit walls,

crevices and/or insulation. When the inﬁ ltration occurs

in a negative pressure atmosphere downstream of the

ﬁ lter, it will lead to unﬁ ltered air being supplied to the

space. Maintaining a low leakage for positive pressure

segments reduces the loss of conditioned air to a po-

tentially warm and humid ambient environment, causing

increased condensation. Condensation can lead to

premature corrosion as well as IAQ concerns.

The Solution foam injected wall panels help to seal and

maintain the leakage at maximum of 1% with a minimum

+/-8” of static pressure. Options for a maximum leakage

rate of 1/2% at a minimum of +/-10” of static pressure

are available for those projects which demand it.

Coil carryover, humidiﬁ cation, and periodic wash downs

are all instances where water is present in the unit.

Foam insulated panels will not absorb, and retain water,

like a ﬁ berglass insulated panel will. In addition the ther-

mal properties of foam are not degraded by an incident

where the insulation comes in contact with water.

JOHNSON CONTROLS 7

FORM 102.20-QG1 (808)

Energy Savings

The energy savings associated with high performing air

handler construction is directly associated with leakage

and insulating properties.

The inﬁ ltration of unconditioned air downstream of a coil,

or the loss of conditioned air downstream of a coil are

just two examples of reduced energy efﬁ ciency in an air

handler. The foam injected panel helps to reduce both

of these potential losses by creating a more rigid, lower

leakage air handling over the life of the unit.

Another form of energy loss associated with air handlers

is the thermal energy that is lost through the cabinet of

the air handler. The Solution foam injected panels lower

energy consumption with better insulating properties.

With the standard R-12.5 and optional R-18.8, or R-25,

the Solution can help to reduce the energy usage. The

injected panel provides additional thermal advantages in

that the foam will ﬁ ll voids, and gaps that aren’t reached

with ﬁ berglass or foam board type constructions.

Solution air handler units are capable of being factory

tested to prove out both leakage and deﬂ ection. With

the Solution product it’s not all about construction, it’s

also about performance.

Pre-engineering Packaged Controls

Pre-engineering of sensors ensures the most accurate

performance. There are great advantages to selecting

factory mounted and wired end devices for your Solution

air handling units.

1. Factory mounting maintains leakage performance

2. Factory wiring is plug and play

3. Factory testing of each mounted and wired device

4. Factory generated control diagrams speciﬁ cally

for each unit

Literature Reference — see Application Guide ‘Applying VSO Option to Solution Air Handling Units’ - Form

102.20-AG14

Factory Installation

Factory installation improves quality and saves time.

While a Solution AHU is being manufactured, Johnson

Controls technicians can easily access all its segments.

So there are no accessibility problems to cramp the

quality of the controls installation, which often occurs

on the jobsite.

All sensor probes have been pre-engineered to deter-

mine the best mounting location, ensuring accurate and

reliable readings.

This improves performance of the unit while eliminat-

ing unwanted air leakage common in ﬁ eld-mounted

solutions.

Factory engineering speeds ﬁ eld connections

The goal is to provide

you with an AHU that

simpliﬁ es ﬁ eld connec-

tion of the controls. For

example, coil valves

are shipped uninstalled,

but pre-wired with quick

connects. If an AHU is

too large to ship in one

piece, you can still count

on fast and easy assem-

bly of Metasys controls

because labeled quick connects come standard on all

shipping splits.

Customized variable size openings

Solution offers the most comprehensive option for facto-

ry provided openings. Custom size, custom location and

custom shapes along with custom sized dampers,are

designed to lower installation costs and risk while dra-

matically improving the quality of the application and

performance of the air handler.

DP FS EE EE FR IP

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

GENERAL INFORMATION

Literature Reference — see Application Guide ‘AMS60 for use with Solution AHU’ - Form 102.20-AG1

State-of-the-Art Certiﬁ cation & Testing

Solution Air Handlers are subject to stringent testing

using certiﬁ ed, comprehensive and industry recognized

testing laboratories. Testing is in accordance with ARI

Standard 430 which evaluates the performance of the

entire unit. This assures that each Certiﬁ ed Solution unit

will indeed perform with certainty and reliability.

Solution AHUs have also undergone extensive and rigor-

ous testing to verify conformance with all U.S. and Cana-

dian safety standards, and they bear the ETL Label.

Extensive testing includes:

• ARI 430 certiﬁ ed performance

• ARI 260 sound data

• Full line of ARI 410 certiﬁ ed coils

• ETL listing for product safety per UL 1995

• ASHRAE 90.1 compliant

• ASHRAE 62 compliant coil and drain pan design

maximizes indoor air quality

• Outstanding thermal capacity proven through

independent testing

• HEPA ﬁ ltration system exceeds the most stringent

military DOP tests

• AMCA 611 certiﬁ ed airﬂ ow measurement stations

• ISO Quality Certiﬁ cation

• Seismic certiﬁ cate of compliance

Labeled Solution units are tested and listed by ETL in

accordance with UL 1995, Standard for Safety Heating

and Cooling Equipment, and thereby fully complying

with NFPA 90A material requirements.

Airﬂ ow Measurement Performance

Solution AMS-60 qualiﬁ es to bear the AMCA Ratings

Seal for Airﬂ ow Measurement Performance. Ventilation

air ﬂ ow can be controlled dynamically with the Solution

AMS-60 which is tested to AMCA Standard 611-95.

The Solution AMS-60 continues to be the best integral

air-ﬂ ow station offered for air handling units which is in-

corporated into mixing box and economizer segments to

meet the most stringent ASHRAE 90.1 requirements

There are 3 damper options to give various measure-

ments of air ﬂ ow. See FIG. 1.

NOTE: Dampers are split vertically

FIG. 1 – DAMPER OPTIONS

100%

25%

75%

25%

75%

New Sound Testing Laboratory

The new AHU laboratory at the Johnson Controls

Grantley Park Tech Center includes the capability for

sound power measurements on Air Handling Units up to

100,000 CFM in accordance with ARI 260. The facility

will also include the capability for testing unit airﬂ ow in

accordance with AMCA 210 to 100,000 CFM. For fan

alone testing, the facility will also have AMCA 300 and

AMCA 210 accreditation. All of this capability will be

available for product development testing and for cus-

tomer witness testing on critical projects. This facility

will allow veriﬁ cation and calibration of sound models

used for unique features of Solution units, which will

increase the accuracy of our predictions and ensure that

our customers will continue to obtain the best available

Solution sound data in the marketplace.

This facility will be the largest AHU sound test facility in

the world. Note that in order for a laboratory to measure

ARI 260 sound data, the laboratory must be pure tone

qualiﬁ ed to 50 Hz. This facility will be pure tone quali-

ﬁ ed to 50 Hz. Pure tone qualiﬁ cation ensures that the

test facility is capable of accurately measuring a noise

source producing tones – such as a fan. Not qualifying

the facility for pure tone response could lead to errone-

ous results with a tonal noise source. This is why ARI

requires pure tone qualiﬁ cation of reverberation rooms in

the HVAC industry for anything other than VAV boxes.

VIEWED

FROM

TOP

JOHNSON CONTROLS 9

FORM 102.20-QG1 (808)

Quality Construction Equals Improved IAQ

Quality construc-

tion is a key to a

minimum amount of

AHU leakage. Leak-

age is an adversary

of indoor air quality.

It will depreciate the

quality of the supply

air by allowing dirty,

unﬁ ltered air to seep

into the air-stream

downstream of the

ﬁ lters.

To prevent this leakage, the rigid, thermally superior

panels of Solution AHUs are matched with a rugged

framework to provide an extraordinary casing perfor-

mance.

The maximum allowable air leakage is less than 1% at

+/- 8" w.g. and a maximum L/240 deﬂ ection.

The Shell of Solution is made up of double wall panels

and doors.

• Standard liner material is galvanized

• Stainless liners are optional

• Perforated aluminum liners are optional

The ﬂ oor is a double wall construction, with a galvanized

steel walk-on surface.

• Optional stainless steel

• Optional aluminum tread plate

Multi-Sloped Drain Pans

The way to control micro-organisms, which can ﬂ ourish

in drain pans, is to control the moisture of cooling-coil

condensate which can remain in the pan during “off” or

“heating” cycles.

Poorly designed drain pans

are often breeding grounds

for mold and poor IAQ.

ASHRAE 62-2001, section

5.11.1 states that drain pans

“...shall be sloped at least

1/8" per foot from the hori-

zontal toward the drain outlet

whether the fan is in the on or

off position.” Section 5.11.2

states that “The drain pan outlet shall be located at the

lowest point(s) of the pan.”

Solution units remove the condensate with a multi-sloped

drain pan that ensures positive drainage. Our pan design

also offers the highest level of accessibility for periodic

cleaning, now required by ASHRAE Standard 62.

Raceways

Raceways are used as the exterior skeletal construction

of Solution.

• Raceways provide the form and shape as well as

structural support for panels, base and internal.

• Raceway material is Galvanized

Solution is offered with a full-perimeter base-rail with

integral lifting lugs.

• Optional base-rails

• Lifting lugs are provided

as necessary for material

handling

A ‘Curb Rest’ is provided to

direct, guide and indicates align-

ment when setting a unit on the

curb.

• Galvanized steel strip at-

tached to the raceway or

base-rail

• ‘Curb Rest’ is not to be

considered a ﬂ ashing

receiver for the curb.

Improve Cost Savings

Solution UV-C light options

eliminate the potential for a build-up of microbiological

agents.

1. Heat exchangers continue to operate at high-

efﬁ ciency levels due to sustainable, like-new,

reduced pressure drop.

2. HVAC equipment operates for shorter periods of

time saving cost on electricity.

3. Improved IAQ as the ﬁ rst line of defense against

sick building syndrome.

Installation of UV-C lamps promotes a cleaner, healther,

more productive work environment.

More detailed information on page 57 of this manual.

Literature Reference — see Application Guide ‘Solution IAQ Series General AHU Construction’ - Form 102.20-

AG3

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

A Complete Line of Filters

A complete line of clean air solutions for industrial plants,

hospitals, schools, pharmaceutical process, airports and

commercial buildings are available to control or remove

airborne contaminants from the air stream.

Achieving acceptable indoor air quality is more involved

than calculating and applying the appropriate ventilation

rate. Speciﬁ c AHU performance and other common

sense speciﬁ cation items, tied to ASHRAE 62.1 rec-

ommendations, can help achieve the healthy indoor air

quality environment desired.

GENERAL INFORMATION

Light pre-ﬁ ltering duty:

– pleated

– extended surface

Higher ﬁ ltration efﬁ cient

– 60% to 95%

– 11 to 14 MERV

– rigid & bags

Stringent ﬁ ltration requirements:

– HEPA

– Ultra-HEPA

– 17 to 18 MERV

– 0.3 & 0.1 microns respectively

– 99.97% & 99.99 % effectiveness

Odor or VOC removal

– Activated carbon

Air puriﬁ cation systems

High-performance

– Near-HEPA performance

– Germicidal capability

– Low-resistance-to-airﬂ ow (initial

pressure drop equal to a low-end

pre-ﬁ lter).

Energy-Saving Fan Options

In any AHU, the fan is the largest energy consumer.

Solution fans offer a range

of energy-saving options

through fan types and con-

trols.

– Light aluminum fan

wheels

– Direct-drive plenum

fans, which eliminate

belt-and-pulley energy

losses

To assure the quietest

possible operation,

fans and motors are

common base isolated

from the cabinet.

Economizers (EE) provide an exhaust path for return

air, allowing the outdoor air conditions, when suitable,

to take advantage of 100% outside air for “free” cooling,

allowing the chillers to be turned off a percentage of the

time during the cooling season. Return and exhaust

fans are available to meet the needs of varying building

pressurization requirements.

Literature Reference — see Application Guide ‘Solution - Reducing AHU Energy Consumption’ - Form 102.20-

AG13

JOHNSON CONTROLS 11

FORM 102.20-QG1 (808)

Energy Consumption

The HVAC industry has taken a leadership role by creat-

ing energy-performance guidelines, such as ASHRAE

90.1. Solution AHUs are designed with ASHRAE 90.1

in mind.

In extreme ambient conditions, heat transfer through

the casing must be controlled. Solution casing offers

maximum thermal performance in the ﬂ oors, walls and

roof. To prevent energy-robbing air leaks, Solution units

are designed for a maximum casing leakage of less

than 1%.

For every 1% of air leakage at the AHU, 1% more air

must be conditioned, and 1% more energy is con-

sumed.

Comparing Apples-to-Apples

Competitors claim “Air leakage rates between 1/2 and

1 percent” on their AHUs, but they don’t mention at what

pressure this performance is achievable, nor do they

even specify a leakage rate for the air units.

This typically makes it difﬁ cult to analyze their leakage

performance by not qualifying it based on air pressure.

However, if we reference to SMACNA class 3 air leakage

this is a good place to begin our analyses.

SMACNA class 3 refers to a standardized method

of classifying duct leakage. While this classiﬁ cation

doesn’t technically apply to AHUs, it is a useful method

of comparing the performance claims of different manu-

facturers. According to SMACNA Duct Leakage Test

Procedures (1985), duct leakage is calculated using

the equation:

Eq. 1 Lmax = CLP0.65

where,

Lmax = maximum permitted leakage in cfm/100ft2 duct surface area;

CL = duct leakage class, cfm/100ft2 at 1 in-w.c.

P0.65 = test pressure in in-w.c.

Literature Reference — see Application Guide Form 102.20-MG1. See also M-42-06.

Rearranging Equation 1 to solve for duct leakage class:

Eq. 2 CL = Lmax/P0.65

CL = (0.5 cfm/ft2 x 100 ft2)/50.65

CL = 17.6

According to this, regardless of unit size or capacity,

this type air-unit is roughly equivalent to a SMACNA

leakage class of 18.

Analyzing Solution units is a little more complex than

analyzing the other typical unit, since Solution strives

for a maximum leakage rate of 1% of the unit design

airﬂ ow at ± 8 in-w.c. That means that the leakage in

cfm/100 ft2 of unit casing varies based on the size and

capacity of the unit. A 4,000 cfm Solution unit will have

a maximum leakage rate of 40 cfm, whether the unit is

8’ long or 10’ long. Therefore, the 10’ long unit will have

an inherently lower cfm/100 ft2 leakage rate than the 8’

long unit, as shown in Table 1.

Using the Solution performance at ± 8 in-w.c. we can use

the SMACNA leakage class as a standard comparator.

By plugging the values from Table 1 into Equation 2, we

ﬁ nd the leakage class for the various Solution units as

shown in Table 2.

Even on large AHUs, the leakage class of a Solution

unit is lower than that of most competition. Many design

engineers don’t realize this, because when they compare

YORK’s performance to others they aren’t comparing

apples-to-apples unless the performance is translated

into the common language of leakage class.

Table 1. Comparative Solution Leakage Rates

Unit CFM: 4000 4000 16000 16000 32000 32000

H (Inches) 36 36 66 66 114 114

W (inches) 54 54 96 96 102 102

L (inches) 98 124 105 132 125 150

Area (ft2)150 182 324 385 537 612

1% Leakage (cfm) 40 40 160 160 320 320

Leakage (cfm/ft²) 0.27 0.22 0.49 0.42 0.60 0.52

Table 2. Solution AHU Leakage Classes

Unit CFM: 4000 4000 16000 16000 32000 32000

Leakage (cfm/ft²) 0.27 0.22 0.49 0.42 0.60 0.52

Leakage Class

at ± 8 in-w.c 7 6 13 11 15 14

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

3. Eliminates need for motor

starter panels.

4. Improved system control

and response – DDC

controls with LED digital

display.

5. Proven reliability.

Typically HVAC systems consume

a third of the energy used in com-

mercial buildings. Therefore an

energy-efﬁ cient HVAC system can

represent a signiﬁ cant savings in

building operating costs. ASHRAE

90.1 provides architects and engi-

neers with guidelines for the design

of energy efﬁ cient buildings, with

the exception of low-rise residential

buildings.

GENERAL INFORMATION

EPAct Efﬁ cient Performance

Consumption of energy can also be reduced by more

efficient motors. Solution AHU motors meet EPAct

efﬁ cient performance standards for general purpose

motors. Standard Solution EPAct efﬁ cient and Premium-

efﬁ ciency motors can be speciﬁ ed and used with fre-

quency control as listed by NEMA Standards Publication

MG 1-2006 (Motors and Generators):

• MG 1-2006 Part 30

Application Considerations for General Purpose

Motors used with Adjustable - Voltage OR Adjust-

able - Frequency Controls or Both

• MG 1-2006 Part 31

Deﬁ nite-Purpose Inverter-Fed Poly-phase Motors

Literature Reference — see Application Guide ‘Solution Air Handling Units AC Induction Motor Data’ -

Form 102.20-AG15.

Literature Reference — See Application Guides ‘ASHRAE 90.1 Guidelines’ – Form 102.20-AG2 & ‘Understand-

ing AHU Casing Leakage’ – Form M-42-06

Energy Saving Air-Modulator™

When the air system is de-

signed for variable-air vol-

ume (VAV), Solution offers

the most efﬁ cient method of

VAV fan control with our Air-

Modulator™ drive, which is

mounted, wired and tested in

our factory.

Fans characteristically require

much less power as the speed

is reduced. With the Air-Modulator™, any reduction in

fan speed results in a cubic reduction in fan horsepower.

For example, a 10% speed reduction results in a 27%

fan horsepower reduction!

Air Modulator beneﬁ ts include:

1. Extended Equipment Life – soft start of motor and

fan.

2. Quieter Fan Operation –

fan operating at reduced speed and constant line

of efﬁ ciency.

JOHNSON CONTROLS 13

FORM 102.20-QG1 (808)

Sound Attenuation

An important component of indoor environmental qual-

ity (IEQ) is acoustics. There are very few constants

when it comes to acoustics, however it is always less

expensive to design and install a system correctly the

ﬁ rst time than it is to make the system quiet after it is

installed. The best way to reduce noise is not to create

it in the ﬁ rst place.

ARI 260 requires that the unit be rated across its entire

operating range according to the AMCA 300 test method.

Johnson Controls/YORK has been and continues to be

fully engaged in a rigorous ARI 260 testing program.

Solution testing includes a wide variety of fan types,

unit sizes and conﬁ gurations. As a result, Solution can

with assurance say sound power levels are reported in

accordance with ARI 260.

Solution AHU offers a variety of noise-reducing tech-

nologies.

Solution AHUs are available

with a nearly endless array

of fan types, all custom

selected for the exacting

requirements of your project.

Direct drive plenum fans

can reduce vibration and

drive noise by eliminating

the belt-and-pulley mecha-

nism. A range of fan-base

construction and isolation techniques are available to

help control sound.

Source attenuation

is the ﬁ rst sound-re-

duction method that

should be consid-

ered, and is typical-

ly least expensive.

Since the fan is the

primary moving part

in an air-handling

system, it’s the ﬁ rst

place to look when

reducing noise.

What little noise is left can be further reduced with direct

methods of sound

attenuation. Using

perforated sound-

absorbing walls as

sound traps in the

fan and discharge-

plenum sections,

Johnson Controls/

YORK equipment

engineers can help

you design units

to meet your criti-

cal sound require-

ments.

Inertia Base

A concrete inertia base, which is inserted between the

fan and its supportive structure, can be quickly and eco-

nomically installed in all Solution unit cabinet sizes.

– Inertia fan bases will accommodate both belt

driven and direct drive fans

– The added mass of the inertia base allows for a

softer isolation system and greater isolation ef-

ﬁ ciencies as well as an effective means of damp-

ening mechanical noise.

– Concrete ﬁ ll is furnished by contractor.

Application Note - As a rule of thumb the inertia base

should be used when:

• Class II & III fans with 40” diameter wheel or larger

• All centrifugal fans driven by motors of 75HP or

larger

RACEWAY ASY

BULKHEAD ASY

SOUND

ATTENUATION

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Quick Selection

The Quick Selection Guide for the Solution AHU was developed and intended to aid the Consulting Engineer, Ar-

chitect, Design/Build Contractor, and Equipment /Controls Engineer in establishing overall estimates for (minimally)

footprint dimensions, unit weight, & max motor horsepower.

Contents consist of:

– Applications, Features & Beneﬁ ts

– Instructions

– Data

– Notes

– Reference Formulas and Conversions

GENERAL INFORMATION

Literature Reference — See Quick Select Tool – Solution Slide Chart – Form 102.20-SC1

JOHNSON CONTROLS 15

FORM 102.20-QG1 (808)

Fan Laws (Recommended Accepted Practice)

The fan laws are used to calculate performance char-

acteristics; fan speed (RPM), fan air capacity (CFM),

static pressure (SP) and brake horsepower (BHP) of

a particular fan at conditions other than those at which

the data was taken.

By using the fan laws in conjunction with a fan curve, the

fan performance can be calculated accurately at various

operating conditions. Every fan has its own unique fan

curve. FIG. 2 shows a fan curve at various RPMs.

The system resistance curve relates the total pres-

sure loss in an air handling system to the ﬂ ow rate of

air through the system. The system curve is unique to

each system because it expresses the pressure losses

associated with the system. (AHU cabinet, coils, ﬁ lters,

supply and return ductwork, grilles and diffusers).The

SP and CFM values are used to create the system curve

for the particular system. FIG. 3 represents a fan curve

with 2 system curves identiﬁ ed.

FAN APPLICATION REVIEW

System curves will always have a square function slope

(parabola) because the SP varies as a square of the

CFM. The point where the system curve intersects the

RPM curve is the operating point of the fan (point A).

If the system resistance changes (i.e., dirty ﬁ lters or

change in ductwork), the operating point will move along

the RPM curve to a different operating point and there-

fore, new system curve (point B). With a ﬁ xed system,

the effects of change in RPM, air density of BHP can

be calculated and plotted on the system curve by using

the following fan laws:

• The CFM varies directly with the RPM:

• The SP varies as a square of the RPM:

• The BHP varies as a cube of the RPM:

• The SP and BHP are directly proportional to the

air density:

The fan laws can only be used to project performance

along a speciﬁ c system curve. Referencing FIG. 3, Point

A can be used to project the performance of Point C and

similarly, Point B can be used to project the performance

of Point D. Point A cannot be used to predict any other

point on the RPM curve, it can only project performance

on the system curve created by Point A.

PEAK EFFICIENCY LINE

50 100 150 200 250 300 350 400 450 500 550 600 650 700

AIRFLOW – CFM (100)

STATIC PRESS. – (IN. WG)

500

7.5

700

900

System 1

System 2

B50

1100

1300

75 MAX. HP

1500

FIG. 3 – FAN CURVE WITH TWO SYSTEM CURVES

PEAK EFFICIENCY LINE

50 100 150 200 250 300 350 400 450 500 550 600 650 700

AIRFLOW – CFM (100)

STATIC PRESS. – (IN. WG)

500 RPM

700 RPM

7.5 HP

10 HP

20HP

900 RPM

25 HP

30 HP

40 HP

50 HP

1100 RPM

60 HP

1300 RPM

75 MAX. HP

1500 RPM

FIG. 2 – CURVE AT VARIOUS RPMs

CFM2 = CFM1 x RPM2

RPM1

SP2 = SP1 x RPM2

RPM1

BHP2 = BHP1 x RPM2

RPM1

SP2 = SP1 x RPM2

RPM1

Density2

Density1

lmlm

BHP2 = BHP1 x Density2

Density1

RPM2

RPM1

lmlm

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Variable Air Volume

A common mistake when selecting a fan with variable

air volume is to assume a fan with VAV will follow a

constant design system curve (passing through the point

0 CFM and 0 TSP) to maintain control. VAV systems

do not have a constant system line, but rather a range

of operating points necessary to satisfy the building

requirements. In VAV systems, the operating point will

continue to move based on the air modulation and as

the CFM and SP change, the fan is modulated to match

the new requirements, developing its own system curve.

This modulation is accomplished by using inlet vanes,

variable speed drives or discharge dampers. Before

ﬁ nalizing the fan selection, plot the new VAV system

curve to conﬁ rm the modulation range required does

not enter into the instability range of operation.

Example

Calculate the minimum CFM and at least 2 arbitrary

points which fall within the stable operating range of

the curve (using equations below) and plot these points

along with the design points to create the new VAV

system. (See FIG. 4.)

Design CFM = 40,000 CFM = CFMd

Design TSP = 4.5 in WG = SPd

Static Pressure Control Point = 1.25 in WG = SPd

FAN APPLICATION REVIEW

Select the most efﬁ cient fan that can deliver both the

design and minimum CFM requirements. If the initial

selection does not provide sufﬁ cient “turn down”, select

the next smallest fan and re-plot the VAV system for the

smaller fan and re-evaluate. Typically, the largest fan that

can supply the required modulation is the most efﬁ cient.

Each application should be considered individually and

evaluated to be sure the fan will not be forced into the

unstable region at modulated condition.

For variable speed drive (VSD) applications, the fan

drive assembly is selected to operate approximately in

the middle of the VSD’s range. When selecting a fan to

be used with a VSD, if the RPM is close to or approach-

ing the Class I limit, select the Class II fan. Selection of

a Class I fan may result in premature bearing failure.

1st: Calculate the Minimum CFM:

Min CFM = CFMd x



SPS

SP1 x CFMd

+ SPS – SPd

m

where: CFM1, SP1 = arbitrary point located on surge line

Min CFM = 10,517

40,000 x



1.25

3 x 40,000 2

+ 1.25 – 4.5

= 10,517

15,000m

CFM1

2nd: Calculate the Arbitrary Points:

where: CFM2 = 30,000

30,000 CFM 20,000 CFM

SP2 = CFM2

x (SPd – SPs) + SPs

CFMd

where: CFM3 = 20,000

SP3 = CFM3

x (SPd – SPs) + SPs

CFMd

SP2 = 30,000 2

x (4.5 – 1.25) + 1.25

m

40,000

SP2 = 3.1

SP3 = 20,000 2

x (4.5 – 1.25) + 1.25

40,000

SP3 = 2.1

JOHNSON CONTROLS 17

FORM 102.20-QG1 (808)

Solution Component Temperature Margins

• Standard motors (Class B Insulation) -104°F.

• Motors with Class F Insulation -140°F.

• Power Wiring - 140°F.

• Controls & Control Wiring - 140°F.

• Pre-ﬁ lters - 150°F.

• High Efﬁ ciency Filters - 200°F.

• Fan Bearings - 120°F (FC), 180°F (AF)

• Gasketing - 200°F

• Foam - Flash Point: 415°F (213°C)

MODULATION

RANGE

50 100 150 200 250 300 350 400 450 500 550 600 650 700

AIRFLOW – CFM (100)

STATIC PRESS. – (IN. WG)

Minimum CFM Design CFM

PEAK EFFICIENCY LINE

Static Pressure

Control Point

10 HP

20 HP

25 HP

30 HP

300 RPM

1100 RPM

1300 RPM

40 HP

50 HP

60 HP

75 MAX. HP

Design Pt.

1500 RPM

FIG. 4 – FAN CURVE AT VARIOUS RPMs

Fan Motor Heat (MBH)

HEAT Horsepower

5 7.5 10 15 20 25 30 40 50 60 75 100

Fan Motor 2.8 3.6 4.4 6.2 7.5 8.7 9.4 13.0 16.0 19.0 21.0 25.0

Fan 12.7 19.1 24.5 38.2 51.0 63.6 76.3 102.0 127.0 153.0 191.0 254.0

Fan & Fan Motor 15.5 22.7 28.9 44.4 58.5 72.3 85.7 115.0 143.0 172.0 212.0 279.0

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Flexibility and Performance illustrate the variety of coils

which are available to meet every application. These

carefully engineered coils are designed for an optimum

balance between air pressure drop and heat transfer

coefﬁ cient, to allow the maximum amount of cooling

or heating capacity without the added expense of high

air-pressure drops. The coil designs are subjected to

constant extensive evaluation studies comparing dif-

ferent ﬁ n corrugations with various tube arrangements.

The Johnson Controls/YORK Equipment Engineer in

your area will welcome the opportunity to assist you

with your coil applications.

Cooling Coils – Water and Direct Expansion

Solution optimizes coil performance with customized coil

options. Solution coils are offered in a wide variety of

types, sizes, arrangements and materials. Coil software

optimizes capacity and pressure drop requirements.

AHU Chilled water cooling coil

• Available in CC, VC, MZ segments

AHU Hot water heating coil

• Available in CC, VC, HC, MZ segments

AHU (DX) Direct Expansion cooling coil

• Available in CC, VC, MZ segments

Coil Performance is certiﬁ ed in accordance with ARI

Standard 410.

Chilled water / Hot water

Direct expansion (DX)

COIL OPTIONS

Header material:

• Copper

• Red Brass

Connector material:

• Red brass

• Steel

Connection Type:

• MPT

• Grooved

Fin type:

• 5/8” tube: Sine or Flat

• 1/2” tube: Sine corrugated only

Fin Material & Thickness:

• Aluminum - 0.006”, 0.008”, 0.010”

• Copper - 0.006”

Notes & Options

Hand of Unit determines connection side of coil. See page 21.

Fin Spacing:

• A vast range of ﬁ ns per inch available

Fin Coatings: (Coatings reduce max face velocities)

• Electro-ﬁ n

• Phenolic

Coil Casing:

• Galvanized

• Stainless Steel

Choice of heat transfer medium:

• Water, Glycol (Ethylene glycol coils are ARI

certiﬁ ed)

• DX – (a variety of refrigerants to choose from)

1/4" FPT PLUGGED

VENT FITTING

RETURN

SUPPLY

RETURN

JOHNSON CONTROLS 19

FORM 102.20-QG1 (808)

Heating Coils – Integral face and bypass

Integral face and bypass coils have alternating channels

of heat transfer surface and bypass zones. The air ﬂ ow

is directed over the heat transfer surface or through the

by-pass zone by modulating dampers that are integral

with the coil construction.

Integral face and bypass coil (IFB/VIFB)

• Coils are available in the ‘IC’ segment

• Tubes either Vertical or Horizontal

• Coils for maximum freeze protection

• Hot water or Steam coils

• Multiple rows deep

Heating Coils – Steam Distributing

The construction of a Steam Distributing Coil is entirely

different than that of a Standard Steam.

Everyplace that you see an outside tube or header, there

is an inside tube and header that you can’t see. Steam is

distributed through these inside tubes and headers and

slowly released to the outside tubes as the steam turns

to condensate. The condensate then ﬂ ows back down

the outside tubes in the same direction that the entering

steam comes from. The idea is that all the steam in the

inside tubes keeps the condensate in the outside tubes

from freezing when air passes across the coil at less

than 32ºF. However, under exactly the correct conditions,

even steam distributing coils can freeze.

Steam Distributing - 1” diameter tube

• Available in CC, VC, HC, MZ segments

• A vast range of ﬁ ns per inch available

• Multiple tube wall thickness options

Coil Style:

• IFB

• VIFB

Coil Type:

• Water (Glycol)

• Steam

Notes & Options

Rows:

• 1,2,3,4

Connection:

• SCH 40 pipe

Thermostat:

• None

• Electric

Fin Material:

• Aluminum

Fin Spacing:

• A range of ﬁ ns per inch available

Coil Casing:

• Galvanized

Steam

Steam or Hot Water

INTEGRAL FACE & BYPASS (IFB) COIL

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

COIL OPTIONS

Typical Application of Air Handling Coils

Heating Coils

Heating coils can use steam or hot water to add heat

to the air stream. In a cooling-only VAV system, the

heating coil is generally placed in the ‘preheat’ position

between the ﬁ lters and cooling coil. The preheat coil

can be omitted in this system if the minimum outside

air requirement is low and would not result in a mixed

air temperature below 50ºF to 55ºF.

Heating coil capacity is controlled by means of a modu-

lating control valve in the water or steam piping. The

control valve position is usually controlled by means of

a thermostat in the supply air duct in sequence with the

cooling coil control valve.

Cooling Coils

Cooling coils remove both sensible and latent heat from

the mixed air and can use chilled water, chilled brine, or

refrigerant as the cooling source. In the case of chilled

water, the supply water temperature generally ranges

from 42ºF to 50ºF, depending on the latent load to be

removed. Brine or a solution of ethylene or propylene

glycol in water is traditionally used at temperatures of

32ºF to 40ºF for applications in which piping is exposed

to freezing temperatures. Control of the cooling coil ca-

pacity at the air-handling unit is achieved by means of

a two-way ‘throttling’ or three-way ‘mixing’ control valve.

In VAV systems, a supply duct thermostat is typically

used to modulate the control valve so as to maintain

a constant temperature of air leaving the unit, usually

55ºF to 60ºF.

When refrigerant is used as the cooling source, it enters

the coil in liquid form from a condensing unit and pro-

vides cooling by a process called ‘direct expansion’. The

liquid refrigerant evaporates as the warmer air moves

across the coil, removing heat from the air during the

process. The evaporated refrigerant is then compressed

in the condensing unit, which also houses the condens-

ing coil where the heat is rejected to the outside. Control

of the coil capacity is typically by means of a series of

solenoid valves in the refrigerant liquid lines, which are

energized to shut-off the ﬂ ow of refrigerant to part of the

coil. There are several problems with the application of

VAV to a direct expansion (DX) coil which require the

designer to take special precautions when considering

this system. First, the balance point temperature for

the DX coil will change as the air ﬂ ow rate changes.

Assuming constant coil capacity, reducing the CFM will

reduce the suction temperature and pressure, making

close control of air temperature difﬁ cult. In addition,

compressor unloading at reduced load will cause step

changes in capacity and suction temperature, which

can cause hunting in the ﬂ ow control loop. In short, the

use of variable air ﬂ ows with a DX coil requires careful

consideration of the effect air ﬂ ow changes make to the

system. Balance point temperatures must be carefully

considered.

Design Considerations

In order to insure predicted coil performance, air distri-

bution must be uniform. There are two design checks

for this:

1. ‘45 degree rule’ – This rule states that the perfor-

mance of the coil will not be affected as long as the

diffusion angle from the most restrictive block-off to

the ﬁ nned portion of the coil is 45 degrees or less.

This rule holds true unless there are unusual ﬂ ow

ﬁ elds, caused by such components as upstream

fans or mixing boxes where not applied properly.

2. ‘Uniform pressure rule’ – This rule states that the

performance of the coil will not be affected as long as

the maximum difference in upstream, downstream,

and combined static pressure due to local velocity

pressure at any one point on the coil compared to

another point that does not exceed 10 percent of

the pressure drop through the coil. The basis for

this rule is that the ﬂ ow rate through the coils at any

one point is a function of the local upstream and

downstream pressures, and if pressure differences

are small, distribution will be uniform.

Literature Reference — See “DX Piping Guide” – Form 050.40-ES2

JOHNSON CONTROLS 21

FORM 102.20-QG1 (808)

FAN SECTION

LEFT HAND (LH)

COIL CONNECTION

RIGHT HAND (RH)

COIL CONNECTION

RETURN AIR

INLET SECTION

OUTSIDE AIR

DRIVE HAND AND COIL HAND DETERMINED

BY FACING THE INLET SECTION

RIGHT

REAR

LEFT

FRONT

FAN SEGMENTS

• FS – Supply

• Forward Curved

• Airfoil

• Industrial Airfoil

• SWSI Plenum

(Belt and Direct Drive)

• FR – Return

• Forward Curved

• Airfoil

• Industrial Airfoil

• SWSI Plenum

(Belt and Direct Drive)

• FE – Exhaust

• Forward Curved

• Airfoil

• Industrial Airfoil

COIL SEGMENTS

• CC – Cooling Coil

• HC – Heating Coil

• VC – Vertical Coil

• MZ - Multizone

Unit & Coil Hand Identiﬁ cation

HEAT SEGMENTS

• IC – Integral Face & Bypass Coil

• IG – Indirect Gas Fired Furnace

• EH – Electric Heater

ENERGY RECOVERY

• ER – Energy Recovery

FILTER SEGMENTS

• FF – Flat Filter (2” or 4”)

• AF – Angle Filter (2” & 4”)

• RF – High Efﬁ ciency Filter

• Rigid Filter (12”)

• Bag Filter (21”)

• Mini-Pleat Filter (4”)

• HF – HEPA Filter

INLET SEGMENTS

• MB – Mixing Box

• FM – Filter/Mixing Box

• EF – Filter/Economizer

• EE – Economizer

• IP – Inlet Plenum

• VE – Vertical Economizer

• VF – Vertical Filter/Economizer

ACCESSORY SEGMENTS

• VP – Vertical Plenum

• DP – Discharge Plenum

• TN – Turning Plenum

• DI – Diffuser

• XA – Access segment

• AB- Air Blender

• EB – External Bypass

• IB – Internal Bypass

• FD – Face Damper

• AT – Attenuator

• HM - Humidiﬁ er

• UV - UVC Lamps

SOLUTION SEGMENT IDENTIFICATION

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Fan Applications

Fan segments are available as supply, return and or exhaust applications. Unit conﬁ gurations have a segment op-

tion of utilizing a single fan or a dual fan arrangement. Isolation consists of 1" or 2" springs with a seismic snubber

option. Thrust restraints and OSHA belt guards are available as required.

Double-width/Double-inlet (DWDI)

• Forward Curve or Airfoil centrifugal

• Belt Driven

Single-width/Single-inlet (SWSI)

• Airfoil plenum

• Belt Drive or Direct Drive

SINGLE FAN SEGMENT – FS, FR AND FE

Bearing options for fans with lubricating bearings: (refer

to Notes & Options)

• Extended Lube Line

• External Lube Line

In most fan systems a segment with a single fan is

adequate for the required system design and rating.

Methods of control can vary and may include dampers

or variable speed drives. Also included in a single fan

design may be the allowance for future expansions.

In some situations, there may be a need for a system design using multiple fans in a cabinet. The following are some

reasons to consider a dual fan arrangement:

Dual Fan Considerations

1. One fan may be too large and not ﬁ t into the desired

space, or it may weigh too much if supported on

upper levels.

2. The required operating range of the system may

necessitate multiple fans instead of one large fan

controlled over a wide operating range.

3. Multiple fans for capacity control may be more eco-

nomical if cost of operation is critical, especially at

very low ﬂ ow rates for long time intervals.

4. Critical systems are often equipped with redundant

or back-up fans in case of a ﬁ re or accident or some

other emergency that requires a sudden increase in

ﬂ ow. Redundant fans are also used to eliminate down-

time during fan maintenance.

5. Some systems for process applications may require

pressures that are greater than a single fan can pro-

duce or when noise may be a special concern.

Dual Fan Applications

Solution dual fan application methods include 50/50 where both fans operate together to share the load equally or

100/100 where only one fan at a time is in operation.

• In a 50/50 application, the failure of one fan will re-

sult in a condition where the other fan will continue

to operate. The single fan will provide partial load

capabilities

• In a 100/100 application, the failure of one fan will

result in the operation of the other (standby) fan to

provide full capacity

Literature Reference — see Application Guide ‘AHU Dual Fan Options’ - Form 102.20-AG17

JOHNSON CONTROLS 23

FORM 102.20-QG1 (808)

Door and Discharge Locations

Fan and fan motor may be oriented in the fan

segment. Consideration must be given to which

orientation is used where. Upstream/downstream

usage follow.

Where Doors are used:

Rear/rear-inverted discharge – Upstream

Top/bottom discharge – Downstream

Front/front inverted discharge – Downstream

Top-inverted/bottom-inverted discharge –

Upstream

REAR (R)

HINGES

DOOR

DOOR DOOR

DOOR

HINGES

TOP (T) BOTTOM (B)

REAR INVERTED (RI) TOP INVERTED (TI) BOTTOM INVERTD (BI)

DOOR

HINGES

FRONT (F)

FRONT INVERTED (FI)

AIRFLOW

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Double-width/Double-inlet (DWDI) Options – Belt Drive

Fan and fan motor may be oriented in the fan segments as shown. Consideration must be given to which orientation

is used where. Upstream/downstream images shown below.

Motor Beside Motor Behind

1. If a discharge plenum is immediately downstream of a fan

section and the discharge plenum has a top discharge, the fan

section will be rear inverted discharge.

2. If the discharge plenum has a rear, side or bottom discharge,

the fan will be rear discharge.

3. When a diffuser is ordered immediately downstream of a fan

section, the fan will be rear or rear inverted discharge.

4. Door width is sized to remove max HP motor with connection

box removed.

NOTE: Doors follow motor location. See door locations illustration

on page 23.

Fan type available

• Forward Curve centrifugal

• Airfoil centrifugal

Class I (S) construction

• Permanently sealed bearings

• Fan sizes: 7x7 thru 18x18 (Forward Curve)

Class 1 Construction

• Lubricating bearings

• Fan sizes: 20x15 thru 40x40

Class II construction

• Lubricating bearings

• Fan sizes: 7x7 thru 40x40

Thrust restraints are optional for rear and front discharge airfoil fans

only.

• Not available for FC fans.

• Required for AF with TSP over 6”

Notes & Options (DWDI)

SINGLE FAN SEGMENT – FS, FR AND FE

JOHNSON CONTROLS 25

FORM 102.20-QG1 (808)

Single-width/Single-inlet (SWSI) Options

Fan and fan motor may be oriented in the fan segments as shown. Consideration must be given to which orientation

is used where. Upstream/downstream images shown below.

1. The plenum fan segments can accommodate multiple duct

outlets, thus reducing the amount of ﬁ eld duct work and

transitions.

2. When any ﬁ lter segment (EF, FM, FF, AF, RF, or HF) or coil

segment (CC or HC) is located upstream of a FS-SWSI,

FR-SWSI or FE-SWSI, sufﬁ cient transition length will be

required between the FS segment and the ﬁ lter segment.

3. Fan discharge locations - rear, front, bottom, top, left and right.

4. Single Width, Single-Inlet (SWSI) air foil plenum fans are

available as Class I, II & III. (with lubricating bearings)

5. Thrust restraints are required with TSP over 3”.

Notes & Options (SWSI)

Belt Drive Direct Drive

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Double-width/Double-inlet (DWDI) Options – Belt Drive

Access doors are provided on both sides of the segment.

• Allow sufﬁ cient access-to and clearance-around the segment

for motor removal from either side.

Separation Panel Option

• Optional safeguard when servicing requires that the system be

in a running status. A separation panel is positioned between

the fans.

Flow Isolation Options

• Optional isolation method to prevent air from an energized fan

going back through a fan that is not energized.

• DWDI option is mounted on fan discharge.

•Note: Not available with fan exhaust (FE)

• Option is required with 100 %/100 % method.

Options include (depending on type of fan):

1. Manual sliding panel

2. Back-draft damper with counter balance

3. Mechanical Control damper

Notes & Options

DUAL FAN SEGMENT – FS, FR AND FE

Fan type available:

• Forward Curve centrifugal

• Airfoil centrifugal

Class I (S) construction

• Fan sizes: 7x7 thru 18x18 (Forward Curve)

Class 1 construction

• Fan sizes: 20x15 thru 22x22

Class II construction

• Fan sizes: 7x7 thru 22x22

DWDI motor location – Behind only

Motor Behind

FE DIRECTION OF AIRFLOW

SLIDING

WALL OPTIONAL

ISOLATION

WALL

DAMPER

DUAL FAN

WITH NO

DAMPER

DUAL FAN

WITH SLIDING

PANEL

DUAL FAN

WITH DISCHARGE

DAMPERS

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

DAMPER

OPTIONAL

ISOLATION

WALL

SLIDING

WALL

NOTES:

1. DAMPER OPTIONS ARE ONLY

AVAILABLE FOR FRONT/FRONT INVERTED/

REAR/REAR INVERTED DISCHARGE.

2. DAMPERS OPTIONS ARE NOT

AVAILABLE FOR TOP/TOP INVERTED/

BOTTOM/BOTTOM INVERTED DISCHARGE.

JOHNSON CONTROLS 27

FORM 102.20-QG1 (808)

Single-width/Single-inlet (SWSI) Options – Belt-Drive or Direct Drive

Access doors are provided on both sides of the segment.

• Allow sufﬁ cient access-to and clearance-around the segment

for motor removal from either side.

Separation Panel Option

• Optional safeguard when servicing requires that the system be

in a running status. A separation panel is positioned between

the fans.

Flow Isolation Options

• Optional isolation method to prevent air from an energized fan

going back through a fan that is not energized.

• SWSI option is mounted on fan inlet.

•Note: Not available with fan exhaust (FE)

• Option is required with 100 %/100 % method.

Options include (depending on type of fan):

1. Manual sliding panel

2. Back-draft damper with counter balance

3. Mechanical Control damper

Notes & Options

Fan type available:

• Standard Airfoil (AF) 10" – 30"

• *Industrial Airfoil (AF) 12" – 30"

• Class I, II, *III

SWSI motor location:

• 10" to 16" fans - behind motor only

• 18" to 30" fans -top motor only

• Fans with top motor location will require thrust

restraint

SLIDING

WALL

DAMPER

FE DIRECTION OF AIRFLOW

DUAL FAN

WITH INLET

DAMPERS

DUAL FAN

WITH NO

DAMPER

DUAL FAN

WITH SLIDING

PANEL

INLET

DAMPER

1 WHEEL

DIAMETER

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL

OPTIONAL

ISOLATION

WALL SLIDING

WALL

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

SWSI Plenum vs. DWDI Housed Fan Application

SWSI Plenum airfoil fans offer superior performance

for many applications. Typical concerns with fan per-

formance are efﬁ ciency, noise, and air velocity proﬁ le

through components. Plenum fans offer advantages

for all three concerns. Additionally, these fans provide

ﬂ exibility with outlet conﬁ gurations, reduced mechanical

space footprint, and the beneﬁ t of direct-drive.

Efﬁ ciency:

DWDI housed fans use a scroll to increase their efﬁ -

ciency. However, optimizing this fan requires a process

referred to as “static regain”. Housed fans are tested

with an outlet duct of 2.5 to 3.5 times the wheel diam-

eter in length. This outlet duct allows the “static regain”

process, where velocity pressure is converted to static

pressure. Housed fans applied without this outlet duct

will require a system effect factor (SEF) which decreases

the fan efﬁ ciency. Housed fans in blow-through positions

will also require an air diffuser which decreases the ef-

ﬁ ciency further. The combination of these two system

effects brings even the best housed DWDI airfoil fan

efﬁ ciency to, or below that, of the SWSI plenum fan,

thereby eliminating the beneﬁ t of the fan scroll.

Noise:

Plenum fans have the beneﬁ t of effectively utilizing the

entire unit as the fan housing, which offers superior at-

tenuation. The same factors that decrease the housed

fan’s efﬁ ciency discussed above also increase the noise

level of the housed fan. Also, since the SWSI plenum

fan has no scroll, typically there is room within the air

handling unit for a larger wheel (33” SWSI plenum vs. 27”

DWDI housed, for example), which generally produces

better sound characteristics. For design pressures at or

below 6.00 in. W.C., it is very common to see supply air

sound power levels lower when using a SWSI plenum

airfoil fan instead of the DWDI housed airfoil fan. Ad-

ditionally, perforated liners may be used in plenum fan

sections for greater attenuation.

Velocity Proﬁ le:

Due to the relatively small outlet/blast area of housed

DWDI fans, an air diffuser must be applied to the dis-

charge of the fan to obtain an acceptable velocity proﬁ le

through the next component. Air diffusers add static

pressure which decreases fan efﬁ ciency and increases

fan noise levels. SWSI plenum fans positively pressurize

the entire cabinet, they do not require a diffuser with its

associated performance losses.

Outlet Flexibility:

SWSI Plenum fans serve to pressure the entire fan ple-

num, allowing for multiple duct take-off from the AHU.

Additionally, these openings can be tailored to match

virtually any duct conﬁ guration, be it rectangular or round

/ ﬂ at-oval with bellmouth ﬁ ttings for improved acoustic

and optimized pressure drop performance.

Mechanical Space Optimization:

A housed DWDI fan requires a straight run of duct per

AMCA guidelines at the outlet of the fan before elbows

can be applied. This constraint imposes restrictions on

duct layout and mechanical space design which gener-

ally increase overall footprint requirements. The ducted

take-offs from pressurized plenums, as in the case of

aSWSI plenum fan, does not have a requirement for a

straight run and affords greater ﬂ exibility to the architect

and engineer in ductwork design.

Direct-Drive Beneﬁ t:

Specialty housed DWDI fans can be used in direct-drive

arrangements, where the fan wheel is directly mounted

onto the motor shaft, most-typically, housed fans are

driven by a belt and sheave system. Belt-drive systems

typically allow for 3-5% of efﬁ ciency loss and impose

maintenance requirements not present in direct-drive

systems. Additionally, belts wear and give off debris in

the form of belt dust. Anymore, discerning engineer’s

apply direct-driven SWSI plenum fans with VFD’s

for efﬁ cient variable air volume duty and trouble-free

maintenance.

FAN SEGMENT – FS, FR AND FE

JOHNSON CONTROLS 29

FORM 102.20-QG1 (808)

Disconnect

This is a device for the source of power (line voltage

as provided through the building electrical utility)

from the controlled device (motor).

• Low Cost

• Constant Volume

• No BAS control needed

Across-the-line Starter

Motor Controller will provide a start / stop operation

of a motor. An integral disconnect (shall incorporate

a “lockout/tag-out” system) shall provide discon-

necting of “line side” power from the electrical utility

system.

The motor controller will also contain the proper

short circuit and thermal overload protection for the

motor that it is controlling.

• Higher Cost

• Constant Volume

• Start/Stop controlled remotely

• Thermal Overload Protection

• Under/over Voltage Relay

• Disconnect Option - Fused only

Indoor Enclosure - NEMA 3R

Indoor Voltages - 200, 208, 230, 380, 460, 575

Outdoor Enclosure - NEMA 3R

Outdoor Voltages - 200, 208, 230, 380, 460, 575

Variable Frequency Drive (VFD)

The Air-Modulator type controller varies speed of the

motor by pulse width modulation of the alternating

current waveform.

An integral disconnect (incorporates a “lockout/tag-

out” system) provides disconnecting of “line side”

power from the electrical utility system.

This motor controller will also contain the proper

short circuit and thermal overload protection for the

motor that it is controlling.

• Highest Cost

• Variable Volume

• Start/Stop controlled remotely

• Integrated basic unitary controller (can also integrate with BAS)

• Comprehensive Protection

• Disconnect Options -Fused, Non-fused, or None

Indoor Enclosure - NEMA 1

Voltages - 200, 208, 230, 460

Outdoor Enclosure - NEMA 3R

Outdoor Voltages - 200, 208, 230, 380, 460, 575

Fan Motor Control Methods

Motor control options can be explained as any one of the 3 items described below.

Literature Reference — See Engineering Guide – ‘Air Modulators’ – Form 100.42-EG1

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Cooling Coil – (CC)

When cooling 100% OA there are precautions required.

Summer design conditions are such that when air is

cooled down to normal coil leaving temperatures, there is

a considerable amount of condensate generated. Many

applications suggest cooling coils should be selected

for an air velocity under 500 FPM. If the unit is selected

as a 100% OA application, the drainage area for larger

face area coils will be increased to properly compensate

for the probable condensate.

COIL SEGMENT – CC, HC AND VC

Coils

• A combination of Water and DX coils in the same segment

requires all coils to be of the same tube diameter.

• Multiple Water coils conﬁ gured in the same segment must be

of the same tube diameter.

• Steam coils may be conﬁ gured with 5/8” tube coils. A spacer

must be used between a steam coil and any water coil or DX

coil.

Headers

• Usual header location is drive side.

• All headers in the same segment must exit the unit on the

same side.

Door

• Usual door location is drive side

• With pipe chase, the door is always opposite the pipe chase

IAQ drain pans material options:

Liner – Galvanized or Stainless Steel

Notes & Options

Heating Coil – (HC)

When heating only is required the heating coil segment

is an excellent minimally sized housing which shall ac-

commodate a single heating coil. Coils are offered with

left or right hand connections. Coils will be individually

mounted and easily removable.

Coil segment panels (side panels and top panel) shall

be easily removable to allow for removal and replace-

ment of coils, without affecting the structural integrity

of the unit.

Coils

• Only hot water and steam coils are available in the HC seg-

ment.

• Only one coil (hot water or steam) is permitted per segment.

Headers

• Usual header location is on the drive side.

Doors

• Doors are not available.

Drain pans

• Auxiliary drain pan is optional.

• Usual drain location is header side.

• The drain is always opposite the pipe chase.

Notes & Options

Literature Reference — See Service Guide – ‘Field Assembly ad Disassembly Indoor/Outdoor’ –

Form 102.20-FA1 & Installation Manual Form 102.20-NOM1

JOHNSON CONTROLS 31

FORM 102.20-QG1 (808)

Coils

• All coils located in the same coil segment must have the same

coil hand.

• Multiple Water coils conﬁ gured in the same segment must be

of the same tube diameter.

• A combination of Water and DX coils in the same segment

requires all coils to be of the same tube diameter.

• The steam coil is available for use in the VC segment. Steam

coils may be conﬁ gured with 5/8” tube coils. A spacer must be

used between a steam coil and any water coil or DX coil.

Headers

• Usual header location is on the drive side.

• All headers in the same segment must exit the unit on the

same side.

Doors

• Usual door location is on the drive side.

• Doors are always last in the air stream of the segment

• With pipe chase, the door is always opposite the pipe chase

Drain pans

• IAQ drain pan liner - Galvanized or Stainless Steel

• Usual drain location is on header side

• With pipe chase, the drain is always opposite the pipe chase

Notes & Options

RIGHT HAND OPPOSITE

LEFT HAND SHOWN

AIRFLOW

CONDENSATE DRAIN

CONNECTION 1 1/4" MPT

SIDE VIEW

FAN

SEGMENT

Vertical Coil – (VC)

This segment shall provide for a 90-degree change in

airﬂ ow direction from horizontal to vertical, after passing

air through the coil space.

Coils are conﬁ gured for horizontal air ﬂ ow to minimize

segment length. Drains pans are extended to assure

complete condensate drainage and coil access. Coil

segment panels (side panels) shall be easily removable

to allow for removal and replacement of coils, without

affecting the structural integrity of the unit.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Staggered Coil conﬁ gurations are available as an option for both the indoor and outdoor Solution® units. Angled Wall

or Back-to-Back conﬁ gurations are available in both heating and cooling coil segments.

Coils

• A staggered coil can not be combined with a non-staggered

coil in the same segment.

• Each coil bank will be located over a drain pan.

• Not available as a reduced face coil option.

Controls

• Optional control valve and valve jack (manifolded together

external of unit).

Drain pans

• Pan connection hand follows coil hand except for outside units

where the drain connection is opposite the coil hand.

• If coil connections are on both sides, the drain pan connection

follows the ”primary” side of the unit.

Headers

• Coil connections can be on the same side or opposite sides.

• Optional factory extended piping connections for each coil to

the exterior of the unit.

• Optional insulation for extended piping.

• Extended piping does not apply to DX coils.

Notes & Options

Coils

• A staggered coil can not be combined with a non-staggered

coil in the same segment.

• Not available as a reduced face coil option.

Drain pans

• The drain pan connection follows the ”primary” side of the unit.

Headers

• Coil connections can be on the same side or opposite sides.

Notes & Options

STAGGERED COIL OPTION – CC, HC, AND VC

Angle Wall

Staggered coil design increases coil face area and al-

lows increased CFM without having to increase cabinet

size.

Back-to-Back

Staggered coil design is speciﬁ cally for a reduced coil

pull distance and for opposite side connections. Two

shorter coils will be used in place of one longer coil.

JOHNSON CONTROLS 33

FORM 102.20-QG1 (808)

Multi-zone Segment – (MZ)

MZ heating and air conditioning units offer design and

application advantages over various smaller single

zone units. The Solution unit is designed to carry on

that tradition by including a MZ segment into the design

of the unit.

MZ and Dual Deck air-handling units can be conﬁ gured

for heating and cooling, or cooling and ventilation, or

ventilation and heating applications.

Rear or Top discharge MZ conﬁ gurations:

• The bottom tier is the cold deck and contains a

diffuser and a cooling coil space.

• The top tier is the hot deck and contains a heating

coil mounted horizontally at the upstream side of

the hot deck.

Air enters the diffuser then splits into two streams.

• One stream turns up through the hot deck coil

and exits the rear or top through the hot deck

damper.

• The other stream continues horizontally through

the cooling coil and exits the rear or top through

the cold deck damper.

The MZ unit is optionally available less the zone damp-

ers for use on dual duct or other blow-thru systems. If a

hot deck opening is not required, it may be blanked-off

in the ﬁ eld.

COLD DECK DAMPER

(FULL WIDTH)

HOT DECK DAMPER

(FULL WIDTH)

HOT DECK

(COLD DECK)

XA DI DWDI < AIR FLOW

-OR-

SWSI < AIR FLOW

The MZ segment is for indoor applications only and will be the last

segment in air-stream.

Air pressure drop balance plates shall be used to equalize pressure

drop across the hot and cold deck coils when required.

Door is optional for cold deck.

Discharge options:

• Top with damper or without damper

• Rear with damper or without damper

Notes & Options

Literature Reference — See Application Guide – ‘Multizone Application of Solution Units’ – Form 102.20-AG12

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Applications ideally suited for:

1. Make-up Air

2. Combustion Air Make-up

3. Penthouse units

4. Air conditioning preheat and

heating/ventilating units.

Features & Beneﬁ ts:

• Maximum freeze protection

• Constant volume

• Minimum temperature

override

• Minimum stratiﬁ cation

• Accurate temperature

control

HEATING SEGMENTS

Integral Face & Bypass – (IC)

The Integral Face & Bypass coil controls air temperature

while full steam pressure or water ﬂ ow is maintained in

the coil at all times. The temperature of the discharge

air is controlled by proportioning the entering air through

the multiple heating and by pass channels.

RIGHT HAND OPPOSITE

LEFT HAND SHOWN

AIRFLOW

WIREWAY

RACEWAY

VIFB COIL CONECTIONS

IFB COIL CONNECTIONS

1. Coil connections must be located opposite the access door.

2. All piping to be supplied by ﬁ eld, coil connections are internal

from factory.

3. Optional pipe chase with outdoor units

4. Pipe chase is not intended for trapping or piping, but for the

connections only.

Headers:

Usual header location is on the drive side. Header location must

be opposite the access door.

Coils:

Only hot water and steam applications are available for this seg-

ment.

Doors:

Access doors and viewing ports must be located in adjacent seg-

ments.

A door is required in the immediate downstream segment from the

IC segment.

Auxiliary Drain pans:

An auxiliary drain pan is optional.

Usual drain location:

• With pipe chase, the drain is always opposite the pipe chase

• IFB on header side

• VIFB on left side of the unit

Notes & Options

IFB

VIFB

JOHNSON CONTROLS 35

FORM 102.20-QG1 (808)

Indirect Gas-Fired Furnace – (IG)

The IG segment must be positive pressure. (Fan segment is not al-

lowed downstream of the IG Segment.)

Furnaces in VAV applications are designed to be used only with 100%

supply fan airﬂ ow.

– Use of furnace in reduced airﬂ ow operation may result in seri-

ous damage to equipment and may be hazardous.

– Indirect Gas-Fired Furnace Maximum Temperature rise = 90F

– Indirect Gas-Fired Furnace Maximum A.P.D. = 2.00” W.C.

– The Maximum Temperature at the IG segment discharge =

190F

Furnace includes a series stainless steel primary heat exchanger. A

secondary stainless steel heat exchanger is also included.

– An access door is required upstream of any IG segment.

– Gas pipe train options are available

The IG segment pipe chase is a single pipe chase that covers only

the IG segment.

– The pipe chase is not intended for trapping or piping, but for

the connections only.

– Pipe chase enclosure is optional for indoor units and required

for Outdoor units.

Notes & Options

I.D. FAN

CONTROL

PANEL

DOOR

HEAT EX.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Turndown Examples and Guidelines – (IG)

Description

Indirect Fired Gas Heater section consists of the stain-

less steel primary and secondary heat exchanger with

the power burner design. The basic design allows the

power burner to inject the correct ratio of air and gas into

the primary heat exchanger where the main combustion

occurs. The heated products of combustion then pass

through the multiple secondary tubes heating each tube

for maximum heat transfer. The products of combustion

then pass to the inducer draft fan and through the ﬂ ue.

The air is heated by passing around the primary and

secondary tubes for optimal heat transfer. The heater

is designed for 80% efﬁ ciency.

• The furnace comes wired with all necessary

safety controls and valves installed.

• The controls vary based on the BTU level and

Insurance Requirements selected.

• These units are designed to handle Natural Gas

as a standard.

• The gas pressure available at the unit needs to be

considered when ordering the equipment.

Equations:

• BTU Output Required = CFM x 1.08 x Tempera-

ture Rise Required

• BTU Input = BTU Output ÷ .80

The Solution furnaces are available with burner ﬁ ring

arrangements:

• 3-1 MODULATION: The burner will modulate for

100% - 33% of full ﬁ re

• 10-1 MODULATION: The burner will modulate

from 100% - 10% of full ﬁ re

• 25-1 MODULATION: The burner will modulate

from 100% - 4% of full ﬁ re

Choosing Considerations

When choosing the proper turn down three issues should

be considered.

1. Greater modulation provides improved temperature

control. If the furnace is modulated to its minimum

ﬁ re position, and controls determine there is too

much furnace capacity, then the furnace is staged

on and off, on carefully chosen time delays, to satisfy

the light load heating requirements. The 3-1 option is

generally sufﬁ cient particularly if design temperature

rise does not exceed 30-40 degrees.

2. The greater the range of modulation the greater

the cost.

3. Experience requires that a furnace should not turn

down to a temperature rise less than 5-8 degrees.

Greater modulation decreases the ﬂ ue stack tempera-

ture at low ﬁ re, increases the amount of condensation,

and can decrease the life of the heat exchanger even

though all Solution furnaces utilizes a stainless steel

primary and stainless steel secondary heat exchanger

tubes along with condensate drains.

The condensate line must be adequately sized, trapped,

along with drainage of the condensate per local code.

Literature Reference — See Installation Operation Manual – Form 102.20-NOM1

HEATING SEGMENTS

JOHNSON CONTROLS 37

FORM 102.20-QG1 (808)

Electric Heat – (EH)

The EH segment can be installed in either a draw

through or blow through arrangement.

Remote Mounted terminal panels

• An electric heat control panel may be selected as

a remote panel.

• In this case the panel will be shipped separate to

the customer for ﬁ eld installation.

An optional wide access door may be ordered on the

opposite side of the electric heater control panel.

An SCR Controller is available on all heaters with a

height dimension greater than 26.5”.

Delta T = kW x 3160

CFM

• Electric heaters are of “open coil” construction, with 80% nickel,

20% chromium coil elements machine crimped to stainless steel

terminals and amply supported on ceramic bushing isolators.

Open coil heaters are furnished with a disk-type, automatic reset

thermal cutout for primary over-temperature protection. Heaters

are also being furnished with disk-type, load-carrying manual

reset thermal cutouts, factory wired in series with heater stages

for secondary protection.

• Heaters are rated for the voltage, phase and number of heating

stages indicated in the schedule. All three-phase heaters will

have equal, balanced, three-phase stages.

• Finned tubular construction - optional

• All internal wiring shall be stranded copper with 105°C minimum

insulation and shall be terminated in crimped connectors or box

lugs.

• Power and control terminal blocks shall be provided and clearly

marked for all ﬁ eld wiring and shall be sized for installation of

75°C copper wire rated in accordance with NEC Table 310-16,

not more than three conductors in a conduit.

• Heaters shall be furnished with built-in fuses per NEC. Heaters

with loads greater than 48 amps will be furnished with built-in

fusing. Heaters shall be sub-circuited into a maximum of 48

amps per circuit. Low resistance single element fuses will be

mounted in phenolic fuse blocks ﬁ tted with extra tension springs

to assure cool connections. Fuses shall be sized at least 125%

of the load.

Notes & Options

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Typical Applications

An electric heating system will use either an open wire

element or an element encased in a sheathed ceramic

material. For most applications either construction can

be used, however, in applications with potentially high

humidity (i.e.100% OA application), the encased ele-

ment will have a longer life expectancy and is recom-

mended.

Selection of the proper unit, heating load and tempera-

ture control system is dependent on the application of

the unit.

1. Make-up Air Unit is used for heating 100% OA air

to the indoor design temperature with a typical dis-

charge temperature of 55-70° F.

2. Space Heating Unit is used for heating 100% RA

from the conditioned space to make up for building

heat loss.

3. Combination Make-up Air & Space Heating

is used to heat OA & RA combined through a

mixing box.

Optional Control Methods

1. Proportional step control – multi-staging control of

circuits

2. SCR Controller – a time proportioning type controller

that modulates the heater and supplies the exact

amount of power to match the heat demand. Preci-

sion controlled from zero to 100% in direct response

to the modulating thermostat signal system. 100%

step-less and noise-less operation. *Note – SCR’s

are limited to a maximum KW. Multiple SCR’s may

be applied to larger heaters. Multiple SCR’s do not

imply full face control. See “Special Application

Considerations”.

3. Vernier Proportional Control – used on larger KW

heaters where very close heat control is required.

The system employs a combination of SCR and non-

SCR steps. This is accomplished by satisfying most

of the heat requirement through the non-SCR steps

and then the last portion of the heat requirement is

“ﬁ ne-tuned” by the modulating SCR controller. The

SCR step is nominally equal to the KW of a non-SCR

step to provide an even transition between steps.

*Special Application Considerations:

(contact factory for special applications)

It is always important to ensure the proper control

method so that the heater effectively treats the required

amount of outdoor air regardless of temperature, with-

out risking over heating and or tripping the low limit

thermostat.

1. In applications where air ﬂ ow varies and temperature

ranges are extreme, the face area of the heater

should be designed for full face simultaneous con-

trol, thus avoiding problems of air and temperature

stratiﬁ cation. This is extremely relevant on heaters

with large face areas. The full face control method,

for a partial of fully active electric heat coil, elimi-

nates the concern of air bypass through inactive

circuits. Thus, almost any load split can be safely

achieved.

2. With lower airﬂ ows under VFD control, one must

assure there is even air ﬂ ow across the face area of

the heater. This may require special consideration

of the air-inlet position and size, (i.e. inlet to be

centered on the front of the unit).

a. Instability in temperature can easily occur if the

variation in the air ﬂ ow characteristic is exces-

sive. Large temperature variations can occur

as speciﬁ c stages and circuits are modulated

on and off. In extreme cases, this instability can

cascade and cause extreme over-heating on the

complete heater face or in spots of the heater

face due to low-air-ﬂ ow augmented by unit inlet

opening locations and distance.

HEATING SEGMENTS

JOHNSON CONTROLS 39

FORM 102.20-QG1 (808)

Recommended Safety Control Options:

A fan relay and an airﬂ ow switch provide added protec-

tion for applications listed above.

– Fan relay provides the advantage of being a posi-

tive electrical interlock between the fan and the

heater.

– Airﬂ ow switch is normally used to prevent a

heater from operating unless air is ﬂ owing.

Minimum Air Flows

Electric heaters differ from steam or hot water coils in

that the heat output is constant as long as the heater

is energized. Therefore, sufﬁ cient air ﬂ ow must be pro-

vided to prevent overheating and nuisance tripping of

the thermal cutouts.

The minimum required velocity is determined from the

graph on the basis of entering air temperature and watts

per square foot of cross segmental heating coil area.

EXAMPLE:

Determine whether the minimum air velocity requirement

is met for a 108 kW heater installed for an air handling

unit operating at 18,000cfm at a maximum inlet tem-

perature of 65°F.

1. Heating Coil Area = 33 sq. ft.

2. kW / sq ft. = 108 kW = 3.3 kW / sq. ft. 33 sq. ft.

3. Use top curve (below 80°F inlet air). Find 3.3 kW

per square foot on the vertical axis.

Read the minimum face velocity required, which

in this case is 250 feet per minute (fpm).

4. AHU FV = 18,000 cfm = 545 fpm 33 sq. ft.

Since 545 FPM exceeds the minimum velocity require-

ment of 250 FPM, this installation is satisfactory for

heater operation.

Equations: Use these formulas as rough guidelines for

estimating purposes only:

EQUATION 1: MBH = kW x 3.412

EQUATION 2: T = kW x 3160

Scfm

EQUATION 3: Actual kW = Rated kW x V actual

V rated

EQUATION 4: Load Amps = kW x 1000

V x 1.732

Literature Reference — See Application Guide ‘Electric Heaters for Air Handling Units’ – Form 102.20-AG4

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

ENERGY RECOVERY – ER

Energy Recovery

An HVAC system that utilizes energy recovery is more

energy efﬁ cient, improves humidity control, and reduces

peak demand charges.

Solution Energy Recovery wheels:

– Improve building HVAC system performance by

efﬁ ciently preconditioning the outdoor air supply.

The ER segment transfers heat & humidity from adjacent

exhaust air & outside air streams.

– Improves HVAC system efﬁ ciency up to 40%

– Improves de-humidiﬁ cation capacity up to 75%

Thermal performance is certiﬁ ed by the manufacturer

in accordance with ASHRAE Standard 84, Method of

Testing Air-to-Air Heat Exchangers and ARI Standard

1060, Rating Air-to-Air Energy Recovery Ventilation

Equipment

Horizontal wheel segment

Vertical wheel segment

ER has only one type of conﬁ guration – supply air fan draw-thru and

exhaust air fan draw-thru for indoor and outdoor applications.

1. Indoor - Vertical wheel segment with stacked construction

a. All doors are usually on drive side with two on top tier

(both sides of wheel) and two on bottom tier (both sides of

wheel).

2. Indoor and Outdoor - Horizontal wheel segment with single

tier construction

a. Outside Air inlet is located on both sides of segment

b. Access door is usually on drive side for horizontal wheel

segments.

Wheel control

• Damper control

• VFD

– Auxiliary drain pan – none

– Purge function – Optional

Notes & Options

Literature Reference — See Application Guide “Energy Recovery Wheels” – Form 102.20-AG6

HEATWHEEL MOTOR

JOHNSON CONTROLS 41

FORM 102.20-QG1 (808)

FILTER SEGMENTS – AF, FF, RF AND HF

Application and Options Table

AF - ANGLE FILTER

Application: (AF)

– Pre-ﬁ lter side-load negative pressure

conﬁ guration

– Single stage ﬁ ltration

Options:

– Auxiliary Drain pan options

– 2” & 4” Low Efﬁ cient media

– 4” High Efﬁ cient media

FF - FLAT FILTER

Application: (FF)

– Pre-ﬁ lter side-load negative pressure

conﬁ guration

– Single stage ﬁ ltration

Options:

– Auxiliary Drain pan

– 2” & 4” media

– Low Efﬁ cient media

RF - RIGID FILTER

Application: (RF)

– Pre ﬁ lter negative pressure conﬁ gura-

tions:

Side-load, front load and rear load

– Final ﬁ lter positive pressure conﬁ gu-

rations:

Front-load (upstream access required)

Rear-load (downstream access required)

Side-load

Options:

– 2-stage ﬁ ltration.

– Auxiliary Drain pan

– 4” & 12” High Efﬁ cient Media

(65%-95%)

RF - BAG FILTER

Application: (Bag)

– Pre ﬁ lter negative pressure conﬁ gura-

tions:

Side-load, front load and rear load

– Final ﬁ lter positive pressure conﬁ gu-

rations:

Front-load (upstream access required)

Rear-load (downstream access required)

Side-load

Options:

– 2-stage ﬁ ltration.

– Auxiliary Drain pan

– High Efﬁ cient Media (65%-95%)

HF - HEPA FILTER

Application: (HF)

– Pre ﬁ lter negative pressure conﬁ gura-

tions:

Front-load (upstream access re-

quired)

– Final ﬁ lter positive pressure conﬁ gu-

rations: Front-load (upstream access

required)

– Face velocity - maximum 500 fpm

– Single stage ﬁ ltration

Options:

– Auxiliary Drain-pan

– Media efﬁ ciency 99.97% & 99.99%

AIRFLOW

Side loading only

AIRFLOW

Side loading only

AIRFLOW

Rear, Front or side loading

(length includes 2" prefilter)

AIRFLOW

Rear, Front or side loading

(length includes 2" prefilter)

AIRFLOW

Front loading

Caution – Never place a blow-thru ﬁ nal ﬁ lter segment directly downstream of a cooling coil with a saturated leaving air tem-

perature. Once the relative humidity has reached 100%, adiabatic cooling applies to the expanding air and associated tem-

perature drop. Moisture deposits may form on ﬁ nal ﬁ lters.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Mechanical Air Filters

Mechanical air ﬁ lters remove dust by capturing it on

the ﬁ lter medium, the ﬁ lter element. A mechanical air

ﬁ lter is any type of dry media ﬁ lter. All of the throwaway

air ﬁ lters used in HVAC systems and Air Handlers are

mechanical air ﬁ lters. Any man made or natural ﬁ ber

ﬁ lter is a mechanical air ﬁ lter. This includes HEPA air

ﬁ lters as well.

Comparing Various Air Filters To MERV Ratings

Dry-media ﬁ lters exhibit an increase in efﬁ ciency as they

collect dirt and dust. A dry media ﬁ lter is at the lowest

efﬁ ciency rating when it is ‘clean’. The increase in ef-

ﬁ ciency corresponds to a decrease in open area as the

media collects ﬁ bers and particles. In dust critical envi-

ronments the user typically can’t wait for the increased

efﬁ ciency. As a result of this type issue, ASHRAE 52.2

deﬁ ned the minimum efﬁ ciency reporting value (MERV)

to describe ﬁ lter performance.

The MERV is based on the worst case performance of

a ﬁ lter through all six stages of dust loading and all par-

ticles 0.3-10 microns. Because the rating represents the

worst-case performance, end users can use it to assure

performance in applications where a maximum particle

count must be maintained over the ﬁ lter’s entire life.

ASHRAE 52.1 arrestance and dust-spot tests used ei-

ther weights or times to generate a ratio, or efﬁ ciency.

This efﬁ ciency was an easy way to describe a ﬁ lter’s per-

formance. Thus, a 50 percent ﬁ lter would stop a nominal

50 percent of the particles in the air stream as averaged

over the test period. Unfortunately, this average over

time told a user nothing about performance for a speciﬁ c

particle size at a speciﬁ c stage in a ﬁ lter’s life.

ASHRAE Standard 52.2 rates ﬁ lter arrestance differently.

Standard 52.2 testing protocol includes the reliable and

consistent testing of ﬁ lter performance on particles of nomi-

nal 0.3-10 microns in diameter. This testing provides an

accurate and clear description of arrestance at each stage,

rather than the average produced by Standard 52.1.

ASHRAE 52.2 Particle Size Ranges

Range Size (in microns) Group

1 0.30 to 0.40 E1

2 0.40 to 0.55 E1

3 0.55 to 0.70 E1

4 0.70 to 1.00 E1

5 1.00 to 1.30 E2

6 1.30 to 1.60 E2

7 1.60 to 2.20 E2

8 2.20 to 3.00 E2

9 3.00 to 4.00 E3

10 4.00 to 5.50 E3

11 5.50 to 7.00 E3

12 7.00 to 10.00 E3

The efﬁ ciency of the ﬁ lter is measured on 12 particle size

ranges. The twelve size ranges are then placed in three

larger groups (E1, E2, E3) and the percentages in each

group are averaged

MERV

Value

Group 1

Av. Eff.%

0.3 to 1

Group 2

Av. Eff.%

1 to 3

Group 3

Av. Eff.%

3 to 10

1 n/a n/a E3<20

2 n/a n/a E3<20

3 n/a n/a E3<20

4 n/a n/a E3<20

5 n/a n/a 20<35

6 n/a n/a 35<50

7 n/a n/a 50<70

8 n/a n/a 70

9 n/a E2<50 85

10 n/a 50<65 85

11 n/a 65<80 85

12 n/a 80 90

13 E1<75 90 90

14 75<85 90 90

15 85<95 90 90

16 95 95 95

The average is called the Particle Size Efﬁ ciency which

is used to determine the Minimum Efﬁ ciency Reporting

Value (MERV).

FILTER SEGMENTS – AF, FF, RF AND HF

JOHNSON CONTROLS 43

FORM 102.20-QG1 (808)

MERV Analysis

The required MERV rating for ﬁ lters will follow directly

from the maximum allowable particle concentrations in

the three bands of 0.3-1.0 microns, 1.0-3.0 microns and

3.0-10.0 microns.

1. A rating of MERV 10 corresponds to 50-65 percent

efﬁ ciency for particles 1-3 microns and above 85

percent efﬁ ciency for particles 3-10 microns.

2. A rating of MERV 13 corresponds to less than 75

percent arrestance efﬁ ciency for particles 0.3-1

microns, above 90 percent efﬁ ciency for particles

1-3 microns, and above 90 percent efﬁ ciency for

particles 3-10 microns.

3. A rating of MERV 15 corresponds to 85-95 percent

arrestance efﬁ ciency for particles 0.3-1.0 microns,

above 90 percent efﬁ ciency for particles 1-3 mi-

crons, and above 90 percent efﬁ ciency for particles

3-10 microns.

4. Ratings of MERV 16 to MERV 20 correspond to

HEPA and ULPA ﬁ lters.

Note: The entire list of MERV ratings based on particle ar-

restance efﬁ ciency is found in Table 12-1 of Standard 52-2.

As an example, if you are concerned with pulling out a

high percentage of molds, mold varies in size from about

4 microns to 40 microns.

• The greatest numbers of mold spores are less than

10 microns in diameter.

• The chart indicates a MERV 8 ﬁ lter will pull out at

least an average of 70% of the particles down to 3

microns.

• Pleated ﬁ lters are available in a MERV 11. The

MERV 11 would give you an average of at least

85% mold removal.

The following comparisons are not meant to be deﬁ nitive:

MERV

Rating

Particle

Size Applications

Filter

Type

1-4 >10 um Residential

Light Commercial

Equipment

Fiberglass

Poly Panel

Permanent

Metal

Foam

5-8 3 to 10 um Commercial

Industrial

Better Res.

Paint Booth

Pleated

Filters

9-12 1 to 3 um Res. – Best

Commercial

Telecommunica-

tions

Industrial

Best

Pleated

Rigid Box

Rigid cell

Bag

13-16 0.3 to 1 um

Smoke Removal

General Surgery

Hospitals

Health Care

Rigid Cell

Bags

V-Cell

Mini-pleat

16-20 0.3 um HEPA /

ULPA

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

MIXING SEGMENTS & ECONOMIZERS – MB, FM, EE, EF, FD, IP, VE AND VF

Mixing Box/Mixing Segment (MB/FM)

Solution has designed a mixing box (MB) which com-

bines fresh air and re-circulated air by means of inter-

connected dampers.

Solution’s space saving combination ﬁ lter mixing seg-

ment (FM) offers an angle ﬁ lter as an integral part of

the mixing segment to economically provide ﬁ ltering

and mixing capability.

FRONT DAMPER

TOP DAMPER

END WALL PANEL

ROOF PANEL

ANGLE FILTER ASY

ECONOMIZER WALL

DAMPER

DOOR

DAMPER

• The MB/FM Segment typically must be the ﬁ rst segment in

direction of airﬂ ow.

• Access doors are optional.

• Auxiliary drain pans optional except when bottom opening is

selected

• Combination ﬁ lter mixing segment (FM) provides a full-height

access door for ﬁ lter service.

• Variable size openings and dampers are optional.

• Safety grate option for bottom openings

Hood application – only the following outdoor segments are avail-

able

• Mixing box (MB or FM) Economizer (EE or EF) outside air

(OA) inlet openings.

Hood Options

• Bird screen is standard with all hoods

• Moisture eliminator is available as an option

Note: When the moisture eliminator option is selected the mois-

ture eliminator acts as the bird screen. A separate bird screen will

not be required.

Notes & Options

• The EE or EF segment may be ﬁ rst in the air-stream or may

be used in conjunction with other segments in an economizer

application.

Hood application – only the following outdoor segments are avail-

able with hoods

• Fan Exhaust (FE) discharge openings

• Economizer (EE or EF) exhaust air (EA) discharge openings

Hood Options

• Bird screen is standard with all hoods

• Moisture eliminator is available as an option

Note: When the moisture eliminator option is selected the mois-

ture eliminator acts as the bird screen. A separate bird screen will

not be required.

Notes & Options

Economizer

Solution offers numerous economizer conﬁ gurations

for various ventilation applications. The economizer is

designed with factory packaged controls in-mind. Cor-

rectly set-up economizers will constantly track building

pressurization as well as both indoor and outdoor air

temperatures using transducers, mixed air sensors

and enthalpy control that monitors air temperature and

humidity.

JOHNSON CONTROLS 45

FORM 102.20-QG1 (808)

• VE segment will have the same construction materials as the

MB or FM segment.

•No optional auxiliary drain pain.

• Optional Access Doors & View-ports.

• Auxiliary drain pans optional except when bottom opening is

selected

• Variable size openings and dampers are optional.

• Safety grate option for bottom openings

Notes & Options

General Considerations:

1. VE segment shall be available for all Solution unit

sizes provided engineering rules for stacking allow

the top section of VE segment to be tiered.

2. VE segment shall be designed for the conﬁ gurations

described in the sketches below.

Vertical Economizer

Solution offers a Vertical Economizer arrangement which consists of tiered segments; top and bottom. Both top and

bottom segments are designed to be of minimum length required. The VE arrangement is designed to be ﬁ rst in the

air-stream unless it is immediately preceded by XA, FR (DWDI), FR (SWSI), FE (DWDI), FE (SWSI).

The VE segment must be conﬁ gured in a top tier arrangement per the following rules:

1. Only one VE per unit

2. Must be tiered over the MB or FM segment

3. MB or FM segment must have a top damper

3. Both top and bottom sections of the VE segment

shall be designed to be of minimum length required.

The design shall allow the two sections of VE seg-

ment to be of different lengths.

4. Sound data shall be provided for all conﬁ gurations

of VE segment.

5. Controls shall be available on VE segment for both

top and bottom sections.

6. Filter option shall be available in the bottom section

of the VE segment similar to FM segment.

7. Doors are available as an option for indoor units

and are required for outdoor units.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

This Mixing Box Optimization chart provides techniques and suggestions to meet the desired needs for your spe-

ciﬁ c mixing box design process. It is a decision-making process in which the effectiveness of a mixing box must be

considered. Ideally, mixing boxes should provide adequate mixing.

MIXING BOX OPTIMIZATION CHART

Mixing Box

Assessment

Mixing

Effectiveness

Advantages Disadvantages

Standard Mixing

Box

with/without

Angle Filter

GOOD APPLICATION

Most effective

1. In constant volume system

• Parallel blade control damper

• Blade orientation and rotation

promotes mixing

• Lowest ﬁ rst cost

• Space saving

• Risk of low mixing effective-

ness

• with ﬁ lter

• with VAV

• Risk of nuisance low limit

tripping

• Risk of stratiﬁ cation

Standard Mixing

Box without ﬁ lters

and

*Sequenced

Controlled

Dampers

(sequence listed

below)

BETTER APPLICATION

Most effective

1 In VAV system

2. With Min Max damper

3. With opposed blade control

damper

* Sequenced damper control is most

suitable for low air ﬂ ow – low veloc-

ity applications

• Lower ﬁ rst cost

• Mixes outside and return air

more proportionately

• Improves system perfor-

mance at low ﬂ ow rates

• Sequence will add stability

to the control loop

• Risk of nuisance low limit

tripping

• Risk of possible stratiﬁ ca-

tion

Standard Mixing

Box

without ﬁ lters and

Static

Air Mixer (blender)

BEST APPLICATION

Most effective

1. Outside air designs at freezing

and sub-freezing temperatures

2. Constant or VAV systems

*Sequenced opposed control

dampers are recommended for

VAV systems

• Greatly improves mixing of

sub-freezing air streams

• Greatly reduces, if not elimi-

nates, stratiﬁ cation in short

distances

• Works effectively and con-

sistently

• Higher ﬁ rst cost among

damper designs

• Increases unit length

• Some additional static

pressure loss

*Suggested sequence of operation as follows:

1) Start the fan with the return air damper fully open and the outdoor air damper fully closed.

a) An independent signal shall be sent to the Outdoor air damper

i) Minimum open position

b) An independent signal shall be sent to the Return air damper

i) Full open position

2) The outdoor air damper shall modulate further open to admit additional outdoor air as required to satisfy the (mixed air), (discharge air)

temperature sensor or IAQ requirements.

3) Once the outdoor air damper is fully open, if additional outdoor air is required, the return air damper shall modulate toward its closed

position.

JOHNSON CONTROLS 47

FORM 102.20-QG1 (808)

Typical Economizer Application

ASHRAE Standards Demanding Economizer Consid-

erations:

ASHRAE 90 - The ‘standard’ details requirements for

a high performance & energy-efﬁ cient design of build-

ings (which includes equipment as part of the building

system).

What is high performance?

• Lower energy usage

• Lower life cycle cost

• Durable

• Healthy

• Productive

How buildings use energy?

• Different building types use it differently

• Occupancy & equipment schedule

• Internal vs. external load dominated buildings

• Building occupants

ASHRAE 62 - The ‘standard’ details Indoor Air Quality

issues with the purpose to establish acceptable ventila-

tion procedures & standard-of care.

What are ventilation procedures?

• Mechanical ventilation systems shall include con-

trols, manual or automatic, that enable the fan

system to operate whenever the spaces served are

occupied

• The system shall be designed to maintain the

minimum outdoor airﬂ ow as required under any load

condition

What is a standard-of-care?

• Guidelines to designers addressing contaminant

source control, minimum maintenance activity &

frequency, ﬁ ltration and managing relative humidity

Building Pressurization

Building Pressurization – is deﬁ ned as the relative air

pressure in a building, as compared to the exterior or am-

bient air pressure. A design amount of outside air must

be introduced to insure design building ventilation.

This difference in pressure has a large impact on how the

building operates and it can have undesirable if not pe-

culiar impacts on building operations. Over-pressurized

buildings will have doorways which are transformed into

wind tunnels. Under-pressurization will create a building

that has become negatively pressurized and inﬁ ltration

makes indoor climate control difﬁ cult.

The difference between the amount of OA and EA must

remain constant at all operating conditions to maintain

proper building ventilation and pressurization.

Over Pressurization caused by -

• Too much OA

• Not enough EA

Results in -

• Excessive energy consumption

• Perimeter doors opening

Under Pressurization caused by -

• Too little OA

• Too much EA

Results in -

• Ventilation problems with occupants

• Excessive building odors

• Poor temperature control (inﬁ ltration)

• Excessive energy costs

• Difﬁ culty in opening doors

Knowing how to correct and avoid pressurization prob-

lems can prevent minor, inconvenient and comfort re-

lated issues from growing into insurmountable problems

and liability issues.

MIXING SEGMENTS & ECONOMIZERS – MB, FM, EE, EF, FD, IP, VE AND VF

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Methods of Pressurization Control

Full Return Air Fan Economizer -

Handles pressure losses through

• Return air system

• Exhaust dampers

Supply Fan handles pressure losses through

• Outside air dampers

• Mixed air dampers

Dedicated Exhaust Fan Economizer -

Fan runs only when economizer opens the OA dampers

Handles pressure losses through

• Return air system when in exhaust mode

• Exhaust air path

Building pressurization provides insight in identifying,

diagnosing, correcting and most importantly, avoiding

some unusual building operational problems.

Literature Reference — See Application Guide ‘Return & Exhaust Fan Economizers and Building Pressuriza-

tion’ – Form 100.00-AG3

MIXING SEGMENTS & ECONOMIZERS – MB, FM, EE, EF, FD, IP, VE AND VF

Economizer Arrangements

LD08032

TOP

VIEW

SIDE

VIEW

L/R SIDE

DAMPER

ANGLED

MIXING

DAMPER

EE - Economizer with

angled mixing damper.

EE - Economizer with vertical

mixing damper. NOTE: Top damp-

ers not available for outdoor units.

EF - Filter/Economizer

EE - Inlet/Economizer

(50% OA on each side with barometric exhaust)

VE - Vertical Economizer

43080DL33080DL

53080DL

TOP

VIEW

SIDE

VIEW

SIDE

VIEW

(100% OA, 100% EA) )AE %001 ,AO %001()AE %001 ,AO %001(

NOTE: VF (VerticalFilter Economizer) is available with filtration.

JOHNSON CONTROLS 49

FORM 102.20-QG1 (808)

Face Damper – (FD)

The FD segment contains a full face damper

• Face dampers are sized to cover whole components down-

stream within tunnel.

The FD is available for both indoor and outdoor applications.

• The FD can be located ﬁ rst in air stream or last in air stream,

only with indoor applications.

Access doors and viewing ports must be located in adjacent seg-

ments.

• Access is required immediately upstream of the FD segment

to access damper actuator and linkage.

Damper material option:

• Galvanized

• Aluminum

Notes & Options

FS XA FD XA

Inlet Plenum – (IP)

The Inlet Plenum is as its name implies; a segment

used to provide a proper means of air entry into the air

handler.

Openings may be applied to top, bottom, front, left side

and right side.

The variable size opening option allows the opening to

be properly aligned and sized for airﬂ ow convergence

and or divergence.

If a plenum fan is used as a return fan and return air is ducted, an IP

segment must be provided upstream of the plenum fan.

• Dampers are not available as an option

• Access Door - Optional

• Auxiliary Drain Pans – Optional

Notes & Options

FRONT INTAKE

FRONT VIEW

SIDE VIEW

TOP/BOTTOM

INTAKE

TOP VIEW

LEFT / RIGHT

SIDE INTAKE

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

ACCESSORY SEGMENTS

Diffuser Segment – (DI)

The diffuser segment is constructed of heavy gauge

galvanized steel with a built-in perforated plate, which

prevents high velocities through the center of the down-

stream component. This segment is mainly used for

blow-thru type applications immediately after a DWDI

fan or locations where even air distribution across the

unit cross section is a necessity.

The Diffuser Segment must be placed immediately downstream of

a DWDI fan segment when ﬁ lters, attenuators, humidiﬁ ers, electric

heater and/or coils immediately follow the fan.

• Auxiliary Drain Pan - Optional

• Access Door – Optional

Notes & Options

Access Segment – (XA)

The Access Segment is a functional segment provided

to allow access-to or inspection-of any component in

adjacent segments. The access segment assists in de-

termining the best segment arrangement for a speciﬁ c

function and or layout.

It is designed for ﬂ exibility with full sized access doors

and variable segment length.

Access Segments may be used at any point in the unit conﬁ gura-

tion; positive pressure (blow thru) or negative pressure (draw thru)

conﬁ gurations.

Access segments may be provided for maintenance, cleaning, service

and or spacing for correct air ﬂ ow requirements.

• Auxiliary Drain Pan - Optional (minimum segment length ap-

plies)

• Access Door – Optional (both sides of the unit -minimum seg-

ment length applies)

Notes & Options

JOHNSON CONTROLS 51

FORM 102.20-QG1 (808)

Vertical Plenum – (VP)

The Vertical Plenum (VP) is a segment designed for

vertical conﬁ gurations (top tier) with unique discharge

arrangements.

Multiple and variable size supply air openings are avail-

able through the VP segment.

The VP segment may be applied as an acoustical

chamber, with perforated panel option, that dampens

low frequency sound. In addition, the air stream expan-

sion reduces turbulence and creates an acoustical end

reﬂ ection.

FS XA AF

Discharge locations available are top, front, rear, left side and right

side.

Discharge opening options are rectangular, round and oval.

Doors are optional (Inward opening for positive pressure)

Notes & Options

Discharge Plenum – (DP)

The Discharge Plenum (DP) is a segment designed

for horizontal conﬁ gurations with unique discharge ar-

rangements.

Multiple and variable size supply air openings are avail-

able through the DP segment.

The DP segment may be applied as an acoustical

chamber, with perforated panel option, that dampens

low frequency sound. In addition, the air stream expan-

sion reduces turbulence and creates an acoustical end

reﬂ ection.

DP FS XA AF

Discharge locations available are top, bottom, rear, left side and

right side.

Discharge opening options are rectangular, round and oval.

• Auxiliary Drain Pan - Optional

• Access Door – Optional (both sides of the unit - Inward open-

ing for positive pressure)

Notes & Options

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Sound Attenuator – (AT)

Sound Attenuators are rated for two ﬂ ow conditions,

FORWARD and REVERSE.

• Forward ﬂ ow occurs when air and sound-waves

travel in the same direction, as in a supply air duct

or fan discharge.

• Reverse ﬂ ow occurs when sound-waves and

air travel in opposing directions, as in a typical

return-air system.

Because attenuation values are generally higher in

the ﬁ rst ﬁ ve octave bands in the reverse ﬂ ow mode,

compared to the forward ﬂ ow mode, more economical

silencer selections can often be made on the return-air

systems. These phenomena are illustrated below.

RACEWAY ASSEMBLY

SOUND

ATTENUATOR

BULKHEAD ASSEMBLY

Under FORWARD FLOW conditions, high-

frequency sound is refracted into the duct-

silencer walls.

Under REVERSE FLOW conditions, sound is

refracted away from the walls and toward the

center of the duct-silencer.

Silencer Length Options:

• 3ft, 5ft, 7ft

Face Velocity

• Low

• Ultra Low

Media Types:

• Standard

• Film-lined (Hospital media)

• None (No media)

Frequency Range

• Normal

• Low

Casing Materials:

• Galvanized

• Stainless Steel

Access doors and viewing ports must be located in adjacent segments.

When AT segment is located immediate downstream of DWDI fan

segment a Diffuser segment is needed to ensure even airﬂ ow dis-

tribution.

Notes & Options

Literature Reference — See Application Guide ‘Acoustichecks for Air Handling Projects’ – Form 100.00-AG2 &

‘Fundamentals of Acoustics’ – Form 102.20-AG4

ACCESSORY SEGMENTS

FORWARD FLOW REVERSE FLOW

JOHNSON CONTROLS 53

FORM 102.20-QG1 (808)

Noise & Vibration

Any mechanical device is capable of generating noise

and vibration for a variety of reasons. The air handler

unit noise emanates simultaneously from three distinct

sources: aerodynamic, mechanical, and electrical.

Noise generally applies to any problem in which the ears

are the main sensor. Noise is made up of many different

sound frequencies at various loudness levels. Noise

when compared to vibration is similar in that they both

have amplitude and frequency. Usually noise is a much

lower amplitude and energy content which is measured

in db referenced to Watts. Typically noise has a much

wider frequency range and a higher upper limit than

vibration (63Hz – 8KHz)

Vibration generally applies to any problem in which

the hands or touching are the main sensor. Amplitude

is large when there is a problem. It has much greater

energy content with a smaller frequency range (3Hz

– 500Hz)

Aerodynamic

Generated noise is caused by turbu-

lence, high velocities, and instabilities

due to pulsation and surge. Technically

speaking it relates to pressure pulsa-

tions and is characterized by a continu-

ous broadband frequency spectrum

with an objectionable superimposed

pure tone.

Mechanical

Generated noise has a different sound

quality and characteristic. It can have

a metallic sound caused by metal-to-

metal contact or working noise radiating

from belts and bearings. This noise may

be constant or intermittent.

Electrical

Generated noise is a function of motors,

relays, motor controls, or unbalanced

line voltages into the motor

Vibration Considerations and Characteristics

Rotating devices, such as air handling units, all create

vibration which can be transmitted to other parts of the

structure. The magnitude of this vibration is subject to

a number of things, the most signiﬁ cant of which is the

amount of unbalance of the rotating components. The

frequency at which this occurs is the operating RPM of

the components. There are many different sources of

vibration. One of the most difﬁ cult tasks is the systematic

identiﬁ cation of the vibration characteristic; amplitude,

frequency, location or direction.

Aerodynamic

Vibration is generated when a forced

vibration in which the energy and char-

acteristics of the air-stream are large

enough to cause turbulence, pulsations

or a blade frequency tone. Vibration can

also be the result of a resonance (rever-

beration).

Mechanical

Vibration may occur from unbalance,

resonance, looseness and rubbing.

Electrical

Vibration generated occurs from torsion

ﬂ uctuations, eddy current induced ﬁ elds

and improper wiring.

Noise Considerations and Characteristics

Mechanical and electrical noise sources usually begin

as vibration and are later transferred into airborne noise.

To avoid unsatisfactory noise levels, many factors should

be considered at the design stage. Noise is generally

considered low quality, unwanted sound. Characteristic

words such as tone, pitch, steady, unsteady and inter-

mittent help to deﬁ ne whether the source of the noise

is aerodynamic, mechanical or electrical.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Features & Beneﬁ ts:

– Provides most mixing in shortest possible dis-

tance

– Requires negligible energy (typical application is

between 0.10 - 0.20” w.g.)

– Provides expected mixing for every cabinet size

– Provides reliable pressure drop rating which

includes the effect of mixer to plenum area ratio.

Applications (When used):

– Eliminates air stratiﬁ cation

– Reduces low limit-stat nuisance trips

– Improves accuracy of temperature control sys-

tems

– Mixes outside ventilation air into supply air stream

to satisfy IAQ/IEQ requirements

– Allows for greater use of economizer operation

– Provides uniform velocity proﬁ le for even ﬁ lter

loading and enhanced coil performance

AB segment should be applied immediately after the mixing box/econo-

mizer segment. AB segment is designed to mix air from openings on

any combinations of: top, bottom, end and sides.

Minimum velocity through a mixer is 400 FPM.

Air mixer arrangements may include one mixer, two horizontal mixers,

three horizontal mixers, two vertical mixers or three vertical mixers.

The arrangement depends upon upstream segment conﬁ guration.

Door - optional

Drain pan - optional

Mixer material option: Aluminum or Stainless Steel

Notes & Options

ACCESSORY SEGMENTS

placed just after the mixing segment improves mixing

outside and return air streams. Mixers work effectively

and consistently. There are no moving parts.

Air Blender/Mixers – (AB)

The static mixer provides a high level of mixing in a

minimal distance and at a low pressure drop. Mixers

JOHNSON CONTROLS 55

FORM 102.20-QG1 (808)

Face & Bypass Damper Segments – (IB), (EB)

Internal Face & Bypass – (TB)

The IB Segment must be located immediately upstream

of a reduced face coil.

• Available for indoor or outdoor applications.

• Designed to divert airﬂ ow around a coil.

When a full face coil is required downstream of the re-

duced face coil, access segment(s) must be included

between the coils.

IB segment is used to control

• Humidity

• Low temperature ﬂ ows across water coils

Access doors and viewing ports must be located in adjacent seg-

ments.

• An 18” access door is required immediately upstream of the IB

segment to access damper actuator and linkage.

Damper material option:

• Galvanized

• Aluminum

Notes & Options

External Face & Bypass – (EB)

Each EB segment must be conﬁ gured with a “bypass air

inlet” downstream in the conﬁ guration for reintroducing

the bypassed air to the unit. The EB segment cannot

exist without such a “bypass air inlet” partner.

• The EB segment is available for indoor

application only

The external face and bypass damper is located up-

stream of a full-face coil. External Bypass damper is

a balanced opposed blade face damper with intercon-

necting linkage.

• Bypass duct is to be ﬁ eld supplied

Damper material option:

• Galvanized

• Aluminum

Drain pan is optional

Door is optional

• It is designed to divert airﬂ ow through an external bypass duct.

• External Bypass segment assumes ‘top’ outlet.

Notes & Options

FS HC EB AF

FS HC IB XA AF

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Turning Segments – (TN)

The purpose of the Turning Segment is to assist air

turning in a vertical direction.

A Turning Segment (TN) can only be located at the end

of a unit conﬁ guration.

Segment lengths are engineered for a variety of tiered

space saving conﬁ gurations.

• Electric, gas and steam-to-steam generator types

• Optional auxiliary drain pan

• Optional access doors

• Optional controls

• The recommended location of the HM segment is downstream

of the HC segment but upstream of the CC segment.

• The humidiﬁ er segment can not be conﬁ gured upstream of a

HEPA ﬁ lter segment.

• The humidiﬁ er segment may be conﬁ gured upstream of RF,

FF, and AF ﬁ lter segments.

• Valve package shall be supplied and shipped loose. Field

Installation and wiring is required.

• The Humidiﬁ er Vendor humidiﬁ er selection software shall size

the valve package.

• Valves cannot be selected as an off-the-shelf item; each valve

has a speciﬁ c plate/oriﬁ ce speciﬁ cally cut per order speciﬁ ca-

tions.

• Control valve actuation shall be electronic and shall be

compatible with either a 0-10V DC signal or a 4-20 mA control

signal.

• Factory mounted controls are not available in the Humidiﬁ er

segment. Any FMED device in a downstream segment should

be located at least the absorption distance away from the

humidiﬁ er manifold.

• Usual humidiﬁ er headers are located the same side as coil

headers.

• Optional stainless steel supports and liner

Notes & Options

DPXAHFXATN

TN FS CC AF MB

FS CC AF TN

TNIP

TN segments are available for conﬁ guring in both top and bottom

tiers.

Drain pan is optional for bottom tier segments.

Access Door – Optional (both sides of the unit - Inward opening for

positive pressure)

Notes & Options

Humidiﬁ er Segment – (HM)

Adding humidiﬁ cation for full winter comfort and produc-

tivity is just as important as air conditioning in the sum-

mer months. Temperature control must be combined with

humidity control to maintain proper comfort parameters.

ASHRAE 62 indicates that relative humidity is part of

acceptable ventilation procedures & standard-of care

Solution provides a standard steam injection distribution

type humidiﬁ er with a short absorption manifold for use

where short steam absorption distances are critical.

• Steam is distributed evenly through the full length

of the manifold.

• The header size, number and spacing of distribu-

tion tubes shall be determined so that all steam

is absorbed by the air before reaching the next

component in the air stream depth.

ACCESSORY SEGMENTS

JOHNSON CONTROLS 57

FORM 102.20-QG1 (808)

Literature Reference — See Application Guide — ‘Solution® Air-Handling Units UV-C Light Options’ – Form:

102.20-AG16 & Speciﬁ cation Sheet – Form: 102.20-S16

UV Segment – (UV)

Johnson Controls has developed UV-C lighting options that control the growth and transfer of surface and airborne

microbial agents. By incorporating UV light options into your air handling unit it is now possible to control micro-

biological infestations, using ultraviolet light technology to disinfect the unit, thereby maintaining the cleanliness of

the unit and the re-circulated air of the space being conditioned. By eliminating a multitude of micro-organisms, IAQ

is improved and occupants are healthier.

Surface Decontamination Option – is done by

incorporating UV-C lights in the coil segment down-

stream of all cooling coils and above all drain pans.

In this application reﬂ ectivity of the UV light is of

dominant importance. Exposure time is unlimited. Any

increase in reﬂ ectivity enhances the UV effectiveness

and efﬁ ciency. The kill rate increases dramatically

with this application method.

Airborne Inactivation Option – is accomplished

by installing the stand-alone “Airborne Inactivation”

segment upstream and/or downstream of all cooling

coil segments to control airborne microbial agents.

UV-C lights for this type of application are of higher

intensity and are designed for “On-the-ﬂ y” kill of air-

borne contaminates. Lamps are conﬁ gured for 360°

UV irradiance for maximum air-stream cleansing.

Combining Both Options – If both Surface Decon-

tamination and Airborne Inactivation options are used

together, they can virtually clean your unit and the air

you breathe. Working together with various ﬁ ltration sys-

tems and complying with the requirements of ASHRAE

Standard 62.1 will assure the best possible IAQ when

a designer combines all of these technologies.

DP HF XA DI FS CC AF MB

UV UV

AIRBORNE OPTION SURFACE OPTION

Optional Radiometer

• Radiometer detects and measures intensity of radiant thermal

energy

Optional Access Door

• Access is optional for servicing the UV lights.

• Mechanical interlock switch to assure that the UVC assembly

will be de-energized when accessed.

• Optional View-port

Optional stainless steel supports and rails

Notes & Options

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

ACCESSORY SEGMENTS

Pipe Chase Enclosure

1. The Pipe Chase may be selected in various

depths.

2. The Pipe Chase may be applied to XA, HC, CC,

VC, IC or IG segment.

a. These segments must be on the bottom tier of

an indoor or outdoor unit.

3. Roof, ﬂ oor, side and end panels will be double

wall construction.

4. Pipe chase doors

• All pipe chases must have at least one door.

5. Pipe chase curb

• The pipe curb under a pipe chase will be level

with the curb under the unit.

WALL PANEL WITH

COIL OUTLETS

PIPE CHASE

CURB ASSY

PIPE CHASE

ACCESS DOOR

PIPE CHASE

PANEL ASSEMBLY

Roof Curb

Johnson Controls recommends that an HVAC factory

curb always be provided. Solution curbs are built to ﬁ t

the unique footprint of each air handler. Solution also

provides speciﬁ c drawing and speciﬁ cation data for each

unit and curb. These documents provide vital data such

as unit dimensions, weight, component details, cross

braces, supply & return opening layout dimensions, and

notes which are unique to each unit.

Although insulated curbs are speciﬁ ed in many cases,

the contractor responsible for the roof typically supplies

the insulation function.

1. Johnson Controls does not recommend vibration isolation be

provided on both the fan skid, inside the unit, and the curb,

outside the unit, without credible testing results.

2. Using improperly designed internal and external isolation

springs can increase vibration.

3. Dual vibration isolation applications must be designed by a

licensed Professional Engineer specializing in vibration isola-

tion design.

4. Units with a baserail and a bottom opening: duct connection is

ﬂ ush with the bottom of the unit, not ﬂ ush with the baserail.

Notes & Options

OUTDOOR: DRAIN CONNECTION IS ALWAYS ON SIDE OPPOSITE PIPE CHASE.

INDOOR: DRAIN CONNECTION IS ALWAYS SAME SIDE AS PIPE CHASE.

JOHNSON CONTROLS 59

FORM 102.20-QG1 (808)

Literature Reference — See Application Guide —‘Roof Curb & Unit Application’ – Form 100.00-AG11

Special Curb Requests

Spring isolation curbs

Roof curbs that incorporate adjustable spring isolators

into the curb as a single component. Most isolation curbs

are designed for 1” static deﬂ ection springs. The springs

are mechanically fastened and sized within the frame

to ensure uniform deﬂ ection for the entire system. The

vibration eleimination portion of the curb is constructed

of structural steel and should be designed to match the

bottom of the rooftop unit. Usual operating height is 21”

with options for different heights.

Seimic isolation curbs

Roof Curbs that incorporate seismic isolation as a fully

adjustable support system speciﬁ cally designed for unit

vibration and seismic/wind restraint. Seismic isolation

curbs are designed to meet superimposed live and

dead loads, including equipment and other construction

loads to be supported by the curb. The curb contains

mountings designed and rated to resist seismic forces

in all directions.

SUPPLY

AIR

RETURN

AIR

OUTSIDE

AIR

ROOFTOP

SUPPLY > RETURN RETURN > SUPPLY

ROOFTOP

OUTSIDE

AIR

RETURN

AIR SUPPLY

AIR

ROOFTOP ROOFTOP

RETURN

AIR IN

RETURN

AIR IN

PIPE

CHASE

PIPE

CHASE

RIGHT > LEFT LEFT > RIGHT

WIDTH-WISE SLOPE

LENGTH-WISE SLOPE

SLOPED CURB

14"

MIN

42"

MAX

*14"

14"

MIN

42"

MAX

14"

MIN 42"

MAX

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

Factory-Packaged Controls – (FPC)

YORK Factory-Packaged Controls assure you of get-

ting:

• A complete factory-engineered system

• Reduce costs by taking the guesswork out of

control installation

• A higher quality control system direct from the fac-

tory

• Full service support

Factory mounted devices are available as packaged ‘Standards’ kits,

which are deﬁ ned as pre-engineered system applications. Most likely

several ‘Standards’ will “ﬁ t” a given AHU conﬁ guration.

Devices are available in a variety of options from mount-only with no

control panel to a complete mounted, wired and factory-tested with

the Johnson Controls Metasys FEC series controller.

Notes & Options

CONTROLS

Location of wiring harnesses are typically opposite the

high voltage. See “Power-Wiring Options diagram on

page 62.

Typical FPC Wiring

JOHNSON CONTROLS 61

FORM 102.20-QG1 (808)

Software Process

The software process will automatically apply the devices to the functional segments required for the control

method.

Field Equipment Controller (FEC)

Our open design FEC conrollers use the industry stan-

dard BACnet MS/TP open communication protocol

– customers can use devices from other vendors on

the network, don’t have to stay with one vendor which

provides wider options to the customer and consulting

engineer

On time, on budget – Standards reduce engineering

and installation time and result in the lowest possible

installed cost. New tools like CCT reduce conﬁ guration

and commissioning time.

Minimize issues – Johnson Controls builds reliability into

each device. Our documentation and training are excel-

lent so the devices are installed correctly the ﬁ rst time.

Reduce operating costs – With adaptive tuning, the sys-

tem uses process condition information it acquires and

adapts for improved control without manual intervention.

State-based control reduces wear and tear on actuators

and other components by allowing the system to be in

only one mode at a time. For example, only heating or

only cooling.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

FAN SEGMENT PRIMARY ACCESS DOOR.

SUPPLY FAN MCC CABINET.

SUPPLY FAN MOTOR WIRING.

CDW - COOLING

CDW - HEATING

ALTERNATE MOTOR WIRING CUTOUT LOCATION

RETURN FAN MCC CABINET.

MOTOR WIRING

OPTIONAL SINGLE POINT

EMAL

RETURN FAN MOTOR WIRING.

LOW VOLTAGE

TOP VIEW

HIGH VOLTAGE

LOW VOLTAGE

Power Wiring Options

All motor wiring will be sized and installed based upon National

Electrical Code requirements. The wire-ways will be categorized as

follows:

• High Voltage – (120V and higher) is usually on drive side of the

product

• Low Voltage – (24V) is usually on opposite drive side.

• All motor wiring will be installed neatly in perpendicular and/or

parallel planes with the unit walls and ﬂ oors.

Single Point Power (SPP) is deﬁ ned as:

1. ALL electrical loads in a speciﬁ c unit conﬁ guration wired to a

common point of connection through the proper motor control

protection devices. This requires the customer to bring only one

source of power to the unit.

2. Where motor controls (VFD, starter or wired disconnect) are NOT

selected, no motor wiring shall be provided. Should 120V or 24V

elements be selected where motor controls are not included, they

shall require ﬁ eld wiring.

3. Where multiple motor control devices are selected, optionally,

single point power connections shall be provided. The ﬁ eld power

supply point shall be the supply fan segment.

4. Where an external wired disconnect option is selected for either

supply or return/exhaust fans (or both), single point wiring shall

NOT be available.

There are three different sizes of transformers available; 150VA,

500VA, and 2000VA.

• The transformer being the device, used to transform power

from a primary voltage of 460 volts, 230 volts, or 575 volts, to

a secondary voltage level. An example of a secondary voltage

would be 120 volts.

A disconnect panel will be required anytime there are (2) or (3)

3-phase loads that require a common factory terminated wiring con-

nection. A maximum of (3) 3-phase loads are allowed for single point

power option.

3-phase loads are as follows:

i. Supply Fan Motor Controller

ii. Return / Exhaust Fan Motor Controller.

iii. Gas Heater.

iv. Electric Heater.

v. Energy Wheel Motor Controller.

Notes & Options

CONTROLS

JOHNSON CONTROLS 63

FORM 102.20-QG1 (808)

INDUSTRY FORMULAS

Electrical

Watts ÷ Amps = Volts

Volts x Amps = Watts

Watts ÷ Volt = Amps

Volt (V) = a measure of electrical potential

Watt (W) = a measure of power an electrical device

consumes

Amp (A) = a measurement of rate of ﬂ ow of electrons along

a wire

Kilowatt (kw) = a thousand watts

BTU = KW x 3415

1KW = 1.34 HP

1 HP = 2545 BTUH

PUMP KW = FLOW (gpm) x PD (ft)

5311 x E pump x E motor

FAN KW = .7457 x BHP

E motor

1.73 = 3 FOR THREE PHASE SERVICE

PUMP HP = FLOW (gpm) x HEAD (ft

5311 x E pump x E motor

FAN HP = CFM x SP

6350 x E fan

FAN STATIC EFF = CFM x SP

6350 x BHP

FAN MECH EFF = CFM x TP

6350 x BHP

Basic Fan Laws

CFM varies directly as the RPM

CFM1 = RPM1

CFM2 RPM2

Static pressure varies as the square of the RPM

SP1 = (RPM1)2 = (CFM1)2

SP2 (RPM2)2 (CFM2)2

HP varies as the cube of the RPM

BHP1 = (RPM1)3 = (CFM1)3

BHP2 (RPM2)3 (CFM2)3

Drive Calculations

Motor RPM x Motor Pulley PD = Blower RPM x Blower

Pulley PD

Example:

1,750 x 7.2 = 1,190 Blower RPM

10.6

10% too much CFM:

1,750 x 7.2 = 11.8 “ PD Blower Pulley

1,190 x (0.90)

Air

TOTAL COOLING LOAD (MBH) = 4.5 x CFM STANDARD AIR x (ENTHALPY ENT. AIR - ENTHALPY LVG. AIR) / 1000

4.5 = 0.075 (WT. OF STD. AIR, # / FT3) x 60 (MIN./HR.)

SENSIBLE COOLING LOAD (MBH) = CFM x 1.08 x (EDB-LDB)

1000

1.08 = 0.075 (WT. OF STD. AIR, # / FT3) x 60 (MIN./HR.) x .24 (Speciﬁ c Heat of dry air)

SENSIBLE HEAT RATIO = SH

MBH/Sq. Ft. x FA x 1000

TOTAL COOLING LOAD (BTW/HR) = GPM x 500 x (EWT-LWT)

500 = 8.33 (WT. OF H20 @ 60 deg F, # / GAL) x 60 (MIN./HR.) x 1.0 (Speciﬁ c heat of water)

Metric Conversions

CFM x 1.6992 = m3/hr Ft/min x 0.00508 = m/s BTU x 0.00029 = kWh

CFM x 0.4719 = L/s Inch x 25.4 = mm Gpm x 0.063 = L/s

HP x 0.7457 = kW Lb x 0.4535 = kg

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

GUIDE SPECIFICATIONS

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Indoor and outdoor air handling units and components as scheduled and shown

on drawings.

B. Motor disconnects, motor starters, and variable frequency drives.

1.02 RELATED SECTIONS

A. The requirements of the General Conditions, Supplementary Conditions, Divi-

sion 1, equipment schedules, and drawings apply.

1.03 REFERENCES

A. AMCA 99 – Standard Handbook

B. AMCA 210 – Laboratory Methods of Testing Fans for Rating Purposes

C. AMCA 500 – Test Methods for Louvers, Dampers, and Shutters

D. AMCA 611-95 – Methods of Testing Airﬂ ow Measurement Stations for Rating

E. ANSI/AFBMA 9 – Load Ratings and Fatigue Life for Ball Bearings

F. ANSI/UL 900 – Test Performance of Air Filter Units

G. ARI 260 – Sound Rating of Ducted Air Moving and Conditioning Equipment

H. ARI 410 – Forced-Circulation Air Cooling and Air Heating Coils

I. ARI 430 – Testing and Rating of Central-Station Air Handling Units

J. ASHRAE 52.1/52.2 – Method of Testing General Ventilation Air Cleaning

Devices for Removal Efﬁ ciency by Particle Size

K. ASHRAE 62 – Ventilation for Acceptable Indoor Air Quality

L. ASHRAE 90.1 – Energy Standard for Buildings Except Low-Rise Residential

Buildings

M. ASTM-C 1338 – Standard Test Method for Determining Fungi Resistance of

Insulation Material and Facings.

N. NFPA 70 – National Electric Code (conductors, equipment and raceways)

O. NFPA 90A – Installation of Air Conditioning and Ventilation Systems

P. SMACNA – HVAC Duct Construction Standards

Q. UL-181 – Mold Growth and Humidity Test

R. UL-1995 – Standard for Safety for Heating and Cooling Equipment

S. ISO/PWD 13261-3 – Sound Power Rating of air-conditioning and air-source

heat pump equipment: Part 3, Ducted Equipment.

T. ISO 9614 – Determination of sound power levels of noise sources using sound

intensity: Part 1, Measurement at discrete points; Part 2, Measurement by scan-

ning, and Part 3, Precision method for measurement by scanning.

1.04 QUALITY ASSURANCE

A. Manufacturer shall have a minimum of 25 years of experience in designing,

manufacturing, and servicing air-handling units.

JOHNSON CONTROLS 65

FORM 102.20-QG1 (808)

B. The design indicated on the schedules and shown on the drawings is based upon

the products of the named manufacturer. Alternate equipment manufacturers

are acceptable if equipment meets scheduled performance requirements and

dimensional requirements.

C. If equipment is supplied by a manufacturer other than the one named, coordinate

with the General Contractor and affected subcontractors to ensure the speciﬁ ed

performance is met. This coordination shall include (but is not limited to) the

following:

1. Structural supports for units

2. Size and location of concrete bases/housekeeping pads

3. Location of roof curbs, unit supports and roof penetrations

4. Ductwork sizes and connection locations

5. Piping size and connection/header locations

6. Interference with existing or planned ductwork, piping and wiring

7. Electrical power requirements and wire/conduit and over current protection

sizes.

8. Trap height requirements

D. The Mechanical Contractor shall be responsible for costs incurred by the General

Contractor, Subcontractors, and Consulting Engineers to accommodate units fur-

nished by a manufacturer other than manufacturer named as basis of design.

1.05 RATINGS AND CERTIFICATIONS

A. Air Handling Unit safety: ETL or UL 1995

B. Air Handling Unit energy use: ASHRAE 90.1

C. Fans: AMCA 210

D. Air Coils: ARI 410

E. Air Handling Unit certiﬁ cation program: ARI 430

F. Filter media: ANSI/UL 900 listed Class I or Class II

G. Control wiring: NEC codes & ETL requirements

H. Motors: Federally mandated Energy Policy Act (EPACT).

I. Airﬂ ow Monitoring Stations: AMCA 611-95

1.06 SUBMITTAL DOCUMENTATION REQUIRED

A. Furnish fan performance ratings and fan curves with speciﬁ ed operating point

clearly plotted.

B. Furnish drawings indicating unit dimensions, required clearances, ﬁ eld connec-

tion locations, wiring diagrams, shipping drawings, and curb drawings.

C. Furnish performance report showing fan, motor, coil, and component performance

details. Performance report shall detail unit casing performance and include

materials, gauges, and ﬁ nishes.

D. Furnish operation and maintenance data, including instructions for lubrication,

ﬁ lter replacement, motor and drive replacement, and condensate pan cleaning;

spare parts lists, and wiring diagrams.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

E. Adjust and report performance ratings for the proper altitude of operation.

F. Report air-handling unit performance ratings in accordance with ARI-430

(static pressure, airﬂ ow, fan speed, and fan brake horsepower).

G. Report static pressure proﬁ les by component section.

H. Report coil ratings in accordance with ARI-410 (capacities and pressure

drops).

I. Report and rate sound power levels in accordance with ARI-260 (ducted dis-

charge, ducted inlet, free inlet sound).

J. Airﬂ ow measuring device performance shall be certiﬁ ed and rated in accordance

with AMCA-611. Report data in accordance with AMCA-611. Provide AMCA

Certiﬁ ed Rating Seal for Airﬂ ow Measurement Performance.

K. Report panel deﬂ ection at +/-8” w.g., stated in terms of ‘L/X’ where ‘L’ is the

casing panel length and ‘X’ is a constant provided by the AHU manufacturer.

L. Report casing leakage rate at +/-8” w.g., speciﬁ ed in terms of percentage of

design airﬂ ow.

M. Report weight loads and distributions by component section.

N. Report product data for ﬁ lter media, ﬁ lter performance data, ﬁ lter assembly, and

ﬁ lter frames.

O. Report electrical requirements for power supply wiring including wiring dia-

grams for interlock and control wiring, clearly indicating factory-installed and

ﬁ eld-installed wiring.

P. Report motor electrical characteristics.

1.07 DELIVERY, STORAGE AND HANDLING

A. Comply with ASHRAE 62, Section 5 (mold and corrosion resistant casings,

ﬁ lters upstream of wetted surfaces, and drain pan design).

B. Comply with ASHRAE 62, Section 7 (practices to be followed during construc-

tion and startup). Protect equipment from moisture by appropriate in-transit and

on-site procedures.

C. Follow manufacturer’s recommendations for handling, unloading and storage.

D. Protect, pack, and secure loose-shipped items within the air-handling units.

Include detailed packing list of loose-shipped items, including illustrations and

instructions for application.

E. Protect, pack and secure controls devices, motor control devices and other elec-

tronic equipment. Do not store electronic equipment in wet or damp areas even

when they are sealed and secured.

F. Enclose and protect control panels, electronic or pneumatic devices, and variable

frequency drives; and pack with desiccant bags. Replace desiccant bags every 60

days. For equipment stored in an environment with a relative humidity greater

than 60%, change bags every 30 days. Do not store equipment in wet or damp

areas even when they are sealed and secured.

G. Seal openings to protect against damage during shipping, handling and stor-

age.

[Tip 5]: ASHRAE 62 established

minimum standards for designing, building

and operating a building to help ensure ac-

ceptable indoor air quality.

[Tip 1]: ARI 430 established testing,

rating and conformance requirements for

AHUs. To claim compliance, manufacturers

must periodically submit production AHUs

to ARI for testing.

[Tip 2]: ARI 410 established testing,

rating and reporting standards for air coils.

This includes special attention to heating

and cooling capacity as well as air and ﬂ uid

pressure drops.

[Tip 3]: ARI 260 standardized the

measurement and reporting of sound data

for AHUs. It does not require manufacturers

to adhere to a certiﬁ cation program to claim

compliance. It does require an extensive

testing program. (Note: AMCA 300 applies

to sound for bare fans only)

[Tip 4]: AMCA 611 details the require-

ments for certifying the performance of

airﬂ ow measuring stations. It assures buy-

ers that the reported data is accurate and

reliable. Testing is performed by AMCA or

by an independent AMCA certiﬁ ed facility.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 67

FORM 102.20-QG1 (808)

H. Provide shrink-wrap around unpainted units. The membrane shall cover entire

AHU during shipping and storage. Cover equipment, regardless or size or shape.

Tarping is not acceptable.

I. Shrink-wrap equipment, including electrical components, for protection against

rain, snow, wind, dirt, sun fading, road salt/chemicals, rust and corrosion. Keep

equipment clean and dry.

J. Tarp painted units to protect against rain and road debris during shipping.

K. Clearly mark AHU sections with unit tag number, segment sequence number,

and direction of airﬂ ow. Securely afﬁ x safety-warning labels.

1.08 EXTRA MATERIALS

A. Provide one set of ﬁ lters for balancing, and one additional set for ﬁ nal turnover

to owner.

B. Provide one extra set of belts, in addition to the factory-installed set.

1.09 WARRANTY

A. Provide warranty for 18 months from date of shipment. Warranty shall cover

manufacturer defects. Warranty shall include labor for 12 months from date of

shipment. Warranty work shall be performed by manufacturer’s factory-trained

and factory-employed technician. Service technician must be based within 50

miles of job site.

B. Include factory-provided controls in the parts and labor warranties.

C. Parts associated with routine maintenance, such as belts and air ﬁ lters shall be

excluded.

1.10 SYSTEM STARTUP

A. Do not operate units for any purpose, temporary or permanent, until ductwork

is clean, ﬁ lters are in place, bearings lubricated, and fan has been test run under

observation.

B. Comply with manufacturer’s start-up requirements to ensure safe and correct

operation and integrity of warranty.

PART 2 PRODUCTS

2.01 ACCEPTABLE MANUFACTURERS

A. YORK Solution

B. Approved Equal (Prior written approval by engineer of record is required)

2.02 GENERAL DESCRIPTION

A. Air Handling Unit (AHU) consists of a structural base, insulated casing, access

doors, fans, motors, motor controls, coils, ﬁ lters, dampers, controls, components,

and accessories; as shown on drawings, schedules, and speciﬁ cations.

B. Provide AHU to meet the speciﬁ ed levels of performance for scheduled items

including airﬂ ow, static pressure, cooling capacity, heating capacity, electrical

characteristics, sound, casing leakage, panel deﬂ ection and casing thermal per-

formance.

[Tip 6]: ASHRAE 62 Section 7.1.3

recommends the protection of equipment

on site and during transport. Shrink wrap is

a cost-effective, high-quality way to comply

with this recommendation.

[Tip 7]: Specifying an 18 month

warranty helps to ensure that the owner will

beneﬁ t from a full 12 months of warranty.

Specifying labor warranty ensures that the

manufacturer will stand by their product

for quality and performance during that

time. Specifying local service support helps

ensure quick response when service is

desired or needed.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

[Tip 9]: This spec item also found in

ASHRAE standard 62, section 5.5.1.

C. AHU shall maintain structural integrity when wall panels are removed.

D. Provide internal components and accessories as speciﬁ ed and scheduled. Com-

ponents and accessories shall be installed by the AHU manufacturer in an ISO-

9002 certiﬁ ed facility.

E. Ship units in one piece. Split units only where necessary for shipping and instal-

lation.

F. Manufacturer shall provide detailed, step-by-step instructions for disassembly

and reassembly.

G. For AHU segments that must be broken down for rigging and installation: seg-

ment shall be disassembled and reassembled by manufacturer’s factory-trained

service personnel.

H. Manufacturer shall perform a ﬁ eld leakage test to conﬁ rm 1% leakage per section

2.25.

I. Manufacturer shall provide a written statement conﬁ rming that the unit is built

to the manufacturer’s factory standards and that the unit will carry the full war-

ranty.

2.03 STANDARDS COMPLIANCE

A. Comply with ratings and certiﬁ cations referenced in this speciﬁ cation.

B. Manufacturers who do not comply with ARI-430 shall factory test EACH unit

to verify brake horsepower rating, airﬂ ow performance and total static pressure

performance. See speciﬁ cation Section 2.23 (VERIFICATION OF PERFOR-

MANCE) for testing requirements.

C. Manufacturers who do not conform to requirements of ARI 260 for ducted dis-

charge and return air sound shall submit EACH unit to an independent sound

test laboratory for ARI 260 testing. The test laboratory shall conform to ARI

260, Section 4.4, Test Equipment and Facilities.

2.04 BASE RAIL

A. Provide a structural base rail under the full perimeter of the unit, formed from

mill galvanized steel.

B. Provide clearance for proper external trapping of drain pans steam conden-

sate.

C. Provide base rail and lifting lug system that does not require additional support

for rigging. Include base rail lifting lugs at each side shipping splits and at unit

corners.

2.05 CASING

A. Provide double wall AHU casing. Exposed insulation is not acceptable.

B. Panel assembly shall meet UL standard 1995 for ﬁ re safety. Panel assembly

shall comply with the requirements of NFPA 90A.

C. Provide an insulation system that is resistant to mold growth in accordance with

a standardized test method such as UL 181 or ASTM C 1338.

D. Encapsulate insulation with sheet metal so that air does not contact insulation.

Panels insulated with ﬁ berglass shall be sealed at each corner and around their

entire perimeter, to eliminate airﬂ ow through the panel and to eliminate microbial

growth potential within the casing wall.

[Tip 8]: ARI 430 established testing,

rating and conformance requirements for

AHUs. To claim compliance, manufacturers

must periodically submit production AHUs

to ARI for testing.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 69

FORM 102.20-QG1 (808)

E. Provide casing with minimum thermal resistance (R-value) of 12 hr-ft2-°F/

BTU.

F. Roof, wall, ﬂ oor, and access door panels shall be galvanized or stainless

steel.

G. Provide an additional .125” aluminum diamond tread plate ﬂ oor liner in access

areas.

H. Provide perforated liner in the fan section and other sections as shown on the

drawings. The perforated panel shall enclose matte-faced ﬁ berglass insulation.

I. Provide a unit frame of galvanized steel that provides the overall structure of

the unit and does not rely on the casing panels for structural integrity. Insulate

frame in the same manner as panels, roof, and ﬂ oors.

J. Provide AHU casing that leaks no more than 1% of design airﬂ ow at +/-8”

w.g.

K. Provide wall panels and access doors that deﬂ ect no more than L/240 when

subjected to +/- 8” w.g. ‘L’ is the panel-span length and ‘L/240’ is the deﬂ ection

at panel midpoint.

L. Provide ﬂ oors and roofs that deﬂ ects no more than L/240 when subjected to a

300 lb load at mid-span. ‘L’ is the panel-span length and ‘L/240’ is the deﬂ ection

at panel midpoint.

M. Provide outdoor AHUs with a roof system that deﬂ ects no more than L/240 when

subjected to a snow load of 30 lb/ft2. ‘L’ is deﬁ ned as the panel-span length and

‘L/240’ is the deﬂ ection at the panel midpoint.

N. Provide outdoor AHUs with a roof sloped at a minimum pitch of 1/4” per foot.

The roof shall overhang side and end panels by a minimum of 2”.

O. Provide an exterior ﬁ nish on outdoor units that shows a breakdown of less than

1/8” on either side of a scribed line when subjected to ASTM B117 500 hour,

5% salt spray conditions. This is equivalent to an ASTM D1654 rating of ‘6’.

2.06 PRIMARY DRAIN PANS

A. Provide drain pans that comply with requirements for the AHU casing (Section

2.07).

B. Comply with the stated intent of ASHRAE Standard 62.

C. Provide a drain pan under each cooling coil and humidiﬁ er. Drain pans for cooling

coils and humidiﬁ ers shall meet the requirements of ASHRAE 62.

D. Provide drain connection made of same material as drain pan. Do not use dis-

similar metals because of the risk of galvanic corrosion. Weld connection to the

drain pan.

E. Drain pan shall be double wall with an R-value of 12 hr-ft2-°F/BTU. The entire

area of the drain pan shall have this level of thermal performance.

F. Insulate plumbing associated with drain pan drains and connections.

G. Provide drain pan under the complete width and length of cooling coil and

humidiﬁ er sections.

H. Drain pan shall allow visual inspection and physical cleaning on 100% of the

pan surface without removal of the coil or humidiﬁ er.

[Tip 10]: Casing thermal performance

has a direct impact on the owner’s utility bill.

Spec R-12 for the utmost in energy savings.

Many manufacturers employ 2” walls with

foam insulation to achieve this high thermal

performance. With ﬁ berglass insulation, 4”

walls may be required to achieve R-12.

[Tip 11]: Some manufacturers do not

insulate the frames of their units, leaving

the casing vulnerable to sweating and

energy loss.

[Tip 12]: Some manufacturer’s cas-

ings leak 5% or more. Ensure that energy

is not wasted by outward leakage and that

conditioned air is not contaminated by

inward leakage. Leaky units are also prone

to sweating at their leak points. 1% leakage

at design static pressure is a very common

benchmark for leak integrity.

[Tip 13]: When static pressure in a

unit changes and panels deﬂ ect, leakage

occurs. Over time, panels experience metal

fatigue, leading to even more leakage.

This wastes energy and compromises IAQ.

Spec L/240 for the most rigid and leak-free

casing. Specifying sheet metal gauges does

not guarantee rigid panels. Foam-insu-

lated panels may be required to meet this

performance.

[Tip 15]: On outdoor units, roof panels

are more prone to leakage than wall panels

due to high thermal stress and snow loads.

Ensure that performance is achieved on the

roof by specifying L/200 or higher.

[Tip 14]: Floor systems are the most

prone to leakage than the other panels of

the casing. Every time someone walks on

the AHU ﬂ oor, panels deﬂ ect, leading to

leakage and sweating. Spec L/240 for the

most rigid and leak-free ﬂ oor. Specifying

sheet metal gauges does not guarantee

rigid a rigid ﬂ oor. Foam-insulated panels

may be required to meet this performance.

[Tip 16]: Poorly designed drain pans

are often breeding grounds for mold and

poor IAQ. ASHRAE 62-2001, section 5.11.1

states that drain pans “…shall be sloped

at least 1/8” per foot from the horizontal to-

ward the drain outlet…whether the fan is in

the on or off position.” Section 5.11.2 states

that “The drain pan outlet shall be located at

the lowest point(s) of the pan.”

[Tip 17]: Some drain pan designs may

call for less insulation at the lowest points

of the pan.

[Tip 18]: This plumbing is difﬁ cult to

access and service. Uninsulated connec-

tions may lead to sweating and puddling

beneath the unit.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

I. Provide a minimum of 1” clearance between the drain pan and any coil casing,

coil support or any other obstruction.

J. Provide drain pan that allows the design rate of condensate drainage regardless

of fan status.

K. Provide drain pan sloped in at least two planes by at least 1/8” per foot toward

a single drain. Locate drain connection at the lowest point of the pan. Pan shall

have no horizontal surfaces.

2.07 ACCESS DOORS

A. Provide access door(s) that meet requirements for the AHU casing.

B. Provide industrial style stainless steel hinges that permit 180 degrees of door

swing.

C. Provide latches with roller cam mechanisms that ensure a tight seal. Rotating

knife-edge or “paw” latches are not acceptable.

D. Provide each door with a single handle linked to multiple latching points or a

separate handle for each latching point. Doors serving access segments shall

have an interior latch handle.

E. Provide access doors with a locking hasp to accommodate a lockout device.

F. Provide double-pane viewing windows as shown on the elevation view drawings.

Windows shall be a non-condensing type consisting of an integrated silica desic-

cant dehumidiﬁ cation layer. Minimum dimension shall be 3” x 8”.

2.08 PIPE CHASE CABINET

A. Provide pipe chases with double wall, insulated panels. Pipe chase shall have

the same thermal performance as the unit casing.

B. Provide a perimeter base rail and/or roof curb under the pipe chase(s) that meets

requirements for the AHU base rail and/or roof curb.

C. Manufacturer may combine the pipe chase enclosures of adjacent segments.

D. Provide a minimum pipe chase depth, as shown on drawings. Pipe chase depth is

the clear inside dimension from inner pipe chase surface to outer unit surface.

E. Manufacturer may ship pipe chases separate from AHU if the chases are pro-

vided with lifting lugs for ﬁ eld installation per the AHU base rail requirements.

Manufacturer shall provide step-by-step instructions with illustrations for proper

pipe chase installation.

2.09 ROOF CURBS

A. Provide factory-fabricated galvanized steel roof curb for outdoor units. Roof

curb shall support the full-perimeter of the air handling equipment, including

pipe chases.

B. Match roof curb to roof slope. Curb surface shall be level in both axes.

C. Provide wood nailing strip to which roofer may nail roof ﬂ ashing.

D. Ship roof curb loose for ﬁ eld installation prior to unit placement.

2.10 FANS

A. Provide double width double inlet (DWDI) housed fans or single width single

inlet (SWSI) plenum fans as equipment schedule and drawings.

[Tip 19]: YORK recommends this

clearance so that the drain pan can be

cleaned and inspected without requiring coil

removal. ASHRAE 62 recommends annual

inspection during the cooling season and

cleaning if necessary.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 71

FORM 102.20-QG1 (808)

[Tip 22]: L-50 implies that bear-

ings have a 50% chance of failure during

200,000 hours of operation. L-10 bearings

have only a 10% chance of failure during

the same time period.

[Tip 23]: L-50 implies that bear-

ings have a 50% chance of failure during

200,000 hours of operation. L-10 bearings

have only a 10% chance of failure during

the same time period.

[Tip 24]: Direct drive plenum fans

provide higher levels of efﬁ ciency and are

typically quieter than belt-driven fans.

B. Airfoil fans shall comply with AMCA standard 99 2408 69 and 99 2401 82.

Provide an AMCA Seal on airfoil fans. Airfoil fan performance shall be based

on tests made in accordance with AMCA standards 210 and comply with the

requirements of the AMCA certiﬁ ed ratings program for air performance.

C. Provide fans with true airfoil blades unless otherwise scheduled.

D. Provide fans with the following accessories:

1. Fan inlet screens in the inlets of fan housing (REQUIRED on SWSI plenum

fans)

2. Access door inlet screen (on AHU casing)

3. OSHA-compliant belt guard enclosing the fan motor and drive

E. Provide airfoil fans with blades formed of extruded aluminum, as scheduled.

Bent sheet metal blades are not acceptable.

F. Provide an access door in the fan scroll, as shown on drawings.

G. Provide fans with polished steel shafts with ﬁ rst critical shaft speed at least 125%

of the maximum operating speed for the fan pressure class. Shaft shall have an

anti-corrosion coating.

H. Provide fan motor on an adjustable base to allow adjustable and consistent belt

tension.

I. Mount the fan and motor assembly on a common adjustable base.

This common base shall attach to vibration isolators, which mount to structural

support channels. These channels shall span the AHU ﬂ oor and mount directly

to the AHU frame. Manufacturers not complying with this requirement must

submit detailed structural and weight data to a licensed structural engineer for

review and stamped certiﬁ cation. The mechanical engineer shall review these

engineers’ ﬁ nal reports prior to submittal approval.

J. Provide vibration isolation springs with 1” or 2” static deﬂ ection, as scheduled.

K. Connect DWDI fans to the unit casing or bulkheads with canvas ﬂ exible con-

nection.

L. Provide horizontal thrust restraints between AHU casing and fan housings with

end discharge. This requirement applies to the following cases:

1. SWSI fans operating at greater than 3” of total static pressure

2. DWDI airfoil fans operating at greater than 6” of total static pressure

3. DWDI airfoil fans operating at greater than 3” of total static pressure

2.11 BEARINGS AND DRIVES

A. Provide bearings complying with ANSI/AFBMA 9 for fatigue life ratings.

B. Provide fan bearings with an average life L50 of at least 200,000 hours.

C. Provide fan bearings with an average life L10 of at least 200,000 hours, as

scheduled.

D. Provide permanently lubricated bearings on forward curved fans smaller than

18.” On other fans, provide re-greaseable bearings with hydraulic grease ﬁ ttings

and lube lines extended to the motor side of the fan or to the exterior of the unit

(primary access side).

E. Provide plenum fans with direct-drive transmissions.

[Tip 20]: True airfoil fans are desirable

as they offer higher efﬁ ciency and have a

non-overloading fan characteristic.

[Tip 21]: Under no circumstances

should the fan and motor assembly mount

to the AHU casing ﬂ oor. This would lead

to excess casing vibration poor acoustics,

panel fatigue and air leakage.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

F. Provide drives selected with a 1.5 service factor. Sheaves shall be machined from

a close grain cast iron and statically balanced by the manufacturer. Provide a

ﬁ xed pitch sheave on the motor.

G. Provide ﬁ xed pitch sheaves on both the fan and motor. Fans with motors rated

at 15 hp or less may be ﬁ eld balanced using variable pitch sheaves. Provide

ﬁ xed pitch sheaves when ﬁ nal balance is complete. Air balancer shall select and

provide ﬁ nal set of sheaves.

H. Provide multiple belt drives on belt driven fans with motors 10 hp or greater.

Belts shall be V-type, precision molded, raw edge construction, anti-static, oil-

resistant and heat-resistant.

2.12 ELECTRICAL MOTORS

A. Provide fan motors built in accordance with the latest standards of the NEMA

and IEEE.

B. Provide AHU and fan motors in compliance with ASHRAE 90.1.

C. Provide fan motors with the following characteristics:

1. 60 hertz, 1750 rpm operation

2. Service factor of 1.15

3. Premium efﬁ ciency, or as required to meet ASHRAE 90.1

4. NEMA design ball bearing type

5. Rated for continuous duty at full load in a 104°F (40°C) ambient

6. Open drip proof (ODP) or totally enclosed, fan cooled (TEFC) as

scheduled.

7. Suitable for use in variable frequency application, per NEMA MG-1 Part

8. Inverter ready per NEMA STD MG1 PART 31.4.4.2

D. Provide direct drive plenum fans coupled to motors with matching speed, as

scheduled.

2.13 FAN-MOTOR DISCONNECTS

A. Provide UL or ETL listed fan-motor disconnects and associated components, as

scheduled and shown on drawings. Disconnects shall comply with applicable

provisions of the National Electric Code.

B. Provide fused or non-fused fan-motor disconnects in NEMA 1, NEMA 3R,

NEMA 4, or NEMA 12 enclosures, as scheduled and shown on drawings.

C. Mount disconnects on the primary access side of the associated fan segment.

1. Mount unit main disconnect (on units with single point power) on the primary

access side of supply fan section.

D. Disconnect shall be suitable for use as an OSHA lockout/tagout disconnect when

applied in accordance with part IV, Department of Labor OSHA 29 CFR Part 1910,

Control of Hazardous Energy Source (lockout/tagout): ﬁ nal rule.

E. Disconnect handles shall be lockable in the “off” position with up to three pad-

locks. Switch mechanism shall be directly lockable in the “off” position via

padlock when door is open.

[Tip 25]: ASHRAE 90.1 has a detailed

requirement for motor efﬁ ciency – typi-

cally requiring what manufacturer’s call

“premium” efﬁ ciency motors. 90.1 also has

a detailed requirement for motor SIZE,

depending on the application, static pres-

sure, etc.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 73

FORM 102.20-QG1 (808)

F. Provide disconnects with integral ground lug.

1. Provide two (2) #14 ground wires on 16A to 100A disconnects.

2. Provide one (1) #6-250 ground wire on 200A to 400A disconnects.

G. Provide auxiliary contacts, as scheduled.

2.14 FAN-MOTOR STARTERS

A. Provide UL or ETL listed motor starters and associated components, as scheduled

and shown on drawings. Starters shall comply with applicable provisions of the

National Electric Code.

B. Provide starter in a NEMA 3R enclosure.

C. Mount starter on the primary access side of its associated fan section, and wire

starter to motor, unless shown otherwise on drawings.

D. Provide the following features in each starter panel:

1. Main power block

2. Motor contactor(s)

3. Individual starter short circuit and overload protection devices

4. Two primary control fuses, one secondary control line size fuse

5. Three phase ambient compensated overload heater elements

6. 115-volt control power transformer with primary and secondary protection

7. Five-point terminal strip for ﬁ eld control connections

8. Factory wired, non-fused or fused main power disconnect, integral with

starter panel

9. Integrated on/off auto switch.

10. Wiring to fan motor

E. Starters on outdoor units shall be suitable for use in ambient temperatures from

5°F to 104°F:

1. Provide low ambient temperature kit suitable for use down to -20°F.

2. Provide high ambient temperature kit suitable for use up to 135°F.

2.15 FAN-MOTOR VARIABLE FREQUENCY DRIVES (VFDS)

A. Provide UL or ETL listed VFDs and associated components, as scheduled and

shown on drawings. VFDs shall comply with applicable provisions of the Na-

tional Electric Code.

B. Mount VFDs in a dedicated NEMA 1 compartment located on the primary ac-

cess side of its associated fan section and wire VFD to motor, unless otherwise

indicated on drawings.

C. Enclose outdoor VFDs in a NEMA-3R enclosure.

D. VFDs on outdoor units shall be suitable for use in ambient temperatures from

5°F to 104°F:

1. Provide low ambient temperature kit suitable for use down to -20°F.

2. Provide high ambient temperature kit suitable for use up to 135°F.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

E. After unit installation, VFD shall be started and programmed by a factory trained

and employed service technician. Refer to Section 3.05.

F. Provide the following VFD disconnect and bypass option:

1. Fused main disconnect

2. 2 contactor VFD bypass

3. 2 contactor VFD bypass with fused disconnect

4. 2 contactor VFD bypass with non-fused disconnect

G. Provide harmonic distortion feedback protection:

1. Equivalent 5% impedance input line reactor

2. Integral RFI/EMI ﬁ ltering to meet EMC EN61800-3 for First Environ-

ment

H. Provide a user interface with the following features:

1. 30 Character multi-lingual alphanumeric display

2. Parameter set-up and operating data

3. Display data shall include:

a. output frequency (Hz)

b. speed (RPM)

c. motor current

d. calculated % motor torque

e. calculated motor power (kW)

f. DC bus voltage

g. output voltage

h. heat sink temperature

i. elapsed time meter (re-settable)

j. kWh (re-settable)

k. input / output terminal monitor

l. PID actual value (feedback) & error

m. fault text

n. warning text

o. scalable process variable display

I. Provide VFD with the following protection circuits:

1. over current

2. ground fault

3. over voltage

4. under voltage

5. over temperature

6. input power loss of phase

7. loss of reference/feedback

[Tip 26]: Select from item a, b, c or d.

Consider that VFDs are a mature, proven

and highly reliable technology. Bypass

packages are therefore not as important as

they used to be. Perhaps specifying a spare

drive in lieu of bypass packages on drives is

a better value for the owner.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 75

FORM 102.20-QG1 (808)

8. adjustable current limit regulator

J. VFD shall be UL 508C approved for electronic motor overload (12t).

K. Provide high input transient protection and surge suppression

1. 4 MOVs ahead of diode bridge

2. 120 Joule rated 1600V diode module

3. Compliant with UL 1449 / ANSI 61.4

L. Provide the following communication features:

1. Two programmable analog inputs

2. Six programmable digital inputs

3. Two programmable analog output

4. Three programmable digital relay outputs

5. Modbus RTU Communications protocol

6. Adjustable ﬁ lters on analog inputs and outputs

7. Input speed signals, including 4-20 mA and 0-10 VDC

8. Accel/Decel contacts (ﬂ oating point control)

9. Auto restart (customer selectable and adjustable)

10. Start/Stop options shall include 2 wire (dry contact closure), 3 wire (mo-

mentary contacts), application of input power, and application of reference

signal (PID sleep/wake-up)

11. Integrated control interface for Siemens FLN, Johnson N2, Modbus RTU,

or BACnet MS/TP or LONworks over RS-485.

M. Provide the following functions:

1. Premagnetization on start

2. DC braking/hold at stop

3. Ramp or coast to stop

4. Seven preset speeds

5. Three critical frequency lockout bands

6. Start function shall include ramp, ﬂ ying start, automatic torque boost, and

automatic torque boost with ﬂ ying start

2.16 FACTORY INSTALLED ELECTRICAL ACCESSORIES

A. In addition to motor power terminals, provide an independent power terminal for

convenience receptacles and lights. Provide switches as shown on drawings.

B. Provide incandescent or ﬂ uorescent lights in segments as scheduled or shown

on drawings. Provide light switches as scheduled or shown on drawings.

C. Provide a 1-hour timer on external light switches.

D. Provide a 120v convenience receptacle on supply fan segment.

2.17 HEATING AND COOLING COMPONENTS

A. Provide coils manufactured by AHU manufacturer, except where noted in contract

documents.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

[Tip 30]: Coil penetrations are a very

common leakage point. Not only can air

leak through the casing, but it can also leak

into individual panels. This leads to a loss

in IAQ and energy efﬁ ciency performance.

Spec a tight seal by specifying coil connec-

tions that are extended through the casing,

and by specifying a spool-shaped grommet

seal that isolates the coil connection from

the panel, and that isolates the interior of

the unit from the exterior. Coil penetrations

are a very common leakage point. Not only

can air leak through the casing, but it can

also leak into individual panels. This leads

to a loss in IAQ and energy efﬁ ciency per-

formance. Spec a tight seal by specifying

coil connections that are extended through

the casing, and by specifying a spool-

shaped grommet seal that isolates the coil

connection from the panel, and that isolates

the interior of the unit from the exterior.

B. Coils shall meet or exceed performance scheduled on drawings.

1. When applicable, provide coils with performance certiﬁ ed in accordance

with ARI Standard 410 for coil capacity and pressure drop. Circuit coils

such that the ﬂ uid velocity is within the range of certiﬁ ed rating conditions

at design ﬂ ow.

C. Provide cooling coils with a maximum face velocity of 550 fpm or 500 fpm or

450 fpm. Face velocity calculations shall be based on the ﬁ nned area of the

coil.

D. Provide cooling coil drain pan that is sufﬁ cient to contain coil condensate. Drain

pan shall extend a minimum of 6” or 10” or 14” downstream of the face of the

coil.

E. Provide coil segment casing to accommodate full-face or reduced-face coils as

scheduled. Provide face and bypass coil segments with factory installed bypass

damper.

F. Provide at least 18” or 24” or 30” of access between coils. Provide an easily

operable access panel or door, as shown on drawings.

G. Provide coil segment casing that meets or exceeds casing performance of the

unit.

H. Provide panels that are easily removable with no special tools.

I. Locate access doors to provide clearance for pipe insulation, connectors, and

accessories. Space shall allow a minimum of 90 degrees of door swing.

J. Provide coils built in their own full perimeter frame. Tube sheets on each end

shall have fully drawn collars to support and protect tubes. Horizontal coil casing

and support members shall allow moisture to drain. Casing and support members

shall not block ﬁ nned area.

K. Individual coils shall be removable from the side of the AHU.

L. Provide an intermediate drain pan on stacked cooling coils. Intermediate drain

pan shall slope in a minimum of two planes toward a single drain connection.

M. Provide a single intermediate vertical coil support on coils with a ﬁ nned length

greater than 62”. Provide two vertical supports on coils with a ﬁ nned length

greater than 100”, and three vertical supports on coils with a ﬁ nned length greater

than 141”.

N. Extend coil connections through AHU casing. Provide a 1/4” FPT plugged

vent/drain tap on each connection. Circuiting shall allow complete draining and

venting when installed. Vent and drain connections shall be on the coil connec-

tion extension outside of the unit casing.

O. Insulate gap between coil stub out connection and AHU casing with a spool-

shaped sleeve grommet. Adhesive rings applied the casing walls are not accept-

able.

P. Water and glycol coils shall be operable at 250 psig working pressure and up to

300° F. Factory test water and glycol coils with 325 psig compressed air under

water.

Q. Direct expansion (DX) coils shall conform to ANSI B9.1 (Safety Code for Me-

chanical Refrigeration) when operating with a maximum refrigerant pressure of

250 psig. Factory test DX coils with 325 psig compressed air under water.

[Tip 27]: Coils with higher face

velocities are more vulnerable to moisture

carryover. A coil’s vulnerability to conden-

sate carryover depends on the coil design.

Coils with densely packed ﬁ ns (12 or 14 fpi)

are more vulnerable. Coils with staggered

tube arrangements (YORK standard) are

less vulnerable. The cleanliness of a coil

also matters.

[Tip 28]: YORK coils are designed

and selected to prevent moisture carryover.

However, dirty coils or coils operating

under non-design conditions may lead

to carryover moisture. Therefore, YORK

recommends at least 6” of drain pan down-

stream to catch moisture. More drain pan is

better, as it will keep moisture from reaching

downstream components such as fans and

fan motors.

[Tip 29]: Because the coil segment is

the coldest part of the AHU, thermal perfor-

mance, leakage and deﬂ ection are critical

here. Cooling coil drainpans are typically

the root of an AHU’s IAQ problems, making

performance even more critical.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 77

FORM 102.20-QG1 (808)

[Tip 32]: Face loading ﬁ lters offer a

tighter seal and less air bypass than side

loading ﬁ lters. For performance reasons,

it is best to not use side loading ﬁ lters in

downstream or “ﬁ nal” positions, where the

ﬁ lters typically have high efﬁ ciencies. Be

sure to specify generous access, as they

require space upstream or downstream of

the rack to change ﬁ lters.

R. Steam distributing coils shall be operable at 50 psig pressure and a corresponding

saturated steam temperature of 298° F. Factory test steam coils with 315 psig

compressed air under water. Dehydrate and seal coils prior to shipping.

S. Provide steam-distributing coils with a tube outer diameter (OD) of 1” and an

inner distribution tube of 5/8” O.D. Circuit coils for gravity drain of condensate

without trapping. Steam shall discharge in the direction of condensate ﬂ ow to

ensure even heat transfer across each tube.

T. Provide water, glycol and DX coils with a tube OD of 5/8” or 1/2”. Mechanically

expand tubes to form ﬁ n bond and provide burnished, work-hardened interior

surface. Tubes shall have a minimum tube wall thickness of 0.020” or 0.025” or

0.035” or 0.049” for 5/8” tubes, and 0.016” or 0.020” or 0.032” for 1/2” tubes.

U. Provide coils with copper tube return bends with the following ﬁ nal minimum

thicknesses:

1. 0.035” for 5/8” diameter tubes

2. 0.032” for 1/2” diameter tubes with 0.020” or 0.032” tube wall thick-

nesses

3. 0.020” for 1/2” diameter tubes with 0.016” tube wall thickness.

V. Provide water, glycol and steam coil headers made of seamless copper or brass

tubing. Pipe connections shall be steel or red brass. Header connections (tubes

and piping connections) shall be silver-brazed or TIG welded.

W. Provide DX coils with brass distributor and solder-type connections. Suction

and discharge connections shall be on the same end regardless of coil depth.

Mount refrigerant specialties outside of unit. Provide DX coils with a hot gas

bypass port on distributor.

X. Provide coils with die-formed, continuous aluminum or copper ﬁ ns. Fins shall

have fully drawn collars to accurately space ﬁ ns and protect tubes. Fins shall be

0.006” or 0.008 or 0.01” thick.

Y. Provide coil coatings as scheduled or indicated on drawings.

2.18 FILTERS

A. Provide ﬁ lter segments and ﬁ lters as scheduled.

B. Provide side loading ﬁ lters for ﬁ lter segments located upstream of coil segment(s)

with an access door on the drive side through which ﬁ lters can be easily loaded.

C. Provide face loading ﬁ lters for segments located downstream of coil segment(s).

Provide an 18” (minimum) access plenum and access door on the drive side

through which face loading ﬁ lters can be easily loaded.

D. Provide ﬁ lter racks integral to the unit and constructed of galvanized steel or

stainless steel.

E. Provide Class 2 or Class 1 ﬁ lter media per U.L. 900 and as required by local

codes.

F. Filter types, efﬁ ciencies, and nominal depths shall be as follows:

1. Flat ﬁ lters – 2” throwaway, 2” permanent cleanable, 2” 30% pleated, or 4”

30% pleated ﬁ lters, as scheduled.

2. Angled ﬁ lters – 2” throwaway, 2” permanent cleanable, or 2” 30% pleated

ﬁ lters, as scheduled.

[Tip 31]: The outer radius of a coil

tube’s return bend can be very vulnerable to

premature failure. Tubes that are machine

bent to create a return bend are especially

susceptible to failure, as the outer radius of

the bend is stretched and has a ﬁ nal thick-

ness that is signiﬁ cantly thinner than the

initial tube thickness. Specifying and enforc-

ing a FINAL thickness of .035” at the outer

radius of the return bend will help ensure a

robust and long-lasting coil

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

3. Rigid ﬁ lters – 4” mini pleated, 12” rigid, or 22” bag ﬁ lters with efﬁ ciencies

of 60-65% (MERV 11), 80-85% (MERV 13), 90-95% (MERV 14), or 90-

95% (MERV 15), respectively; as scheduled.

a. Provide a pre-ﬁ lter rack in rigid ﬁ lter segments. Pre-ﬁ lters shall have 2”

throwaway, 2” permanent cleanable, 2” 30% pleated, or 4” 30% pleated

ﬁ lters as scheduled.

4. Carbon ﬁ lters – 2” deep rechargeable, incinerable, or disposable panels ﬁ lled

with 60% activity carbon, as scheduled.

a. Carbon ﬁ ltration system shall be designed for a minimum contact ef-

ﬁ ciency of 99% with a residence time of at least 0.08 seconds.

b. Provide post-ﬁ lter and/or pre-ﬁ lter rack in carbon ﬁ lter segments with 2”

throwaway, 2” permanent cleanable, 2” 30% pleated, or 4” 30% pleated

ﬁ lters, as scheduled.

5. HEPA ﬁ lters – 12” 99.97%, or 99.99% efﬁ cient media, as scheduled.

a. Performance of installed ﬁ ltration system shall be certiﬁ ed via a DOP test

and classiﬁ ed as UL Class 1 when tested in accordance with UL Standard

586.

b. Filter frame shall be speciﬁ cally developed for HEPA ﬁ lters, with ap-

propriate quantities of ﬁ lter clamps.

G. Provide a ﬂ ush mounted, factory installed magnahelic differential pressure gage

on the drive side of unit to measure pressure drop across ﬁ lters. Manufacturer

shall provide fully functional gauges, complete with tubing.

2.19 DAMPERS

A. Provide dampers tested in accordance with AMCA 500.

B. Provide factory-installed dampers, as shown on drawings.

C. Dampers shall have airfoil blades, extruded vinyl edge seals, and ﬂ exible metal

compressible jamb seals.

D. Dampers shall have a maximum leakage rate of 4 CFM/square foot at 1” w.g.,

and shall comply with ASHRAE 90.1.

E. Damper blades shall be parallel acting unless otherwise indicated.

F. Damper blades shall be galvanized steel or aluminum, as scheduled.

2.20 AIRFLOW MONITORING STATIONS

A. Provide airﬂ ow monitoring stations, as scheduled or shown on drawings.

B. Provide airﬂ ow monitoring stations tested in accordance with AMCA Standard

611 in an AMCA registered laboratory. Airﬂ ow monitoring stations shall bear

the AMCA Ratings Seal for Airﬂ ow Measurement Performance.

C. If airﬂ ow station incorporates a control damper, control damper shall comply

with leakage rates per ASHRAE 90.1 and with speciﬁ cation section 2.19 DAMP-

ERS.

D. Provide a factory-installed transducer that sends a CFM-proportional, 4-20 mA

or 0-10V signal, as speciﬁ ed.

2.21 DIFFUSERS

A. Provide diffuser segments as shown on drawings.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 79

FORM 102.20-QG1 (808)

B. Diffuser plates shall ensure proper air ﬂ ow across components downstream of

DWDI fans.

2.22 APPURTENANCES

A. Provide rain hoods on outdoor unit air intakes, as shown on drawings. Provide

moisture screens on outdoor air inlet rain hoods.

B. Provide safety grates over bottom openings, as shown on drawings.

1. Safety grates shall be capable of supporting a 300 lb. center load.

2.23 FINISHES

A. Manufacturer shall clean the exterior surfaces of units prior to ﬁ nishing, painting,

or shipment.

B. Manufacturer shall paint outdoor units prior to shipment. Manufacturer shall

paint indoor units, as scheduled or shown on drawings.

1. Manufacturer shall apply a primer prior to painting units.

2. Manufacturer shall apply a ﬁ nish coat of acrylic polyurethane paint.

3. Finished unit shall exceed 500-hour salt spray solution (5%) test without

any sign of red rust when tested in accordance with ASTM B-117.

2.24 TESTS AND INSPECTIONS

A. Manufacturer shall dynamically balance fan/motor/base assembly.

1. Balance constant volume fan assemblies at design RPM.

2. Balance variable volume fan assemblies from 10% to 100% of design

RPM.

3. Take ﬁ lter-in measurements in the horizontal and vertical axes on the drive

and opposite-drive sides of fan shafts.

4. Take ﬁ lter-out measurements in the horizontal, vertical, and axial axes on

the drive and opposite-drive side of fan shafts.

5. Constant speed fan vibration limits: ﬁ lter-in measurements shall not exceed

4 mils. Filter-out measurements shall not exceed 6 mils in the horizontal

and vertical axes, and 7 mils in the axial axis.

6. Variable speed fan vibration limits: ﬁ lter -in measurements shall not exceed

7 mils. Filter-out measurements shall not exceed 9.5 mils.

B. Manufacturer shall hipot test wiring intended to carry voltages greater than

30Vac.

2.25 VERIFICATION OF PERFORMANCE

A. Factory test one out of every ﬁ ve AHUs (or a minimum of one unit) to verify

compliance with airﬂ ow, static pressure, casing leakage, and panel deﬂ ection

requirements. Owner and engineer reserve the right to select units to be tested.

Manufacturer shall pay food, lodging, and travel expenses for up to two wit-

nesses.

1. Alternatively, ﬁ eld test units to verify compliance with airﬂ ow, static pres-

sure, casing leakage, and panel deﬂ ection requirements. Follow testing pro-

cedures outlined in this speciﬁ cation. Manufacturer shall hire a mechanical

engineer of record to supervise testing.

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

[Tip 34]: It is not practical or reason-

able to test for thermal performance or

sweating. However a manufacturer should

know their performance capabilities and

should willingly write this letter.

B. One representative from both the owner and the engineer shall witness the test.

Manufacturer shall pay food, lodging and transportation expenses for two wit-

nesses.

C. Perform test on a fully assembled unit with sections joined per manufacturer’s

installation instructions. Use of additional material (tape, sealant, caulk) is not

acceptable.

D. Perform tests to verify the following performance criteria:

1. Casing leaks no more than 1% of design CFM at +/-8” w.g.

2. Casing panels deﬂ ect no more than L/240 at +/-8” w.g. ‘L’ is deﬁ ned as the

panel span length and ‘L/X’ is the deﬂ ection at panel midpoint.

E. Unit shall meet the Large Missile Impact Test for AHU casing (walls, roof, and

doors) and base. Unit shall carry a Notice of Acceptance (NOA) from the Mi-

ami-Dade County Product Control Division. Label equipment per NOA labeling

instructions.

F. Provide written letter of guarantee from manufacturer stating that no condensa-

tion will form on the exterior of units, under given design conditions.

G. Should a unit fail a test, treat unit with a permanent remedy at manufacturer’s

expense until test is successfully passed.

2.26 FACTORY TEST SETUP AND METHODS

A. AHU Preparation

1. Assemble and seal AHU sections per manufacturer’s installation manual.

2. Close and latch access doors. No additional sealing is permitted.

3. Seal duct, damper and louver openings.

4. Blank off and seal supply fan opening(s).

5. Blank off and seal supply fan bulkhead to isolate positive and negative

pressure sections.

B. Pressurization procedure

1. Pressurize positive pressure side to speciﬁ ed static pressures using a pres-

sure blower.

2. Pressurize negative pressure side to speciﬁ ed static pressures using a pres-

sure blower.

3. Measure and monitor differential pressure exerted on the cabinet with a

pressure gage.

C. Test measurement

1. Measure panel deﬂ ections at the centers (length and width) or four panels

chosen by owner and engineer.

2. Measure pressure drop through an ASME long radius nozzle, mounted n

the test module.

3. Monitor leakage at the same time panel deﬂ ection is measured.

D. While under pressure, inspect units failing to meet speciﬁ ed leakage and deﬂ ec-

tion. Treat failing areas with a permanent remedy. Repeat test and inspection.

Re-treat unit as necessary to pass both tests.

E. Provide test data and results in a complete report to the owner.

[Tip 33]: Make sure that bidders to

your speciﬁ cation are held accountable for

their performance. Specifying leakage and

deﬂ ection tests are an important part of

ensuring the owner gets the performance

that was speciﬁ ed.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 81

FORM 102.20-QG1 (808)

[Tip 35]: Improper storage can de-

grade the longevity and performance of an

AHU. Rust and bacteria may form if units

are not kept dry. IAQ and energy efﬁ ciency

may be negatively impacted once improp-

erly stored AHUs are operating.

[Tip 36]: A thorough inspection and

necessary corrections ensure a proper

installation. A proper installation is neces-

sary to fully realize the energy, IAQ and

acoustical beneﬁ ts of a high-performance

AHU and system.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install equipment per industry standards, applicable codes, and manufacturer’s

instructions.

B. Do not use AHUs for temporary heating, cooling or ventilation prior to complete

inspection and startup performed per this speciﬁ cation.

C. Install AHUs on a concrete pad, roof curb, or structural steel base, as shown on

drawings.

D. Install AHUs with manufacturer’s recommended clearances for access, coil pull,

and fan removal.

E. Provide one complete set of ﬁ lters for testing, balancing, and commissioning.

Provide second complete set of ﬁ lters at time of transfer to owner.

F. Install AHU plumb and level. Connect piping and ductwork according to

manufacturer’s instructions.

G. Install seismic restraints and anchors per applicable local building codes. Refer

to speciﬁ cation Section 230548 (15240 / 15070) for product and installation

requirements.

H. Install pipe chases per manufacturer’s instructions.

3.02 FIELD QUALITY CONTROL

A. Store per AHU manufacturer’s written recommendations. Store AHUs indoors in

a warm, clean, dry place where units will be protected from weather, construc-

tion trafﬁ c, dirt, dust, water and moisture. If units will be stored for more than

6 months, follow manufacturer’s instruction for long-term storage.

B. Rig and lift units according manufacturer’s instructions.

3.03 AHU INSPECTION

A. Hire manufacturer’s factory-trained and factory-employed service technician to

perform an inspection of unit and installation prior to startup. Technician shall

inspect and verify the following as a minimum:

1. Damage of any kind

2. Level installation of unit

3. Proper reassembly and sealing of unit segments at shipping splits.

4. Tight seal around perimeter of unit at the roof curb

5. Installation of shipped-loose parts, including ﬁ lters, air hoods, bird screens

and mist eliminators.

6. Completion and tightness of electrical, ductwork and piping connections

7. Tight seals around wiring, conduit and piping penetrations through AHU

casing.

8. Supply of electricity from the building’s permanent source

9. Integrity of condensate trap for positive or negative pressure operation

10. Condensate traps charged with water

11. Removal of shipping bolts and shipping restraints

JOHNSON CONTROLS

FORM 102.20-QG1 (808)

[Tip 37]: A thorough inspection and ad-

justment of the fan assembly helps ensure

that the energy, IAQ and acoustical beneﬁ ts

of a high-performance AHU and system are

realized.

12. Sealing of pipe chase ﬂ oor(s) at penetration locations.

13. Tightness and full motion range of damper linkages (operate

manually)

14. Complete installation of control system including end devices and

wiring

15. Cleanliness of AHU interior and connecting ductwork

16. Proper service and access clearances

17. Proper installation of ﬁ lters

18. Filter gauge set to zero

B. Resolve any non-compliant items prior to proceeding with the inspection of the

fan assembly.

3.04 INSPECTION AND ADJUSTMENT: AHU FAN ASSEMBLY

A. Hire the manufacturer’s factory-trained and factory-employed service technician

perform an inspection of the AHU fan assembly subsequent to general AHU

inspection and prior to startup. Technician shall inspect and verify the following

as a minimum:

1. Fan isolation base and thrust restraint alignment

2. Tight set screws on pulleys, bearings and fan

3. Tight fan bearing bolts

4. Tight fan and motor sheaves

5. Tight motor base and mounting bolts

6. Blower wheel tight and aligned to fan shaft

7. Sheave alignment and belt tension

8. Fan discharge alignment with discharge opening

9. Fan bearing lubrication

10. Free rotation of moving components (rotate manually)

B. Manufacturer shall perform service to bring fan performance within factory

speciﬁ cations.

3.05 STARTUP SERVICE AND OWNER TRAINING

A. Manufacturer’s factory-trained and factory-employed service technician shall

startup AHUs. Technician shall perform the following steps as a minimum:

1. Energize the unit disconnect switch

2. Verify correct voltage, phases and cycles

3. Energize fan motor brieﬂ y (“bump”) and verify correct direction of rota-

tion.

4. Re-check damper operation; verify that unit cannot and will not operate

with all dampers in the closed position.

5. Energize fan motors and verify that motor FLA is within manufacturer’s

tolerance of nameplate FLA for each phase.

GUIDE SPECIFICATIONS

JOHNSON CONTROLS 83

FORM 102.20-QG1 (808)

[Tip 38]: A ﬁ eld leakage test is a pru-

dent step to ensure that the AHU performs

as promised. The test is a ﬁ nal conﬁ rmation

that the AHU will perform. Field testing con-

ﬁ rms that the AHU withstood the stresses

of shipping, rigging and installation and can

still provide high performance.

B. Provide a minimum of 4 hours of training for owner’s personnel by manufac-

turer’s factory-trained and factory-employed service technician. Training shall

include AHU controls, motor starter, VFD, and AHU.

C. Training shall include startup and shutdown procedures as well as regular opera-

tion and maintenance requirements.

D. If AHU is provided with a factory-mounted variable frequency drive (VFD), hire

the VFD manufacturer’s factory-trained and factory-employed service technician

to inspect, test, adjust, program and start the VFD. Ensure that critical resonant

frequencies are programmed as ‘skip frequencies’ in the VFD controller.

E. Submit a startup report summarizing any problems found and remedies per-

formed.

3.06 FIELD PERFORMANCE VERIFICATION

A. Leakage: Pressurize casing to +/-8” w.g. and measure leakage. Pressurize casing

to –8”w.g. and measure leakage. If leakage exceeds 1% of design airﬂ ow, seal

leakage points with a permanent solution. Repeat test. If the AHU still does not

pass, contact the manufacturer to seal unit.

B. Submit a ﬁ eld test report with testing data recorded. Include description of cor-

rective actions taken.

3.07 CLEANING

A. Clean unit interior prior to operating. Remove tools, debris, dust and dirt.

B. Clean exterior prior to transfer to owner.

3.08 DOCUMENTATION

A. Provide Installation, Operation & Maintenance Manuals in the supply fan

section of each unit. Provide six additional copies for owner’s project system

manual.

B. Provide six copies of Spare Parts Manual for owner’s project system manual.

Printed on recycled paper

Form: 102.20-QG1 (808) Supersedes: 102.20-QG1 (707)

www.johnsoncontrols.com

Solution Air Handling Units 200 To 100,000 CFM (Indoor & Outdoor S), Engineering Guide, 102.20 QG1 060 Solutions Ahu

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