York Air Conditioner 66441 Yum D 1011 User Manual

®
CONTENTS  
USER’S, MAINTENANCE  
and  
SERVICE INFORMATION  
MANUAL  
15 THRU 25 TON  
SINGLE PACKAGE  
AIR CONDITIONER  
GAS/ELECTRIC  
CLEANING FLUE PASSAGES AND  
& ELECTRIC/ELECTRIC  
The manufacturer recommends that the “User” read all sections of this manual and  
keep the manual for future reference.  
FIRE OR EXPLOSION HAZARD  
Failure to follow safety warnings exactly could  
result in serious injury, death, or property dam-  
age.  
- Do not store or use gasoline or other flamma-  
ble vapors and liquids in the vicinity of this or  
any other appliance.  
- WHAT TO DO IF YOU SMELL GAS:  
•Do not try to light any appliance.  
•Do not touch any electrical switch; do not use any  
phone in your building.  
•Leave the building immediately.  
•Immediately call your gas supplier from a neigh-  
bor’s phone. Follow the gas supplier’s instruc-  
tions.  
•If you cannot reach your gas supplier, call the fire  
department.  
- Installation and service must be performed by  
a qualified installer, service agency or the gas  
supplier.  
66441-YUM-D-1011  
66441-YUM-D-1011  
When the thermostat calls for heat, pilot gas is supplied and  
at the same time, sparking occurs to light the pilot gas. With  
the pilot lit, the flame sensor rod closes a circuit to the ignitor  
control which then opens the gas valve to admit main burner  
gas.  
5. The draft fan will operate. After an adequate purge time,  
the electric spark igniter will light the burners.  
6. The burners will extinguish and relight automatically upon  
the demand of the room thermostat.  
When the room thermostat is satisfied, the electrical circuit to  
the gas valve is opened, closing off both main burner and  
pilot gas simultaneously. If the pilot burner should fail to light,  
contact your heating contractor or gas utility for service to  
insure that proper operating conditions are restored.  
VENT SAFETY SYSTEM:  
This gas furnace is equipped with an automatic reset high  
temperature sensor or rollout switch which in the unlikely  
event of a sustained main burner flame rollout will shut off the  
flow of gas by closing the main gas valve. The ignition mod-  
ules will also be disabled, preventing the flow of gas to the  
valves. The switch is located inside the gas heat access  
panel above the burner inlet. Flame rollout can be caused by  
blockage of the power vent system, improper gas pressure or  
adjustment. If this event occurs the furnace will not operate  
properly, gas supply to the furnace should be shut off and no  
attempt should be made to place the furnace in operation.  
The system should be inspected by a qualified service techni-  
cian. Refer to Figure 2 for a typical installation.  
INPUT  
The correct heat capacity of the furnace is regulated by the  
burner orifices and the gas pressure. The proper orifices are  
furnished but the gas pressure regulator must be adjusted by  
the installer or gas utility service technician.  
OPERATING INSTRUCTIONS  
TO SHUT DOWN THE FURNACE:  
1. Close the main gas shutoff valve(s).  
2. Turn off the electric power supply.  
100% SHUT OFF:  
The ignition modules are designed for 100% shut-off. If the  
furnace fails to ignite within 85 seconds after a call for heat,  
the flow of gas (including pilot) will be shut off and the ignition  
module will lock out. The module can be reset by:  
TO LIGHT THE FURNACE:  
1. Do not attempt to light manually.  
2. Open the main gas shutoff valve(s).  
A. Turning the system switch on the room thermostat to the  
“OFF” position and back to the “HEAT” position.  
B. Decreasing the set point of the room thermostat below  
the temperature in the conditioned space and returning it  
to its original setting.  
3. Adjust the set point of the room thermostat above the tem-  
perature in the space.  
4. Turn on the electric power supply.  
C. Opening and closing the unit's main disconnect switch.  
FIGURE 2 - TYPICAL INSTALLATION  
Johnson Controls Unitary Products  
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66441-YUM-D-1011  
If the furnace continues to lock out, a qualified service techni-  
cian should be called to determine the cause of the problem.  
bustion and ventilation. Adequate air is important to the safe  
and proper operation of the unit.  
HEATING SYSTEM INSPECTION  
It is the owner's responsibility to insure that an annual inspec-  
tion of the entire heating portion of the unit is made by a qual-  
ified service technician. This should include inspection of the  
burner, heating element and flue for any corrosion or soot  
accumulation which may require cleaning and also checking  
of burner and controls for proper operation.  
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD  
Failure to follow safety warnings exactly could result in dan-  
gerous operation, serious injury, death or property damage.  
Improper servicing could result in dangerous operation,  
serious injury, death or property damage.  
In addition, at least once during the heating season, the  
owner shall make a visual inspection of the flue outlet for evi-  
dence of black soot or blockage of flue outlet by leaves or  
other debris. If any soot is found, it is recommended a quali-  
fied service technician be called immediately. If any blockage  
is found, it must be cleared immediately.  
Before servicing, disconnect all electrical power to fur-  
nace.  
When servicing controls, label all wires prior to discon-  
necting. Reconnect wires correctly.  
Check for obvious signs of deterioration of the unit. Check  
that the return and supply ducts attached to the unit are  
sound and air tight. Check that the unit's physical support,  
concrete slab or roof curb, is sound and not in need of repair.  
Make sure there are no gaps between the roof curb and the  
unit where rain could leak into the building.  
Verify proper operation after servicing.  
Start the furnace. The vent motor should start, the igniter will  
start to spark and ignite the pilot flame. After a short delay the  
main burner should ignite. If it does not, contact a qualified ser-  
vice technician for assistance. Check the appearance of the  
main burner flame. Adjust burner shutters so no yellow flame is  
observed in the heat exchanger tubes. (See Figure 3.) If flame  
adjustment cannot be made, obtain the assistance of a quali-  
fied service technician and refer to the PILOT CHECKOUT  
and BURNER AIR SHUTTER ADJUSTMENT sections in the  
UNIT INSTALLATION INSTRUCTION.  
Prior to any of the following maintenance procedures, shut  
off all power to the unit, to avoid personal injury.  
EXPLAIN UNIT FUNCTION  
When the system is functioning properly, show the owner the  
location of all disconnect switches and the thermostat.  
Explain how to start and stop the unit and how to adjust tem-  
perature settings within the limitations of the system. Advise  
that the flue exhaust hood surface and the immediate area  
will experience high temperatures during the heating cycle,  
and that all unauthorized personnel and debris must be kept  
away from this area.  
GENERAL MAINTENANCE  
In order to insure long and trouble free service from your sys-  
tem, we recommend periodic inspection, cleaning, lubrication  
and adjustment by your installing Dealer/Contractor. Be sure  
to ask about this service. For those who prefer to do-it-your-  
self, please follow the instructions listed below to care for  
your system.  
FIGURE 3 - TYPICAL FLAME APPEARANCE  
BURNER AND PILOT CHECK  
Periodically (at least annually at the beginning of each heat-  
ing season) make a visual check of the pilot and main burner  
flame. If necessary, adjust main burner primary air shutters to  
give a distinct, sharp blue flame as explained under BURNER  
AIR SHUTTER ADJUSTMENT. If it is not possible to adjust  
for the proper flame, the burners may need cleaning.  
Snow or debris should not be allowed to accumulate in or  
around the unit. Do not permit overhanging structures or  
shrubs to obstruct outdoor air discharge, combustion air  
inlets or vent outlets on your unit. These provide air for com-  
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Johnson Controls Unitary Products  
       
66441-YUM-D-1011  
12. When replacing the center and top of the flue collector box,  
be careful not to tear the adjoining insulation.  
CLEANING BURNERS  
Remove them from the furnace as explained in BURNER  
INSTRUCTIONS section in the Unit Installation Instructions.  
Clean burners with wire brush and vacuum as needed.  
13. Ensure that all seams on the vent side of the combustion  
system are air tight. Apply a high temperature (+500°F)  
sealing compound where needed.  
CLEANING FLUE PASSAGES AND  
HEATING ELEMENTS  
With proper combustion adjustment, the heating element of a  
gas fired furnace will seldom need cleaning. If the element  
should become sooted, it can be cleaned as follows:  
1. Remove the burner assembly as outlined in “BURNER  
INSTRUCTIONS” of the unit installation instructions.  
2. Remove the unit roof from over the gas heat section.  
3. Remove the top plate and the top draft blower wheel from  
the upper draft blower housing.  
4. Remove the screws holding the top of the flue collector  
box. Carefully remove the top of the flue collector box with-  
out ripping the adjacent insulation. Then remove the center  
divider plate separating the upper and lower flue boxes.  
FIGURE 4 - TYPICAL FLUE BAFFLE INSTALLATION  
AIR FILTERS  
All units contain 2" filters. Filters can be installed in the build-  
ing at a suitable return air location if an economizer or outside  
air accessory is not used. Filters must always be used. They  
should be inspected once a month and thoroughly cleaned or  
replaced if it appears they are beginning to accumulate  
excessive dirt. Filter sizes and quantities are shown in the fol-  
lowing table.  
5. On the inside of the flue collector box, remove the flue baf-  
fles from the tube interiors. Note the last bend of the baffle  
fits tightly against the tube forcing the end of the baffle to  
lock into the tube collar. This collar is formed when the tube  
is expanded into the end sheet. To remove, move the end  
of the baffle toward the center of the tube releasing the end  
of the baffle from the tube collar, then pull straight out of the  
tube. Refer to Figure 4.  
QUANTITY PER UNIT (Nom, Tons)  
THROWAWAY  
FILTER  
15, 20, 25  
TON REHEAT 25 TON  
20 TON  
STD & HIGH  
EFF.  
15 - 25  
TON  
ULTRA  
HIGH  
EFF.  
15 TON  
STD  
& HIGH  
EFF.  
6. Using a wire brush on a flexible wand, brush out the inside  
of each heat exchanger from the burner inlet and flue outlet  
ends.  
SIZES  
(Inches)  
STD  
EFF.  
12 x 24  
16x 20  
16 x 25  
18 x 24  
-
-
-
4
4
-
12  
-
12  
-
7. Brush out the inside of the flue collector box and the flue  
baffles.  
-
-
-
8. Run the wire brush down the vent hoods from the flue col-  
lector end.  
5
-
-
To install the filters, remove the filter access panel located to  
the left of the condensate drain connection as shown in Fig-  
ure 5.  
9. If soot build-up is particularly bad, remove the vent motor  
and clean the wheel and housings. Run the wire brush  
down the flue extensions at the outlet of the vent housings.  
NOTE: Filters must be installed with “Air Flow” arrows point-  
ing inward -- toward the indoor coil. In the event the  
spacers in the filter section are removed, they must  
be reinstalled in their original position.  
10. After brushing is complete, blow all brushed areas with air  
or nitrogen. Vacuum as needed.  
11. Replace parts in the order they were removed in Steps 1  
thru 5.  
Slide filters all the way into the filter racks provided. When  
more than one filter in a filter rack is required, they must butt  
each other when sliding into position. Replace the filter  
access panel.  
Johnson Controls Unitary Products  
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66441-YUM-D-1011  
15 TON  
(2) 18" X 24"  
FILTERS  
20 TON  
15,20,25 TON REHEAT  
(4) 16" X 20"  
Excessive lubrication may accelerate the accu-  
mulation of dust.  
INDOOR COIL  
FILTERS  
15 TON  
(3) 18" X 24"  
FILTERS  
CONDENSATE  
DRAIN  
CONNECTION  
BLOWER ASSEMBLY  
20 TON  
Even with good filters properly in place, blower wheels and  
motors will become dust laden after many months of opera-  
tion. The entire blower assembly should be inspected annu-  
ally. If the motor and wheel are heavily coated with dust, they  
can be brushed and cleaned with a vacuum cleaner.  
15,20,25 TON REHEAT  
(4) 16" X 25"  
FILTERS  
15, 20, 25 TON REHEAT UNITS  
15 & 20 TON STANDARD & HIGH EFFICIENCY UNITS  
BLOWER SHAFT BEARING  
Blower shaft bearings should be inspected on a monthly  
basis. At a minimum, the bearings should be relubricated  
every 6 months using a lithium-based grease (NLGI grade 2)  
recommended for ball bearing service.  
(6) 12" X 24"  
FILTERS  
INDOOR COIL  
(6) 12" X 24"  
FILTERS  
CONDENSATE  
DRAIN  
CONNECTION  
25 TON STANDARD EFFICIENCY  
Perform all maintenance operations on the blower  
motor with electric power disconnected from the  
unit. Do not attempt to lubricate bearings with the  
unit in operation.  
15, 17.5, 20, 25 TON ULTRA-HIGH EFFICIENCY UNITS  
FIGURE 5 - END VIEW LESS FILTER ACCESS  
PANEL  
ECONOMIZER  
Even with good filters properly in place, the economizer  
assembly will become dust laden after many months of use.  
The entire assembly should be inspected annually. If the  
assembly is heavily coated with dust, it can be brushed and  
cleaned with a vacuum. A common aerosol contact cleaner  
will help remove excess accumulation.  
Damage can occur if the bearings are overlubri-  
cated. Use grease sparingly.  
MOTORS  
After the dust and debris is removed, a silicon based spray  
lubricant should be applied to each of the gears used to con-  
nect and ensure proper alignment of the damper blades.  
Outdoor fan motors are permanently lubricated and require  
no maintenance.  
Ventor motor is factory lubricated for an estimated 10 year  
life.  
Indoor Blower Motor and Drive - The indoor blower motor fea-  
tures ball bearings that do not require periodic lubrication.  
Periodic lubrication of the motor and bearings can extend the  
life of components but is optional.  
Perform all maintenance operations on the  
damper assembly with power disconnected. Do  
not clean or lubricate with the unit in operation.  
If desired, every three years, using a low pressure grease  
gun, pump grease into the bearing grease fitting until grease  
just begins to show at the seals. Do not over lubricate. Use  
any lithium base grease recommended for ball bearing ser-  
vice.  
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Johnson Controls Unitary Products  
       
CONDENSER COIL  
TROUBLESHOOTING  
An annual check and cleaning, if necessary, of the outdoor  
coil should be done. Cleaning should be as often as neces-  
sary to keep the coil clean. Clean any debris and dirt from the  
outside coil face with a brush being careful not to damage the  
fins. If extremely dirty, a hose can be used to wash the coil  
from the inside out while brushing a soapy solution on the  
outside.  
BEFORE CALLING A SERVICE PERSON:  
A. Check thermostat setting and insure thermostat is calling  
for heat or cooling.  
B. Check thermostat for lint, etc.  
C. Check fuses or circuit breakers.  
REGISTERS  
D. Check filters for excessive dust accumulation.  
Supply and return air registers must be open when the unit is  
in operation. Obstructions must not be allowed to block air-  
flow in or out of the registers.  
Subject to change without notice. Printed in U.S.A.  
66441-YUM-D-1011  
Copyright © 2011 by Johnson Controls, Inc. All rights reserved.  
Supersedes: 66441-YUM-C-0711  
Johnson Controls Unitary Products  
5005 York Drive  
Norman, OK 73069  
       

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