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INSTALLATION
MILLENNIUM™ ROOFTOP
MANUAL
25, 30 & 40 TON
MODELS: Z42
Z33
CONTENTS
Z34
NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GAS HEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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882108-YIM-B-1012 TABLE OF CONTENTS SUPPLY AIR FAN INSTRUCTIONS . . . . . . . . . . . . . . . . 59 NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CHECK BLOWER BEARING SET SCREWS . . . . . . . . . . . . . 59 CHECKING SUPPLY AIR CFM. . . . . . . . . . . . . . . . . . . . . . . . 59 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 7 FAN ROTATION . . . . . . . . . . . . . . . . . . . . . . .
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882108-YIM-B-1012 LIST OF FIGURES Fig. # Pg. # Fig. # Pg. # 1 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 6 29 HOT WATER COIL - 25 & 30 TON, 1 ROW, AT 30 GPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 2 TYPICAL RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 30 HOT WATER COIL - 25 & 30 TON, 1 ROW, 3 CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . 11 AT 40 GPM . . . . . . . . . . . . . . . . . . . . . . .
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882108-YIM-B-1012 LIST OF TABLES Tbl. # Pg. # Tbl. # Pg. # 1 COOLING & ELECTRICAL APPLICATION . . . . . . . . . 8 30 FAN PERFORMANCE - 25 TON . . . . . . . . . . . . . . . . . 47 2 COOLING & ELEC. APP. LIMITATIONS . . . . . . . . . . . 8 31 FAN PERFORMANCE - 30 TON . . . . . . . . . . . . . . . . . 49 3 STANDARD GAS HEATING CAPACITIES . . . . . . . . . 9 32 FAN PERFORMANCE - 40 TON . . . . . . . . . . . . . . . . . 51 4 TEMPERATURE RISE . . . . . . . . . . . . . . . . . . . . . . . . .
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882108-YIM-B-1012 NOMENCLATURE Johnson Controls Unitary Products 5 Z 3 3 A N 3 4 B 1 A A C A D 1 2 3 4 5 6 7 8 9 10 11 12 13 1412 3 4 PACKAGE ADDITIONAL Z = York Brand R-410A CONFIGURATION VOLTAGE FILTERS OPTIONS 2 = 208/230-60 A = STAND. Cu/Cu Condenser Coil CONTROL 3 = 380-60 B = 65% Cu/Cu Evaporator Coil 4 = 460-60 C = 95% D = SYNTHESYS CONTROL Exhaust VFD (Customer) 5 = 575-60 D = 2" HI-EFF (see note 3) E = SYNTHE
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882108-YIM-B-1012 EVAPORATOR COIL AND DRAIN PAN ACCESS POWER & CONTROL WIRING FILTER ACCESS COMPRESSOR ACCESS REAR RIGHT END HEAT SECTION FRONT OPTIONAL POWER LEFT END OUTLET (115V) POWER EXHAUST ACCESS HEAT SECTION EVAPORATOR COIL AND DRAIN PAN ACCESS FILTER DRIERS FILTER ACCESS REAR SUPPLY BLOWER & MOTOR FIGURE 1 - COMPONENT LOCATION 6 Johnson Controls Unitary Products
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882108-YIM-B-1012 GENERAL York Model Z42/Z33/Z34 units are single package cooling only or cooling with gas, electric, hot water or steam heating This Furnace is not to be used for temporary heat- designed for outdoor installation on a rooftop and for non-res- ing of buildings or structures under construction. idential use. ALL MODELS The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electri- cal wiring is factory installed and teste
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882108-YIM-B-1012 After installation, gas fired units must be adjusted to obtain a REFERENCE temperature rise within the range specified on the unit rating Additional information is available in the following reference plate. form: If components are to be added to a unit to meet local codes, • 246837 - Technical Guide they are to be installed at the contractor's and/or the cus- tomer's expense. APPROVALS Size of unit for proposed installation should be based on heat Designed certified by CSA, ET
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882108-YIM-B-1012 TABLE 3: STANDARD GAS HEATING CAPACITIES 1 3 INPUT CAPACITY (MBH) OUTPUT GAS RATE, CU. FT./HR. GAS HEAT AVAILABLE ON CAPACITY OPTION MODELS 2 1ST STAGE TOTAL (MBH) 1ST STAGE TOTAL N3 Z42/Z33/Z34 267 267 213 247 247 N5 Z42/Z33/Z34 267 533 426 247 495 4 N8 Z34 ONLY 267 800 638 247 742 1. Heating capacity is only staged on CV models. VAV models use only one stage at full capacity. 2. Blower motor heat not included. 3. 3 Based on a heat content of 1075 Btu/Ft. 4. Unit Control Bo
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882108-YIM-B-1012 TABLE 7: MODULATING HEAT STAGES OF GAS CONTROL (% OF FULL HEAT OUTPUT) GAS HEAT OPTION AVAILABLE ON MODELS STEP INPUT OUTPUT % OF TOTAL OUTPUT 1 69,333 55,466 26% 2 106,666 85,333 40% D3 3 165,332 132,266 62% (Turn down ratio Z42, Z33, Z34 4 202,665 162,132 76% 3.8 to 1) 5 229,332 183,466 86% 6 266,666 213,333 100% 1 69,333 55,466 13% 2 106,666 85,333 20% 3 165,332 132,266 31% 4 202,665 162,132 38% 5 229,332 183,466 43% D5 6 266,666 213,333 50% (Turn down ratio Z42, Z33, Z34
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882108-YIM-B-1012 TABLE 8: UNIT WEIGHTS TABLE 9: SUPPLY FAN MOTOR VFD WEIGHTS COMPONENT 25 TON 30 TON 40 TON Supply Fan Motor VFD 230V 460V 575V Basic Unit 4410 4565 4845 W/O Bypass Gas Heat 7.5hp 60 25 30 267 MBH 180 180 180 533 MBH 320 320 320 10hp 60 25 30 800 MBH - - 450 15hp 75 50 60 Electric Heat 40KW 40 40 40 20hp 75 50 60 80KW 105 105 105 25hp 115 50 60 108KW 110 110 110 W/Bypass Hot Water Heat 1 Row Coil 70 70 70 7.5hp 155 90 120 2 Row Coil 85 85 85 10hp 155 90 120 Steam Heat 15hp 185 1
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882108-YIM-B-1012 RIGGING AND HANDLING This unit is not designed to be handled with a fork-truck. All panels must be secured in place when the unit is lifted. Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig The condenser coils should be protected from the unit by attaching cable slings to the lifting lugs provided in damage by the rigging cables with plywood or the unit base rails. Spreaders MUST be used across the top other s
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882108-YIM-B-1012 When the unit is equipped with power exhaust fans or return air fan the return duct should have a 90 elbow before opening to the building space to abate noise. (GAS HEATING OPERATION) The supply and return air duct systems should be designed for the CFM and static pressure requirements of the job. They Excessive exposure to contaminated combustion should NOT be sized to match the dimensions of the duct air will result in safety and performance related connections on the unit. p
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882108-YIM-B-1012 FILTERS
Throwaway or rigid filters are supplied with each unit. Filters
must always be installed ahead of evaporator coil and must
be kept clean or replaced with same size and type. Dirty fil- ters will reduce the capacity of the unit and will result in frosted coils or safety shutdown. Required filter sizes are shown in Table 15. The unit should not be operated without
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882108-YIM-B-1012 Refer to Figure 5 for typical field wiring and to the appropriate POWER AND CONTROL WIRING unit wiring diagram mounted inside control doors for control circuit and power wiring information. Field wiring to the unit must conform to provisions of National Electrical Code (NEC) ANSI / NFPA 70-Latest Edition and / or POWER WIRING DETAIL local ordinances. The unit must be electrically grounded in accordance with the NEC and / or local codes. Voltage toler- Units are factory wired fo
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882108-YIM-B-1012 GAS HEATING On VAV units with gas fired furnace, ALL INDIVID- UAL ROOM DAMPER BOXES MUST BE CON- TROLLED FULL OPEN DURING HEATING OPERATION TO ENSURE PROPER AIRFLOW OVER THE FURNACE. A control contact powered by the “VAV OPEN” terminals on the Simplicity® control is provided for the damper box interlock. this contact is normally open, and is closed during FIGURE 6 - TYPICAL GAS PIPING CONNECTION heating operation. Gas piping recommendations: GAS PIPING 1. A drip leg and a groun
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882108-YIM-B-1012 VENT AND COMBUSTION AIR NOTE: All the hoods and hardware are shipped within the evaporator section. Each hood must be properly Disconnect gas piping from unit when leak testing attached to the furnace doors to assure proper at pressures greater than 0.5 psig. Pressures operation and compliance with CSA/ETL safety cer- greater than 0.5 psig will cause gas valve damage tification. (Refer to Figure 7.) resulting in a hazardous condition. If gas valve is subjected to pressure great
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882108-YIM-B-1012 ELECTRIC HEAT Units with electric heat are fully wired and operational when shipped. Constant volume units are designed for two equal There are no provisions in the coil or control steps of capacity for 80 and three for 108 kWH heat; 40 kW sequence to prevent freezing of condensate. The heat is one step only. Heat outputs on VAV units are all turned control valve, piping and field installed wiring con- on together at full heat capacity. nections are particularly vulnerable beca
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882108-YIM-B-1012 DO NOT use tin based solder. Brazing with tin All piping and control valves, and wiring that is based solder could cause equipment damage or field installed must be properly insulated and con- possible injury to tenants of the structure that is form to all local and national codes. being conditioned. There are no provisions in the coil or control sequence to prevent freezing of condensate. The control valve, piping and field installed wiring con-
nection
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882108-YIM-B-1012 STATIC PRESSURE CONTROL PLASTIC TUBING EXHAUST STATIC PRESSURE On units with variable frequency drives (VFD’s) or inlet guide If a modulating-damper or variable frequency drive power vanes (IGV's) on the supply blower and/or power exhaust exhaust is installed, there will be a building pressure sensor fans, pressure sensing tubing must be field supplied and (BPS) in the control box directly below the Millennium Sim- installed. All tubing must be installed from the transducers pl
