Millennium Enterprises Z42 manual

ISO 9001 Certified Quality Management System CONTENTS NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GAS HEATING . . . [...]

882108-YIM-B-1012 2 Johnson Controls Unitary Products T ABLE OF CONTENTS NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 7 NOTES, CAUTIONS AND WARNINGS . . . . . . . . . . . . . . . 7 GAS FIRED M[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 3 LIST OF FIGURES Fig. # Pg. # 1 COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . 6 2 TYPICAL RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3 CENTER OF GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . 11 4 RECOMMENDED DRAIN PIPING . . . . . . . . . . . . .[...]

882108-YIM-B-1012 4 Johnson Controls Unitary Products LIST OF TABLES Tbl. # Pg. # 1 COOLING & ELECTRICAL APPLICATION . . . . . . . . . 8 2 COOLING & ELEC. APP. LIMITATIONS . . . . . . . . . . . 8 3 STANDARD GAS HEATING CAPACITIES . . . . . . . . . 9 4 TEMPERATURE RISE . . . . . . . . . . . . . . . . . . . . . . . . . 9 5 MINIMUM HEATING CFM[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 5 NOMENCLATURE 12 3 4 CONTROL ADDITIONAL D = SYNTHESYS CONTROL CONFIGURATION VOLTAGE E = SYNTHESYS CONTROL, OPTIONS 2 = 208/230-60 DISC., 110V OUTLET Cu/Cu Condenser Coil 3 = 380-60 F = SYNTHESYS, DISC. Cu/Cu Evaporator Coil 4 = 460-60 Exhaust VFD (Customer) 5 = 575-60 H = SIMPLICITY CONTROL (see [...]

882108-YIM-B-1012 6 Johnson Controls Unitary Products FIGURE 1 - COMPONENT LOCA TION FILTER ACCESS EVAPORATOR COIL AND DRAIN PAN ACCESS POWER & CONTROL WIRING COMPRESSOR ACCESS HEAT SECTION POWER EXHAUST ACCESS FILTER ACCESS HEAT SECTION SUPPLY BLOWER & MOTOR FILTER DRIERS RIGHT END LEFT END FRONT REAR REAR OPTIONAL POWER OUTLET (115V) EVAP[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 7 GENERAL Y ork Model Z42/Z33/Z34 units are single package cooling only or cooling with gas, electric, hot water or steam heating designed for outdoor installation on a rooftop and for non-res- idential use. The units are completely assembled on rigid, permanently attached base rails. All piping, [...]

882108-YIM-B-1012 8 Johnson Controls Unitary Products REFERENCE Additional information is available in the following reference form: • 246837 - T echnical Guide APPROV ALS Designed certified by CSA, ETL, CETL as follows: 1. For use as a forced air furnace with cooling unit (gas heat models). 2. For outdoor installation only . 3. For installation [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 9 T ABLE 3: STANDARD GAS HEA TING CAP ACITIES G AS H EAT O PTION A VAILABLE ON M ODELS I NPUT C APACITY (MBH) 1 1. Heating capacity is only staged on CV models. V A V models use only one stage at full capacity . O UTPUT C APACITY (MBH) 2 2. Blower motor heat not included. G AS R ATE , C U . F T ./[...]

882108-YIM-B-1012 10 Johnson Controls Unitary Products FIGURE 2 - TYPICAL RIGGING T ABLE 7: MODULATING HEAT S TAGES OF G AS C ONTROL (% OF F ULL H EAT O UTPUT ) G AS H EAT O PTION A VAILABLE ON M ODELS S TEP I NPUT O UTPUT % OF TOTAL OUTPUT D3 (T urn down ratio 3.8 to 1) Z42, Z33, Z34 1 69,333 55,466 26% 2 106,666 85,333 40% 3 165,332 132,266 62% 4[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 11 NOTE: If the Millennium is V A V with ERV , add the weight of an exhaust VFD - it will be in the unit. . T ABLE 8: UNIT WEIGHTS COMPONENT 25 TON 30 TON 40 TON Basic Unit 4410 4565 4845 Gas Heat 267 MBH 180 180 180 533 MBH 320 320 320 800 MBH - - 450 Electric Heat 40KW 40 40 40 80KW 105 105 105 [...]

882108-YIM-B-1012 12 Johnson Controls Unitary Products RIGGING AND HANDLING This unit is not designed to be handled with a fork-truck. Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching cable slings to the lifting lugs provided in the unit base rails. Spreaders[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 13 DUCTWORK Ductwork should be designed and sized according to the methods in Manual Q of the Air Conditioning Contractors of America (ACCA). A closed return duct system should be used. This will not pre- clude use of economizers or outdoor fresh air intake. The supply and return air duct connecti[...]

882108-YIM-B-1012 14 Johnson Controls Unitary Products SERVICE ACCESS Access to all serviceable components is provided by the fol- lowing hinged doors: • Furnace compartment • Supply Air Fan compartment Evaporator Coil compart- ment (three doors) • Filter compartment economizer compartment (two doors) • Power Exhaust compartment (two doors)[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 15 POWER AND CONTROL WIRING Field wiring to the unit must conform to provisions of National Electrical Code (NEC) ANSI / NFP A 70-Latest Edition and / or local ordinances. The unit must be electrically grounded in accordance with the NEC and / or local codes. V oltage toler- ances which must be ma[...]

882108-YIM-B-1012 16 Johnson Controls Unitary Products GAS HEA TING GAS PIPING Proper sizing of gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas and the length of run. National Fuel Gas Code Z223.1-Latest Edition should be followed in all cases unless superseded by local codes or gas company requiremen[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 17 7. A 1/8 inch N.P .T . plugged tapping, accessible for test gage connection, must be installed immediately upstream of the gas supply connection to the furnace. VENT AND COMBUSTION AIR NOTE: All the hoods and hardware are shipped within the evaporator section. Each hood must be properly attache[...]

882108-YIM-B-1012 18 Johnson Controls Unitary Products ELECTRIC HEA T Units with electric heat are fully wired and operational when shipped. Constant volume units are designed for two equal steps of capacity for 80 and three for 108 kWH heat; 40 kW heat is one step only . Heat outputs on V A V units are all turned on together at full heat capacity [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 19 STEAM HEA T The YORK Millennium units (25, 30 and 40 T on sizes) can be furnished with a YORK single row steam coil. YORK steam coils are a factory installed option. NOTE: The steam control valve, power and control wiring to the actuator of the valve is the responsibility of the installing part[...]

882108-YIM-B-1012 20 Johnson Controls Unitary Products ST A TIC PRESSURE CONTROL PLASTIC TUBING On units with variable frequency drives (VFD’s) or inlet guide vanes (IGV's) on the supply blower and/or power exhaust fans, pressure sensing tubing must be field supplied and installed. All tubing must be installed from the transducers (located i[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 21 FIGURE 1 1 - BOTTOM SUPPLY AND RETURN 8 8.7 " C L C L 240" 38. 59" 83" 4.5" 4.5" 64" 92" 80. 93" SEE DET AIL A 26" 4.5" 15. 89" 71. 61" 127. 5" 72.25” OPEN 3.625" 6.46" 12" MI N SUPPL Y AIR RETURN AIR REAR RE[...]

882108-YIM-B-1012 22 Johnson Controls Unitary Products FIGURE 12 - END RETURN, BOTTOM SUPPLY RETURN AIR SUPPL Y AIR 1-1/2" FPT 2.31” 3-5/8" 6.45" 2-1/2" NOTE: F ACTORY INST ALLED POWER EXHAUST CANNOT BE ORDERED WITH END RETURN. DET AIL A (DRAIN CONNECTION) DET AIL B (ELECTRICAL CONNECTION) FOR COOLING ONL Y AND ALL HEA TING AP[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 23 FIGURE 13 - BOTTOM RETURN, FRONT & REAR SUPPLY 1-1/2" FPT 2.31” 3-5/8" 6.45" 2-1/2" DET AIL A (DRAIN CONNECTION) DET AIL B (ELECTRICAL CONNECTION) FOR COOLING ONL Y AND ALL HEA TING APPLICA TIONS BASE RAIL BASE RAIL 28” 2-1/2” DIA. HOLES TO GAS V AL VE MANIFOLD 7?[...]

882108-YIM-B-1012 24 Johnson Controls Unitary Products FIGURE 14 - END RETURN, FRONT & REAR SUPPLY FRONT SUPPL Y : FOR COOLING ONL Y APPLICA TIONS REAR SUPPL Y : FOR COOLING ONL Y OR GAS HEA T APPLICA TIONS RETURN AIR SUPPL Y AIR 2 4 0 " 64” 92” 8 0 . 9 3 " SEE DET AIL A 99.5” 131.5” SEE DET AIL C SEE DET AIL B 26" 55&quo[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 25 T ABLE 15: GENERAL PHYSICAL DA T A U NIT S IZE 25 TON 30 TON 40 TON U NIT EER / IPL V (S TANDARD C APACITY E VAPORATOR ) 10.5 / 12.3 10.1 1 / 1 1.0 10.5 / 1 1.2 C OMPRESSOR D ATA N UMBER /S IZE 4 x 5.7T on 4 x 7 T on 4 x 8.6 T on T YPE Scroll Scroll Scroll U NIT C APACITY S TEPS 25%, 50%, 75%, [...]

882108-YIM-B-1012 26 Johnson Controls Unitary Products T ABLE 16: REFRIGERANT F ACTOR Y CHARGE R-410A UNIT (T ONS ) MODEL C HARGE SYSTEM #1 SYSTEM #2 SYSTEM #3 SYSTEM #4 25 wo/HGBP 13lb 8oz 12lb 8oz 12lb 8oz 12lb 8oz 25 w/HGBP 14lb 12lb 8oz 12lb 8oz 12lb 8oz 30 wo/HGBP 16lb 16lb 8oz 14lb 18lb 4oz 30 w/HGBP 16lb 8oz 17lb 14lb 8oz 18lb 12oz 40 wo/HGB[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 27 T ABLE 18: ELECTRICAL DA T A 30 T ON BASIC UNIT R-410A V oltage Compressors (each) OD Fan Motors Supply Blower Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC Qty FLA HP FLA 208-3-60 4 25.0 164 39 4 5.8 10 30.8 162 175 15 46.2 181 225 25 74.8 217 250 20 59.4 197 250 230-3-[...]

882108-YIM-B-1012 28 Johnson Controls Unitary Products T ABLE 20: ELECTRICAL DA T A 25 T ON W/ELECTRIC HEA T R-410A V oltage Compressors (each) OD Fan Motors (each) Supply Blower Motor Electric Heat Option MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC FLA HP FLA Option KW Applied Stages Amps 208-3-60 4 22.4 149 35 4.5 7.5 24.2 E4 [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 29 T ABLE 21: ELECTRICAL DA T A 30 T ON W/ELECTRIC HEA T R-410A V oltage Compressors (each) OD Fan Motors (each) Supply Blower Motor Electric Heat Option MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC FLA HP FLA Option KW Applied Stages Amps 208-3-60 4 25.0 164 39 5.8 10 30.8 E4 4[...]

882108-YIM-B-1012 30 Johnson Controls Unitary Products T ABLE 22: ELECTRICAL DA T A 40 T ON W/ELECTRIC HEA T R-410A V oltage Compressors (each) OD Fan Motors (each) Supply Blower Motor Electric Heat Option MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC FLA HP FLA Option KW Applied Stages Amps 208-3-60 4 30.1 255 47 5.8 10 30.8 E4 4[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 31 T ABLE 23: ELECTRICAL DA T A 25 T ON W/POWER EXHAUST R-410A V oltage Compressors (each) OD Fan Motors (each) Supply Blower Motor Pwr Exh Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC FLA HP FLA HP FLA 208-3-60 4 22.4 149 35 4.5 7.5 24.2 5 16.7 155 175 7.5 24.2 162 175 10[...]

882108-YIM-B-1012 32 Johnson Controls Unitary Products T ABLE 24: ELECTRICAL DA T A 30 T ON W/POWER EXHAUST R-410A V oltage Compressors (each) OD Fan Motors (each) Supply Blower Motor Pwr Exh Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC Qty FLA HP FLA HP FLA 208-3-60 4 25.0 164 39 4 5.8 10 30.8 7.5 24.2 186 200 10 30.8 193 [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 33 T ABLE 25: ELECTRICAL DA T A 40 T ON W/POWER EXHAUST R-410A V oltage Compressors (each) OD Fan Motors (each) Supply Blower Motor Pwr Exh Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Qty RLA LRA MCC Qty FLA HP FLA HP FLA 208-3-60 4 30.1 225 47.0 4 5.8 10 30.8 7.5 24 206 225 10 31 213 22[...]

882108-YIM-B-1012 34 Johnson Controls Unitary Products T ABLE 26: ELECTRICAL DA T A 25 T ON W/ELECTRIC HEA T AND POWER EXHAUST R-410A V oltage Electric Heat Option Compressors (each) OD Fan Motors (each) Supply Blower Motor Pwr Exh Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Model KW Stages Amps Qty RLA LRA MCC Qty FLA HP FLA HP FLA 208-3[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 35 460-3-60 E4 40 1 46 4 10.6 75 16.5 4 2.15 7.5 1 1 5 7.6 79 80 7.5 1 1 82 90 10 14 86 90 10 14 5 7.6 83 90 7.5 1 1 86 90 10 14 89 90 15 21 5 7.6 92 100 7.5 1 1 95 100 10 14 98 1 10 20 27 5 7.6 99 1 10 7.5 1 1 102 1 10 10 14 105 125 E8 80 2 92 4 10.6 75 16.5 4 2.15 7.5 1 1 5 7.6 1 14 125 7.5 1 1 [...]

882108-YIM-B-1012 36 Johnson Controls Unitary Products 575-3-60 E4 40 1 40 4 7.7 54 12 4 1.7 7.5 9 5 6.1 68 70 7.5 9 71 70 10 1 1 73 80 10 1 1 5 6.1 70 70 7.5 9 73 80 10 1 1 75 80 15 17 5 6.1 78 80 7.5 9 81 90 10 1 1 83 90 20 22 5 6.1 84 90 7.5 9 87 90 10 1 1 89 100 E8 80 2 80 4 7.7 54 12 4 1.7 7.5 9 5 6.1 98 1 10 7.5 9 101 1 10 10 1 1 103 1 10 10 [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 37 T ABLE 27: ELECTRICAL DA T A 30 T ON W/ELECTRIC HEA T AND POWER EXHAUST R-410A V oltage Electric Heat Option Compressors (each) OD Fan Motors (each) Supply Blower Motor Pwr Exh Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Model KW Stages Amps Qty RLA LRA MCC Qty FLA HP FLA HP FLA 208-3[...]

882108-YIM-B-1012 38 Johnson Controls Unitary Products 460-3-60 E4 40 1 46 4 12.0 100 19 4 2.9 10 14 7.5 1 1 88 100 10 14 91 100 15 21 100 1 10 15 21 7.5 1 1 97 1 10 10 14 100 1 10 15 21 107 125 20 27 7.5 1 1 104 125 10 14 107 125 15 21 1 14 125 25 34 7.5 1 1 1 13 125 10 14 1 16 150 15 21 123 150 E8 80 2 92 4 12.0 100 19 4 2.9 10 14 7.5 1 1 121 125[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 39 575-3-60 E4 40 1 40 4 9.0 78 14 4 2.2 10 1 1 7.5 9 73 80 10 1 1 75 80 15 17 83 90 15 17 7.5 9 81 90 10 1 1 83 90 15 17 89 100 20 22 7.5 9 87 100 10 1 1 89 100 15 17 95 1 10 25 27 7.5 9 93 1 10 10 1 1 95 1 10 15 17 101 1 10 E8 80 2 80 4 9.0 78 14 4 2.2 10 1 1 7.5 9 103 1 10 10 1 1 105 1 10 15 17[...]

882108-YIM-B-1012 40 Johnson Controls Unitary Products T ABLE 28: ELECTRICAL DA T A 40 T ON W/ELECTRIC HEA T AND POWER EXHAUST R-410A V oltage Electric Heat Option Compressors (each) OD Fan Motors (each) Supply Blower Motor Pwr Exh Motor MCA 1 (Amps) Max Fuse 2 / Breaker 3 Size (Amps) Model KW Stages Amps Qty RLA LRA MCC Qty FLA HP FLA HP FLA 208-3[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 41 460-3-60 E4 40 1 46 4 16.7 1 14 26 4 2.9 10 14 7.5 1 1 108 1 10 10 14 1 1 1 125 15 21 1 19 125 15 21 7.5 1 1 1 16 125 10 14 1 19 125 15 21 126 150 20 27 7.5 1 1 123 150 10 14 126 150 15 21 133 150 25 34 7.5 1 1 132 150 10 14 135 150 15 21 142 175 E8 80 2 92 4 16.7 1 14 26 4 2.9 10 14 7.5 1 1 12[...]

882108-YIM-B-1012 42 Johnson Controls Unitary Products 575-3-60 E4 40 1 40 4 12.2 80 19 4 2.2 10 1 1 7.5 9 81 90 10 1 1 83 90 15 17 90 100 15 17 7.5 9 88 100 10 1 1 90 100 15 17 96 1 10 20 22 7.5 9 94 1 10 10 1 1 96 1 10 15 17 102 1 10 25 27 7.5 9 100 125 10 1 1 102 125 15 17 108 125 E8 80 2 80 4 12.2 80 19 4 2.2 10 1 1 7.5 9 103 1 10 10 1 1 105 1 [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 43 FIGURE 15 - FIELD INST ALLED DISCONNECT 31" MAXIMUM DRILL & BOLT THROUGH UNIT SHEET METAL (4 PLACES) 34" * 6-1/2" MINIMUM MAXIMUM DOOR SWING OF HEAT SECTION DOOR WHEN OPEN UNISTRUT 1-5/8" W x 7/8" H OR EQUIVALENT 47" *34 INCHES IS THE MINIMUM LENGTH REQUIRED TO[...]

882108-YIM-B-1012 44 Johnson Controls Unitary Products FIGURE 17 - P ARTIAL ROOF CURB MODEL 1RC0455P 8 3 . 0 0 8 7 . 0 0 3 8 . 5 9 9 5 . 0 9 2 6 . 0 0 2 3 5 . 0 0 4 . 0 0 2 . 0 0 1 4 . 0 0 7 1 . 6 1 1 1 . 3 9 S U P P L Y A I R O P E N I N G R E T U R N A I R O P E N I N G BASE R AI L ( Y O R K U N I T ) C U R B G A S K E T 2 " X 4 " N A I[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 45 CFM, STATIC PRESSURE, AND POWER - ALTI- TUDE AND T EMPERATURE CORRECTIONS The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level. The air flow rates listed in the standard blower performance tables are b[...]

882108-YIM-B-1012 46 Johnson Controls Unitary Products FIGURE 18 - AL TITUDE/TEMPERA TURE CONVERSION F ACTOR[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 47 4. Shaded RPMs require Class II blower . T ABLE 30: F AN PERFORMANCE - 25 TON 1, 2 AIRFLOW CFM A V AILABLE EXTERNAL ST A TIC PRESSURE (IWG) 0.2 0.4 0.6 0.8 1.0 RPM BHP 3 RPM BHP 3 RPM BHP 3 RPM BHP 3 RPM BHP 3 4000 302 0.5 365 0.7 422 1.0 475 1.3 523 1.5 5000 341 0.9 396 1.1 447 1.4 495 1.7 540[...]

882108-YIM-B-1012 48 Johnson Controls Unitary Products FIGURE 19 - F AN PERFORMANCE - 25 TON 0123456789 10 11 12 13 CFM (x1000) 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 Total Static Pressure (IWG) 1 1 0 0R P M 90 0 800 7 00 6 0 0 5 00 100 0 A 25 Ton Forward Curve 1 0 1 5 B H P 20 7.5 A - Standard Unit Note: Standard Unit [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 49 4. Shaded RPMs require Class II blower . T ABLE 31: F AN PERFORMANCE - 30 TON 1, 2 A IRFLOW (CFM) A VAILABLE E XTERNAL S TATIC P RESSURE (IWG) 0.2 0.4 0.6 0.8 1.0 RPM BHP 3 RPM BHP 3 RPM BHP 3 RPM BHP 3 RPM BHP 3 6000 405 1.3 450 1.6 494 2.0 535 2.3 575 2.7 7000 444 1.9 485 2.3 524 2.7 562 3.0 [...]

882108-YIM-B-1012 50 Johnson Controls Unitary Products FIGURE 20 - F AN PERFORMANCE - 30 TON FIGURE 23 - F AN PERFORMANCE - 30 TON 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CFM (x1000) 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 Total Static Pressure (IWG) 1 1 0 0 R P M 9 0 0 8 0 0 7 0 0 6 0 0 5 0 0 1 0 0 0 A 30 Ton Forward Curv 10[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 51 4. Shaded RPMs require Class II blower . T ABLE 32: F AN PERFORMANCE - 40 TON 1,2 A IRFLOW (CFM) A VAILABLE E XTERNAL S TATIC P RESSURE (IWG) 0.2 0.4 0.6 0.8 1.0 RPM BHP 3 RPM BHP 3 RPM BHP 3 RPM BHP 3 RPM BHP 3 8000 367 1.9 409 2.3 448 2.8 485 3.3 519 3.8 9000 396 2.5 433 3.0 469 3.5 504 4.0 5[...]

882108-YIM-B-1012 52 Johnson Controls Unitary Products FIGURE 21 - F AN PERFORMANCE - 40 TON 40 Ton Forward Curve A - Standard Unit Note: Standard Unit includes wet evaporator coil, clean 2" throwaway filters, sy stem and cabinet effects at standard air density and 0' elevation. 0 2 4 6 8 10 12 14 16 18 20 CFM (x1000) 0.0 0.5 1.0 1.5 2.0 [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 53 T ABLE 33: COMPONENT ST A TIC RESIST ANCE 1, 2 COMPONENT COIL LOSSES CFM 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 COIL LOSSES 25T 3 Row , 16 FPI, dry -0.14 -0.18 -0.24 -0.34 -0.45 - - - 3 Row , 16 FPI, wet Baseline Baseline Baseline Baseline Baseline - - - COIL LOSSES 30T 4 Row , 16[...]

882108-YIM-B-1012 54 Johnson Controls Unitary Products T ABLE 34: SUPPL Y F AN MOTOR AND DRIVE DA T A Model Blower RPM Range Motor Motor Pulley Blower Pulley Belts HP Frame Size Motor Efficiency (Std. Motor) Motor Efficiency (Ultra Hi Eff Opt) Pitch Dia (Inches) Bore (Inches) Pitch Dia (Inches) Bore (Inches) Designation Qty 25 T on 567 7.5 213T 88.[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 55 T ABLE 36: POWER EXHAUST - ONE FORW ARD CUR VED F AN 25 TON 1 AIRFLOW CFM A V AILABLE EXTERNAL ST A TIC PRESSURE (IWG) 0.2 0.4 0.6 0.8 1.0 RPM BHP 2 RPM BHP 2 RPM BHP 2 RPM BHP 2 RPM BHP 2 2000 --- --- --- --- 524 0.3 609 0.4 685 0.6 3000 --- --- 450 0.4 531 0.5 605 0.7 672 0.8 4000 442 0.7 496[...]

882108-YIM-B-1012 56 Johnson Controls Unitary Products FIGURE 22 - POWER EXHAUST - ONE FORW ARD CURVE F AN - 25 TONS[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 57 T ABLE 37: POWER EXHAUST - TWO FORW ARD CUR VED F ANS - 30 & 40 TON 1 A IRFLOW CFM A VAILABLE E XTERNAL S TATIC P RESSURE (IWG) 0.2 0.4 .06 0.8 1.0 RPM BHP 2 3 RPM BHP 2 3 RPM BHP 2 3 RPM BHP 2 3 RPM BHP 2 3 4000 363 0.32 468 0.53 560 0.74 641 0.95 716 1.16 5000 402 0.53 494 0.74 576 1.05 6[...]

882108-YIM-B-1012 58 Johnson Controls Unitary Products FIGURE 23 - POWER EXHAUST - TWO FORW ARD CURVED F ANS - 30 & 40 TONS[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 59 ST ART -UP COMPRESSOR ROT A TION Check for proper compressor rotation (See page 66 for symp- toms of reverse compressor operations). Millennium units are properly phased at the factory . If the blower , condenser fan, or compressor , rotate in the wrong direction at start-up, the electrical con[...]

882108-YIM-B-1012 60 Johnson Controls Unitary Products CHECKING AIR QUANTITY 1. Remove the dot plugs from the two 5/16 inch holes in the blower motor and the filter access doors. 2. Insert at least 8 inch of 1/4 inch metal tubing into each of these holes for sufficient penetration into the air flow on both sides of the indoor coil. 3. Using an incl[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 61 SUPPL Y AIR DRIVE ADJUSTMENT At unit start-up the measured CFM based on Figures 52 and 53 may be higher or lower than the specified CFM. T o achieve the specified CFM, the speed of the drive may have to be decreased or increased by changing the pitch diameter (PD) of the motor sheave as outline[...]

882108-YIM-B-1012 62 Johnson Controls Unitary Products T ABLE 40: 25 TON DRIVE ADJUSTMENT 7.5 HP M OTOR & 567 RPM D RIVE 10 HP M OTOR & 692 RPM D RIVE 15 HP M OTOR & 793 RPM D RIVE 20 HP M OTOR & 894 RPM D RIVE %RPM & CFM R EQ ’ D PD B ROWNING 2 B 5 V _ _ %RPM & CFM R EQ ’ D PD B ROWNING 2 B 5 V _ _ %RPM & CFM R EQ ?[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 63 T ABLE 42: 40 TON DRIVE ADJUSTMENT 10 HP M OTOR & 617 RPM D RIVE 15 HP M OTOR & 652 RPM D RIVE 20 HP M OTOR & 728 RPM D RIVE 25 HP M OTOR & 780 RPM D RIVE %RPM & CFM R EQ ’ D PD B ROWNING 2B5V_ _ % RPM & CFM R EQ ’ D PD B ROWNING 2B5V_ _ %RPM & CFM R EQ ’ D PD [...]

882108-YIM-B-1012 64 Johnson Controls Unitary Products GAS FURNACE OPERA TING INSTRUCTIONS TO LIGHT THE MAIN BURNERS 1. T urn off electric power to unit. 2. T urn space temperature sensor to lowest setting. 3. T urn gas valve knobs to on position (Refer to Figure 25). 4. T urn on electric power to unit. 5. On Constant V olume units, set space setpo[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 65 BURNER INSTRUCTIONS T o check or change burners, pilot or orifices, CLOSE MAIN MANUAL SHUT -OFF V AL VE AND SHUT OFF ALL POWER TO THE UNIT . 1. Remove the screws holding either end of the manifold to the burner supports. 2. Open the union fitting in the gas supply line just upstream of the unit[...]

882108-YIM-B-1012 66 Johnson Controls Unitary Products Example: By actual measurement, it takes 7 seconds for the hand on the one cubic foot dial to make a revolution with just a 570,000 Btuh furnace running. Read across to the column in T able 24, headed 1 Cubic Foot where you will determine that 525 cubic feet of gas per hour are consumed by the [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 67 T ABLE 46: STEAM COIL (1 ROW , 25 & 30 TON) 1 CFM Capacity (MBH) at Steam Pressure (PSI) 2 6 10 15 6000 194.1 207.9 219.8 232.6 8000 221.1 236.9 250.4 265.0 10000 243.2 260.5 275.4 291.4 12000 261.9 280.6 296.6 313.9 15000 285.6 306.0 323.5 342.4 1. Based on 60°F entering air temperature, [...]

882108-YIM-B-1012 68 Johnson Controls Unitary Products T ABLE 51: HOT W A TER COIL (1 ROW , 40 TON) 1 1. Based on 60°F entering air temperature, 2.00” maximum pressure drop across the hot water coil. GPM CFM Capacity (MBH) at Entering W ater T emperature 140 °F 160 °F 180 °F 200 °F 10 8000 102 128.8 155.8 182.9 1 1000 1 14 144.1 174.4 205.1 [...]

882108-YIM-B-1012 Johnson Controls Unitary Products 69 NOTE: W ater pressure drop numbers are based on 60°F entering air temperature, 2.00” maximum air pres- sure drop across the hot water coil(s). AHRI certi- fied ratings at covering other conditions are available upon request. Hot water coils are approved for use with glycol (rates available u[...]

882108-YIM-B-1012 70 Johnson Controls Unitary Products FIGURE 27 - HOT W A TER COIL - 25 & 30 TON, 1 ROW , A T 10 GPM FIGURE 28 - HOT W A TER COIL - 25 & 30 TON, 1 ROW , A T 20 GPM[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 71 FIGURE 29 - HOT W A TER COIL - 25 & 30 TON, 1 ROW , A T 30 GPM FIGURE 30 - HOT W A TER COIL - 25 & 30 TON, 1 ROW , A T 40 GPM[...]

882108-YIM-B-1012 72 Johnson Controls Unitary Products FIGURE 31 - HOT W A TER COIL - 25 & 30 TON, 2 ROW , A T 60 GPM FIGURE 32 - HOT W A TER COIL - 25 & 30 TON, 2 ROW , A T 80 GPM[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 73 FIGURE 33 - HOT W A TER COIL - 40 TON, 1 ROW , A T 10 GPM FIGURE 34 - HOT W A TER COIL - 40 TON, 1 ROW , A T 20 GPM[...]

882108-YIM-B-1012 74 Johnson Controls Unitary Products FIGURE 35 - HOT W A TER COIL - 40 TON, 1 ROW , A T 30 GPM FIGURE 36 - HOT W A TER COIL - 40 TON, 1 ROW , A T 40 GPM[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 75 FIGURE 37 - HOT W A TER COIL - 40 TON, 2 ROW , A T 20 GPM FIGURE 38 - HOT W A TER COIL - 40 TON, 2 ROW , A T 40 GPM[...]

882108-YIM-B-1012 76 Johnson Controls Unitary Products FIGURE 39 - HOT W A TER COIL - 40 TON, 2 ROW , A T 60 GPM FIGURE 40 - HOT W A TER COIL - 40 TON, 2 ROW , A T 80 GPM[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 77 FIGURE 41 - STEAM COIL - 25 & 30 TON (1 ROW) FIGURE 42 - STEAM COIL - 40 TON (1 ROW)[...]

882108-YIM-B-1012 78 Johnson Controls Unitary Products FIGURE 43 - TYPICAL CONTROL WIRING[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 79 FIGURE 44 - LEGEND[...]

882108-YIM-B-1012 80 Johnson Controls Unitary Products FIGURE 45 - TYPICAL 25 T ON POWER WIRING[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 81 FIGURE 46 - TYPICAL STANDARD GAS HEAT WIRING[...]

882108-YIM-B-1012 82 Johnson Controls Unitary Products FIGURE 47 - TYPICAL MODULATING GAS HEAT WIRING[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 83 GAS FURNACE SAFETY FEA TURES COMBUSTION AIR PROVING Combustion air proving is provided by a pressure switch. As the motor approaches full speed, this switch closes before any other circuit or gas component can be energized. ROLLOUT Rollout protection is provided by a switch mounted on the heat [...]

882108-YIM-B-1012 84 Johnson Controls Unitary Products On an annual basis, check the motor for accumulations of dust, etc. That may block the cooling slots in the motor shell. Check for loose, damaged or misaligned drive components. Check that all mounting bolts are tight. Replace defective parts as required. If desired, every three years remove bo[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 85 10. Assure that all seams on the vent side of the combustion systems are air tight. Apply a high temperature (+500°F) sealing compound where needed (Dow Corning, Silastic 736, Loctite Superflex 596 or equivalent). The restrictor plate must also be sealed to furnace tube sheet. SECURE OWNERS AP[...]

882108-YIM-B-1012 86 Johnson Controls Unitary Products FIGURE 49 - 25 TON CHARGING CURVE 25 TON CHARGING CURVE 200 250 300 350 400 450 500 550 75 100 125 150 175 SUCTION PRESSURE (PSIG) DISCHARGE PRESSURE (PSIG) 65 F 75 F 85 F 95 F 105 F[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 87 FIGURE 50 - 30 TON CHARGING CURVE 30 TON CHARGING CURVE 200 250 300 350 400 450 500 550 75 100 125 150 175 SUCTION PRESSURE (PSIG) DISCHARGE PRESSURE (PSIG) 105 F 95 F 85 F 75 F 65 F[...]

882108-YIM-B-1012 88 Johnson Controls Unitary Products FIGURE 51 - 40 TON CHARGING CURVE 40 TON CHARGING CURVE 200 250 300 350 400 450 500 550 75 100 125 150 175 SUCTION PRESSURE (PSIG) DISCHARGE PRESSURE (PSIG) 105 F 95 F 85 F 75 F 65 F[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 89 FIGURE 52 - PRESSURE DROP DRY EV APORA TOR COIL VS SUPPL Y AIR CFM - 25 T ON PRESSURE DROP ACROSS A DRY EVAPORATOR COIL 25T 0 0.1 0.2 0.3 0.4 0.5 0.6 0123456789 1 0 1 1 1 2 1 3 NOMINAL CFM (THOUSANDS) PRESSURE DROP (in. wg.)[...]

882108-YIM-B-1012 90 Johnson Controls Unitary Products FIGURE 53 - PRESSURE DROP DRY EV APORA TOR COIL VS SUPPL Y AIR CFM - 30 T ON PRESSURE DROP ACROSS A DRY EVAPORATOR COIL - 30T 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NOMINAL CFM (THOUSANDS) PRESSURE DROP (in. wg.)[...]

882108-YIM-B-1012 Johnson Controls Unitary Products 91 FIGURE 54 - PRESSURE DROP DRY EV APORA TOR COIL VS SUPPL Y AIR CFM - 40 T ON L I O C R O T A R O P A V E Y R D A S S O R C A P O R D E R U S S E R P T 0 4 0 1 . 0 2 . 0 3 . 0 4 . 0 5 . 0 6 . 0 7 . 0 8 . 0 9 . 0 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0 1 9 8 7 6 5 4 3 2 1 0 ) S D N A S U O H T ( M F C [...]

Subject to change without notice. Printed in U.S.A. 882108-YIM-B-1012 Copyright © 2012 by Johnson Controls, Inc. All rights reserved. Supersedes: 882108-YIM-A-0712 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069 FIGURE 55 - R-410A QUICK REFERENCE GUIDE R-410A QUICK REFERENCE GUIDE Refer to Installation Instruction s for specific[...]