Millennium Enterprises Z33, Z34, Z42 R-410A QUICK REFERENCE GUIDE

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 Instructions for specific installation requirements.

R-410A Refrigerant operates at 50 - 70 percent higher pressures than R-22. Be sure that servicing

equipment and replacement components are designed to operate with R-410A.

R-410A Refrigerant cylinders are rose colored.

Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400, or DOT BW400.

Recovery equipment must be rated for R-410A.

Do Not use R-410A service equipment on R-22 systems. All hoses, gages, recovery cylinders, charging

cylinders and recovery equipment must be dedicated for use on R-410A systems only.

Manifold sets must be at least 700 psig high side, and 180 psig low side, with 550 psig retard.

All hoses must have a service pressure rating of 800 psig.

Leak detectors must be designed to detect HFC refrigerants.

Systems must be charged with liquid refrigerant. Use a commercial type metering device in the

manifold hose.

R-410A can only be used with POE type oils.

POE type oils rapidly absorb moisture from the atmosphere.

Vacuum pumps will not remove moisture from POE type oils.

Do not use liquid line driers with a rated working pressure rating less than 600 psig.

Do not install suction line driers in the liquid line.

A liquid line drier is required on every unit.

Do not use a R-22 TXV. If a TXV is to be used, it must be a R-410A TXV.

Never open system to atmosphere when under a vacuum.

If system must be opened for service, evacuate system then break the vacuum with dry nitrogen and

replace all filter driers.

Contents

Main INSTALLATION MANUAL MILLENNIUM ROOFTOP 25, 30 & 40 TON 882108-YIM-B-1012 MODELS: Z42 Z33 Z34 TABLE OF CONTENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GAS HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 GAS FURNACE OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 LIST OF FIGURES LIST OF TABLES NOMENCLATURE 123 4 CONTROL BASIC UNIT Z 3 Page GENERAL SAFETY CONSIDERATIONS NOTES, CAUTIONS AND WARNINGS GAS FIRED MODELS ALL MODELS INSTALLATION PRECEDING INSTALLATION LIMITATIONS LOCATION TABLE 1: COOLING & ELECTRICAL APPLICATION TABLE 3: STANDARD GAS HEATING CAPACITIES TABLE 4: TEMPERATURE RISE TABLE 5: MINIMUM HEATING CFM TABLE 6: MODULATING GAS HEATING CAPACITIES 882108-YIM-B-1012 FIGURE 2 - TYPICAL RIGGING TABLE 7: MODULATING HEAT TABLE 8: UNIT WEIGHTS TABLE 9: SUPPLY FAN MOTOR VFD WEIGHTS TABLE 10: EXHAUST FAN MOTOR VFD WEIGHTS FIGURE 3 - CENTER OF GRAVITY RIGGING AND HANDLING TABLE 11: UNIT CORNERWEIGHT TABLE 12: UNIT CENTER OF GRAVITY DUCTWORK AIR HOODS FOR FIXED OUTSIDE AIR (UNITS WITH MANUAL ECONOMIZER) AIR HOODS FOR ECONOMIZER AIR HOODS FOR EXHAUST AIR CONDENSATE DRAIN SERVICE ACCESS COMPRESSORS FILTERS THERMOSTAT (CONSTANT VOLUME UNITS) SPACE SENSOR (VARIABLE AIR VOLUME UNITS) POWER AND CONTROL WIRING GAS HEATING GAS PIPING GAS CONNECTION TABLE 14: PIPE SIZES FIGURE 6 - TYPICAL GAS PIPING CONNECTION VENT AND COMBUSTION AIR FIGURE 7 - VENT AND COMBUSTION AIR HOODS FIGURE 8 - CLEARANCES ELECTRIC HEAT HOT WATER HEAT STEAM HEAT FIGURE 9 - HOT WATER PIPING CROSS-SEC- TION FIGURE 10 - STEAM PIPING CROSS-SECTION STATIC PRESSURE CONTROL PLASTIC TUBING EXHAUST STATIC PRESSURE 882108-YIM-B-1012 SUPPLY AIR C REAR FRONT LEFT RIGHT END FRONT REAR RIGHT END LEFT END FRONT FRONT RIGHT END LEFT END REAR FIGURE 13 - BOTTOM RETURN, FRONT & REAR SUPPLY LEFT END RIGHT END RIGHT END FIGURE 14 - END RETURN, FRONT & REAR SUPPLY OPEN B C TABLE 15: GENERAL PHYSICAL DATA TABLE 16: REFRIGERANT FACTORY CHARGE R-410A TABLE 17: ELECTRICAL DATA 25 TON BASIC UNIT R-410A TABLE 18: ELECTRICAL DATA 30 TON BASIC UNIT R-410A TABLE 19: ELECTRICAL DATA 40 TON BASIC UNIT R-410A TABLE 20: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT R-410A TABLE 21: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT R-410A TABLE 22: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT R-410A TABLE 23: ELECTRICAL DATA 25 TON W/POWER EXHAUST R-410A TABLE 24: ELECTRICAL DATA 30 TON W/POWER EXHAUST R-410A TABLE 25: ELECTRICAL DATA 40 TON W/POWER EXHAUST R-410A TABLE 26: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A Page TABLE 26: ELECTRICAL DATA 25 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED) TABLE 27: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A Page TABLE 27: ELECTRICAL DATA 30 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED) TABLE 28: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A Page TABLE 28: ELECTRICAL DATA 40 TON W/ELECTRIC HEAT AND POWER EXHAUST R-410A (CONTINUED) FIGURE 15 - FIELD INSTALLED DISCONNECT * FIGURE 16 - 40 TON CONDENSER DETAIL FIGURE 17 - PARTIAL ROOF CURB MODEL 1RC0455P A B CFM, STATIC PRESSURE, AND POWER - ALTI- TUDE AND TEMPERATURE CORRECTIONS TABLE 29: ALTITUDE CORRECTION FACTORS Page TABLE 30: FAN PERFORMANCE - 25 TON 1, 25 Ton Forward Curve TABLE 31: FAN PERFORMANCE - 30 TON 1, 2 30 Ton Forward Curv TABLE 32: FAN PERFORMANCE - 40 TON1,2 40 Ton Forward Curve TABLE 33: COMPONENT STATIC RESIST ANCE TABLE 34: SUPPLY FAN MOTOR AND DRIVE DATA TABLE 35: EXHAUST FAN DRIVE DATA TABLE 36: POWER EXHAUST - ONE FORWARD CURVED FAN 25 TON Page TABLE 37: POWER EXHAUST - TWO FORWARD CURVED FANS - 30 & 40 TON Page START-UP COMPRESSOR ROTATION FIGURE 24 - BELT TENSION ADJUSTMENT SUPPLY AIR FAN INSTRUCTIONS TABLE 38: BELT ADJUSTMENT SYSTEM SETPOINTS TABLE 39: BLOWER SPEED RATE OF CHANGE TABLE 40: 25 TON DRIVE ADJUSTMENT TABLE 41: 30 TON DRIVE ADJUSTMENT TABLE 42: 40 TON DRIVE ADJUSTMENT TABLE 43: DRIVE ADJUSTMENT FOR POWER EXHAUST - 25 TON GAS FURNACE OPERATING INSTRUCTIONS TO LIGHT THE MAIN BURNERS TO SHUT DOWN POST-START CHECKLIST (GAS) MANIFOLD GAS PRESSURE ADJUSTMENT C --------------------------------------------------------------------------= FM Btuh 0.8 1.08 F Degrees Temp Rise ELECTRIC HEATING COOLING OPERATING INSTRUCTIONS SERVICE FIGURE 26 - TYPICAL FLAME APPEARANCE REFRIGERATION SYSTEM COMPRESSORS MOTORS TABLE 46: STEAM COIL (1 ROW, 25 & 30 TON) TABLE 47: STEAM COIL (1 ROW, 40 TON) TABLE 48: STATIC RESIST ANCE STEAM COIL (25 & 30 TON) TABLE 49: STATIC RESISTANCE STEAM COIL (40 TON) TABLE 50: HOT WATER COIL (1 ROW 25 & 30 TON) TABLE 51: HOT WATER COIL (1 ROW , 40 TON) TABLE 52: WATER PRESSURE DROP (1 ROW , 25 & 30 TON) TABLE 53: WATER PRESSURE DROP (1 ROW, 40 TONS) TABLE 54: HOT WATER COIL (2 ROW, 25 & 30 TON) Page Page Page Page Page Page Page Page Page Page Page Page Page Page GAS FURNACE SAFETY FEATURES MAINTENANCE NORMAL MAINTENANCE GAS BURNER TABLE 59: INDOOR BLOWER BEARING LUBRICATION SCHEDULE SECURE OWNERS APPROVAL NOTE: FIGURE 48 - TYPICAL FLUE BAFFLE 25 TON CHARGING CURVE DISCHARGE PRESSURE (PSIG) 30 TON CHARGING CURVE 40 TON CHARGING CURVE DISCHARGE PRESSURE (PSIG) PRESSURE DROP ACROSS A DRY EVAPORATOR COIL 25T PRESSURE DROP ACROSS A DRY EVAPORATOR COIL - 30T LIOC ROTAROPAVE YRD A SSORCA PORD ERUSSERP T04 PRESSURE DROP (in. wg.) FIGURE 55 - R-410A QUICK REFERENCE GUIDE R-410A QUICK REFERENCE GUIDE Refer to Installation Instructions for specific installation requirements.