York ZW Series Installation Manual
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York ZW Series Installation Manual

York ZW Series Installation Manual

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R-410A
ZW SERIES W/SMART EQUIPMENT™
3 - 5 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 29
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 29
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1 ZW-A3 thru -A5 Unit Limitations . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZW-A3 thru -A5 Unit Accessory Weights . . . . . . . . . . . . . 8
5 ZW-A3 thru -A5 Unit Clearances . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 25
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 26
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 27
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Component Location (ZW-A3 Shown) . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZW-A3 thru -A4 Physical Dimensions . . . . . . . . . . . . . . . 9
9 ZW-A5 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . 10
11 ZW-A3 thru -A5 Unit Electrical Entry . . . . . . . . . . . . . . . 13
14 ZW-A3 thru -A5 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZW-A3 thru -A5 Transition Roof Curb . . . . . . . . . . . . . . 15
16 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 15

TABLE OF CONTENTS

Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 44
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 44
Electric Heating Sequence Of Operations . . . . . . . . . . . . 45
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 46
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 47
Ignition Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 47
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control Board Navigation Components . . . . . . . . . . . . . . . . . 51
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LIST OF TABLES
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . 40
21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 40
22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 42
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 43
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 46
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 46
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 48
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 50
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . 52
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . 58
LIST OF FIGURES
17 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 16
18 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19
23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 26
24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 26
25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 31
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
29 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
30 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . 51
31 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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Summary of Contents for York ZW Series

  • Page 1: Table Of Contents

    R-410A ZW SERIES W/SMART EQUIPMENT™ 3 - 5 Ton 60 Hertz TABLE OF CONTENTS General ......... . 2 Free Cooling Operation.

  • Page 2: General

    5803640-BIM-B-0620 General Ducted Systems ZW units are single package air conditioners with optional gas heating designed for outdoor installation on a Before performing service or maintenance operations on rooftop or slab and for non-residential use. These units can be unit, turn off main power switch to unit. Electrical shock equipped with factory or field installed electric heaters for could cause personal injury.
  • Page 3 5803640-BIM-B-0620 Inspection Renewal Parts As soon as a unit is received, it should be inspected for possible Contact your local Ducted Systems parts distribution center for damage during transit. If damage is evident, the extent of the authorized replacement parts. damage should be noted on the carrier’s freight bill.
  • Page 4 5803640-BIM-B-0620 Nomenclature 3-5 Ton ZW Model Number Nomenclature -A3 C A 2 A 1 Product Generation Product Category 2 = Second Generation 3 = Third Generation Z = A/C, Single Pkg., R-410A Cabinet Options Product Identifier A = Std Cabinet W = Pkg AC R410A High Eff E = SSD (SST Drain Pan) R = Reverse Drain Pan...

  • Page 5: Installation

    5803640-BIM-B-0620 Installation Remove the condenser coil external protective covering prior to operation. Installation Safety Information Remove the toolless doorknobs and instruction packet prior to installation. Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit.

  • Page 6: Limitations

    Roof curbs for transitioning (stainless steel option) from DHB/DUC/DHC/DUS footprint to the ZW Series footprint Two-stage gas heating to are available Side entry power maintain warm, comfortable (field-installed accessory) and control wiring...

  • Page 7: Location

    5803640-BIM-B-0620 Table 1: ZW-A3 thru -A5 Unit Limitations Unit Limitations Size Model Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-3-60 460-3-60 (3.50) 575-3-60 208/230-3-60 460-3-60 (4.0) 575-3-60 208/230-3-60 460-3-60 (5.0) 575-3-60 Location Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2, 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) - Use the following guidelines to select a suitable location for Latest Edition, and/or applicable provisions of the local building...

  • Page 8: Weights And Dimensions

    5803640-BIM-B-0620 All panels must be secured in place when the unit is lifted. The condenser coils should be protected from rigging cable damage with plywood or other suitable material. FRONT LEFT Figure 6: Unit 6 Point Load Weight FRONT LEFT FRONT LEFT Figure 5: Unit 4 Point Load Weight...

  • Page 9: Zw-A3 Thru -A4 Physical Dimensions

    5803640-BIM-B-0620 29.75 15.51 29.52 59.00 Ø 25.31 See detail A for gas inlet 11 3/8 See detail B for drain location LEFT 4 3/16 FRONT 21 3/16 27 5/16 Figure 8: ZW-A3 thru -A4 Physical Dimensions Johnson Controls Ducted Systems...

  • Page 10: Zw-A5 Physical Dimensions

    5803640-BIM-B-0620 29.69 15.25 15.38 59.00 15.38 2X Ø 24.38 SEE DETAIL A FOR GAS INLET 11.38 SEE DETAIL B 59.00 4.19 FOR DRAIN LOCATION LEFT 27.31 21.19 89.00 FRONT Figure 9: ZW-A5 Physical Dimensions Johnson Controls Ducted Systems...

  • Page 11: Zw-A3 Thru -A5 Unit Physical Dimensions

    5803640-BIM-B-0620 Table 4: ZW-A3 thru -A5 Unit Physical Dimensions Dimension (in.) Unit Model Number ZW-A3 22 1/8 18 3/16 15 3/16 6 3/16 ZW-A4 22 1/8 18 3/16 15 3/16 6 3/16 ZW-A5 22 1/8 18 3/16 15 3/16 6 3/16 Detail A Detail B 3.184...

  • Page 12: Zw-A3 Thru -A5 Unit Bottom Duct Openings

    5803640-BIM-B-0620 32 11/16 6 13/16 6 13/16 RETURN SUPPLY 27 1/2 LEFT RIGHT 20 1/8 19 1/8 17 1/8 12 5/16 Bottom condensate drain 14 1/2 25 9/16 Bottom gas supply entry 16 3/8 18 1/16 FRONT TOP VIEW Bottom power, control and convenience outlet wiring entry 3X Ø...

  • Page 13: Side Duct Dimensions

    5803640-BIM-B-0620 Disconnect Swith Cover Power Entry Ø 2-1/2 Control Entry Ø 7/8 Power Entry Ø 2-1/2 Convenience Outlet Cover Convenience Outlet Power Entry Ø 7/8 FRONT Figure 11: ZW-A3 thru -A5 Unit Electrical Entry 1 8 - 1 /4 D o t P l u g s Return Supply Air 2 - 3 1 /3 2...

  • Page 14: Left/End Duct Dimensions

    5803640-BIM-B-0620 4-5/16 Figure 13: ZW-A3 thru -A5 Unit Left/End Duct Opening Table 7: Left/End Duct Dimensions Dimension (in.) Unit Model Number ZW-A3 30.357 13.365 22.516 ZW-A4 30.357 13.365 22.516 ZW-A5 30.357 13.365 22.516 RIGHT 80-5/8 INSULATED DECK UNDER CONDENSER SECTION SUPPLY RETURN 2 TYP.

  • Page 15: Ductwork

    5803640-BIM-B-0620 2 TYP 23 4 30-1/2 50-1/2 80-5/8 RETURN SUPPLY 76-5/8 59-1/4 FRONT RIGHT 64-1/4 Figure 15: ZW-A3 thru -A5 Transition Roof Curb Ductwork painted surface DOWN, facing the down flow duct opening. The supply panel is secured with the bracket (already in place from Ductwork should be designed and sized according to the the factory) and two screws.

  • Page 16: Side Panels

    5803640-BIM-B-0620 Condensate Drain The side condensate drain is reversible and maybe re-oriented to the rear of the cabinet to facilitate condensate piping. A condensate drain connection is available through the base pan for piping inside the roof curb. Trap the connection per Figure 20. The trap and drain lines should be protected from freezing.

  • Page 17: Filters

    5803640-BIM-B-0620 Exposure, even if immediately cleaned up, may cause 208/230-3-60 and 380/415-3-50 units control embrittlement (leading to cracking) to occur in one year transformers are factory wired for 230v and 415v power or more. When performing any service that may risk supply respectively.

  • Page 18: Field Wiring Disconnect

    5803640-BIM-B-0620 Power Wiring Detail Units are factory wired for the voltage shown on the unit Power wiring is brought into the unit through the side of the unit nameplate. Refer to Electrical Data Table 9 to size power or the basepan inside the curb. wiring, fuses, and disconnect switch.

  • Page 19: Control Wire Sizes

    5803640-BIM-B-0620 Thermostat Wiring unit. Refer to Table 8 for control wire sizing and maximum length. The thermostat should be located on an inside wall approximately 56 inch above the floor where it will not be Table 8: Control Wire Sizes subject to drafts, sun exposure or heat from electrical fixtures or Wire Size Maximum Length...

  • Page 20: Electrical Data

    5803640-BIM-B-0620 Table 9: Electrical Data ZW-A3 thru -A5 Standard Indoor Blower - Without Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ (Tons) (Amps)
  • Page 21 5803640-BIM-B-0620 ZW-A3 thru -A5 Hi Static Indoor Blower - Without Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ (Tons) (Amps) Size Pwr Exh...
  • Page 22 5803640-BIM-B-0620 ZW-A3 thru -A5 Standard Indoor Blower - With Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ (Tons) (Amps) Size Pwr Exh RLA LRA...
  • Page 23 5803640-BIM-B-0620 ZW-A3 thru -A5 Hi Static Blower - With Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ (Tons) (Amps) Size Pwr Exh RLA LRA...

  • Page 24: Physical Data

    5803640-BIM-B-0620 Table 10: Physical Data ZW-A3 thru -A5 Two Stage Gas Heat Physical Data Models Component ZW-A3 ZW-A4 ZW-A5 Nominal Tonnage AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (MBh) 36000 48500 59000 AHRI net capacity (MBh) 35000 47000 57000 12.2 12.2...

  • Page 25: Optional Electric Heat

    5803640-BIM-B-0620 ZW-A3 thru -A5 Two Stage Gas Heat Physical Data (Continued) Models Component ZW-A3 ZW-A4 ZW-A5 Nominal Tonnage CONDENSER FAN DATA Quantity of fans Fan diameter (Inch) Type Prop Prop Prop Drive type Direct Direct Direct Quantity of motors Motor HP each No.

  • Page 26: Optional Gas Heat

    5803640-BIM-B-0620 Optional Gas Heat These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition. OPTIONAL Gas Piping COIL GUARD Proper sizing of gas piping depends on the cubic feet per hour SHOWN of gas flow required, specific gravity of the gas and the length of run.

  • Page 27: Gas Heat Minimum Supply Air

    5803640-BIM-B-0620 Table 13: Gas Heat Minimum Supply Air Supply Air (CFM) Size Model Heat Size Heating (Tons) 2220 2370 1130 1800 2220 2370 1290 2250 2370 1380 2570 1580 2630 Gas Connection The gas supply line can be routed within the space and roof curb, exiting through the unit’s basepan.

  • Page 28: Options/Accessories

    5803640-BIM-B-0620 For satisfactory operation, LP gas pressure must be 10.5 inch electric heaters are fused and intended for use with single point W.C. at the unit under full load. Maintaining proper gas power supply. pressure depends on three main factors: Smoke Detectors The vaporization rate which depends on the temperature of the liquid and the “wetted surface”...

  • Page 29: Economizer Sequences

    5803640-BIM-B-0620 the assembly. Field installed Motorized Outdoor Damper Free Cooling accessories include complete instructions for installation. Four types of free cooling options are available: dry bulb changeover, single enthalpy, dual enthalpy changeover, and Economizer Auto. The Economizer can be a factory installed option or a field installed accessory.

  • Page 30: Power Exhaust

    5803640-BIM-B-0620 In free cooling, with a thermostat input to Y1, the dampers If at any time the economizer output goes above the minimum modulate to control the supply air temperature to the position the timer stops and resets when the economizer output Economizer Setpoint +/- 1°F (default 55°F).

  • Page 31: Smart Equipment™ Economizer Board Details

    5803640-BIM-B-0620 Figure 25: SE-ECO1001-0 Economizer Controller Table 14: Smart Equipment™ Economizer Board Details Board Cover Description Function & Comments Label Label Directional orientation: viewed with the center text of the cover label upright ANALOG INPUTS Terminal at left on upper edge of economizer board 24 VAC common/0-10 VDC negative for Connects through circuit trace to 24V~ IN pin COM economizer actuator position feedback...
  • Page 32 5803640-BIM-B-0620 Table 14: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label EconCtrlr parameter reports UCB-to-economizer board SA BUS communication status. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts lower –...
  • Page 33 5803640-BIM-B-0620 Table 14: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC hot connection to power the economizer board. 24 VAC transformer HOT Connects through circuit traces to R/24V~ terminals and pins distributed on the economizer board. ANALOG INPUTS Terminal on lower edge of economizer board 24 VAC hot supplied for the outdoor air 24V~...

  • Page 34: Supply Air Limitations

    5803640-BIM-B-0620 Table 14: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC common/0-5 VDC negative for the Connects through circuit trace to 24V~ IN pin COM building pressure sensor BINARY INPUTS at right on lower edge of economizer board Purge parameter reports input status (False with 0 VAC input- True with 24 VAC input).

  • Page 35: Altitude/Temperature Correction Factors

    5803640-BIM-B-0620 Belt Tension The tension on the belt should be adjusted as shown in Figure 26. Procedure for adjusting belt tension: 1. Loosen six nuts (top and bottom) A. 2. Adjust by turning (B). 3. Never loosen nuts (C). 4. Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown.

  • Page 36: Altitude/Temperature Correction Factors

    5803640-BIM-B-0620 1.100 1.050 1.000 Sea Level 0.950 1000 ft 0.900 2000 ft 3000 ft 0.850 4000 ft 0.800 5000 ft 6000 ft 0.750 7000 ft 8000 ft 0.700 9000 ft 10000 ft 0.650 0.600 Air Temperature (ºF) Figure 27: Altitude/Temperature Correction Factors The examples below will assist in determining the airflow blower tables to select the blower speed and the BHP performance of the product at altitude.
  • Page 37 5803640-BIM-B-0620 Drive Selection Determine side or bottom supply duct Application. Determine desired airflow. Calculate or measure the amount of external static pressure. Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table.

  • Page 38: Airflow Performance

    5803640-BIM-B-0620 Airflow Performance Table 17: Airflow Performance - Side Duct Application ZW-A3 (3.0 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 1.5 HP &...

  • Page 39: Airflow Performance - Bottom Duct Application

    5803640-BIM-B-0620 Table 18: Airflow Performance - Bottom Duct Application ZW-A3 (3.0 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 1.5 HP &...

  • Page 40: Air Balance

    5803640-BIM-B-0620 Table 19: RPM Selection Size Motor Blower 6 Turns 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Open Closed 1VP34 AK69 1VL44 AK69 1008 1062 1VP34 AK56 1VL44 AK56 1062...

  • Page 41: Dry Coil Delta P

    5803640-BIM-B-0620 Select the correct blower performance table for the unit from Tables 17 and 18. Tables are presented for side and down flow configuration. Determine the unit Measured CFM from the Blower Failure to properly adjust the total system air quantity Performance Table, External Static Pressure and the can result in extensive blower damage.

  • Page 42: Motor Sheave Datum Diameters

    5803640-BIM-B-0620 Supply Air Drive Adjustment EXAMPLE A 4 ton unit was selected to deliver 1,700 CFM with a 1.5 HP motor, but the unit is delivering 1,400 CFM. The variable pitch motor sheave is set at 3 turns open. Before making any blower speed changes review the Use the equation to determine the required DD for the new installation for any installation errors, leaks or undesirable motor sheave,...

  • Page 43: Additional Static Resistance

    5803640-BIM-B-0620 Table 23: Additional Static Resistance Electric Heat kW Size Model CFM Cooling Only Economizer 4” Pleated Filter (Tons) 0.05 -0.05 0.01 0.00 0.00 0.00 0.01 0.01 0.01 1000 0.05 -0.03 0.02 0.00 0.00 0.00 0.02 0.02 0.02 1100 0.04 -0.02 0.03 0.01...

  • Page 44: Operation

    Once the thermostat has been satisfied, it will de-energize “Y1”. If the compressor has satisfied its minimum run time, the For the ZW series of units, the thermostat makes a circuit compressor and condenser fan are de-energized. Otherwise, the between "R" and "Y1" for the first stage of cooling.

  • Page 45: Electric Heating Sequence Of Operations

    5803640-BIM-B-0620 the ASCD (Anti-short cycle delay), and stop the condenser When operating in low ambient mode, an evaporator low limit fans. If the call for cooling is still present at the conclusion of the sensor (EC1) temperature below 26ºF will de-energize the ASCD, the UCB will re-energize the halted compressor.

  • Page 46: Electric Heat Operation Errors

    5803640-BIM-B-0620 heater relay (RB) will be energized. After completing the Table 24: Electric Heat Limit Setting specified fan on delay for heating, the UCB will energize the blower motor. LIMIT HEATER UNIT (TONS) VOLTAGE SWITCH b The thermostat will cycle the electric heat to satisfy the OPENS °F heating requirements of the conditioned space.

  • Page 47: Gas Heating Sequence Of Operations

    5803640-BIM-B-0620 Gas Heating Sequence Of Operations Recycle Operation When a flame is lost after the flame stabilization period, a recy- When the thermostat calls for the first stage of heating, the low- cle operation occurs. If the unit fails after five recycle attempts, voltage control circuit from “R”...

  • Page 48: Start-Up (Cooling)

    5803640-BIM-B-0620 the UCB will de-energize the indoor blower following the elapse Internal Microprocessor Failure of the fan off delay for heating. If the ICB detects an internal failure, it will cease all outputs, If voltage has been sensed at the GV for at least 15 seconds ignore inputs, and display the proper flash code for control during the fan on delay for heating and GV voltage or “W1”...

  • Page 49: Start-Up (Gas Heat)

    5803640-BIM-B-0620 NOTE: Prior to each cooling season, the crankcase heaters must be energized at least 10 hours before the system is put into operation. Set the room thermostat setting to lower than the room FIRE OR EXPLOSION HAZARD temperature. Failure to follow the safety warning exactly could result in serious injury, death or property damage.

  • Page 50: Gas Rate Cubic Feet Per Hour

    5803640-BIM-B-0620 To determine the rate of gas flow (First Stage) NOTE: To find the Btu input, multiply the number of cubic feet of gas consumed per hour by the Btu content of the gas Turn off all other gas appliances connected to the gas in your particular locality (contact your gas company for meter.

  • Page 51: Charging The Unit

    5803640-BIM-B-0620 Table 28: Gas Heat Stages Unit 2nd Stage Total # of Burner 1st Stage HEAT EXCHANGER TUBE Input Input Size Opt. Tubes Input (Mbh) (Mbh) (Mbh) SUPPLY PIPE BURNER BURNER FLAME (BLUE ONLY) BURNER BRACKET IGNITOR Figure 29: Typical Flame MATE-N-LOCK HIGH &...

  • Page 52: Smart Equipment™ Ucb Details

    5803640-BIM-B-0620 THERMOSTAT WIRED HERE SD-24 Figure 31: Unit Control Board Table 29: Smart Equipment™ UCB Details Description Function & Comments Terminal Directional orientation: viewed with silkscreen labels upright Limit, 24 VAC power and shutdown connections from unit wiring harness at left on upper edge of UCB Monitored 24 VAC input through heat section limit If voltage is absent, indicating the heat section is over- LIMIT...
  • Page 53 5803640-BIM-B-0620 Table 29: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal Thermostat connection strip on left edge of UCB 1st stage heating request, 24 VAC input switched Not effective for cooling-only units from R 2nd stage heating request, 24 VAC input switched Not effective for cooling-only units or units with single-stage from R heat sections...
  • Page 54 5803640-BIM-B-0620 Table 29: Smart Equipment™ UCB Details (Continued) Description Function & Comments Input required for operation; 3.625 VDC reading RAT+ to RAT– Return Air Temperature sensor input from 10KΩ with open circuit. Used in return air enthalpy calculation. RAT+ @ 77°F, Type III negative temperature coefficient Substitutes for space temperature if no other space thermistor temperature input is present.
  • Page 55 5803640-BIM-B-0620 Table 29: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal at lower right corner of UCB Output relay circuitry is isolated from other UCB components 24 VAC hot for H1, H2, CN-FAN, AUX HGR, FAN 24V FOR OUTPUTS and the 24 VAC hot source may be from a second transformer C1 and C2 output relay contact switching in the unit...
  • Page 56 5803640-BIM-B-0620 Table 29: Smart Equipment™ UCB Details (Continued) Description Function & Comments Not effective for one stage compressor UCBs. Input is only considered if C2 output is needed; input must be present to HPS2 24 VAC hot return from refrigerant circuit 2 High allow C1 output.
  • Page 57 5803640-BIM-B-0620 Table 29: Smart Equipment™ UCB Details (Continued) Description Function & Comments Factory wired SA Bus connector Optional communication sub-board at center of UCB Terminal FC BUS connections on left edge of the communication board Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts FC (“Field Connected”) BUS BACnet MSTP reading to COM;...

  • Page 58: Cable For Fc Buses And Sa Buses In Order Of Preference . 58 31 Ignition Control Flash Codes

    5803640-BIM-B-0620 Table 30: Cable for FC Buses and SA Buses in Order of Preference Non-Plenum Applications Plenum Applications Bus and Cable Type Part Number O.D. Part Number O.D. Anixter: Anixter: CBL-22/3-FC-PLN CBL-22/3-FC-PVC 0.138 in. 0.140 in. FC Bus: 22 AWG Stranded, 3-Wire Twisted Shielded Cable Belden: B6501FE Belden®: B5501FE Anixter:...

  • Page 59: Start-Up Sheet

    5803640-BIM-B-0620 Start-Up Sheet Johnson Controls Ducted Systems...
  • Page 60 5803640-BIM-B-0620 Johnson Controls Ducted Systems...
  • Page 61 5803640-BIM-B-0620 Johnson Controls Ducted Systems...
  • Page 62 5803640-BIM-B-0620 Johnson Controls Ducted Systems...
  • Page 63 5803640-BIM-B-0620 Johnson Controls Ducted Systems...

  • Page 64: 5803640-Bim-B-0620

    Subject to change without notice. Printed in U.S.A. 5803640-BIM-B-0620 Copyright © 2020 by Johnson Controls, Inc. All rights reserved. Supersedes: 5803640-BIM-A-0220 York International Corporation 5005 York Drive Norman, OK 73069...

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