Johnson Controls TempMaster ZD Series Installation Manual
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Johnson Controls TempMaster ZD Series Installation Manual

Johnson Controls TempMaster ZD Series Installation Manual

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R-410A
ZD SERIES
3 - 6 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . 15
Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical Cool/Heat Control Wiring (Smart Equipment™ ZDT03
through TA6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34
Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . . 35
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 ZDT03 through TA6 Unit Limitations . . . . . . . . . . . . . . . . . . . . 6
2 ZDT03 through TA6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZDT03 through TA6 Unit Accessory Weights . . . . . . . . . . . . . 8
4 ZDT03 through TA6 Unit Clearances . . . . . . . . . . . . . . . . . . 10
5 ZDT03 through TA6 Utilities Entry . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 ZDT03 through TA6 Physical Data . . . . . . . . . . . . . . . . . . . . 29
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31
11 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 41
15 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 44
16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 45
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 47
1 ZDT03 through TA6 Component Location . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZDT03 through TA6 Disconnect Location . . . . . . . . . . . . . . 10
10 ZDT03 through TA6 Roof Curb . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13

TABLE OF CONTENTS

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 50
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 51
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 52
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 56
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 57
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
LIST OF TABLES
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 47
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 48
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 51
24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 53
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 53
26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56
27 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
28 ZDT03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59
29 ZDT04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59
30 ZDT05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
31 ZDTA6 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
33 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 65
34 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 66
35 Cable for FC Buses and SA Buses in Order of Preference . 71
LIST OF FIGURES
14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 34
17 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . 34
18 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 37
19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
20 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
21 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 48
22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
23 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 54
24 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 54
25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 55
26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 55
27 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 65
28 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 66

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Summary of Contents for Johnson Controls TempMaster ZD Series

  • Page 1: Table Of Contents

    R-410A ZD SERIES 3 - 6 Ton 60 Hertz TABLE OF CONTENTS General ..........2 Power Exhaust .

  • Page 2: General

    Refer to this manual for assistance or Installation and service must be performed by a qualified for additional information, consult a qualified contractor, installer, service agency or the gas supplier. installer or service agency. Johnson Controls Ducted Systems...
  • Page 3 1/2 PSIG. This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. Johnson Controls Ducted Systems...
  • Page 4 Y = Options 4 & 5 Z = Options 3, 4 & 5 Options 1 = Disconnect 2 = Non-Pwr'd Conv. Outlet 3 = Smoke Detector S.A. 4 = Smoke Detector R.A. 5 = Pwr'd Conv. Outlet Johnson Controls Ducted Systems...

  • Page 5: Installation

    30° F. 208/230-3-60 and 380/415-3-50 units with factory installed Powered Convenience Outlet Option are wired for 230v and 415v power supply respectively. Change tap on transformer for 208-3-60 or 380-3-50 operation. See unit wiring diagram. Johnson Controls Ducted Systems...

  • Page 6: Zdt03 Through Ta6 Unit Limitations

    Size Unit Voltage SCCR (kVA) Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-1-60 208/230-3-60 ZDT03 (3.0) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 ZDT04 (4.0) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 ZDT05 (5.0) 460-3-60 575-3-60 208/230-3-60 ZDTA6 460-3-60 (6.0) 575-3-60 Johnson Controls Ducted Systems...

  • Page 7: Location

    7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) - The condenser coils should be protected from rigging Latest Edition, and/or applicable provisions of the local building cable damage with plywood or other suitable material. Johnson Controls Ducted Systems...

  • Page 8: Zdt03 Through Ta6

    Unit Accessory Shipping Operating Economizer Power Exhaust Electric Heat Gas Heat 1. Weight given is for the maximum heater size available (30KW). 2. Weight given is for the maximum number of tube heat exchangers available (5 tube). Johnson Controls Ducted Systems...

  • Page 9: Zdt03 Through Ta6 Cooling Only/Electric Heat Front View Physical Dimensions

    5742640-TIM-A-0419 Figure 5: ZDT03 through TA6 Cooling Only/Electric Heat Front View Physical Dimensions Figure 6: ZDT03 through TA6 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Ducted Systems...

  • Page 10: Zdt03 Through Ta6 Unit Clearances

    A, B, or C roof covering material. and Motor Access Panel for 2. Units must be installed outdoors. Overhanging structures Unit with “Belt-Drive” Option or shrubs should not obstruct condenser air discharge outlet. Figure 8: ZDT03 through TA6 Disconnect Location Johnson Controls Ducted Systems...

  • Page 11: Zdt03 Through Ta6 Utilities Entry

    1-1/2” KO Gas Piping (Bottom) 1. Opening in the bottom to the unit can be located by the slice in the insulation. 2. Do not remove the 2” knockout ring. Figure 10: ZDT03 through TA6 Roof Curb Johnson Controls Ducted Systems...

  • Page 12: Ductwork

    Units are shipped with compressor mountings which are factory-adjusted and ready for operation. Units with scroll compressors have a shipping bracket which must be removed after the unit is set in place. See Figure 12. Figure 11: Condensate Drain Johnson Controls Ducted Systems...

  • Page 13: Filters

    NEC and CEC as normal operation. The above water-proofing conditions specified above and/or local codes. will also apply when installing a field supplied disconnect switch. Johnson Controls Ducted Systems...

  • Page 14: Control Wire Sizes

    Table 6: Control Wire Sizes the unit using the (4) screws provided. Wire Size Maximum Length 18 AWG 150 Feet 1. From the unit to the thermostat and back to the unit. Johnson Controls Ducted Systems...

  • Page 15: Typical Field Power And Control Wiring

    R, RC, or RH. OCC is an output from the thermostat to indicate the Occupied X is an input to the thermostat to display Error Status condi ons. Figure 13: Typical Smart Equipment™ Control Wiring Johnson Controls Ducted Systems...

  • Page 16: Electrical Data

    230-3-60 13.7 83.1 21.4 10.6 25.5 37.2 15.9 38.2 53.2 21.2 69.1 NONE 11.1 12.8 460-3-60 10.1 12.1 17.8 13.6 16.4 23.1 19.5 23.5 31.9 NONE 10.6 10.2 15.1 575-3-60 15.9 15.3 21.5 21.2 20.4 27.9 Johnson Controls Ducted Systems...
  • Page 17 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. 4. Electrical data for single phase gas heating units with belt drive is at the end of the electrical data section. Johnson Controls Ducted Systems...
  • Page 18 230-3-60 13.7 83.1 21.4 10.6 25.5 37.2 15.9 38.2 53.2 21.2 69.1 NONE 11.1 12.8 460-3-60 10.1 12.1 17.8 13.6 16.4 23.1 19.5 23.5 31.9 NONE 10.6 10.2 15.1 575-3-60 15.9 15.3 21.5 21.2 20.4 27.9 Johnson Controls Ducted Systems...
  • Page 19 23.1 21.2 20.4 29.5 30.4 29.3 40.6 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. 4. Single phase, high static belt drive motors not available on gas heating units. Johnson Controls Ducted Systems...
  • Page 20 66.2 92.3 21.2 88.3 119.9 (4.0) NONE 11.1 15.5 28.9 208-3-60 13.7 83.1 21.4 22.2 37.3 11.9 50.8 15.9 44.1 64.7 NONE 12.7 32.1 230-3-60 13.7 83.1 21.4 10.6 25.5 41.4 15.9 38.2 57.3 21.2 73.2 Johnson Controls Ducted Systems...
  • Page 21 44.1 64.7 22.2 61.6 86.5 NONE 12.7 32.1 230-3-60 24.9 10.6 25.5 41.4 15.9 38.2 57.3 21.2 73.2 29.6 71.2 98.5 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...
  • Page 22 13.7 83.1 21.4 10.6 25.5 49.7 15.9 38.2 65.7 21.2 81.6 NONE 16.1 19.1 460-3-60 10.1 12.1 24.1 13.6 16.4 29.3 19.5 23.5 38.2 NONE 12.9 10.6 10.2 20.1 575-3-60 15.9 15.3 26.5 21.2 20.4 32.9 Johnson Controls Ducted Systems...
  • Page 23 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. 4. Electrical data for single phase gas heating units with belt drive is at the end of the electrical data section. Johnson Controls Ducted Systems...
  • Page 24 13.7 83.1 21.4 10.6 25.5 49.7 15.9 38.2 65.7 21.2 81.6 NONE 16.1 19.1 460-3-60 10.1 12.1 24.1 13.6 16.4 29.3 19.5 23.5 38.2 NONE 12.9 10.6 10.2 20.1 575-3-60 15.9 15.3 26.5 21.2 20.4 32.9 Johnson Controls Ducted Systems...
  • Page 25 28.1 21.2 20.4 34.5 30.4 29.3 45.6 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. 4. Single phase, high static belt drive motors not available on gas heating units. Johnson Controls Ducted Systems...
  • Page 26 104.8 21.2 88.3 132.4 (4.0) NONE 11.1 15.5 41.4 208-3-60 13.7 83.1 21.4 22.2 49.8 11.9 63.3 15.9 44.1 77.2 NONE 12.7 37.9 44.6 230-3-60 13.7 83.1 21.4 10.6 25.5 53.9 15.9 38.2 69.8 21.2 85.7 Johnson Controls Ducted Systems...
  • Page 27 63.3 15.9 44.1 77.2 22.2 61.6 NONE 12.7 44.6 230-3-60 24.9 10.6 25.5 53.9 15.9 38.2 69.8 21.2 85.7 29.6 71.2 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...

  • Page 28: Electrical Data: Single-Phase Gas Heat, Belt Drive

    208-1-60 19.6 17.4 None 54.2 230-1-60 19.6 17.4 None 54.2 208-1-60 24.4 144.2 17.4 None 62.3 230-1-60 24.4 144.2 17.4 None 62.3 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...

  • Page 29: Zdt03 Through Ta6 Physical Data

    Face area (Sq. Ft.) 16.3 16.3 16.3 16.3 Rows Fins per inch Tube diameter (in.) 0.71 / 18 0.71 / 18 1.00 / 25.4 1.00 / 25.4 Circuitry Type 2-pass Microchannel 2-pass Microchannel 2-pass Microchannel 2-pass Microchannel Johnson Controls Ducted Systems...
  • Page 30 3. FER or Fan Energy Rating is a Department of Energy (DOE) requirement for single phase gas/electric product rated 65K or less of cooling capacity. DOE ruling effective 7/2019. 4. ECM O.D. Fan Motor 5. Only available on 208/230 Volt Models Johnson Controls Ducted Systems...

  • Page 31: Optional Electric Heat

    NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with Kit Model No. 1NP0440 or 1NP0485 (2 Stage). All furnaces meet the latest California seasonal efficiency requirements. 1. Based on 1075 Btu/Ft. 2. The air flow must be adjusted to obtain a temperature rise within the range shown. Johnson Controls Ducted Systems...

  • Page 32: Gas Pipe Sizing - Capacity Of Pipe

    After the gas connections have been completed, open the main shut-off valve admitting normal gas pressure to the mains. Check all joints for leaks with soap solution or other material suitable for the purpose. NEVER USE A FLAME. Johnson Controls Ducted Systems...
  • Page 33 “wetted surface” area of the container(s). The products of combustion are discharged horizontally through The proper pressure regulation. (Two-stage regulation is this screened, hooded vent opening on the gas heat access panel. recommended). Johnson Controls Ducted Systems...

  • Page 34: Options/Accessories

    Units with Simplicity Lite Controls will have a field installed (RRS) Economizer Kit Offered. The LEDs at the center-left of the RRS Economizer Controller indicate: This section describes how to use the Economizer’s user interface for: • POWER (green) Johnson Controls Ducted Systems...

  • Page 35: Smart Equipment™ Economizer Sequences

    The control determines the type of free cooling changeover Units with the Smart Equipment™ Control will have a factory based on which sensors are present and reliable. Conditions option or field kit with Johnson Controls Economizer. include: Several functions can drive the economizer, including: minimum •...

  • Page 36: Power Exhaust

    Economizer Damper Position For Exhaust Fan On. is less than Economizer Setpoint -1°F, the control starts a 12- c. De-energizes exhaust fan when economizer output is minute timer to de-energize a compressor output. below the Economizer Damper Position for Exhaust Fan Johnson Controls Ducted Systems...

  • Page 37: Smart Equipment™ Economizer Board Details

    USB flash drive) Lit/flickering indicates UCB-to-economizer board SA bus Green UCB SA bus communication SA BUS SA BUS communication is currently active, off indicates the economizer transmission indicator board is awaiting SA bus communication Johnson Controls Ducted Systems...
  • Page 38 Non-Modulating, Modulating Damper or Variable EX-FAN fan contactor coil/VFD enable relay coil Frequency Fan. Used to turn on/enable the power exhaust fan motor. 24 VAC common/0-10 VDC negative for Connects through circuit trace to 24V~ IN pin COM economizer actuator Johnson Controls Ducted Systems...
  • Page 39 24 VAC common/0-10 VDC negative for the air Connects through circuit trace to 24V~ IN pin COM monitoring station sensor 24 VAC hot supplied for the building pressure 24V~ Connects through circuit trace to 24V~ IN pin HOT sensor Johnson Controls Ducted Systems...
  • Page 40 If it is obtain proper rotation. (Scroll compressors operate in only one necessary to change 3 phase motor rotation, swap A or direction. If the scroll is drawing low amperage, has similar L1 and C or L3 only. Johnson Controls Ducted Systems...

  • Page 41: Altitude/Temperature Correction Factors

    0.743 0.715 0.688 0.982 0.947 0.913 0.880 0.848 0.817 0.787 0.758 0.730 0.702 0.676 0.964 0.929 0.897 0.864 0.833 0.802 0.772 0.744 0.716 0.689 0.663 0.946 0.912 0.880 0.848 0.817 0.787 0.758 0.730 0.703 0.676 0.651 Johnson Controls Ducted Systems...

  • Page 42: Altitude/Temperature Correction Factors

    This value must be corrected for elevation. Example 2: A system, located at 5,000 feet of elevation, is to deliver 1,400 CFM at a static pressure of 1.5". Use the unit BHP at 5,000 ft. = 0.7 x .832 = 0.58 Johnson Controls Ducted Systems...
  • Page 43 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Closed 1.73 1VL44 AK56 1060 1130 1195 1260 1VP56 AK56 1325 1395 1460 1525 1590 1660 Johnson Controls Ducted Systems...

  • Page 44: Zd Blower Performance Side Duct

    1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. 4. Field Supplied Drive. Johnson Controls Ducted Systems...

  • Page 45: Zd Blower Performance Bottom Duct

    1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. Johnson Controls Ducted Systems...
  • Page 46 1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. 1kW = BHP x 0.862. Johnson Controls Ducted Systems...

  • Page 47: Belt Drive Rpm Selection

    Table 19: Power Exhaust Specifications Motor Motor Fuse CFM @ Model Voltage Size 0.1 ESP 2PE04703725 208/230-1-60 1725 23.7 1350 2PE04703746 460-1-60 1725 1350 2PE04703758 575-3-60 1725 1350 1. Motors are multi-tapped and factory wired for high speed. Johnson Controls Ducted Systems...

  • Page 48: Checking Supply Air Cfm

    3. The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation. Johnson Controls Ducted Systems...

  • Page 49: Sequence Of Operation

    Each cooling system is monitored for operation outside of the off delay for cooling. intended parameters. Errors are handled as described below. All system errors override minimum run times for compressors. Johnson Controls Ducted Systems...

  • Page 50: Electric Heating Sequence Of Operations

    10 minutes on, 5 minutes off. The indoor blower is operated throughout the cycle. The 5-minute off period is necessary to The following sequence describes the operation of the electric defrost the indoor coil. heat section. Johnson Controls Ducted Systems...

  • Page 51: Electric Heat Operation Errors

    0.35 heater and energizing the blower. 0.35 0.35 230-3-60 0.35 0.19 0.35 0.38 0.35 0.38 0.35 0.35 460-3-60 0.35 0.37 0.29 0.37 0.29 Johnson Controls Ducted Systems...

  • Page 52: Gas Heating Sequence Of Operations

    2 of the S3 connector on the (UCB) unit blower heating off delay. control board to P2-4 on the ignition control board. Cut the wire 1/2" from the S3 mate-n-lock connector. Wire nut or tape off the Johnson Controls Ducted Systems...

  • Page 53: Error Messages

    Phasing Section in general information section. • Check blower drive belt tension. Check the unit supply air (CFM). See “CHECKING SUPPLY AIR CFM” on page 48. Measure evaporator fan motor's amp draw. Set the room thermostat fan switch to off. Johnson Controls Ducted Systems...

  • Page 54: Start-Up (Gas Heat)

    To Shut Down: (Under Screw) Turn “off” electric power to unit. Figure 24: Typical 2 Stage Gas Valves Depress knob of gas valve while turning to “off” position or position the switch to the “off” position. Johnson Controls Ducted Systems...

  • Page 55: Checking Gas Input

    Btu content of the gas Remove the screws holding either end of the manifold to in your particular locality (contact your gas company for the burner supports. this information - it varies widely from city to city.) Johnson Controls Ducted Systems...

  • Page 56: Start Up For Units Equipped For Fer

    Refer to the In Door Blower Specification Table 18. 1ClgStg-% Cmd Adjust based on application (CV IS 1 Stg Cool) (Occupied: One 1HtgStg-%Cmd Adjust based on application Stage of Heat % Command) Johnson Controls Ducted Systems...

  • Page 57: Troubleshooting (Simplicity Lite Only)

    If 24 volts are not present between the UCB terminals, e.g. if LPS1 has opened, there from the room thermostat, check for the following: will be a 24-volt potential between the LPS1 terminals. Johnson Controls Ducted Systems...
  • Page 58 This programming can be checked or changed by the terminal. If 24 volts is not present, check for loose wiring local distributor. from the Y1 “OUT” terminal to the Mate-N-Lock plug, the 15. If none of the above correct the error, replace the UCB. Johnson Controls Ducted Systems...

  • Page 59: Zdt03 (3.0 Ton) Operating Pressures

    Indoor Db/Wb DB/WB Pressure Temp. Pressure Temp. Evap Db Evap Db Amps 300 Cfm/Ton 80/62 300 Cfm/Ton 80/67 300 Cfm/Ton 80/72 300 Cfm/Ton 75/63 400 Cfm/Ton 80/62 400 Cfm/Ton 80/67 400 Cfm/Ton 80/72 400 Cfm/Ton 75/63 Johnson Controls Ducted Systems...

  • Page 60: Zdt05 (5.0 Ton) Operating Pressures

    12.0 300 Cfm/Ton 80/72 13.6 15.3 11.9 300 Cfm/Ton 75/62 13.3 14.8 11.8 400 Cfm/Ton 80/62 13.3 14.8 11.9 400 Cfm/Ton 80/67 13.4 14.9 11.9 400 Cfm/Ton 80/72 13.5 15.1 11.8 400 Cfm/Ton 75/62 13.3 14.8 Johnson Controls Ducted Systems...
  • Page 61 If debris is present, then clear debris and verify Power to the unit should be interrupted during the proper furnace operation. If clear, then replace the draft troubleshooting of individual components unless otherwise motor and verify proper furnace operation. Johnson Controls Ducted Systems...
  • Page 62 Either the air flow through the up procedures. furnace is not sufficient or the gas input rate to the furnace Johnson Controls Ducted Systems...
  • Page 63 24 volts is present at the room thermostat short delay (the room thermostat fan switch is in “AUTO” but not at the UCB, check for proper wiring between the position). thermostat and the UCB, i.e. that the thermostat “W1” Johnson Controls Ducted Systems...
  • Page 64 Pressing the button three times within five seconds forces CHECK LIST” on page 54. Make adjustments as the control to reset its address to 1, which is the factory necessary. default. Make sure that the pilot burner is not bent or damaged. Johnson Controls Ducted Systems...

  • Page 65: Smart Equipment™ Control Board Navigation Components

    Lock Out From Too Many Flame Losses 6 Flashes High Temperature Switch Open (Primary or Aux.) 7 Flashes Rollout Switch Open 8 Flashes Flame Present With Gas Off 9 Flashes Gas Valve Stuck Off or On 10 Flashes Flame Sense Circuit Failure Johnson Controls Ducted Systems...

  • Page 66: Smart Equipment™ Ucb Details

    Connects through circuit trace to the thermostat connection 24 VAC hot for switched inputs to the UCB strip R terminal, right FAN OVR pin, right HPS1 pin, right HPS2 pin, lower DFS pin and lower APS pin Johnson Controls Ducted Systems...
  • Page 67 Supply Air Temperature sensor input from 10KΩ with open circuit. Used in heat/cool staging cutouts, free cooling SAT+ @ 77°F, Type III negative temperature coefficient operation, demand ventilation operation, comfort ventilation thermistor operation, economizer loading operation, VAV cooling operation, hydronic heat operation. Johnson Controls Ducted Systems...
  • Page 68 The VFD alarm contact switches from R within the unit wiring 24 VAC hot input from the normally open VFD VFDFLT harness. 24 VAC input results in unit shutdown and a “VFD alarm contact fault” alarm Johnson Controls Ducted Systems...
  • Page 69 Lockout” and C1 output is then prevented until alarm reset. HPS2 24 VAC hot out for refrigerant circuit 2 High Not effective for one stage compressor UCBs. Connects (right pin) Pressure Switch through circuit trace to the R terminal Johnson Controls Ducted Systems...
  • Page 70 4-way Joystick for display menu navigation Item USB connector at right of UCB Used for backup, restoration, & copying of board parameters as Type A female Universal Serial Bus connector well as board software updating through a flash drive Johnson Controls Ducted Systems...
  • Page 71 2. We recommend 26 AWG solid, 6-wire (3 twisted pairs) cable as the best fit for fabricating modular cables with the modular jack housing assembly. Be sure the cable you use fits the modular jack housing. The preassembled cables that are available from Anixter (Part No. CBL-NETWORKxxx) use 24 gauge wire. Johnson Controls Ducted Systems...

  • Page 72: Start-Up Sheet

    5742640-TIM-A-0419 Start-Up Sheet Johnson Controls Ducted Systems...
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  • Page 76 5742640-TIM-A-0419 Johnson Controls Ducted Systems...

  • Page 77: 5742640-Tim-A-0419

    Subject to change without notice. Printed in U.S.A. 5742640-TIM-A-0419 Copyright © 2019 by Johnson Controls, Inc. All rights reserved. Supersedes: 5506653-TIM-A-0718 York International Corporation 5005 York Drive Norman, OK 73069...

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