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R-410A
ZK 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1 ZKTA3 thru TA5 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZKTA3 thru TA5 Unit Accessory Weights . . . . . . . . . . . . . . . . 8
4 ZKTA3 thru TA5 Unit Physical Dimensions . . . . . . . . . . . . . . 11
5 ZKTA3 thru TA5 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 . . . . . . . . . . . . . . . . . . . . . 27
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 28
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 29
14 Smart Equipment™ Economizer Board Details . . . . . . . . . . 33
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38
17 ZKTA3 thru TA5 Side Duct Application . . . . . . . . . . . . . . . . . 40
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 ZK Component Location (ZKTA3 Shown) . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZKTA3 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZKTA4 thru TA5 Physical Dimensions . . . . . . . . . . . . . . . . . 10
10 ZKTA3 thru TA5 Unit Bottom Duct Openings . . . . . . . . . . . . 12
11 ZKTA3 thru TA5 Unit Electrical Entry . . . . . . . . . . . . . . . . . . 13
12 ZKTA3 thru TA5 Unit Side Duct Openings . . . . . . . . . . . . . . 13
13 ZKTA3 thru TA5 Unit Left/End Duct Opening . . . . . . . . . . . . 14
14 ZKTA3 thru TA5 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZKTA3 thru TA5 Transition Roof Curb . . . . . . . . . . . . . . . . . 15
16 Side Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
17 Return Panel In Place For Side Duct Conversion . . . . . . . . 16
TABLE OF CONTENTS
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . . . . 48
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 49
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 49
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 50
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 50
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
LIST OF TABLES
18 ZKTA3 thru TA5 Bottom Duct Application . . . . . . . . . . . . . . 41
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 42
21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 42
22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . . 44
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 45
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 49
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 51
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 53
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 56
32 ZKTA3 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
33 ZKTA4 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
34 ZKTA5 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
LIST OF FIGURES
18 Supply Panel In Place For Side Duct Conversion . . . . . . . . 16
19 Save Side Panels For Economizer Hood Tops . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Typical Low Voltage Field Wiring . . . . . . . . . . . . . . . . . . . . . 19
23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 33
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
29 Reheat Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48
30 Cooling Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48
31 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
32 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . . 55
33 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . 55
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5566230-TIM-A-0818
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Summary of Contents for TempMaster ZK Series
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Page 1: Table Of Contents
R-410A ZK SERIES W/SMART EQUIPMENT™ 3 - 5 Ton 60 Hertz TABLE OF CONTENTS General ..........2 Auto . -
Page 2: General
5566230-TIM-A-0818 General TempMaster ZK 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 Inspection Renewal Parts As soon as a unit is received, it should be inspected for possible Contact your local TempMaster 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. A separate Approvals request for inspection by the carrier’s agent should be made in...
- Page 4 5566230-TIM-A-0818 Nomenclature 3-12.5 Ton Model Number Nomenclature Z K TA5 N 16 A 2 A A C 2 1 B A 8 Product Category Product Generation 8 = Eighth Generation Z = A/C, Single Pkg., R-410A Coated Coils Product Identifier A = Un-Coated K = AC Std Eff Reheat B = E-Coat Cond &...
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Page 5: Installation
5566230-TIM-A-0818 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 ZK Series footprint One or Two stage gas heating to are available Side entry power maintain warm, comfortable (field-installed accessory) -
Page 7: Location
If a unit is to be installed on a roof curb other than a personal injury. Typical contaminates include: TempMaster roof curb, gasketing must be applied to all permanent wave solution, chlorinated waxes and surfaces that come in contact with the unit underside. -
Page 8: Weights And Dimensions
5566230-TIM-A-0818 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: Zkta3 Physical Dimensions
5566230-TIM-A-0818 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: ZKTA3 Physical Dimensions Johnson Controls Ducted Systems... -
Page 10: Zkta4 Thru Ta5 Physical Dimensions
5566230-TIM-A-0818 29.69 15.25 15.38 59.00 15.38 Ø 24.47 TYP. 2 PL. 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 9: ZKTA4 thru TA5 Physical Dimensions Johnson Controls Ducted Systems... -
Page 11: Zkta3 Thru Ta5 Unit Physical Dimensions
5566230-TIM-A-0818 Table 4: ZKTA3 thru TA5 Unit Physical Dimensions Dimension (in.) Unit Model Number ZKTA3 22 1/8 18 3/16 15 3/16 6 3/16 ZKTA4 22 1/8 18 3/16 15 3/16 6 3/16 ZKTA5 22 1/8 18 3/16 15 3/16 6 3/16 Detail A Detail B 3.184... -
Page 12: Zkta3 Thru Ta5 Unit Bottom Duct Openings
5566230-TIM-A-0818 TOP VIEW 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 Bottom power, control and convenience outlet wiring entry 3X Ø... -
Page 13: Side Duct Dimensions
5566230-TIM-A-0818 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: ZKTA3 thru TA5 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
5566230-TIM-A-0818 4-5/16 Figure 13: ZKTA3 thru TA5 Unit Left/End Duct Opening Table 7: Left/End Duct Dimensions Dimension (in.) Unit Model Number ZKTA3 30.357 13.365 22.516 ZKTA4 30.357 13.365 22.516 ZKTA5 30.357 13.365 22.516 RIGHT 80-5/8 INSULATED DECK UNDER CONDENSER SECTION SUPPLY RETURN 2 TYP. -
Page 15: Ductwork
5566230-TIM-A-0818 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: ZKTA3 thru TA5 Transition Roof Curb Ductwork in place from the factory) and two screws. It’s a snug fit for the panel when sliding it between the heat exchanger and unit Ductwork should be designed and sized according to the bottom, but there is room. -
Page 16: Side Panels
5566230-TIM-A-0818 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
5566230-TIM-A-0818 Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1. Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. -
Page 18: Field Wiring Disconnect
5566230-TIM-A-0818 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
5566230-TIM-A-0818 Thermostat Wiring thermostat to the unit. Refer to Table 8 for control wire sizing and maximum length. A two stage thermostat must be used and should be located on an inside wall approximately 56 inch above the floor where it will Table 8: Control Wire Sizes not be subject to drafts, sun exposure or heat from electrical Wire Size... -
Page 20: Electrical Data
5566230-TIM-A-0818 Table 9: Electrical Data ZKTA3 thru TA5 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 5566230-TIM-A-0818 ZKTA3 thru TA5 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 5566230-TIM-A-0818 ZKTA3 thru TA5 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 5566230-TIM-A-0818 ZKTA3 thru TA5 Hi Static 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...
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Page 24: Physical Data
5566230-TIM-A-0818 Table 10: Physical Data ZKTA3 thru TA5 Single Stage Gas Heat Physical Data Models Component ZKTA3 ZKTA4 ZKTA5 Nominal Tonnage AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 37600 48500 60200 AHRI net capacity (Btu) 35600 47000 58000 12.2 12.1... - Page 25 5566230-TIM-A-0818 ZKTA3 thru TA5 Single Stage Gas Heat Physical Data (Continued) Models Component ZKTA3 ZKTA4 ZKTA5 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 5566230-TIM-A-0818 ZKTA3 thru TA5 Two Stage Gas Heat Physical Data Models Component ZKTA3 ZKTA4 ZKTA5 Nominal Tonnage AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 37600 48500 60200 AHRI net capacity (Btu) 35600 47000 58000 12.2 12.1 12.1 SEER 14.5 14.5...
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Page 27: Optional Electric Heat
5566230-TIM-A-0818 ZKTA3 thru TA5 Two Stage Gas Heat Physical Data (Continued) Models Component ZKTA3 ZKTA4 ZKTA5 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 28: Optional Gas Heat
5566230-TIM-A-0818 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 29: Gas Heat Minimum Supply Air
Figures 23 and 24. All pipe nipples, fittings, and the Failure to follow the safety warning exactly could result gas cock are field supplied or may be purchased in TempMaster in serious injury, death or property damage. -
Page 30: Options/Accessories
5566230-TIM-A-0818 For satisfactory operation, LP gas pressure must be 10.5 inch electric heaters have either fuses or circut breaker and are W.C. at the unit under full load. Maintaining proper gas intended for use with single point 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 31: Economizer Sequences
5566230-TIM-A-0818 Economizer Dry Bulb Changeover The Economizer can be a factory installed option or a field For dry bulb economizer operation, the outside air is suitable for installed accessory. If factory installed, refer to the instructions free cooling if the outside air temperature is 1°F below the included with the outdoor air hood to complete the assembly. -
Page 32: Power Exhaust
5566230-TIM-A-0818 If the supply air temperature cannot be maintained within 5°F of compressor outputs will be de-energized as long as their the economizer setpoint, the first stage compressor (C1) will be minimum run timers have expired. turned on. Second stage compressor (C2) will be added as Power Exhaust needed to keep the supply air temperature within the 5°F of the economizer setpoint. -
Page 33: Smart Equipment™ Economizer Board Details
5566230-TIM-A-0818 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 34 5566230-TIM-A-0818 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 35 5566230-TIM-A-0818 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~...
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Page 36: Supply Air Limitations
5566230-TIM-A-0818 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 37 5566230-TIM-A-0818 Altitude and Temperature Correction for CFM, Static Pressure and Power. The information below should be used to assist in application of Procedure for adjusting belt tension: product when being applied at altitudes at or exceeding 1000 feet above sea level. 1.
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Page 38: Altitude/Temperature Correction Factors
5566230-TIM-A-0818 Table 16: Altitude/Temperature Correction Factors Altitude (Ft.) Temp. 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 1.060 1.022 0.986 0.950 0.916 0.882 0.849 0.818 0.788 0.758 0.729 1.039 1.002 0.966 0.931 0.898 0.864 0.832 0.802 0.772 0.743 0.715 1.019 0.982... - Page 39 5566230-TIM-A-0818 Drive Selection Determine side or bottom supply duct Application. Determine desired airflow. Calculate or measure the amount of external static pressure. • Add or deduct any additional static resistance from “Additional Static Resistance Table”. Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table.
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Page 40: Zkta3 Thru Ta5 Side Duct Application
5566230-TIM-A-0818 Airflow Performance Table 17: ZKTA3 thru TA5 Side Duct Application ZKTA3 (3.0 Ton) Side Duct Available External Static Pressure - IWG 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 41: Zkta3 Thru Ta5 Bottom Duct Application
5566230-TIM-A-0818 Table 18: ZKTA3 thru TA5 Bottom Duct Application ZKTA3 (3.0 Ton) Bottom Duct Available External Static Pressure - IWG 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 42: Air Balance
5566230-TIM-A-0818 Table 19: RPM Selection Size Airflow Motor Blower 6 Turns 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Option Sheave Sheave Open Open Open Open Open Open Closed 1VP34 AK61 Std. (3.0) 1VL44 AK59 1004 1066 1129... -
Page 43: Dry Coil Delta P
5566230-TIM-A-0818 Select the correct blower performance table for the unit from Tables 17 and 18. Tables are presented for side and downflow 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 44: Motor Sheave Datum Diameters
5566230-TIM-A-0818 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 45: Additional Static Resistance
5566230-TIM-A-0818 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 46: Operation
When there is a call for “Y2”, the low voltage control circut from “R” to “Y2 is completed. The UCB energizes the compressor. If For the ZK series of units, the thermostat makes a circuit the outdoor air is below the set point fo the enthalpy controller between "R"... - Page 47 5566230-TIM-A-0818 High-Pressure Limit Switch throughout the cycle. The 5-minute off period is necessary to defrost the indoor coil. During cooling operation, if a high-pressure limit switch opens, Low ambient mode always begins with compressor operation. the UCB will de-energize the compressor, initiate the ASCD Compressor minimum run time may extend the minutes of (Anti-short cycle delay).
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Page 48: Reheat Mode Sequence Of Operation
5566230-TIM-A-0818 Reheat Mode Sequence Of Operation refrigerant flow in the evaporator reheat coil and condenser coil #1. See Figure 29. The MagnaDRY reheat mode of operation is designed to When there is a call for the first stage of cooling while there is remove latent heat (Humidity) from a space when there are low still a call for dehumidification, no operational change is made. -
Page 49: Electric Heating Sequence Of Operations
5566230-TIM-A-0818 Electric Heating Sequence Of Operations Table 24: Electric Heat Limit Setting The following sequence describes the operation of the electric LIMIT heat section. HEATER UNIT (TONS) VOLTAGE SWITCH OPENS °F Single stage heating: a. Upon a call for heating by the thermostat, the heater ZKTA3 (3) 208/230 relay (RA) will be energized. -
Page 50: Gas Heating Sequence Of Operations
5566230-TIM-A-0818 Gas Heating Sequence Of Operations Recycle Operation When a flame is lost after the flame stabilization period, a recy- Single stage heating: cle operation occurs. If the unit fails after five recycle attempts, When the thermostat calls for the first stage of heating, the low- the furnace is locked-out for one hour. -
Page 51: Start-Up (Cooling)
5566230-TIM-A-0818 voltage is no longer sensed at the GV, the UCB will de-energize Rollout Switch (ROS) the indoor blower following the elapse of the fan off delay for The rollout switch is wired in series with the pressure switch. As heating. -
Page 52: Start-Up (Gas Heat)
5566230-TIM-A-0818 Check blower drive belt tension. Post Start Checklist Check the unit supply air (CFM). After the entire control circuit has been energized and the heating section is operating, make the following checks: Measure evaporator fan motor's amp draw. Check for gas leaks in the unit piping as well as the supply Set the room thermostat fan switch to off. -
Page 53: Gas Rate Cubic Feet Per Hour
5566230-TIM-A-0818 If necessary, adjust the regulator as discussed in the Table 27: Gas Rate Cubic Feet Per Hour section "Manifold Gas Pressure Adjustment". Repeat Size of Test Dial Seconds for Steps 1-5. One Rev. 1/2 cu. ft. 1 cu. ft. Two Stage Gas Heat This unit has two stages of gas heat. -
Page 54: Gas Heat Stages
5566230-TIM-A-0818 Turn on power to the unit. Table 28: Gas Heat Stages Set thermostat to call for heat and start furnace. Unit 2nd Stage Total # of Burner 1st Stage If necessary, using a screwdriver, turn the adjustment Input Input Tubes Input (Mbh) Size... -
Page 55: Charging The Unit
5566230-TIM-A-0818 Remove the heat shield on top of the manifold supports. ELECTRICAL Burners are now accessible for inspection and/or ADJUSTMENT TERMINALS replacement. NOTE: Reverse the above procedure to replace the assemblies. Make sure that burners are level and seat at the rear of the gas INLET OUTLET PRESSURE... -
Page 56: Smart Equipment™ Ucb Details
5566230-TIM-A-0818 THERMOSTAT WIRED HERE SD-24 Figure 34: 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 57 5566230-TIM-A-0818 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 58 5566230-TIM-A-0818 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 59 5566230-TIM-A-0818 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 60 5566230-TIM-A-0818 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 61 5566230-TIM-A-0818 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;...
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Page 62: Cable For Fc Buses And Sa Buses In Order Of Preference . 61 31 Flash Codes For The Gas Heat Ignition Control Board
5566230-TIM-A-0818 Table 31: Flash Codes for the Gas Heat Ignition Control Board Flash Description Technician Corrective Action Code Normal Operation - no staus or error information Heartbeat currently needs to be displayed Verify line voltage is present at the primary of the 75VA transformer, verify No Power to Control - 24v AC is not present to the 24v AC is present at the secondary of the 75VA transformer. -
Page 63: Zkta3 Charging Table
5566230-TIM-A-0818 Table 32: ZKTA3 Charging Table Air Flow Outdoor Suction Suction Liquid Liquid Delta T Compr. Indoor Db/Wb Pressure Temp. Pressure Temp. 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... -
Page 64: Zkta5 Charging Table
5566230-TIM-A-0818 Table 34: ZKTA5 Charging Table Air Flow Outdoor Suction Suction Liquid Liquid Delta T Compr. Indoor Db/Wb Pressure Temp. Pressure Temp. amps 300 Cfm/Ton 80/62 300 Cfm/Ton 80.000001/66.999999 300 Cfm/Ton 80/72 300 Cfm/Ton 75/62 400 Cfm/Ton 80/62 400 Cfm/Ton 80.000001/66.999999 400 Cfm/Ton 80/72... -
Page 65: Start-Up Sheet
5566230-TIM-A-0818 Start-Up Sheet Johnson Controls Ducted Systems... - Page 66 5566230-TIM-A-0818 Johnson Controls Ducted Systems...
- Page 67 5566230-TIM-A-0818 Johnson Controls Ducted Systems...
- Page 68 5566230-TIM-A-0818 Johnson Controls Ducted Systems...
- Page 69 5566230-TIM-A-0818 Johnson Controls Ducted Systems...
- Page 70 Subject to change without notice. Printed in U.S.A. 5566230-TIM-A-0818 Copyright © 2018 by Johnson Controls, Inc. All rights reserved. Supersedes: 5121834-TIM-I-0518 York International Corporation 5005 York Drive Norman, OK 73069...
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