Johnson Controls ZE Series Installation Manual
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Johnson Controls ZE Series Installation Manual

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R-410A
ZE 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™ ZE036-
072) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Field Installed Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 35
Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . . 36
Dry Bulb Changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 ZE036-072 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZE036-072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZE036-072 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 8
4 ZE036-072 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 ZE036-072 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 ZE036-072 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 32
11 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 33
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
15 ZE Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45
16 ZE Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 46
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1 ZE036-072 Component Location . . . . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZE036-072 Disconnect Location . . . . . . . . . . . . . . . . . . . . . 10
9 ZE036-072 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 11
10 ZE036-072 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13

TABLE OF CONTENTS

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 50
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 54
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start Up For Units Equipped for FER . . . . . . . . . . . . . . . . . . . . . . 57
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 58
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LIST OF TABLES
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53
24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 54
25 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56
26 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
27 ZE036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
28 ZE048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
29 ZE060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
30 ZE072 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
32 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66
33 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 67
LIST OF FIGURES
15 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
16 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
17 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 35
18 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . . 35
19 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38
20 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
21 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
22 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 49
23 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
24 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 55
25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 56
26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 66
28 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 67

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Summary of Contents for Johnson Controls ZE Series

  • Page 1: Table Of Contents

    R-410A ZE SERIES 3 - 6 Ton 60 Hertz TABLE OF CONTENTS General ..........2 Free Cooling Operation .

  • Page 2: General

    If you cannot reach your gas supplier, call the fire for additional information, consult a qualified contractor, department. installer or service agency. Installation and service must be performed by a qualified installer, service agency or the gas supplier. 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 C = Economizer w/o Barometric RLF 2 = DSC (Disconnect Switch) F = Econ BAS Rdy w/o Barometric RLF 3 = NCO (Non-PWR Conv. Outlet) 4 = PCO (Powered Conv. Outlet) 5 = DSC,NCO 6 = DSC,PCO 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: Ze036-072 Unit Limitations

    Size Unit Voltage SCCR (kVA) Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-1-60 208/230-3-60 ZE036 (3.0) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 ZE048 (4.0) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 ZE060 (5.0) 460-3-60 575-3-60 208/230-3-60 ZE072 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: Ze036-072

    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: Ze036-072 Cooling Only Front View Physical Dimensions

    6021974-UIM-A-1120 Figure 5: ZE036-072 Cooling Only Front View Physical Dimensions Figure 6: ZE036-072 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Ducted Systems...

  • Page 10: Ze036-072 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: ZE036-072 Disconnect Location Johnson Controls Ducted Systems...

  • Page 11: Ze036-072 Utilities Entry

    Gas Piping (Front) 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: ZE036-072 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 Field Power and Simplicity Lite Control Wiring Johnson Controls Ducted Systems...

  • Page 16: Typical Cool/Heat 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 14: Typical Smart Equipment™ Control Wiring Johnson Controls Ducted Systems...

  • Page 17: 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 18 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 19 230-3-60 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 27 104.8 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 28 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 29: 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 30: Ze036-072 Physical Data

    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 EVAPORATOR COIL DATA Face area (Sq. Ft.) 5.06 5.06 5.06 5.01 Rows Johnson Controls Ducted Systems...
  • Page 31 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 32: Field Installed Electric Heat

    NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with Kit Model No. 1NP0440. 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 33: 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 34 The proper pressure regulation. (Two-stage regulation is The products of combustion are discharged horizontally through recommended). this screened, hooded vent opening on the gas heat access panel. Johnson Controls Ducted Systems...

  • Page 35: Options/Accessories

    This section describes how to use the Economizer’s user • Lit whenever 24 volts AC power is present to the RRS interface for: Economizer Controller C and R pins • FAULT (red) • Keypad and menu navigation • Settings and parameter changes Johnson Controls Ducted Systems...

  • Page 36: Smart Equipment™ Economizer Sequences

    Units with the Smart Equipment™ Control will have a factory • Return and outside air dry bulb = dry bulb changeover option or field kit with Johnson Controls Economizer. • Return and outside air dry bulb and outside air humidity =...

  • Page 37: Power Exhaust

    Economizer Damper Position For Exhaust Fan On. returns to minimum position. c. De-energizes exhaust fan when economizer output is below the Economizer Damper Position for Exhaust Fan Johnson Controls Ducted Systems...

  • Page 38: Smart Equipment™ Economizer Board Details

    Negative of the SA BUS communication Common for SA BUS power and circuit to the UCB. Through the unit wiring harness, may continue communication circuits on to the 4-stage board and/or fault detection & diagnostics board Johnson Controls Ducted Systems...
  • Page 39 24V~ IN Pin connections at right on upper edge of economizer board 24 VAC common connection to power the economizer board. 24 VAC transformer Common referenced to Connects through circuit traces to C/COM terminals and pins cabinet ground distributed on the economizer board. Johnson Controls Ducted Systems...
  • Page 40 Connects through circuit trace to 24V~ IN pin HOT sensor BldgPres parameter reports input status (-.250-.250”/w/-.062- BLDG 0-5 VDC positive input from the Building .062kPa). Used for modulating power exhaust functions when PRES Pressure sensor ExFType selection is Modulating Damper or Variable Frequency Fan. Johnson Controls Ducted Systems...
  • Page 41 Check for proper supply air blower rotation. If the blower is rotating backwards, the line voltage at the unit point of power connection is misphased (See ‘PHASING’). The tension on the belt should be adjusted as shown in Figure 20. Belt Tension Johnson Controls Ducted Systems...

  • Page 42: 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 43: 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 44 Sheave Open Open Open Open Open Closed 1.73 1VL44 AK56 1060 1130 1195 1260 1VP56 AK56 1325 1395 1460 1525 1590 1660 If return static reaches -0.2" static, unit could experience a degradation in airflow performance. Johnson Controls Ducted Systems...

  • Page 45: Ze 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 46: Ze 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 47 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 48: 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 49: 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 50: Operation

    When the “R” to “G” the compressor has been completed. After the compressor de- circuit is opened, the damper spring returns fully closed. Johnson Controls Ducted Systems...

  • Page 51: Cooling Operation Errors

    If the call for cooling is still present at the at 38 ± 5°F) or an evaporator low limit sensor (EC1) conclusion of the ASCD, the UCB will re-energize the halted (Located on the Suction Line at the Evaporator Coil.) compressor. Johnson Controls Ducted Systems...

  • Page 52: Field Installed Electric Heating Sequence Of Operations

    (1S) will be energized. After completing the 1,2,3,4,5 specified fan on delay for heating, the UCB will energize the blower motor. 1,2,3,4,5,6 b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space. Johnson Controls Ducted Systems...

  • Page 53: Gas Heating Sequence Of Operations

    ICB will energize the draft motor while the 0.37 0.29 primary limit is open. When the primary limit closes and the call for heat still exists, the ICB will start the ignition sequence Johnson Controls Ducted Systems...

  • Page 54: Flash Codes Or Error Messages

    In the event of the flame spilling out into the burner manifold area the roll-out switch will open, the ICB will close both the Check the electrical supply voltage being supplied. Be sure that it is the same as listed on the unit nameplate. Johnson Controls Ducted Systems...

  • Page 55: Start-Up (Gas Heat)

    Adjustments to the high-fire gas flow may be made by turning the pressure regulator adjusting screws on the automatic gas To Light Pilot And Main Burners: valve. Turn “off” electric power to unit. Johnson Controls Ducted Systems...

  • Page 56: Checking Gas Input

    Remove the gas piping closure panel. Disconnect wiring to the gas valves and spark ignitors. Remove the manifold-burner gas valve assembly by lifting up and pulling back. Johnson Controls Ducted Systems...

  • Page 57: Start Up For Units Equipped For Fer

    Direct drive FER units come from the factory with the following (Occupied: One 1HtgStg-%Cmd Adjust based on application Stage of Heat % three leads that lead to the indoor motor. Command) • A yellow cooling lead Johnson Controls Ducted Systems...

  • Page 58: Troubleshooting (Simplicity Lite Only)

    “FAN”. If 24 volts is present at the FAN, check for loose b. Proper wiring between the room thermostat and the wiring between the UCB and M2. UCB, i.e. Y1 to Y1, Y2 to Y2 c. Loose wiring from the room thermostat to the UCB. Johnson Controls Ducted Systems...
  • Page 59 Y1 “OUT” for incorrect wiring. If 24 volts is not time. This programming can be checked or changed by the present at the Y1 “OUT” terminal, the UCB must be local distributor. replaced. 15. If none of the above correct the error, replace the UCB. Johnson Controls Ducted Systems...

  • Page 60: Ze036 (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 61: Ze060 (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 62 Restore power to unit and induce a call for heat. indicated. All troubleshooting procedures assume the unit is Measure the voltage across the two draft motor leads Johnson Controls Ducted Systems...
  • Page 63 Cracked heat exchanger tube(s). If a heat exchanger tube or above the minimum inlet pressure stated on unit data label, tubes is cracked, then the flow through the heat exchanger then adjust the pilot pressure per the start up procedures. If Johnson Controls Ducted Systems...
  • Page 64 “ON,” check that line voltage is being code other than the heartbeat, then troubleshoot the device supplied to the contacts of the M2 contactor, and that the indicated by the fault code. If not, then remove power to the Johnson Controls Ducted Systems...
  • Page 65 1, which is the factory Make sure that the ground connections at the pilot burner, default. gas valve and ignition control are intact. Check the igniter wire for good electrical connection. If all are intact, replace the ignition control. Johnson Controls Ducted Systems...

  • Page 66: Smart Equipment™ Control Board Navigation Components

    Equipment™ control, refer to the Smart Equipment™ 11 Flashes Economizer Is Using Free Cooling Controls Sequence of Operation Overview LIT- 13 Flashes Compressor Held Off Due To Low Voltage 12011950. 14 Flashes EEPROM Storage Failure (Control Failure) No Power or Control Failure Johnson Controls Ducted Systems...

  • Page 67: 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 68 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 69 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 70 Lockout” and C1 output is then prevented until alarm reset. 24 VAC hot out for refrigerant circuit 2 High Not effective for one stage compressor UCBs. Connects HPS2 (right pin) Pressure Switch through circuit trace to the R terminal Johnson Controls Ducted Systems...
  • Page 71 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 72: Cable For Fc Buses And Sa Buses In Order Of Preference

    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 73: Start-Up Sheet

    6021974-UIM-A-1120 Start-Up Sheet Johnson Controls Ducted Systems...
  • Page 74 6021974-UIM-A-1120 Johnson Controls Ducted Systems...
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  • Page 77 6021974-UIM-A-1120 Johnson Controls Ducted Systems...

  • Page 78: 6021974-Uim-A-1120

    Subject to change without notice. Printed in U.S.A. 6021974-UIM-A-1120 Copyright © 2020 by Johnson Controls, Inc. All rights reserved. York International Corporation 5005 York Drive Norman, OK 73069...

This manual is also suitable for:

Ze036Ze048Ze060Ze072

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