Johnson Controls ZD Series Installation Manual
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Johnson Controls 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 (Simplicity Lite ZD-03 through -
05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
through -A6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Optional 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 ZD-03 through -A6 Unit Limitations . . . . . . . . . . . . . . . . . . . . . 6
2 ZD-03 through -A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZD-03 through -A6 Unit Accessory Weights . . . . . . . . . . . . . . 8
4 ZD-03 through -A6 Unit Clearances . . . . . . . . . . . . . . . . . . . 10
5 ZD-03 through -A6 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 ZD-03 through -A6 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 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45
16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 46
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48
1 ZD-03 through -A6 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
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZD-03 through -A6 Disconnect Location . . . . . . . . . . . . . . . 10
10 ZD-03 through -A6 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 Heating Sequence Of Operations. . . . . . . . . . . . . . . . 52
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 54
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 57
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 58
Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LIST OF TABLES
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53
24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 54
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 57
27 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
28 ZD-03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
29 ZD-04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
30 ZD-05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
31 ZD-A6 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
32 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 66
33 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66
34 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 67
35 Cable for FC Buses and SA Buses in Order of Preference . 72
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 . . . . . . . . . . . . . . . . . . . . . 56
25 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 56
26 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 56
28 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
29 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 67

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Summary of Contents for Johnson Controls ZD Series

  • Page 1: Table Of Contents

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

  • 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 4 = 460-3-60 5 = 575-3-60 2. 3 - 5 ton only Outdoor Air Option A = No Economizer C = Economizer w/o Barometric RLF F = Econ BAS Rdy w/o Barometric RLF H = Motorized Damper 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: Through -A6 Unit Limitations

    Size Unit Voltage SCCR (kVA) Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-1-60 208/230-3-60 ZD-03 (3.0) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 ZD-04 (4.0) 460-3-60 575-3-60 208/230-1-60 208/230-3-60 ZD-05 (5.0) 460-3-60 575-3-60 208/230-3-60 ZD-A6 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: Through -A6

    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: Through -A6 Cooling Only/Electric Heat Front View Physical Dimensions

    5742638-BIM-C-0220 Figure 5: ZD-03 through -A6 Cooling Only/Electric Heat Front View Physical Dimensions Figure 6: ZD-03 through -A6 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Ducted Systems...

  • Page 10: Through -A6 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: ZD-03 through -A6 Disconnect Location Johnson Controls Ducted Systems...

  • Page 11: Through -A6 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: ZD-03 through -A6 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 (Smart Equipment™ Zd-03 Through -A6)

    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: Through -A6 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 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: 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 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 “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 35: 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 36: 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 37: 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 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 level, the scroll is misphased.) rotating backwards, the line voltage at the unit point of power connection is misphased (See ‘PHASING’). 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: 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 46: 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 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

    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. (Smart Equipment™ Control) to protect against low Johnson Controls Ducted Systems...

  • Page 52: Electric Heating Sequence Of Operations

    2,4,6 a. Upon a call for first-stage heat by the thermostat, the 2,4,6 heater sequencer (1S) (15, 20, 30 kW 230 volt) and 460-3-60 2,4,6 contactor (2M) (20, 30 kW 460 and 575 volt) will be Johnson Controls Ducted Systems...

  • Page 53: Gas Heating Sequence Of Operations

    ICB. The UCB also monitors the After the centrifugal switch closes, a 15 second heat exchanger primary limit and gas valve. Johnson Controls Ducted Systems...

  • Page 54: Flash Codes Or Error Messages

    (See Table 33) or sent error message to the LCD Smart will lock out the furnace and flash a code (Table 33). If open, Equipment™ Control. then the ICB will energize the draft motor and verify that the Johnson Controls Ducted Systems...

  • Page 55: Resets

    A fire or explosion may result causing property damage, Measure the condenser fan amp draw. personal injury or loss of life. Johnson Controls Ducted Systems...

  • Page 56: Typical Single Stage Gas Valves

    3.50 IWG. The actual manifold pressure exchanger. depends on the local fuel heating value. Burner Air Shutter Adjustment Adjust burner shutters so no yellow flame is observed in the heat exchanger tubes. Johnson Controls Ducted Systems...

  • Page 57: Checking Gas Input

    The result is 99,750 the rise range stated on the rating plate and the data in Btuh, which is close to the 100,000 Btuh rating of the furnace. Table 11. Johnson Controls Ducted Systems...

  • Page 58: Troubleshooting (Simplicity Lite Only)

    R and G in the AUTO the compressor housing. If it is hot, the compressor may be position during calls for cooling. off on inherent protection. Cancel any calls for cooling and Johnson Controls Ducted Systems...
  • Page 59 This programming can be checked or changed by the out, the UCB may have the compressor in an ASCD. local distributor. Check the LED for an indication of an ASCD cycle. The 15. If none of the above correct the error, replace the UCB. Johnson Controls Ducted Systems...

  • Page 60: 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: 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 Verify both conditions are If the flame is weak or unstable in the flame sensor area, within the published ranges. then verify the gas inlet pressure. If gas inlet pressure is Johnson Controls Ducted Systems...
  • Page 64 UCB, i.e. that the thermostat “W1” terminal is connected to the “W1” terminal of the UCB, and Place the thermostat fan switch in the “ON” position. If the for loose wiring. supply air blower motor energizes, go to Step 10. Johnson Controls Ducted Systems...

  • Page 65: Fan On And Off Delays

    Check the igniter • Gas Heat Option #1 - Press the LAST ERROR and wire for good electrical connection. If all are intact, replace TEST RESET buttons simultaneously and then release. the ignition control. Johnson Controls Ducted Systems...

  • Page 66: Smart Equipment™ Control Board Navigation Components

    LPS1 - Compressor Lock out 7 Flashes FS1 - Compressor Lock out MAP Gateway Instruction P/N 24-10737-8 For more information on the Smart Equipment™ unit control board navigation, refer to the Smart Equipment™ Quick Start Guide. 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 C1 output. Three HPS2 trips in a two hour period cause a (left pin) Pressure Switch “High Pressure Switch 1 Lockout” and C2 output is then prevented until alarm reset. Connects through circuit trace to the right LPS2 pin. Johnson Controls Ducted Systems...
  • Page 71 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 Factory wired SA Bus connector Johnson Controls Ducted Systems...
  • Page 72 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

    5742638-BIM-C-0220 Start-Up Sheet Johnson Controls Ducted Systems...
  • Page 74 5742638-BIM-C-0220 Johnson Controls Ducted Systems...
  • Page 75 5742638-BIM-C-0220 Johnson Controls Ducted Systems...
  • Page 76 5742638-BIM-C-0220 Johnson Controls Ducted Systems...
  • Page 77 5742638-BIM-C-0220 Johnson Controls Ducted Systems...

  • Page 78: 5742638-Bim-C-0220

    Subject to change without notice. Printed in U.S.A. 5742638-BIM-C-0220 Copyright © 2020 by Johnson Controls, Inc. All rights reserved. Supersedes: 5742638-BIM-B-1119 York International Corporation 5005 York Drive Norman, OK 73069...

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