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York ZW-06 Installation Manual

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R-410A
ZW SERIES W/SMART EQUIPMENT™
6-1/2 - 12-1/2 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . . 36
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 ZW-06 thru -12 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZW-06 thru -12 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9
4 ZW-06 thru -12 Unit Physical Dimensions . . . . . . . . . . . . . . . 11
5 ZW-06 thru -12 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 32
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
16 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 ZW Component Location (ZW-10 Shown) . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZW-06 thru -10 Physical Dimensions . . . . . . . . . . . . . . . . . . . 9
9 ZW-12 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZW-06 thru -12 Unit Bottom Duct Openings . . . . . . . . . . . . . 12
11 ZW-06 thru -12 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13
12 ZW-06 thru -10 Unit Side Duct Openings . . . . . . . . . . . . . . . 13
13 ZW-12 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . 14
15 ZW-06 thru -12 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZW-06 thru -12 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . . 16

TABLE OF CONTENTS

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 52
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 55
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 55
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 56
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control Board Navigation Components . . . . . . . . . . . . . . . . . . . . 60
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
LIST OF TABLES
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 49
22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . . 51
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 52
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 55
26 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 57
27 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 57
28 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 59
29 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
30 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 61
32 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 67
LIST OF FIGURES
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . 18
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
28 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38
29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
30 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
31 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
32 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
33 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5565604-BIM-B-1018

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Summary of Contents for York ZW-06

  • Page 1: Table Of Contents

    30 Altitude/Temperature Correction Factors ....43 15 ZW-06 thru -12 Roof Curb ......15 31 Dry Coil Delta P .

  • Page 2: General

    5565604-BIM-B-1018 General Ducted Systems ZW units are single package air conditioners with optional gas heating designed for outdoor installation on a Before performing service or maintenance operations on rooftop or slab and for non-residential use. These units can be unit, turn off main power switch to unit. Electrical shock equipped with factory or field installed electric heaters for could cause personal injury.
  • Page 3 Additional information is available in the following reference forms: • Technical Guide - ZW-06 thru -12, 5167796 • General Installation - ZW-06 thru -12, 5565604 Improper installation may create a condition where the • Smart Equipment™ Control Quick Start Guide - 1136326 operation of the product could cause personal injury or •...
  • Page 4 5565604-BIM-B-1018 Nomenclature 6.5-12.5 Ton ZW Model Number Nomenclature -10 C A 2 A 1 Product Generation Product Category 1 = First Generation 2 = Second Generation Z = A/C, Single Pkg., R-410A Cabinet Options Product Identifier A = Std Cabinet W = Pkg AC R410A High Eff E = SSD (SST Drain Pan) R = Reverse Drain Pan...

  • Page 5: Installation

    5565604-BIM-B-1018 Remove the toolless doorknobs and instruction packet Installation prior to installation. Installation Safety Information Condenser Read these instructions before continuing this appliance Coil External installation. This is an outdoor combination heating and cooling Protective unit. The installer must assure that these instructions are made Covering available to the consumer and with instructions to retain them for future reference.

  • Page 6: Zw Component Location (Zw-10 Shown)

    5565604-BIM-B-1018 Gas-Fired Central Furnace Standard, ANSI Z21.47 Latest Size of unit for proposed installation should be based on heat Edition loss/heat gain calculation made according to the methods of Air Conditioning Contractors of America (ACCA). Local building codes, and This furnace is not to be used for temporary heating of buildings Local gas utility requirements or structures under construction.

  • Page 7: Location

    5565604-BIM-B-1018 Table 1: ZW-06 thru -12 Unit Limitations Unit Limitations Size Model Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-3-60 460-3-60 (6.5) 575-3-60 208/230-3-60 460-3-60 (7.5) 575-3-60 208/230-3-60 460-3-60 (8.5) 575-3-60 208/230-3-60 460-3-60 (10) 575-3-60 208/230-3-60 460-3-60 (12.5)

  • Page 8: Weights And Dimensions

    5565604-BIM-B-1018 Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly. Units may be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose. LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES.

  • Page 9: Thru -12 Unit Accessory Weights

    5565604-BIM-B-1018 Table 3: ZW-06 thru -12 Unit Accessory Weights Weight (lbs.) Unit Accessory Shipping Operating Economizer Power Exhaust Electric Heat Gas Heat Variable Frequency Drive 1. Weight given is for the maximum heater size available (54KW). 2. Weight given is for the maximum number of tube heat exchangers available (8 tube).

  • Page 10: Physical Dimensions

    5565604-BIM-B-1018 28.86 29.66 44.09 15.23 14.85 29.03 29.03 14.85 Ø 24.58 TYP. 4 PL. 15.23 See detail A for gas inlet 11 3/8 See detail B for drain location 21 3/16 LEFT 4 3/16 FRONT 27 5/16 Figure 9: ZW-12 Physical Dimensions Johnson Controls Ducted Systems...

  • Page 11: Thru -12 Unit Physical Dimensions

    5565604-BIM-B-1018 Table 4: ZW-06 thru -12 Unit Physical Dimensions Dimension (in.) Unit Model Number ZW-06 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZW-07 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZW-08 50 3/4 30 3/16...

  • Page 12: Thru -12 Unit Bottom Duct Openings

    14 1/2 25 9/16 Bottom gas supply entry 16 3/8 18 1/16 FRONT TOP VIEW Bottom power, control and convenience outlet wiring entry 3X Ø 0.875 Ø 2.469 Figure 10: ZW-06 thru -12 Unit Bottom Duct Openings Johnson Controls Ducted Systems...

  • Page 13: Thru -12 Unit Electrical Entry

    D o t P l u g s Return Supply Air 2 - 3 1 /3 2 5 - 5 /3 2 3 1 - 1 1 /1 6 Figure 12: ZW-06 thru -10 Unit Side Duct Openings Johnson Controls Ducted Systems...

  • Page 14: Side Duct Dimensions

    28 1/4 18 1/16 28 1/4 18 1/4 ZW-10 28 1/4 18 1/16 28 1/4 18 1/4 ZW-12 28 1/4 18 1/16 28 1/4 18 1/4 4-5/16 Figure 14: ZW-06 thru -12 Unit Left/End Duct Opening Johnson Controls Ducted Systems...

  • Page 15: Left/End Duct Dimensions

    50-1/2 COMPRESSOR SECTION FRONT 8 or 14 Figure 15: ZW-06 thru -12 Roof Curb 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 16: ZW-06 thru -12 Transition Roof Curb Johnson Controls Ducted Systems...

  • Page 16: Ductwork

    5565604-BIM-B-1018 Ductwork Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA. A closed return duct system should be used. This will not preclude use of economizers or outdoor fresh air intake.

  • Page 17: Compressors

    5565604-BIM-B-1018 for piping inside the roof curb. Trap the connection per Figure 21. The trap and drain lines should be protected from freezing. Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install condensate drain line from the 1 Exposure, even if immediately cleaned up, may cause inch NPT female connection on the unit to an open drain.

  • Page 18: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat And All Units With Vfd Option

    5565604-BIM-B-1018 The internal wiring harnesses furnished with this unit are an a separate branch circuit fed directly from the meter panel and integral part of the design certified unit. Field alteration to properly fused. comply with electrical codes should not be required. If any of Refer to Figures 22, 23 and 24 for typical field wiring and to the the wire supplied with the unit must be replaced, replacement appropriate unit wiring diagram mounted inside control doors...

  • Page 19: Field Wiring Disconnect - Cooling Unit With Gas Heat Without Vfd Option

    5565604-BIM-B-1018 CONTACTOR 1M FACTORY OR FIELD GROUND SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 23: Field Wiring Disconnect - Cooling Unit With Gas Heat Without VFD Option Johnson Controls Ducted Systems...

  • Page 20: Control Wire Sizes

    5565604-BIM-B-1018 unit. Refer to Table 8 for control wire sizing and maximum Thermostat Wiring length. The thermostat should be located on an inside wall approximately 56 inch above the floor where it will not be Table 8: Control Wire Sizes subject to drafts, sun exposure or heat from electrical fixtures or appliances.

  • Page 21: Electrical Data

    5565604-BIM-B-1018 Table 9: Electrical Data ZW-06 thru -12 Standard Motor - 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/ Pwr...
  • Page 22 5565604-BIM-B-1018 ZW-06 thru -12 Standard Motor - Without Powered Convenience Outlet (Continued) 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/ Pwr (Tons)
  • Page 23 5565604-BIM-B-1018 ZW-06 thru -12 Hi Static Motor - 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/ Pwr (Tons)
  • Page 24 5565604-BIM-B-1018 ZW-06 thru -12 Hi Static Motor - Without Powered Convenience Outlet (Continued) 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/ Pwr...
  • Page 25 5565604-BIM-B-1018 ZW-06 thru -12 Standard Motor - 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/ Pwr (Tons) (Amps)
  • Page 26 5565604-BIM-B-1018 ZW-06 thru -12 Standard Motor - With Powered Convenience Outlet (Continued) 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/ Pwr (Tons)
  • Page 27 5565604-BIM-B-1018 ZW-06 thru -12 Hi Static Motor - 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/ Pwr (Tons)
  • Page 28 5565604-BIM-B-1018 ZW-06 thru -12 Hi Static Motor - With Powered Convenience Outlet (Continued) 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/ Pwr...

  • Page 29: Physical Data

    5565604-BIM-B-1018 Table 10: Physical Data ZW-06 thru -12 Physical Data Models Component ZW-06 ZW-07 ZW-08 ZW-10 ZW-12 Nominal Tonnage 12.5 AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 76000 88000 99700 124000 154000 AHRI net capacity (Btu) 74000...
  • Page 30 2. Cooling Unit with Gas Heat 3. 1 Stage 50% of Full Capacity. 4. ZW-06 through ZW-12 have crankcase heaters standard. 5. 2 In. Throwaway, Standard, MERV (Minimum Efficiency Reporting Value) 3. 6. 2 In. Pleated, Optional, MERV 8. 7. 4 In. Pleated, Optional, MERV 13.

  • Page 31: Optional Electric Heat

    5565604-BIM-B-1018 These CSA approved heaters are located within the central Optional Electric Heat compartment of the unit with the heater elements extending in The factory-installed heaters are wired for single point power to the supply air chamber. supply. Power supply need only be brought into the single point Fuses are supplied, where required, by the factory.

  • Page 32: Gas Pipe Sizing - Capacity Of Pipe

    5565604-BIM-B-1018 Table 12: Gas Pipe Sizing - Capacity of Pipe Nominal Iron Pipe Size Length of Pipe (ft.) 3/4 in. 1 in. 1-1/4 in. 1050 OPTIONAL COIL GUARD SHOWN NOTE: Maximum capacity of pipe in cubic feet of gas per hour based upon a pressure drop of 0.3 inch W.C.

  • Page 33: Options/Accessories

    5565604-BIM-B-1018 A 1/8-inch NPT plugged tapping, accessible for test gage The proper pressure regulation. (Two-stage regulation is connection, must be installed immediately upstream of the recommended). gas supply connection to the unit. The pressure drop in the lines between regulators and After the gas connections have been completed, open the between the second stage regulator and the appliance.

  • Page 34: Optional Variable Air Volume (Vav)

    5565604-BIM-B-1018 Smoke Detectors Economizer The Economizer can be a factory installed option or a field installed accessory. If factory installed, refer to the instructions included with the outdoor air hood to complete the assembly. Field installed Economizer accessories include complete The use of duct smoke detectors have specific limitations instructions for installation.
  • Page 35 5565604-BIM-B-1018 the transducer to a static pressure tap (field supplied) in the • LINE (or BYPASS) - routes power directly to the motor supply duct located at a point where constant pressure is which provides full-speed motor operation and complete expected.

  • Page 36: Optional Hot Gas Bypass (Hgbp)

    5565604-BIM-B-1018 The VFD should also be grounded per the manufacturer's The economizer minimum position is set during occupied mode specifications. when outside air is not suitable for free cooling. The position of the damper is set proportionally between the "Economizer Minimum Position and the Economizer Minimum Position Low ELEMENTARY DIAGRAM Speed Fan"...

  • Page 37: Free Cooling Operation

    5565604-BIM-B-1018 If at any time the economizer output goes above the minimum Free Cooling Operation position the timer stops and resets when the economizer output When the control determines that the outside air is suitable, the returns to minimum position. first stage of cooling will always be free cooling.

  • Page 38: Smart Equipment™ Economizer Board Details

    5565604-BIM-B-1018 Figure 28: 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 39 5565604-BIM-B-1018 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 40 5565604-BIM-B-1018 Table 14: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC hot connection to power the economizer board. 24 VAC transformer HOT Connects through circuit traces to R/24V~ terminals and pins distributed on the economizer board. ANALOG INPUTS Terminal on lower edge of economizer board 24 VAC hot supplied for the outdoor air 24V~...

  • Page 41: Supply Air Limitations

    5565604-BIM-B-1018 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 42: Belt Adjustment

    5565604-BIM-B-1018 Procedure for adjusting belt tension: 1. Loosen six nuts (top and bottom) A. 2. Adjust by turning (B). 3. Never loosen nuts (C). 4. Use belt tension checker to apply a perpendicular * NEVER LOOSEN force to one belt at the midpoint of the span as shown.

  • Page 43: Altitude/Temperature Correction Factors

    5565604-BIM-B-1018 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 44 5565604-BIM-B-1018 Drive Selection Determine side or bottom supply duct Application. Determine desired airflow. Calculate or measure the amount of external static pressure. Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table.

  • Page 45: Airflow Performance

    5565604-BIM-B-1018 Airflow Performance Table 17: Airflow Performance - Side Duct Application ZW-06 (6.5 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 1.5 HP &...
  • Page 46 5565604-BIM-B-1018 ZW-10 (10 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard 2 HP & Drive Hi Static 3 HP &...

  • Page 47: Airflow Performance - Bottom Duct Application

    5565604-BIM-B-1018 Table 18: Airflow Performance - Bottom Duct Application ZW-06 (6.5 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 1.5 HP &...

  • Page 48: Rpm Selection

    5565604-BIM-B-1018 ZW-10 (10 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Standard 2 HP & Drive Hi Static 3 HP &...

  • Page 49: Air Balance

    5565604-BIM-B-1018 Table 20: Indoor Blower Specifications Motor Motor Sheave Blower Sheave Size Model Datum Dia. Datum Dia. Belt (Tons) Eff. Frame Bore (in.) Model Bore (in.) Model (in.) (in.) 1-1/2 1725 1.15 2.6 - 3.6 1VL40 AK74 (6.5) 1725 1.15 3.6 - 4.6 1VM50 AK74...

  • Page 50: Dry Coil Delta P

    Failure to properly adjust the total system air quantity measurement, be certain that the air filters are clean. can result in extensive blower damage. Determine the number of turns the variable motor sheave is open. ZW-06 ZW-07 0.45 ZW-08 ZW-10 ZW-12 0.35...

  • Page 51: Motor Sheave Datum Diameters

    5565604-BIM-B-1018 EXAMPLE Supply Air Drive Adjustment A 12.5 ton unit was selected to deliver 4,000 CFM with a 3 HP motor, but the unit is delivering 3,800 CFM. The variable pitch motor sheave is set at 2 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 52: Operation

    5565604-BIM-B-1018 Table 23: Additional Static Resistance Electric Heat kW Size Model Cooling Only Economizer 4” Filter (Tons) 1900 0.06 0.02 0.12 0.05 0.06 0.07 0.08 0.10 2100 0.07 0.02 0.13 0.06 0.07 0.08 0.09 0.11 2300 0.08 0.04 0.14 0.07 0.08 0.09 0.10...
  • Page 53 5565604-BIM-B-1018 Once placed into the Occupied Mode, the speed of the indoor * To be available, a compressor must not be locked-out due to a blower motor is controlled by duct static pressure. The Duct high or low-pressure switch or the Evaporator Low Limit Static set point (default = 1.5") is the pressure that the VFD Sensor (EC1, 2) detects a temperature below 26 Deg.

  • Page 54: Cooling Operation Errors

    5565604-BIM-B-1018 by the thumbwheel on the damper motor. When the "R" to "G" detects a temperature below 26 Deg. F (default), the UCB will circuit is opened, the damper spring returns fully closed. de-energize the associated compressor, initiate the ASCD, and, if the other compressor is idle, stop the condenser fans.

  • Page 55: Electric Heating Sequence Of Operations

    UNIT (TONS) VOLTAGE SWITCH Electric Heating Sequence Of Operations OPENS °F The following sequence describes the operation of the electric ZW-06, 07 heat section. (6.5, 7.5) 208/230 ZW-08, -10, -12 (8.5,10, 12.5) For units with VFD and electric heat, the speed of the indoor blower motor continues to be controlled by duct static pressure via the Smart Equipment™...

  • Page 56: Gas Heating Sequence Of Operations

    5565604-BIM-B-1018 When “W2” is satisfied, the second main valve is closed. Gas Heating Sequence Of Operations Retry Operation When a flame is lost or is not detected during an attempt to achieve ignition, a retry operation occurs. A 30-second purge is For units with VFD and gas heat, the speed of the indoor performed between ignition attempts.

  • Page 57: Gas Heat Limit Control Settings

    Main Limit Setting and may result in the lowering of the temperature within the °F Size Opt. conditioned space. Refer to Table 27 for the required gas heat ZW-06 anticipator setting. ZW-07 Table 27: Gas Heat Anticipator Setpoints SETTING, AMPS ZW-08 ZW-10 0.65...

  • Page 58: Start-Up (Cooling)

    5565604-BIM-B-1018 Start-Up (Cooling) Lighting The Main Burners Turn “OFF” electric power to unit. Prestart Check List Turn room thermostat to lowest setting. After installation has been completed: Turn gas valve counter-clockwise to “ON” position (See Check the electrical supply voltage being supplied. Be sure Figure 33).

  • Page 59: Gas Rate Cubic Feet Per Hour

    5565604-BIM-B-1018 To determine the rate of gas flow (Second Stage). Table 28: Gas Rate Cubic Feet Per Hour Turn off all other gas appliances connected to the gas Size of Test Dial Seconds for meter. One Rev. 1/2 cu. ft. 1 cu.

  • Page 60: Charging The Unit

    5565604-BIM-B-1018 If necessary, using a screwdriver, turn the first stage Make sure that burners are level and seat at the rear of the gas adjustment screw (adjacent to the “LO” marking on the orifice. valve) clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure.

  • Page 61: Smart Equipment™ Ucb Details

    5565604-BIM-B-1018 THERMOSTAT WIRED HERE SD-24 Figure 34: Unit Control Board Table 30: 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 62 5565604-BIM-B-1018 Table 30: 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 63 5565604-BIM-B-1018 Table 30: 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 64 5565604-BIM-B-1018 Table 30: 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 65 5565604-BIM-B-1018 Table 30: 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 24 VAC hot return from refrigerant circuit 2 High allow C1 output.
  • Page 66 5565604-BIM-B-1018 Table 30: Smart Equipment™ UCB Details (Continued) Description Function & Comments Factory wired SA Bus connector Optional communication sub-board at center of UCB Terminal FC BUS connections on left edge of the communication board Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts FC (“Field Connected”) BUS BACnet MSTP reading to COM;...

  • Page 67: Cable For Fc Buses And Sa Buses In Order Of Preference . 67 32 Ignition Control Flash Codes

    5565604-BIM-B-1018 Table 31: Cable for FC Buses and SA Buses in Order of Preference Non-Plenum Applications Plenum Applications Bus and Cable Type Part Number O.D. Part Number O.D. Anixter: Anixter: CBL-22/3-FC-PLN CBL-22/3-FC-PVC 0.138 in. 0.140 in. FC Bus: 22 AWG Stranded, 3-Wire Twisted Shielded Cable Belden: B6501FE Belden®: B5501FE Anixter:...

  • Page 68: Start-Up Sheet

    5565604-BIM-B-1018 Start-Up Sheet Johnson Controls Ducted Systems...
  • Page 69 5565604-BIM-B-1018 Johnson Controls Ducted Systems...
  • Page 70 5565604-BIM-B-1018 Johnson Controls Ducted Systems...
  • Page 71 5565604-BIM-B-1018 Johnson Controls Ducted Systems...
  • Page 72 5565604-BIM-B-1018 Johnson Controls Ducted Systems...
  • Page 73 Subject to change without notice. Printed in U.S.A. 5565604-BIM-B-1018 Copyright © 2018 by Johnson Controls, Inc. All rights reserved. Supersedes: 5565604-BIM-A-0818 York International Corporation 5005 York Drive Norman, OK 73069...

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Zw seriesZw-07Zw-08Zw-10Zw-12

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