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R-410A
ZJ 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 ZJ078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZJ078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 9
4 ZJ078-150 Unit Physical Dimensions . . . . . . . . . . . . . . . . . . 11
5 ZJ078-150 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
14 Smart Equipment™ Economizer Board Details . . . . . . . . . . 38
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 Component Location (ZJ120 Shown) . . . . . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZJ078-120 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 9
9 ZJ150 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZJ078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . . . 12
11 ZJ078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . . 13
12 ZJ078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 13
13 ZJ150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . . 14
14 ZJ078-150 Unit Left/End Duct Opening . . . . . . . . . . . . . . . . 14
15 ZJ078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZJ078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Down Flow 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control Board Navigation Components . . . . . . . . . . . . . . . . . . . . 61
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
LIST OF TABLES
17 Airflow Performance - Side Duct Application . . . . . . . . . . . . 45
18 Airflow Performance - Bottom Duct Application . . . . . . . . . . 47
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 . . . . . . . . . . . . . . . . . . . . 56
26 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 57
27 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 58
28 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 59
29 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
30 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 62
32 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 67
LIST OF FIGURES
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Save Side Panels For Economizer Hood Tops . . . . . . . . . . 16
21 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . 18
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
24 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . . 20
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
5803635-YIM-A-0220
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Related Manuals for Johnson Controls ZJ Series
Summary of Contents for Johnson Controls ZJ Series
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Page 1: Table Of Contents
R-410A ZJ SERIES W/SMART EQUIPMENT™ 6-1/2 - 12-1/2 Ton 60 Hertz TABLE OF CONTENTS General ..........2 Dual Enthalpy Changeover . -
Page 2: General
Observe all precautions in the literature, labels, and tags accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other applicable safety precautions and codes including ANSI Z223.1 or CSA- B149.1- latest edition. Johnson Controls Ducted Systems... - Page 3 This system uses R-410A Refrigerant which operates at • Manual Outdoor Air Damper (0-100%) higher pressures than R-22. No other refrigerant may be • Manual Outdoor Air Damper (0-35%) used in this system. • Gas Heat Propane Conversion Kit Johnson Controls Ducted Systems...
- Page 4 5 = 575-3-60 4 = PCO (Powered Conv. Outlet) 5 = DSC,NCO 6 = DSC,PCO Outdoor Air Option A = No Economizer B = Economizer w/Barometric RLF D = Economizer w/Power EXH H = Motorized Damper Johnson Controls Ducted Systems...
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Page 5: Installation
In U.S.A.: Remove the condenser coil external protective covering National Electrical Code, ANSI/NFPA No. 70 - Latest prior to operation. Edition National Fuel Gas Code, ANSI Z223.1 - Latest Edition Johnson Controls Ducted Systems... -
Page 6: Component Location (Zj120 Shown)
Compressor #1 access Side entry power York Sunline™ footprint to Toolless (high-efficiency compressor and control wiring the ZJ Series footprints door latch w/crankcase heater) knockouts are also available (field installed accessory) Figure 4: Component Location (ZJ120 Shown) -
Page 7: Location
If a unit is to be installed on a roof curb other than a ® varnishes, hydrochloric acid, cements and glues, York roof curb, gasketing must be applied to all antistatic fabric softeners for clothes dryers, masonry surfaces that come in contact with the unit underside. acid washing materials. Johnson Controls Ducted Systems... -
Page 8: Weights And Dimensions
Table 2: Weights and Dimensions Size Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.) 6 Point Load Location (lbs.) Model (Tons) Shipping Operating 1035 1030 (6.5) 1055 1050 (7.5) 1065 1060 (8.5) 1075 1070 (10) 1285 1280 (12.5) Johnson Controls Ducted Systems... -
Page 9: Zj078-150 Unit Accessory Weights
3. Weight includes mounting hardware, controls and manual bypass option. 29.69 15.25 15.38 59.00 15.38 2X Ø 24.38 SEE DETAIL A FOR GAS INLET 11.38 SEE DETAIL B 59.00 4.19 FOR DRAIN LOCATION LEFT 27.31 21.19 89.00 FRONT Figure 8: ZJ078-120 Physical Dimensions Johnson Controls Ducted Systems... -
Page 10: Zj150 Physical Dimensions
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: ZJ150 Physical Dimensions Johnson Controls Ducted Systems... -
Page 11: Zj078-150 Unit Physical Dimensions
1. Units must be installed outdoors. Over hanging structure or shrubs should not obscure condenser air discharge outlet. 2. Units may be installed on combustable floors made from wood or class A, B or C roof covering materials. Johnson Controls Ducted Systems... -
Page 12: Zj078-150 Unit Bottom Duct Openings
Bottom condensate drain 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: ZJ078-150 Unit Bottom Duct Openings Johnson Controls Ducted Systems... -
Page 13: Zj078-150 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: ZJ078-120 Unit Side Duct Openings Johnson Controls Ducted Systems... -
Page 14: Side Duct Dimensions
18 1/4 ZJ102 28 1/4 18 1/16 28 1/4 18 1/4 ZJ120 28 1/4 18 1/16 28 1/4 18 1/4 ZJ150 28 1/4 18 1/16 28 1/4 18 1/4 4-5/16 Figure 14: ZJ078-150 Unit Left/End Duct Opening Johnson Controls Ducted Systems... -
Page 15: Left/End Duct Dimensions
2 TYP. INSULATED DECK UNDER 50-1/2 COMPRESSOR SECTION FRONT 8 or 14 Figure 15: ZJ078-150 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: ZJ078-150 Transition Roof Curb Johnson Controls Ducted Systems... -
Page 16: Ductwork
The side condensate drain is reversible and maybe re-oriented to NOTE: Orientation. Panel is “insulation” side up. the rear of the cabinet to facilitate condensate piping. A condensate drain connection is available through the base pan Johnson Controls Ducted Systems... -
Page 17: Compressors
Rating Plate and Table 1. 208/230-3-60 and 380/415-3-50 units control transformers are factory 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 18: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat And All Units With Vfd Option
TERMINAL BLOCK TB1 FACTORY OR FIELD GROUND SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 22: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat and All Units With VFD Option Johnson Controls Ducted Systems... -
Page 19: Field Wiring Disconnect - Cooling Unit With Gas Heat Without Vfd Option
5803635-YIM-A-0220 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
Figure 24: Typical Electronic Thermostat Field Wiring 208/230-3-60 and 380/415-3-50 units control transformers are factory 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 21: Electrical Data
69.5 57.7 80.6 87.5 81.8 110.8 117.6 (8.5) None 20.8 10.8 20.8 21.7 31.4 34.1 28.9 40.4 43.1 40.9 55.4 58.1 None 18.6 20.4 18.6 20.4 1.35 17.3 24.6 26.9 23.1 31.9 34.1 32.7 43.9 46.1 Johnson Controls Ducted Systems... - Page 22 None 25.8 27.6 18.0 17.3 26.2 28.4 62.0 13.5 24.0 23.1 33.4 35.6 34.0 32.7 45.4 47.6 54.0 52.0 56.5 58.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...
- Page 23 3.03 43.3 66.1 57.7 84.1 81.8 114.3 121.1 (8.5) None 22.1 24.3 10.8 22.1 24.3 21.7 35.8 28.9 44.8 40.9 59.8 None 19.8 21.6 19.8 21.6 1.35 17.3 26.1 28.4 23.1 33.4 35.6 32.7 45.4 47.6 Johnson Controls Ducted Systems...
- Page 24 None 27.4 29.2 18.0 17.3 28.2 30.4 62.0 13.5 24.0 23.1 35.4 37.6 34.0 32.7 47.4 49.6 54.0 52.0 58.5 60.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...
- Page 25 43.3 75.1 57.7 93.1 81.8 123.3 130.1 (8.5) None 25.8 10.8 25.8 21.7 37.6 40.4 28.9 46.6 49.4 40.9 61.6 64.4 None 22.6 24.4 22.6 24.4 1.35 17.3 29.6 31.9 23.1 36.9 39.1 32.7 48.9 51.1 Johnson Controls Ducted Systems...
- Page 26 None 29.8 31.6 18.0 17.3 31.2 33.4 62.0 13.5 24.0 23.1 38.4 40.6 34.0 32.7 50.4 52.6 54.0 52.0 61.5 63.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...
- Page 27 78.6 85.5 57.7 96.6 103.5 81.8 126.8 133.6 (8.5) None 27.1 29.3 10.8 27.1 29.3 21.7 39.3 28.9 48.3 40.9 63.3 None 23.8 25.6 23.8 25.6 1.35 17.3 31.1 33.4 23.1 38.4 40.6 32.7 50.4 52.6 Johnson Controls Ducted Systems...
- Page 28 None 31.4 33.2 18.0 17.3 33.2 35.4 62.0 13.5 24.0 23.1 40.4 42.6 34.0 32.7 52.4 54.6 54.0 52.0 63.5 65.7 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Ducted Systems...
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Page 29: Physical Data
2-pass Microchannel 2-pass Microchannel 2-pass Microchannel 2-pass Microchannel 2-pass Microchannel EVAPORATOR COIL DATA Face area (Sq. Ft.) 13.2 13.2 13.2 13.2 13.2 Rows Fins per inch Tube diameter 0.375 0.375 0.375 0.375 0.375 Circuitry Type Intertwined Intertwined Intertwined Intertwined Intertwined Refrigerant control Johnson Controls Ducted Systems... - Page 30 Stage 50% of Full Capacity. 4. ZJ078 through ZJ150 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. Johnson Controls Ducted Systems...
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Page 31: Optional Electric Heat
Refer to the Pipe Sizing Table 12. The heating value of the gas may differ with locality. The value should be checked with the local gas utility. Figure 25: Side Entry Gas Piping Johnson Controls Ducted Systems... -
Page 32: Gas Pipe Sizing - Capacity Of Pipe
The gas supply should be a separate line and installed in accordance with all safety codes as prescribed under “Limitations”. Johnson Controls Ducted Systems... -
Page 33: Options/Accessories
W.C. at the unit under full load. Maintaining proper gas power supply. pressure depends on three main factors: The vaporization rate which depends on the temperature of the liquid and the “wetted surface” area of the container(s). Johnson Controls Ducted Systems... -
Page 34: Optional Variable Air Volume (Vav)
(1/4" diameter) must be field supplied and the assembly. Field installed Motorized Outdoor Damper installed from the transducer to both the ductwork and to the accessories include complete instructions for installation. atmosphere. Connect the tubing from the 'HIGH' pressure tap of Johnson Controls Ducted Systems... - Page 35 • DRIVE - routes power through the VFD for modulating nuts. After removing the wire nuts, connect the wires to the control of the indoor blower motor. field-installed VFD per the VFD wiring diagram (See Figure 27). Johnson Controls Ducted Systems...
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Page 36: Optional Hot Gas Bypass (Hgbp)
• Return and outside air dry bulb and return and outside air outdoor air supply. humidity = dual enthalpy • If either the return or outside air dry bulb sensors are unreliable, free cooling is not available Johnson Controls Ducted Systems... -
Page 37: Free Cooling Operation
Economizer Damper Position for Exhaust Fan If the economizer output goes to minimum position and the SAT is less than Economizer Setpoint -1°F, the control starts a 12- minute timer to de-energize a compressor output. 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...
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Page 41: Supply Air Limitations
Change the phasing of the Field Line Connection at the factory or field supplied disconnect to The tension on the belt should be adjusted as shown in Figure 29. obtain proper rotation. (Scroll compressors operate in only one Johnson Controls Ducted Systems... -
Page 42: Belt Adjustment
Air density correction factors are shown in Table 16 and Figure 30. 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 6,000 CFM at a static pressure of 1.5". Use the unit BHP at 5,000 ft. = 3.2 x .832 = 2.66 Johnson Controls Ducted Systems... - Page 44 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Open Closed 1.73 1VM50 AK74 1035 1079 1126 2.30 1VM50 AK64 1039 1094 1150 1207 1256 1308 Johnson Controls Ducted Systems...
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Page 45: Airflow Performance
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. Johnson Controls Ducted Systems... - Page 46 1. Blower performance includes gas heat exchangers and 2” 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...
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Page 47: Airflow Performance - Bottom Duct Application
1. Blower performance includes gas heat exchangers and 2” 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 48: Rpm Selection
2.30 1VM50 AK89 (8.5) 3.45 1VM50 AK74 1035 1084 1134 2.30 1VM50 AK84 (10) 3.45 1VM50 AK74 1035 1084 1134 3.45 1VM50 AK74 1035 1084 1134 (12.5) 5.75 1VP56 BK77 1052 1095 1136 1175 1216 1272 Johnson Controls Ducted Systems... -
Page 49: Air Balance
Re-checking set screws replace the dot plugs. after 10-12 hrs. run time is recommended. Tighten blower pulley and motor sheave set screws after any adjustments. Re-check set screws after 10-12 hrs. run time is recommended. Johnson Controls Ducted Systems... -
Page 50: Dry Coil Delta P
Determine the number of turns the variable motor sheave is open. ZJ078 ZJ090 0.45 ZJ102 ZJ120 ZJ150 0.35 0.25 0.15 0.05 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 Airflow (CFM) Figure 31: Dry Coil Delta P Johnson Controls Ducted Systems... -
Page 51: Motor Sheave Datum Diameters
CFM. Adjustments of the blower speed and belt tension are REQUIRED. Verify proper sheave alignment; tighten blower pulley and motor sheave set screws after these adjustments. Re-checking set screws after 10-12 hrs. run time is recommended. Johnson Controls Ducted Systems... -
Page 52: Operation
30 seconds. Additionally, the indoor blower has a delay of 10 is available and if so, which components to energize. With a seconds minimum off. "Y2" call for first stage cooling the UCB will determine if a Johnson Controls Ducted Systems... - Page 53 #1 is energized. If compressor #1 is active for first stage cooling efficiency. or the first compressor is locked-out, compressor #2 is energized. In free-cooling mode, if the call for the second stage Johnson Controls Ducted Systems...
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Page 54: Cooling Operation Errors
If the condenser motor failure, (opens at 625 ± 25 psig). low-pressure switch opens for greater than 5 seconds, the UCB Johnson Controls Ducted Systems... -
Page 55: Electric Heating Sequence Of Operations
“ON” cycles If the UCB senses zero volts from the high temperature limit, and may result in the lowering of the temperature within the the indoor blower motor is immediately energized. Johnson Controls Ducted Systems... -
Page 56: Gas Heating Sequence Of Operations
If “W1” is present, a flame is sensed, but the GV is not heat to control second stage operation of the GV. energized, the draft motor is energized until the flame detection is lost. Normal operation is now allowed. When “W1” is satisfied, both valves are closed. Johnson Controls Ducted Systems... -
Page 57: Gas Heat Limit Control Settings
Consequently, the control will respond in the same manner as outlined above under “Limit Switch”. Gas Heat Anticipator Setpoints It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater Johnson Controls Ducted Systems... -
Page 58: Start-Up (Cooling)
10.5 in. or the operating pressure drop below 4.5 in for natural gas units. If gas pressure is outside these limits, contact the local gas utility or propane supplier for corrective action. Johnson Controls Ducted Systems... -
Page 59: Checking Gas Heat Input
Using the outlet pressure port on the gas valve, connect a NOTE: To find the Btu input, multiply the number of cubic feet manometer to monitor the manifold pressure. of gas consumed per hour by the Btu content of the gas Johnson Controls Ducted Systems... -
Page 60: Charging The Unit
All ZJ units use Thermal Expansion Devices. Charge the unit to Burners/Orifices Inspection/Servicing nameplate charge. Before checking or changing burners, pilot or orifices, CLOSE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL POWER TO THE UNIT. Johnson Controls Ducted Systems... -
Page 61: Control Board Navigation Components
Equipment™ control, refer to the Smart Equipment™ Local LCD on Unit Control Board. Controls Sequence of Operation Overview LIT- Mobile Access Portal (MAP) Gateway (Portable). 12011950. • Source 1 P/N S1-JC-MAP1810-OP THERMOSTAT WIRED HERE SD-24 Figure 34: Unit Control Board Johnson Controls Ducted Systems... -
Page 62: Smart Equipment™ Ucb Details
SD-24 and R 24 VAC common for thermostat power LEDs on left edge of UCB POWER Green UCB power indicator Lit indicates 24 VAC is present at C and 24V terminals Johnson Controls Ducted Systems... - Page 63 Used in return air enthalpy calculation, 100% RH sensor temperature/humidity setpoint reset, reheat operation. Supply Duct Pressure input from 0-5 VDC @ 0-5” Input required for variable air volume units. Used in VAV indoor DCT PRS+ w.c. sensor blower operation. Johnson Controls Ducted Systems...
- Page 64 VFD enable relay coil If demand is present and permissions allow compressor 1 24 VAC hot output for compressor 1 operation; output with compressor cooling, comfort ventilation cooling, reheat or heat pump heating demands Johnson Controls Ducted Systems...
- Page 65 1.5 to 3.5 volts reading to C; at least 0.25 volts lower – Communication for SA BUS devices than +) SA BUS communication circuit to optional economizer board, 4-stage board, fault detection & diagnostics board, netstat and/or Multi Touch gateway Johnson Controls Ducted Systems...
- Page 66 Green communication board Isolated Power Lit indicates the UCB is supplying power to the communication ISO PWR indicator sub-board 1. When wiring unit and other devices using the SA Bus and FC Bus, see Table 31. Johnson Controls Ducted Systems...
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Page 67: Cable For Fc Buses And Sa Buses In Order Of Preference . 67 32 Ignition Control Flash Codes
Energized With W1 Off Second Stage Gas Valve Gas Valve Energized With First Stage Gas Valve Off Gas Flow Gas Pressure Ignition Lockout Gas Valve Flame Sensor STEADY OFF No Power Or Control Failure 24VAC or Control Johnson Controls Ducted Systems... -
Page 68: Start-Up Sheet
5803635-YIM-A-0220 Start-Up Sheet Johnson Controls Ducted Systems... - Page 69 5803635-YIM-A-0220 Johnson Controls Ducted Systems...
- Page 70 5803635-YIM-A-0220 Johnson Controls Ducted Systems...
- Page 71 5803635-YIM-A-0220 Johnson Controls Ducted Systems...
- Page 72 5803635-YIM-A-0220 Johnson Controls Ducted Systems...
- Page 73 Subject to change without notice. Printed in U.S.A. 5565603-YIM-C-1019 Copyright © 2020 by Johnson Controls, Inc. All rights reserved. Supersedes: 5565603-YIM-B-1018 York International Corporation 5005 York Drive Norman, OK 73069...
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Questions and answers
How is the gas valve wired to the Ignition Control Board
The gas valve in the Johnson Controls ZJ Series is wired to the Ignition Control Board (ICB) through the following sequence:
1. When the thermostat calls for the first stage of heating, a low-voltage control circuit is completed from terminal "R" to "W1".
2. This call for heat is monitored by the Unit Control Board (UCB), which then sends a signal to the Ignition Control Board (ICB).
3. The ICB initiates the fan-on delay for heating and energizes the first stage ignition module ("IC1").
4. The ignition module ("IC1") starts sparking the igniter and opens the redundant valve inside the first stage main gas valve ("GV1"), allowing gas flow to the first stage carryover tube.
5. Once the pilot flame is ignited and detected by the flame sensor, a signal is sent back to "IC1" to confirm flame presence, allowing normal burner operation.
This wiring sequence ensures that the gas valve operates safely and only when ignition conditions are met.
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Need electrical schematic for heater ignition wiring
Ignition Control Board Wiring to the gas valve