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S e r v i c e L i t e r a t u r e
The ZGB packaged gas units are available in standard
cooling efficiency (036S, 048S, 060S, 074S). Cooling ca-
pacities are 3, 4, 5 and 6 tons (10.6 to 20.3kW).
All units are available in single-stage 65,000 BTUH (19
kW), single-stage 108,000 BTUH (32 kW) and two-stage
81/108,000 BTUH (24/32 kW) heat capacities. ZGB048,
060 and 074 units are available in singe-stage 150,000
BTUH (44 kW) and two-stage 113/150,000 BTUH (33/44
KW) heat capacities. Gas heat sections are designed with
aluminized steel tube heat exchangers.
Information contained in this manual is intended for use
by qualified service technicians only. All specifications are
subject to change. Procedures outlined in this manual are
presented as a recommendation only and do not super-
sede or replace local or state codes.
If the unit must be lifted for service, rig unit by attaching
four cables to the holes located in the unit base rail (two
holes at each corner). Refer to the installation instructions
for the proper rigging technique. Stacking brackets can be
removed or left on the unit permanently. If brackets are
removed, any screws removed during installation must be
replaced.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional HVAC installer or
equivalent, service agency, or the gas supplier.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at disconnect
switch(es). Unit may have multiple power
supplies.
CAUTION
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal
injury. Take care while handling this equipment and
wear gloves and protective clothing.
UNIT INFORMATION
UNIT INFORMATION
Corp1807-L2
Revised 09/2021
ZGB036, 048, 060, 074
Page 1
WARNING
To prevent serious injury or death:
1- Lock-out/tag-out before performing maintenance.
2- If system power is required (e.g., smoke detector
maintenance), disable power to blower, remove
fan belt where applicable, and ensure all
controllers and thermostats are set to the "OFF"
position before performing maintenance.
3- Always keep hands, hair, clothing, jewelry, tools,
etc., away from moving parts.

Table of Contents

Options / Accessories . . . . . . . . . . . . . . . . . . . . . Page 2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
Spec. Gas Heat High Altitude. . . . . . . . . . . . . . . . . . . Page 7
Blower Data . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .Page 7
Electrical Data . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .Page 21
I Unit Components. . . . . . . . . . .. . . . . . . . . . . . . . . . .Page 25
II Placement and Installation . . . . .. . . . . . . . . . . . . .Page 35
III Start-Up and Installation . . . . . . . . . . .. . . . . . . . .Page 35
IV Charging. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . .Page 37
V System Service Checks. . . . . . . . . . . .. . . . . . .Page 41
VI Maintenance. .. . . . . . . . .. . . . . . . . .. . . . . . . . .. Page 43
VII Accessories . . . .. . . . . . . . .. . . . . . .. . . . . . . . .. Page 45
VIII Diagrams . .. . . . ... . . . . . .. . . . ... . . . . . .. . . . .Page 51
ZGB SERIES
3, 4, 5 and 6 Ton
10.6 to 20.3 kW

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Summary of Contents for Lennox ZGB Series

  • Page 1: Table Of Contents

    ZGB SERIES UNIT INFORMATION UNIT INFORMATION 3, 4, 5 and 6 Ton 10.6 to 20.3 kW Corp1807-L2 S e r v i c e L i t e r a t u r e Revised 09/2021 ZGB036, 048, 060, 074 The ZGB packaged gas units are available in standard cooling efficiency (036S, 048S, 060S, 074S).
  • Page 2: Options / Accessories

    OPTIONS / A C C ESSORIES Item Catalog Unit Model No. COOLING SYSTEM Condensate Drain Trap 22H54 Copper 76W27 Drain Pan Overflow Switch 99W59 Low Ambient Kit 99W67 HEATING SYSTEM Gas Heat Input Standard One-Stage - 65 kBtuh input Factory Medium One-Stage - 108 kBtuh input Factory Medium Two-Stage - 81/108 kBtuh input...
  • Page 3 OPTIONS / A C C ESSORIES Item Catalog Unit Model No. ECONOMIZERS Standard Economizer With Outdoor Air Hood (Not for Title 24) Standard Economizer (Downflow) 14D94 Includes Barometric Exhaust Dampers and Exhaust Hood Standard Economizer (Horizontal) 14D92 Includes Barometric Exhaust Dampers and Exhaust Hood Standard Economizer Controls (Not for Title 24) Single Enthalpy Control 21Z09...
  • Page 4: Specifications

    SP EC IFIC ATIONS DIR ECT D RIVE M O DELS - 3 TO N | 5 TO N General Data Nominal Tonnage 3 Ton 4 Ton 5 Ton Model No. ZGB036S4E ZGB048S4E ZGB060S4E Efficiency Type Standard Standard Standard Blower Type Direct Drive Direct Drive Direct Drive...
  • Page 5 SP ECIFICATIONS B ELT D RIVE MOD ELS - 3 TO N | 5 TO N General Data Nominal Tonnage 3 Ton 4 Ton 5 Ton Model No. ZGB036S4B ZGB048S4B ZGB060S4B Efficiency Type Standard Standard Standard Blower Type Single Speed Single Speed Single Speed Belt Drive...
  • Page 6 SP ECIFICATIO NS B ELT D RIVE M O DELS - 6 TO N General Data Nominal Tonnage 6 Ton 6 Ton Model No. ZGB074S4B ZGB074S4T Efficiency Type Standard Standard Blower Type Single Speed Two Speed Belt Drive Belt Drive Cooling Gross Cooling Capacity - Btuh 68,500...
  • Page 7: Spec. Gas Heat High Altitude

    SP ECIF ICATIONS - STAND ARD GAS HEAT T H R EE P H AS E MO D ELS Model No. 036, 036, 036, 048, 048, 048, 048, 048, Heat Input Type Standard Medium Medium High High (1 Stage) (1 Stage) (2 Stage) (1 Stage) (2 Stage)
  • Page 8 B LO WER DATA - 3 TON D IRECT DR IVE - SIN GLE PH ASE ZGB036S4E - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 9 B LO WER DATA - 4 TON D IRECT DR IVE - SIN GLE PH ASE ZGB048S4E - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 10 BLOWER DATA - 5 TON DIRECT D RIVE - SING LE P H AS E ZGB060S4E - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 11 B LO WER DATA - 3 TON D IRECT DR IVE - THR EE P H AS E ZGB036S4E - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 12 B LO WER DATA - 4 TON D IRECT DR IVE - THR EE P H AS E ZGB048S4E - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 13 B LO WER DATA - 5 TON D IRECT DR IVE - THR EE P H AS E ZGB060S4E - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, etc.).
  • Page 14 BLOWER DATA - 3 TON BELT D RIVE - THREE P H ASE ZGB036S4B - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.). 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
  • Page 15 BLOWER DATA - 4 TON BELT D RIVE - THREE P H ASE ZGB048S4B - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.). 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
  • Page 16 BLOWER DATA - 5 TON BELT D RIVE - THREE P H ASE ZGB060S4B - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.). 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
  • Page 17 BLOWER DATA - 6 TON BELT D RIVE - THREE P H ASE ZGB074S4B - BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.). 2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
  • Page 18: Blower Data

    BLOWER DATA BELT DRIVE KIT SPECIFICATIONS - ZGB036-060 Model Motor HP No. of Drive Kits and RPM Range Speeds Nominal Maximum ZA01 ZA02 ZA03 ZA04 ZA05 ZA06 ZGB036S4B 1.15 678 - 1035 - - - - - - 964 - 1471 - - - - - - 678 - 1035...
  • Page 19 BLO WER DATA OPTIONS / ACCESSORIES AIR RESISTANCE - in. w.g. Wet Indoor Coil Gas Heat Exchanger Economizer Air Volume ZGB036, ZGB060, Medium High Downflow Horizontal ZGB048 ZGB074 0.01 - - - 0.05 0.06 0.03 0.04 1000 0.02 - - - 0.06 0.06 0.03...
  • Page 20 BLO WER DATA CEILING DIFFUSERS AIR RESISTANCE (in. w.g.) RTD9-65S Step–Down Diffuser RTD11-95S Step–Down Diffuser FD9-65S FD11-95S Air Volume Flush Flush 2 Ends 1 Side & All Ends & 2 Ends 1 Side & All Ends & Diffuser Diffuser Open 2 Ends Open Sides Open Open...
  • Page 21: Electrical Data

    ELECT RICA L DATA 3 TO N DIRECT DRIVE BLOWER - ZGB036S4E Voltage - 60hz 208/230V-1 Ph 208/230V-3 Ph Compressor Rated Load Amps 15.3 Locked Rotor Amps Outdoor Fan Full Load Amps Motor Power Exhaust Full Load Amps (1) 0.5 HP Indoor Blower Horsepower Motor...
  • Page 22 ELECTRIC AL DATA 3 TO N BELT DRIVE BLOWER - ZGB036S4B Voltage - 60hz 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Compressor Rated Load Amps Locked Rotor Amps Outdoor Fan Full Load Amps Motor Power Exhaust Full Load Amps (1) 0.5 HP Indoor Blower...
  • Page 23 ELECTRIC AL DATA 6 TO N BELT DRIVE BLOWER - ZGB074S4B Voltage - 60hz 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph Compressor Rated Load Amps 17.6 Locked Rotor Amps 66.1 55.3 Outdoor Fan Motor Full Load Amps Power Exhaust (1) 0.5 HP Full Load Amps Indoor Blower Motor...
  • Page 24 ZGB PARTS ARRANGEMENT IGNITION EVAPORATOR CONTROL CONTROL BLOWER COIL PANEL MOTOR CONDENSER COMPRESSOR BLOWER HOUSING HEAT EXCHANGER VENT CAP COMBUSTION CONDENSER AIR INDUCER COIL GAS VALVE SIDE POWER BURNERS ENTRY BOTTOM POWER ENTRY FIGURE 1 ZGB CONTROL BOX IGNITION CONTROL TRANSFORMER FAN RELAY GAS RELAY...
  • Page 25: I Unit Components

    I-UNIT COMPONENTS 5-Compressor Contactor K1 The ZGB unit components are shown in figure 1. All units In all ZGB units, K1 energizes compressors B1 in re- come standard with removable unit panels. All L1, L2, and sponse to thermostat demand. Three phase units use two L3 wiring is color coded;...
  • Page 26 14-Burner Control A3 TABLE 1 WARNING STATUS Slow Flash Normal operation. No call for heat Electric shock hazard. Can cause injury Fast Flash Normal operation. Call for heat. or death. Before attempting to perform Staedy Off nternal Control Fault, No Power To any service or maintenance, turn the Board or Gas Valve Relay Fault electrical power to unit OFF at disconnect...
  • Page 27 Operation 1-Compressor B On a heating demand, the ignition control checks for a IMPORTANT closed limit switch and open (to prove switch is not failed closed prior to start-up) combustion air prove switch. Once he Clean Air Act of 1990 bans the intentional venting this check is complete and conditions are correct, the ig- of refrigerant (CFC’s and HCFC’s) as of July 1, nition control then allows 30 seconds for the combustion...
  • Page 28 ZGB PLUMBING FIXED ORIFICE REFRIGERANT METERING DEVICE (RFC) DRIER EVAPORATOR COIL S4 HIGH PRESSURE LIMIT DISCHARGE PRESSURE TAP LIQUID PRESSURE TAP SUCTION PRESSURE TAP COMPRESSOR CONDENSER COIL FIGURE 5 Page 28...
  • Page 29 2-High Pressure Switch S4 2-Indoor Blower Motor B3 The high pressure switch is an automatic reset SPST N.C. Belt drive units use single or three phase motors (same switch which opens on a pressure rise. S4 is located in as supply voltage). CFM adjustments are made by adjust- the compressor discharge line and wired in series with the ing the motor pulley (sheave).
  • Page 30 1 - The following measurements must be made with air 4 - The blower RPM can be adjusted at the motor pulley. filters in place and no cooling demand. Loosen Allen screw and turn adjustable pulley clockwise to increase CFM. Turn counterclockwise 2 - With all access panels in place, measure static to decrease CFM.
  • Page 31 C-Blower Belt Adjustment D-Check Belt Tension Maximum life and wear can be obtained from belts only if Overtensioning belts shortens belt and bearing life. Check proper pulley alignment and belt tension are maintained. belt tension as follows: Tension new belts after a 24-48 hour period of operation. 1 - Measure span length X.
  • Page 32 HEAT EXCHANGER ASSEMBLY Heat Exchanger Tubes Combustion Air Inducer S10 High Temperature Limit Vent Connector FIGURE 10 Page 32...
  • Page 33 D-GAS HEAT COMPONENTS Orifice Each burner uses an orifice which is matched to the burn- 036, 048, 060, 074 Std gas heat; 1-stage 65Kbtuh input er input. The orifice is threaded into the burner manifold. 036, 048, 060, 074 Med gas heat; 1-stage 108Kbtuh input The burner is supported by the orifice and will easily slide 036, 048, 060, 074 Med gas heat;...
  • Page 34 7-Combustion Air Motor Capacitor C3 BURNER BOX ASSEMBLY The combustion air inducer motors in all ZGB units require Vent Connector run capacitors. Capacitor C3 is connected to combustion Combustion Air Inducer air inducer B6. Ratings will be on side of capacitor or com- bustion air motor nameplate.
  • Page 35: Placement And Installation

    III-START UP - OPERATION IMPORTANT A-Preliminary and Seasonal Checks n order to maximize spark energy to electrode, high 1- Make sure the unit is installed in accordance with the voltage wire should touch unit cabinet as little as installation instructions and applicable codes. possible 2- Inspect all electrical wiring, both field and factory in- stalled for loose connections.
  • Page 36 C-Heating Startup 12 - If the furnace does not light the first time (gas line not fully purged), it will attempt up to two more FOR YOUR SAFETY READ BEFORE LIGHTING ignitions before locking out. BEFORE LIGHTING smell all around the appliance area 13 - If lockout occurs, repeat steps 1 through 10.
  • Page 37: Charging

    C-Cooling Start-Up 5 - Make sure the connections are tight. Discharge and suction pressures should operate at their A-Operation normal start-up ranges. 1 - Initiate first and second stage cooling demands D-Safety or Emergency Shutdown according to instructions provided with thermostat. Turn off power to unit.
  • Page 38 TABLE 8 ZGB036 NORMAL OPERATING PRESSURES - ALL-ALUMINUM COIL Outdoor Coil Entering Air Temperature 65 °F 75 °F 85 °F 95 °F 105 °F 115 °F Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc Suct Disc (psig) (psig) (psig) (psig) (psig)
  • Page 39 ZGB036 CHARGING CURVE - ALL-ALUMINUM COIL Outdoor Temperature (°F) 115° 105° 95° 85° 75° 65° Suction Pressure (psig) ZGB048 CHARGING CURVE - ALL-ALUMINUM COIL Outdoor Temperature (°F) 115° 105° 95° 85° 75° 65° Suction Pressure (psig) Page 39...
  • Page 40 ZGB060 CHARGING CURVE - ALL-ALUMINUM COIL Outdoor Temperature (°F) 115° 105° 95° 85° 75° 65° Suction Pressure (psig) ZGB074 CHARGING CURVE - ALL-ALUMINUM COIL Outdoor Temperature (°F) 115° 105° 95° 85° 75° 65° Suction Pressure (psig) Page 40...
  • Page 41: System Service Checks

    V- SYSTEM SERVICE CHECKS 3-Testing Gas Supply Pressure When testing gas supply pressure, connect test gauge to A-Heating System Service Checks the inlet pressure tap located on unit gas valve GV1. Test All ZGB units are C.S.A. design certified without modifi- supply gas pressure with unit firing at maximum rate (both cation.
  • Page 42 5-Proper Gas Flow 6-Heat Exchanger Furnace should operate at least 5 minutes before check- Visually inspect heat exchanger. If replacement is neces- ing gas flow. Determine time in seconds for two revolu- sary refer to the instruction provided with the replacement tions of gas through the meter.
  • Page 43: Maintenance

    VI-MAINTENANCE BACK OF UNIT The unit should be inspected once a year by a qualified LIFT UP AND PULL service technician. OUT (TOOLLESS) WARNING Electric shock hazard. Can cause injury FILTER ACCESS PANEL or death. Do not use this unit if any part has been under water.
  • Page 44 Under normal operating conditions, the combustion air IGNITOR inducer wheel should be checked and cleaned prior to the heating season. However, it should be examined pe- riodically during the heating season to establish an ideal SPARK GAP cleaning schedule. SHOULD BE 1/8” Clean combustion air inducer as follows: 1 - Shut off power supply and gas to unit.
  • Page 45: Accessories

    VII-ACCESSORIES TYPICAL FLASHING DETAIL UNIT BASE The accessories section describes the application of most BOTTOM of the optional accessories which can be factory or field installed to the ZGB units. UNIT BASE RAIL A-Z1CURB When installing the ZGB units on a combustible surface FIBERGLASS INSULATION for downflow discharge applications, a Z1CURB 8-inch,...
  • Page 46 ECONOMIZER - HORIZONTAL (FIELD-INSTALLED OPTION) DAMPER MOTOR ENTHALPY CONTROL FIGURE 24 R1 MIXED AIR SENSOR S175 OUTDOOR SENSIBLE SENSOR BLOWER MOTOR BLOWER HOUSING DOWNFLOW HEAT SECTION R1 MIXED AIR OR S175 SUPPLY AIR SENSOR HORIZONTAL FIGURE 25 An optional IAQ sensor (A63) may be used to lower oper- ating costs by controlling outdoor air based on CO2 level or room occupancy (also called demand control ventila- tion or DCV).
  • Page 47 Damper Minimum Position A6 ENTHALPY CONTROLLER 1 - Set thermostat to occupied mode if the feature is available. Make sure unit 24V control leads R and OC are connected if using a thermostat which does MUM POSITION not have the feature. 2 - Rotate MIN POS SET potentiometer to approximate desired fresh air percentage.
  • Page 48 CHART 1 CALCULATE MINIMUM FRESH AIR PERCENTAGE MIXED AND RETURN AIR TEMPERATURE TABLE 14 ECONOMIZER OPERATION OUTDOOR AIR IS SUITABLE FOR FREE COOLING -- FREE COOL LED “ON DAMPER POSITION THERMOSTAT DEMAND MECHANICAL COOLING UNOCCUPIED OCCUPIED CLOSED CLOSED CLOSED MINIMUM OPEN* OPEN* OPEN*...
  • Page 49 E-Outdoor Air Dampers Set damper minimum position in the same manner as economizer minimum position. Adjust motorized damper position as shown in figure 29. Manual damper fresh air OUTDOOR AIR DAMPER intake percentage can be determined in the same manner. MOTORIZED F-Power Exhaust Relay K65 (power exhaust units) DAMPER...
  • Page 50 Different types of control systems may be used with the WRE15 is available for horizontal air flow units. Fans pro- ZGB series units. All thermostat wiring is connected to low vide exhaust air pressure relief and also run when return voltage pigtails located in the control box.
  • Page 51: Diagrams

    VIII-Wiring Diagrams and Sequence of Operation KEY LIST COMPONENT JACK/PLUG DESCRIPTION J/P # ELECTRONIC SENSOR GAS LIMIT BURNER CONTROL BOARD FLAME ROLLOUT SWITCH HEAT THERMOSTAT OPEN −20F , CLOSE 10F SOLID STATE ENTHALPY CONTROL ECONOMIZER SOLID STATE ENTHALPY SENSOR S149 OVERFLOW SWITCH ECONOMIZER CO2 SENSOR (IAQ)
  • Page 52 ZGB036, 048, 060, 074 Unit Diagram (1 of 2) P, G, J, Y, M Voltage Page 52...
  • Page 53 ZGB036, 048, 060, 074 Unit Diagram (2 of 2) P, G, J, Y, M Voltage Page 53...
  • Page 54 ZGB036, 048, 060, 074 P, Y, G, J & M Voltage Sequence of Operation Power: 1. Line voltage from unit disconnect energizes transformer T1. T1 provides 24VAC power to the unit cooling, heating and blower controls. Blower Operation: 2. Indoor thermostat terminal G, via A3 ignition control, energizes blower contactor K3 with 24VAC. 3.
  • Page 55 TYPICAL TWO-SPEED BLOWER SCHEMATIC This schematic is typical. See the wiring schematic on the unit for actual unit wiring. J / P JACK / PLUG DESCRIPTION K3 - A BLOWER HI/LO MECHANICAL SWITCHING K239-1 BLOWER HI/LO MECHANICAL SWITCHING TB1 - W1 COMPONENT TB1 - Y1 MOTOR, BLOWER...

This manual is also suitable for:

Zgb036Zgb048Zgb060Zgb074

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