Johnson Controls Unitary Products ZS-03 Installation Manual
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Johnson Controls Unitary Products ZS-03 Installation Manual

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R-410A
ZS 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
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . 50
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 ZS-03 thru -A6 Unit Limitations . . . . . . . . . . . . . . . . . . . . . 6
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZS-03 thru -A6 Unit Accessory Weights . . . . . . . . . . . . . . 8
4 ZS-03 thru -A6 Unit Clearances . . . . . . . . . . . . . . . . . . . 10
5 ZS-03 thru -A6 Utilities Entry. . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 38
10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . 38
11 Gas Pipe Sizing - CapacIty of Pipe . . . . . . . . . . . . . . . . . 39
13 ZS Blower Performance Side Duct . . . . . . . . . . . . . . . . . 46
1 ZS-03 thru -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
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rain Hood Physical Dimensions . . . . . . . . . . . . . . . . . . 10
8 ZS-03 thru -A6 Disconnect Location . . . . . . . . . . . . . . . 10
9 ZS-03 thru -A6 Unit Side Duct Openings . . . . . . . . . . . . 11
10 ZS-03 thru -A6 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . 13
13 Typical Field Power and Control Wiring . . . . . . . . . . . . . 15
14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 39

TABLE OF CONTENTS

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 51
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 52
Electric Heating Sequence Of Operations . . . . . . . . . . . . 53
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 53
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 54
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 54
Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Heat Anticipator Setpoints. . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking Gas Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
LIST OF TABLES
14 ZS Blower Performance Bottom Duct . . . . . . . . . . . . . . . 48
15 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . 49
17 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 50
18 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 51
19 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 53
20 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 54
22 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . 55
23 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 56
24 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . 58
25 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 67
26 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . 67
LIST OF FIGURES
15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 39
16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . 41
17 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 42
18 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 42
19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
20 Altitude/Temperature Correction Factors . . . . . . . . . . . . 43
21 Pressure Drop Across Coil. . . . . . . . . . . . . . . . . . . . . . . 50
22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
23 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . 57
24 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . 57
25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . 57
26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . 57
27 ZS-03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . 61
28 ZS-04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . 61
29 ZS-05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . 62
30 ZS-A6 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . 62
31 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
570570-BIM-A-0310

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Summary of Contents for Johnson Controls Unitary Products ZS-03

  • Page 1: Table Of Contents

    26 Typical Flame Appearance ..... . 57 10 ZS-03 thru -A6 Roof Curb ..... . . 11 27 ZS-03 (3.0 Ton) Operating Pressures .

  • Page 2: General

    Refer to this manual for assistance or department. for additional information, consult a qualified contractor, Installation and service must be performed by a qualified installer or service agency. installer, service agency or the gas supplier. Johnson Controls Unitary Products...
  • Page 3 Untrained personnel can perform basic maintenance functions • Technical Guide - ZS-03 thru -A6, 254604 of cleaning coils and filters and replacing filters. • General Installation - ZS-03 thru -A6, 570570...
  • Page 4 3 = Smoke Detector S.A. 4 = Smoke Detector R.A. 1. 3 thru 5 Ton Units 5 = Pwr'd Conv. Outlet 2. 6 Ton Units Cooling Only / Cooling With Electric Heat 3. 6 Ton Unit Cooling With Gas Heat Johnson Controls Unitary Products...

  • Page 5: Installation

    (computer rooms, switchgear, etc.), please reference applications bulletin AE-011-07 or call the applications department for Unitary Products @ 1-877-UPG-SERV for guidance. Additional accessories may be needed for stable operation at temperatures below 30° F. Johnson Controls Unitary Products...

  • Page 6: Thru -A6 Unit Limitations

    GFCI Simplicity ® convenience outlet control board Knockout for side power and control entry Figure 1: ZS-03 thru -A6 Component Location Table 1: ZS-03 thru -A6 Unit Limitations Unit Limitations Size Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°F)

  • 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 Unitary Products...

  • Page 8: Weights And Dimensions

    (Tons) Shipping Operating 18.25 (3.0) 31.5 18.5 (4.0) (5.0) (6.0) Table 3: ZS-03 thru -A6 Unit Accessory Weights Weight (lbs.) Unit Accessory Shipping Operating Economizer Power Exhaust Electric Heat Gas Heat 1. Weight given is for the maximum heater size available (30KW).

  • Page 9: Thru -A6 Cooling Only/Electric Heat Front View Physical Dimensions

    570570-BIM-A-0310 Figure 5: ZS-03 thru -A6 Cooling Only/Electric Heat Front View Physical Dimensions Figure 6: ZS-03 thru -A6 Cooling Only/Gas Heat Front View Physical Dimensions Johnson Controls Unitary Products...

  • Page 10: Thru -A6 Unit Clearances

    Fixed Outdoor Air Damper Detail “B” Motorized 16-1/2 Damper Figure 7: ZS-03 thru -A6 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions Table 4: ZS-03 thru -A6 Unit Clearances Location Clearance Filter Access 24” (Cooling/Electric Heat) Front 32” (Gas Heat) Blower Motor Access 12”...

  • Page 11: Thru -A6 Utilities Entry

    570570-BIM-A-0310 Figure 9: ZS-03 thru -A6 Unit Side Duct Openings Table 5: ZS-03 thru -A6 Utilities Entry Hole Opening Size (Dia.) Used For Side 7/8” KO Control Wiring Bottom Side 2” KO Power Wiring Bottom 1-5/8” KO Gas Piping (Front) 1-1/2”...

  • 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 Unitary Products...

  • Page 13: Filters

    Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1. Johnson Controls Unitary Products...

  • Page 14: Control Wire Sizes

    1. From the unit to the thermostat and back to the unit. Power Wiring Detail Units are factory wired for the voltage shown on the unit nameplate. Refer to Electrical Data Table 7 to size power wiring, fuses, and disconnect switch. Johnson Controls Unitary Products...

  • Page 15: Typical Field Power And Control Wiring

    REMOVE JUMPER J2 FROM TERMINALS 4 AND 9 ON JUMPER PLUG CONNECTOR P6 ON UNITS WITH ECONOMIZER. TERMINALS A1 AND A2 PROVIDE A RELAY OUT-PUT TO CLOSE THE OUTDOOR ECONOMIZER DAMPERS WHEN THE THERMOSTAT SWITCHES TO THE SET-BACK POSITION. Figure 13: Typical Field Power and Control Wiring Johnson Controls Unitary Products...

  • Page 16: Electrical Data

    570570-BIM-A-0310 Table 7: Electrical Data ZS-03 thru -05 - Without Powered Convenience Outlet (Belt Drive) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages...
  • Page 17 570570-BIM-A-0310 ZS-03 thru -05 - Without Powered Convenience Outlet (Belt Drive) (Continued) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 42.7...
  • Page 18 (Amps) 208-3-60 19.0 123.0 29.7 31.3 40.0 230-3-60 (6.0) 460-3-60 9.7 62.0 15.2 16.0 25.0 575-3-60 7.4 50.0 11.6 12.3 15.0 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 19 570570-BIM-A-0310 ZS-03 thru -05 Without Powered Convenience Outlet (Belt Drive High Static) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 28.3...
  • Page 20 570570-BIM-A-0310 ZS-03 thru -05 Without Powered Convenience Outlet (Belt Drive High Static) (Continued) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 32.5...
  • Page 21 208-3-60 19.0 123.0 29.7 10.9 37.0 50.0 230-3-60 (6.0) 460-3-60 9.7 62.0 15.2 18.7 25.0 575-3-60 7.4 50.0 11.6 14.4 20.0 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 22 570570-BIM-A-0310 ZS-03 thru -05 Without Powered Convenience Outlet (Direct Drive) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 29.1 19.2 31.5...
  • Page 23 570570-BIM-A-0310 ZS-03 thru -05 Without Powered Convenience Outlet (Direct Drive) (Continued) OD Fan Supply Compressors Motors Blower Conv Electric Heat Option Fuse Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 45.9 19.2...
  • Page 24 Size (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA (Amps) 208-3-60 19.0 123.0 29.7 33.7 45.0 (6.0) 230-3-60 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 25 570570-BIM-A-0310 ZS-03 thru -05 - With Powered Convenience Outlet (Belt Drive) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 38.3...
  • Page 26 570570-BIM-A-0310 ZS-03 thru -05 - With Powered Convenience Outlet (Belt Drive) (Continued) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages Amps None 52.7...
  • Page 27 208-3-60 19.0 123.0 29.7 10.0 41.3 60.0 230-3-60 (6.0) 460-3-60 9.7 62.0 15.2 21.0 30.0 575-3-60 7.4 50.0 11.6 16.3 20.0 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 28 570570-BIM-A-0310 ZS-03 thru -05 With Powered Convenience Outlet (Belt Drive High Static) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size RLA LRA Model Stages Amps (Amps) None 38.3...
  • Page 29 570570-BIM-A-0310 ZS-03 thru -05 With Powered Convenience Outlet (Belt Drive High Static) (Continued) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (Tons) (each) Motor Outlet (Amps) Size (Amps) RLA LRA Model Stages...
  • Page 30 19.0 123.0 29.7 10.9 10.0 47.0 60.0 230-3-60 (6.0) 460-3-60 9.7 62.0 15.2 23.7 30.0 575-3-60 7.4 50.0 11.6 18.4 25.0 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 31 570570-BIM-A-0310 ZS-03 thru -05 With Powered Convenience Outlet (Direct Drive) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size (Amps) RLA LRA Model Stages Amps None 36.7 19.2...
  • Page 32 570570-BIM-A-0310 ZS-03 thru -05 With Powered Convenience Outlet (Direct Drive) (Continued) OD Fan Supply Max Fuse Compressors Motors Blower Conv Electric Heat Option Size Breaker (each) Volt (each) Motor Outlet (Tons) (Amps) Size (Amps) RLA LRA Model Stages Amps None 52.7...
  • Page 33 (each) Volt (each) Motor Outlet Breaker (Tons) (Amps) Size RLA LRA (Amps) 208-3-60 19.0 123.0 29.7 10.0 43.7 60.0 (6.0) 230-3-60 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 34: Physical Data

    570570-BIM-A-0310 Table 8: Physical Data ZS-03 thru -05 Physical Data Models Component ZS-03 ZS-04 ZS-05 Nominal Tonnage ARI COOLING PERFORMANCE Gross Capacity @ ARI A point (Btu) 38500 50500 59500 ARI net capacity (Btu) 36000 47500 57000 11.0 11.0 10.8 SEER 13.0...
  • Page 35 570570-BIM-A-0310 ZS-03 thru -05 Physical Data (Continued) Models Component ZS-03 ZS-04 ZS-05 Nominal Tonnage CONDENSER FAN DATA Quantity Fan diameter (Inch) Type Prop Prop Prop Drive type Direct Drive Direct Drive Direct Drive Quantity of motors Motor HP each No. speeds...
  • Page 36 Rows Fins per inch Tube diameter (in.) 1.0 / 25.4 Circuitry Type 2-pass Microchannel EVAPORATOR COIL DATA Face area (Sq. Ft.) 5.06 Rows Fins per inch Tube diameter 0.375 Circuitry Type Intertwined Refrigerant control Fixed Orifice Johnson Controls Unitary Products...
  • Page 37 1. Cooling Only or Cooling with Electric Heat Unit 2. Cooling with Gas Heat Unit 3. Cooling Only or Cooling with Electric Heat Unit (ECM O.D. Fan Motor) 4. Cooling with Gas Heat Unit (PSC O.D. Fan Motor) Johnson Controls Unitary Products...

  • Page 38: 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 Unitary Products...

  • Page 39: 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 Unitary Products...
  • Page 40 “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 Unitary Products...

  • Page 41: Options/Accessories

    When there is no call for free cooling, the damper will be made. position is limited by the IAQ Max damper position setting. When the signal exceeds it's set point (Demand Control Ventilation Set Point) setting and there is a call for free cooling, Johnson Controls Unitary Products...

  • Page 42: Enthalpy Set Point Chart

    Figure 19: Belt Adjustment Screw Indoor Air Quality Max. Adjustment Screw Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw Figure 18: Honeywell Economizer Control W7212 Johnson Controls Unitary Products...

  • Page 43: Altitude/Temperature Correction Factors

    0.950 1000 ft 0.900 2000 ft 3000 ft 0.850 4000 ft 0.800 5000 ft 6000 ft 0.750 7000 ft 8000 ft 0.700 9000 ft 10000 ft 0.650 0.600 Air Temperature (ºF) Figure 20: Altitude/Temperature Correction Factors Johnson Controls Unitary Products...
  • Page 44 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 Unitary Products...
  • Page 45 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Closed 1.73 1VL44 AK56 1060 1130 1195 1260 1VP56 AK56 1325 1395 1460 1525 1590 1660 Johnson Controls Unitary Products...

  • Page 46: Zs Blower Performance Side Duct

    570570-BIM-A-0310 Table 13: ZS Blower Performance Side Duct ZS-03 (3 Ton Belt Drive) 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...
  • Page 47 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. ZS-03 thru -A6 (3-6 Ton Direct Drive) Side Duct AVAILABLE EXTERNAL STATIC PRESSURE - IWG UNIT...

  • Page 48: Zs Blower Performance Bottom Duct

    570570-BIM-A-0310 Table 14: ZS Blower Performance Bottom Duct ZS-03 (3 Ton Belt Drive) 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...

  • Page 49: Belt Drive Rpm Selection

    2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. ZS-03 thru -A6 (3-6 Ton Direct Drive) Bottom Duct AVAILABLE EXTERNAL STATIC PRESSURE - IWG UNIT...

  • Page 50: Checking Supply Air Cfm

    1000 1500 2000 2500 3000 3500 Using an inclined manometer, determine the pressure drop NOMINAL CFM across a dry evaporator coil. Since the moisture on an Figure 21: Pressure Drop Across Coil Johnson Controls Unitary Products...

  • Page 51: Operation

    If the unit is in continues fan operation the economizer damper goes to the min. position. Johnson Controls Unitary Products...

  • Page 52: Cooling Operation Errors

    If the call for cooling is still present at the conclusion of the electric heat units and the temperature limit switch and the gas ASCD, the UCB will re-energize the compressor. valve of gas furnace units. Johnson Controls Unitary Products...

  • Page 53: Electric Heating Sequence Of Operations

    Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This resets any If the UCB senses zero volts from the high temperature limit, flash codes. the indoor blower motor is immediately energized. Johnson Controls Unitary Products...

  • Page 54: Gas Heating Sequence Of Operations

    The UCB will energize the indoor blower and the ICB will energize the draft motor while the primary limit is open. When the primary limit closes and the call for heat still exists, the ICB will start the ignition sequence Johnson Controls Unitary Products...

  • Page 55: Flash Codes

    ICB will close both the conditioned space. main and pilot gas valves and flash a code (Table 26). The ICB will not retry the ignition sequence during the same call for heat. Johnson Controls Unitary Products...

  • Page 56: Start-Up (Cooling)

    If gas pressure is outside these limits, contact the Check the type of gas being supplied. Be sure that it is the local gas utility for corrective action. same as listed on the unit nameplate. Johnson Controls Unitary Products...

  • Page 57: Typical Single Stage Gas Valves

    NOTE: The factory set high-fire manifold pressure for these furnaces is 3.50 IWG. The actual manifold pressure Burner Flame Pilot Tube depends on the local fuel heating value. (Blue Only) Gas Supply Pipe Figure 26: Typical Flame Appearance Johnson Controls Unitary Products...

  • Page 58: Checking Gas Input

    Multiply 95 X 1050 (the Btu rating of the gas obtained from the local gas company). The result is 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace. Johnson Controls Unitary Products...

  • Page 59: Charging The Unit

    If no economizer is installed or the economizer is not supply air blower motor does not energize, go to Step 3. opening to provide free cooling and the compressor does not energize on a call for cooling, check for line voltage at Johnson Controls Unitary Products...
  • Page 60 15. If none of the above correct the error, replace the UCB. 10. If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked Johnson Controls Unitary Products...

  • Page 61: 3.0 Ton) Operating Pressures

    2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. Figure 27: ZS-03 (3.0 Ton) Operating Pressures 4 Ton Charging Chart Outdoor Temp (ºF)

  • Page 62: 5.0 Ton) Operating Pressures

    2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been adjusted in the field, the charging chart may no longer apply. Figure 30: ZS-A6 (6.0 Ton) Operating Pressures Johnson Controls Unitary Products...
  • Page 63 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 Unitary Products...
  • Page 64 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 Unitary Products...
  • Page 65 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 Unitary Products...
  • Page 66 Pressing the button three times within five seconds forces Make sure that the pilot burner is not bent or damaged. the control to reset its address to 1, which is the factory default. Johnson Controls Unitary Products...

  • Page 67: Fan On And Off Delays

    Flame Sense Circuit Failure 1. These flash codes do not represent alarms. Subject to change without notice. Printed in U.S.A. 570570-BIM-A-0310 Copyright © 2010 by Johnson Controls, Inc. All rights reserved. Supersedes: 542298-BIM-A-1109 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...

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