Johnson Controls ZX Series Installation Manual
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Johnson Controls ZX Series Installation Manual

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R-410A
ZX SERIES
3 - 12.5 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ZX04-14 Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 18
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Blower Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1 ZX04-14 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZX04-14 Corner Weights . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZX04-14 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . 9
4 ZX04-07 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . 15
5 ZX08-14 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 46
12 Gas Heat Supply Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 ZX04-06 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . 10
7 ZX07 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 ZX08 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 ZX09/12 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . 13
10 ZX14 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13 Side Duct Cover Panels . . . . . . . . . . . . . . . . . . . . . . . . . 17

TABLE OF CONTENTS

IntelliSpeed Supply Fan Control . . . . . . . . . . . . . . . . . . . . 64
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 65
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 65
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gas Heat Board Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
LIST OF TABLES
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . 61
21 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 62
22 ZX04-14 Additional Static Resistance . . . . . . . . . . . . . . 63
23 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 70
24 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
26 ZX04 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
27 ZX05 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
28 ZX06 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
29 ZX07 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
30 ZX08 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 78
31 ZX08 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 78
32 ZX09 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 79
33 ZX09 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 79
34 ZX12 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 80
35 ZX12 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 81
36 ZX14 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 81
37 ZX14 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 82
LIST OF FIGURES
16 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
17 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 46
18 Flue Exhaust Hood Shipping Location . . . . . . . . . . . . . . 48
19 Flue Exhaust Hood Installed . . . . . . . . . . . . . . . . . . . . . 49
20 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Altitude/Temperature Correction Factors . . . . . . . . . . . . 51
22 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
23 Ignition Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 66
24 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
27

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Summary of Contents for Johnson Controls ZX Series

  • Page 1: Table Of Contents

    R-410A ZX SERIES 3 - 12.5 Ton 60 Hertz TABLE OF CONTENTS General ......... . 2 IntelliSpeed Supply Fan Control .

  • Page 2: General

    Refer to this manual. For assistance or additional information consult a Observe all precautions in the literature, labels, and tags qualified installer, service agency or the gas supplier. accompanying the equipment whenever working on air Johnson Controls Unitary Products...
  • Page 3 This system uses R-410A Refrigerant which operates at • Economizer Accessory - higher pressures than R-22. No other refrigerant may be Vertical Flow Dry Bulb Economizer Field Installed used in this system. Horizontal Flow Dry Bulb Economizer Field Installed Johnson Controls Unitary Products...
  • Page 4 B = Standard Indoor Coil & ElectroFin Outdoor Coil C = E-Coat Indoor Coil & Standard Outdoor Coil D = E-Coat Indoor & Outdoor Coils Airflow Options 1 = None 3 = VFD IntelliSpeed (ZX12 & ZX14 Only) Johnson Controls Unitary Products...

  • Page 5: Installation

    Remove the two screws holding the brackets in the side 208/230-3-60 and units with factory installed Powered fork-lift slots. Convenience Outlet Option are wired for 230v power supply. Change tap on transformer for 208-3-60 operation. See unit wiring diagram. Johnson Controls Unitary Products...

  • Page 6: Limitations

    Where a choice of location is possible, position the unit on either north or east side of building. Maintain level tolerance to 1/2” across the entire width and length of unit. Suitable for mounting on roof curb. Johnson Controls Unitary Products...

  • Page 7: Rigging And Handling

    All panels must be secured in place when the unit is obstruct condenser air discharge outlet, combustion air lifted. inlet or vent outlets. The condenser coils should be protected from rigging cable damage with plywood or other suitable material. Johnson Controls Unitary Products...

  • Page 8: Zx04-14 Unit Weights

    FRONT LEFT Figure 5: Center of Gravity Table 2: ZX04-14 Corner Weights Size Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.) 6 Point Load Location (lbs.) Model (Tons) Shipping Operating (7.5) (8.5) (10) (12.5) Johnson Controls Unitary Products...

  • Page 9: Zx04-14 Unit Accessory Weights

    Hail Guard Kit Small Tall Factory Installed Hail Guard Kit Large Short Factory Installed Hail Guard Kit Large Tall Factory Installed Curb Rigid 14" Small Footprint Curb Rigid 14" Large Footprint Curb Rigid 24" Small Footprint Curb Rigid 24" Large Footprint Johnson Controls Unitary Products...

  • Page 10: Zx04-06 Unit Dimensions

    1046270-UIM-D-0714 Figure 6: ZX04-06 Unit Dimensions Johnson Controls Unitary Products...

  • Page 11: Zx07 Unit Dimensions

    1046270-UIM-D-0714 Figure 7: ZX07 Unit Dimensions Johnson Controls Unitary Products...

  • Page 12: Zx08 Unit Dimensions

    1046270-UIM-D-0714 Figure 8: ZX08 Unit Dimensions Johnson Controls Unitary Products...

  • Page 13: Zx09/12 Unit Dimensions

    1046270-UIM-D-0714 Figure 9: ZX09/12 Unit Dimensions Johnson Controls Unitary Products...

  • Page 14: Zx14 Unit Dimensions

    1046270-UIM-D-0714 Figure 10: ZX14 Unit Dimensions Johnson Controls Unitary Products...

  • Page 15: Zx04-07 Unit Clearances

    1. Sides, ends and cross support are 18-G90. Deck pans, R/A & S/A supports are 20-G90. 2. Full perimeter wood nailer. 3. Insulated deck pans. Figure 11: 1RC0456, 1RC0458 Roof Curb Dimensions Table 6: Unit Models used with 1RC0456, 1RC0458 Roof Curb ZX04 ZX05 ZX06 ZX07 Johnson Controls Unitary Products...

  • Page 16: Ductwork

    But keep in mind that the supply and return panels are should NOT be sized to match the dimensions of the duct installed with the painted surface DOWN, facing the bottom connections on the unit. duct opening. The gasket must be removed from the insulation Johnson Controls Unitary Products...

  • Page 17: Condensate Drain

    NOTE: Shown with duct connection cover panel as shipped. 3” Minimum Figure 16: Condensate Drain Compressors The compressor used in this product is specifically designed to operate with R-410A Refrigerant and cannot be interchanged. Figure 14: Bottom Return Opening For Side Duct Conversion Johnson Controls Unitary Products...

  • Page 18: Filters

    Refer to physical data tables, for the number and switch. size of filters needed for the unit. The unit should not be operated without filters properly installed. Johnson Controls Unitary Products...

  • Page 19: Unit Models Used With 1Rc0456, 1Rc0458 Roof Curb . 15 7 Unit Models Used With 1Rc0457, 1Rc0459 Roof Curb . 16 8 Control Wire Sizes

    Wire Size Maximum Length enclosed with thermostat for general installation procedure. 18 AWG 150 Feet Seven (7) color-coded, insulated wires should be used to 1. From the unit to the thermostat and back to the unit. Johnson Controls Unitary Products...

  • Page 20: Electrical Data

    208-3-60 15.6 110 None 45.4 48 252 47.6 50 257 230-3-60 15.6 110 None 45.4 48 255 47.4 50 260 (10) 460-3-60 None 22.8 24 122 23.8 25 125 575-3-60 None 17.2 18 119 19 121 Johnson Controls Unitary Products...
  • Page 21 8.2 66.1 None 25.5 27 178 26.5 28 180 575-3-60 6.6 55.3 6.6 55.3 None 20.3 21 148 21.1 22 150 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 22 15.6 110 None 50.2 53 262 52.4 56 267 230-3-60 15.6 110 None 50.2 53 265 52.2 55 269 (10) 460-3-60 None 25.7 27 132 26.7 28 134 575-3-60 None 19.1 20 128 19.9 21 130 Johnson Controls Unitary Products...
  • Page 23 8.2 66.1 8.2 66.1 None 28.4 30 187 29.4 31 190 575-3-60 6.6 55.3 6.6 55.3 None 22.2 24 158 24 159 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 24 15.6 110 10.2 None 50.4 53 293 52.6 56 298 230-3-60 15.6 110 10.2 None 50.4 53 299 52.4 56 304 (10) 460-3-60 None 26 144 28 147 575-3-60 None 18.6 20 136 19.4 21 138 Johnson Controls Unitary Products...
  • Page 25 8.2 66.1 None 26.1 28 184 27.1 29 186 575-3-60 6.6 55.3 6.6 55.3 None 21.4 23 162 22.2 24 164 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 26 10.2 None 55.2 59 302 57.4 61 307 230-3-60 15.6 110 10.2 None 55.2 59 309 57.2 61 313 (10) 460-3-60 None 27.9 30 154 28.9 31 156 575-3-60 None 20.5 22 146 21.3 23 148 Johnson Controls Unitary Products...
  • Page 27 8.2 66.1 8.2 66.1 None 31 193 32 195 575-3-60 6.6 55.3 6.6 55.3 None 23.3 25 172 24.1 26 173 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 28 66 393 64.7 69 398 (12.5) 460-3-60 None 28.1 30 194 29.1 31 196 575-3-60 None 22.5 24 162 23.3 25 164 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...
  • Page 29 8.2 66.1 8.2 66.1 None 33 204 34 206 575-3-60 6.6 55.3 6.6 55.3 None 24.4 26 172 25.2 27 173 1. Minimum Circuit Ampacity. 2. Dual Element, Time Delay Type. 3. HACR type per NEC. Johnson Controls Unitary Products...

  • Page 30: Physical Data

    COIL DATA Tube diameter (in./MM) .63/16 .63/16 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Orifice Orifice Johnson Controls Unitary Products...
  • Page 31 Motor HP each 1725 1725 1725 1725 Frame size Quantity - Size 2 - (16 x 25 x 2) 2 - (16 x 25 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 32 COIL DATA Tube diameter (in./MM) .63/16 .63/16 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Orifice Orifice Johnson Controls Unitary Products...
  • Page 33 Motor HP each 1725 1725 1725 1725 Frame size Quantity - Size 2 - (16 x 25 x 2) 2 - (16 x 25 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 34 Fins per inch COIL DATA Tube diameter (in./MM) .79/20 .79/20 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Johnson Controls Unitary Products...
  • Page 35 Motor HP each 1725 1725 1725 1725 Frame size Quantity - Size 2 - (16 x 25 x 2) 2 - (16 x 25 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 36 Circuitry Type Intertwined Intertwined Refrigerant control Quantity of fans Fan diameter (Inch) Type Prop Prop Drive type Direct Direct CONDENSER Quantity of motors FAN DATA Motor HP each No. speeds 1085 1085 Nominal total CFM 4600 4600 Johnson Controls Unitary Products...
  • Page 37 1725 1725 1725 Frame size 56HZ 56HZ Quantity - Size 4 - (16 x 16 x 2) 4 - (16 x 16 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 38 COIL DATA Tube diameter (in./MM) 1/25 1/25 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Orifice Orifice Johnson Controls Unitary Products...
  • Page 39 1725 1725 1725 Frame size 56HZ 56HZ Quantity - Size 4 - (16 x 20 x 2) 4 - (16 x 20 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 40 Tube diameter (in./MM) 1/25 1/25 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) 11.1 11.1 Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Orifice Orifice Johnson Controls Unitary Products...
  • Page 41 1725 1725 1725 Frame size 56HZ 56HZ Quantity - Size 4 - (20 x 20 x 2) 4 - (20 x 20 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 42 Tube diameter (in./MM) 1/25 1/25 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) 11.1 11.1 Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Orifice Orifice Johnson Controls Unitary Products...
  • Page 43 1725 Frame size 56HZ 145TY 56HZ 145TY Quantity - Size 4 - (20 x 20 x 2) 4 - (20 x 20 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...
  • Page 44 COIL DATA Tube diameter (in./MM) 1.26/32 1.26/32 Circuitry Type 2-pass Microchannel 2-pass Microchannel Face area (Sq. Ft.) 11.1 11.1 Rows Fins per inch EVAPORATOR COIL DATA Tube diameter 0.375 0.375 Circuitry Type Intertwined Intertwined Refrigerant control Johnson Controls Unitary Products...
  • Page 45 1750 Frame size 184TZ 184TZ 184TZ 184TZ Quantity - Size 4 - (16 x 16 x 2) 4 - (16 x 16 x 2) FILTERS 1. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Johnson Controls Unitary Products...

  • Page 46: Optional Gas Heat

    Units require either a 1/2 or 3/4 inch pipe connection at the entrance fitting. Line should not be sized smaller than the entrance fitting size. Figure 17: Side Entry Gas Piping Johnson Controls Unitary Products...

  • Page 47: Gas Heat Supply Air

    The gas supply line can be routed within the space and roof curb, or explosion may result causing property damage, exiting through the unit’s basepan. Refer to Figures 6 thru 10 for personal injury or loss of life. the gas piping inlet location. Typical supply piping arrangements Johnson Controls Unitary Products...

  • Page 48: Flue Exhaust Hood Shipping Location

    Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life. Johnson Controls Unitary Products...

  • Page 49: Options/Accessories

    ZX units are properly phased at the factory. Check for proper following adjustments will be made. blower rotation. If the blower rotates in the wrong direction at start-up, the electrical connection to the unit is misphased. Johnson Controls Unitary Products...

  • Page 50: Supply Air Limitations

    Air density correction factors are shown 5. After adjustments are completed re-tighten nuts (A, B in Table 14 and Figure 21. and C). Johnson Controls Unitary Products...

  • Page 51: Altitude/Temperature Correction Factors

    Corrected BHP = 2.0 x 0.832 = 1.66 rpm needed at 5,000 ft. Suppose that the corresponding BHP listed in the table is 2.0. This value must be corrected for elevation. BHP at 5,000 ft. = 2.0 x .832 = 1.66 Johnson Controls Unitary Products...

  • Page 52: Airflow Performance

    08 (7.5), 3800 0.16 0.25 0.22 09 (8.5), 4000 0.17 0.28 0.24 12 (10.0), 4400 0.20 0.33 0.27 14 (12.5) 4800 0.22 0.38 0.31 5200 0.24 0.43 0.35 5600 0.26 0.46 0.39 6000 0.28 0.50 0.43 Johnson Controls Unitary Products...

  • Page 53: Zx04-14 Side Duct Application (Belt Drive)

    2400 1301 1.61 1368 1.72 1441 1.83 1516 1.94 1592 2.05 1668 2.16 1741 2.27 2500 Medium Static Option with Motor rated at 2.4-hp High Static Option with Motor rated at 2.9-hp Exceeds recommended Blower speed Johnson Controls Unitary Products...

  • Page 54: Exceeds Recommended Blower Speed

    2.60 2.80 2.98 1014 3.17 1064 3.35 4250 Standard Static Option with Motor rated at 2.4-hp Medium Static Option with Motor rated at 2.4-hp High Static Option with Motor rated at 3.7-hp Exceeds recommended Blower speed Johnson Controls Unitary Products...
  • Page 55 Standard Static Option with Motor rated at 2.9-hp Medium Static Option with Motor rated at 3.7-hp High Static Option with Motor rated at 5.25-hp Field-supplied BK95 x 1 fixed pulley (p/n 1074787) with Motor rated at 5.25-hp Bold Exceeds recommended Blower speed Johnson Controls Unitary Products...

  • Page 56: Zx04-06 Side Duct Application (Direct Drive)

    3 (MED) 1842 1079 1801 1123 1644 1147 1461 1162 1110 1177 4 (MED/HI) 1919 1112 1828 1135 1661 1153 1447 1164 1088 1177 5 (HI) 1978 1147 1845 1155 1677 1164 1470 1175 1111 1185 Johnson Controls Unitary Products...

  • Page 57: Zx04-14 Bottom Duct Application (Belt Drive)

    1729 2.33 2400 1411 1.85 1483 1.99 1556 2.12 1630 2.25 1703 2.37 1776 2.50 2500 Medium Static Option with Motor rated at 2.4-hp High Static Option with Motor rated at 2.9-hp Exceeds recommended Blower speed Johnson Controls Unitary Products...
  • Page 58 2.17 2.34 2.52 2.70 2.88 1000 3.07 1051 3.24 1100 3.42 4250 Standard Static Option with Motor rated at 2.4-hp Medium Static Option with Motor rated at 2.4-hp High Static Option with Motor rated at 3.7-hp Johnson Controls Unitary Products...
  • Page 59 4.47 1003 4.70 1051 4.92 1099 5.15 5800 4.87 1034 5.10 6000 Standard Static Option with Motor rated at 2.4-hp Medium Static Option with Motor rated at 3.7-hp High Static Option with Motor rated at 5.25-hp Johnson Controls Unitary Products...

  • Page 60: Zx04-06 Bottom Duct Application (Direct Drive)

    1162 1177 ZX06 3 (MED) 1812 1107 1718 1140 1575 1155 1382 1169 1182 4 (MED/HI) 1853 1131 1727 1146 1576 1155 1372 1169 1183 5 (HI) 1901 1154 1738 1162 1603 1169 1378 1177 1185 Johnson Controls Unitary Products...

  • Page 61: Rpm Selection

    BK85 BX52 Std. 1750 0.87 1.15 2.8 - 3.8 1VL44 AK79 A50 Med. 1750 0.90 1.15 184TZ 3.4 - 4.4 1VP50 AK79 A52 (12.5) H. Static 5.25 1750 0.90 1.15 184TZ 4.3 - 5.3 1VP56 BK85 BX54 Johnson Controls Unitary Products...

  • Page 62: Motor Sheave Datum Diameters

    Use Table 19 to locate the DD nearest to 2.28 in. Close the alignment; tighten blower pulley and motor sheave set sheave to 2 turn open. screws after these adjustments. Re-checking set screws and belt tension after 10-12 hrs. run time is recommended. Johnson Controls Unitary Products...

  • Page 63: Zx04-14 Additional Static Resistance

    3. The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation. Johnson Controls Unitary Products...

  • Page 64: Operation

    NOTE: A Y2 input without a Y1 input energizes a C1 first and then C2 30 seconds later. • 2-10vdc output from VFD terminal on UCB will operate supply fan VFD proportional to the min and max frequency settings of VFD drive (defaults 25hz - 60hz) Johnson Controls Unitary Products...

  • Page 65: Economizer Sequences

    Economizer Outside Air Enthalpy Setpoint. At no time will a compressor output be turned ON if the economizer output is less than 100%, even if the differential between zone (or return) temperature and the current cooling Johnson Controls Unitary Products...

  • Page 66: Power Exhaust

    If 24 V is lost on the LIMIT input 3 times in 1 hour, an alarm appears and the FAN output is energized. The heating H1 and H2 outputs are de-energized until the alarm is cleared. Johnson Controls Unitary Products...

  • Page 67: Gas Heat Board Function

    If the call for heat is lost during an ignition trial period, the with the heat cycle. control immediately de-energizes spark and gas. The control Johnson Controls Unitary Products...

  • Page 68: Start-Up (Cooling)

    15 seconds, the control re-energizes the inducer to attempt to vent the unburned gas. In either case, the control locks out. This furnace is equipped with an automatic re-ignition system. DO NOT attempt to manually light the pilot. Johnson Controls Unitary Products...

  • Page 69: Checking Gas Heat Input

    60 Hz power only. If necessary, adjust the low pressure regulator as To determine the rate of gas flow (Single Stage). discussed in the section "Manifold Gas Pressure Adjustment". Be sure not to under-fire the furnace on first Johnson Controls Unitary Products...

  • Page 70: Gas Rate Cubic Feet Per Hour

    HI and LO pressure adjustment screws. This gas furnace has one stage of gas heat. Therefore, the gas valve has one adjustment screw located under a plastic protective cover on the valve (See Figure 25). Johnson Controls Unitary Products...

  • Page 71: Gas Heat Stages

    Take readings of both the return air and the CSA B149.1. heated air in the ducts (about 6 feet from the furnace) where they will not be affected by radiant heat. Increase the blower Johnson Controls Unitary Products...

  • Page 72: 25 3 Thru 6 Ton, 1/2" Single Stage Gas Valve

    SPADE TERMINALS (3) INLET OUTLET REGULATOR COVER SCREWS (REG. ADJ. BENEATH THESE SCREWS) OUTLET PRESSURE TAP (SET SCREW: 3/32" HEX HEAD) ACCEPT 5/16 " HOSE CONNECTION Figure 26: 3 Thru 6 Ton, 1/2” Two Stage Gas Valve Johnson Controls Unitary Products...

  • Page 73: Troubleshooting

    If this occurs, the UCB energize the supply air blower motor until the high temperature limit has reset. Caution should be used at all times as the supply air blower may energize regardless of the room thermostat fan switch position. Johnson Controls Unitary Products...

  • Page 74: Flash Codes For The Gas Heat Ignition Control Board

    Verify that there are no conditioned air leaks or heat exchanger breaches to interfere with ignition or the burners. Johnson Controls Unitary Products...
  • Page 75 1 second at the when commanded on. first stage and/or second stage gas valve output (P1-7 pin and/or P1-4 pin) when the gas valve is commanded on by the ignition control Johnson Controls Unitary Products...

  • Page 76: Zx04 Charging Table

    11.2 300 Cfm/Ton 12.9 80/67 14.5 11.2 300 Cfm/Ton 12.9 80/72 14.6 11.2 300 Cfm/Ton 12.8 75/62 14.4 11.3 400 Cfm/Ton 12.9 80/62 14.6 11.4 400 Cfm/Ton 13.0 80/67 14.7 11.4 400 Cfm/Ton 13.1 80/72 14.9 Johnson Controls Unitary Products...

  • Page 77: Zx06 Charging Table

    10.4 300 Cfm/Ton 11.6 80/62 12.8 10.5 300 Cfm/Ton 11.7 80/67 12.9 10.6 300 Cfm/Ton 11.8 80/72 13.0 10.4 300 Cfm/Ton 11.6 75/62 12.8 10.5 400 Cfm/Ton 11.7 80/62 12.9 10.6 400 Cfm/Ton 11.8 80/67 13.0 Johnson Controls Unitary Products...

  • Page 78: Zx08 Charging Table System 1

    Table 31: ZX08 Charging Table System 2 Air Flow Indoor Db/ Outdoor DB Suction P Suction Temp. Liquid P Liquid Temp. Delta T Db Compr. amps 300 Cfm/Ton 80/62 300 Cfm/Ton 80/67 300 Cfm/Ton 80/72 300 Cfm/Ton 75/62 400 Cfm/Ton 80/62 Johnson Controls Unitary Products...

  • Page 79: Zx09 Charging Table System 1

    Table 33: ZX09 Charging Table System 2 Air Flow Outdoor DB Suction P Suction Temp. Liquid P Liquid Temp. Delta T Db Compr. amps Indoor Db/Wb 300 Cfm/Ton 80/62 10.3 300 Cfm/Ton 80/67 10.3 300 Cfm/Ton 80/72 10.4 300 Cfm/Ton 75/62 10.2 Johnson Controls Unitary Products...

  • Page 80: Zx12 Charging Table System 1

    11.0 300 Cfm/Ton 10.2 80/67 11.3 300 Cfm/Ton 10.4 80/72 11.6 300 Cfm/Ton 10.0 75/62 11.0 400 Cfm/Ton 10.0 80/62 11.0 400 Cfm/Ton 10.1 80/67 11.2 400 Cfm/Ton 10.2 80/72 11.3 400 Cfm/Ton 10.0 75/62 11.0 Johnson Controls Unitary Products...

  • Page 81: Zx12 Charging Table System 2

    11.2 300 Cfm/Ton 12.7 80/72 14.2 11.1 300 Cfm/Ton 12.3 75/62 13.5 11.1 400 Cfm/Ton 12.3 80/62 13.5 11.2 400 Cfm/Ton 12.5 80/67 13.8 11.3 400 Cfm/Ton 12.7 80/72 14.1 11.1 400 Cfm/Ton 12.3 75/62 13.5 Johnson Controls Unitary Products...

  • Page 82: Zx14 Charging Table System 2

    11.3 300 Cfm/Ton 12.8 80/72 14.4 11.2 300 Cfm/Ton 12.4 75/62 13.7 11.3 400 Cfm/Ton 12.5 80/62 13.8 11.4 400 Cfm/Ton 12.7 80/67 14.0 11.4 400 Cfm/Ton 12.8 80/72 14.2 11.2 400 Cfm/Ton 12.5 75/62 13.8 Johnson Controls Unitary Products...

  • Page 83: Start-Up Sheet

    30 days from installation. Refer to current standard EQUIPMENT STARTUP warranty policy and warranty manual found on UPGnet for details. In the event that communication with Johnson Controls/UPG is Simplicity PC is required to complete the start-up. Simplicity required regarding technical and/or warranty concerns, all parties PC software can be downloaded from www.york.com.
  • Page 84 1034349-UCL-A-0313 SAFETY WARNINGS The inspections and recording of data outlined in this procedure are required for start-up of Johnson Controls/UPG's packaged Lethal voltages are present during some start-up products. Industry recognized safety standards and practices checks. Extreme caution must be used at all times.
  • Page 85 See Notes sensor installed Check economizer setting A Prove economizer open/close through PC or Control Module Reheat Mode Normal or Alternate Not Applicable Humidistat Location _____________________________________________ Note: BAS System Control Reheat through Intellicomfort/VAV Board Unitary Products Group Johnson Controls Unitary Products...
  • Page 86 1. VAV units with heat section - simulate heat call to drive VAV boxes and VFD/IGV to maximum design airflow position. 2. VAV units without heat section - VAV boxes must be set to maximum design airflow position. Unitary Products Group Johnson Controls Unitary Products...
  • Page 87 Manifold Pressure Stage 2 (If Equipped) Stage 3 (If Equipped) Supply gas pressure at full fire Check temperature rise measured at full fire °F 1. Input X Eff. (BTU output) 1.08 X Temp. Rise Unitary Products Group Johnson Controls Unitary Products...

  • Page 88: 1046270-Uim-D-0714

    ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ Subject to change without notice. Printed in U.S.A. 1046270-UIM-C-0114 Copyright © 2014 by Johnson Controls, Inc. All rights reserved. Supersedes: 1046270-UIM-D-0714 York International Corporation 5005 York Drive Norman, OK 73069...

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