Table of Contents
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R-410A
ZJ SERIES W/SIMPLICITY SE
15 - 25 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 14
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 29
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 30
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 ZJ180-300 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZJ180-300 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9
4 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Supply Fan VFD Weights, In Lbs. . . . . . . . . . . . . . . . . . . . 9
6 ZJ180-300 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 ZJ180-300 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 25
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 26
11 Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 27
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 27
14 Simplicity SE Economizer Board Details . . . . . . . . . . . . 31
1 ZJ180-300 Component Location . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZJ180-300 Unit Dimensions Front View . . . . . . . . . . . . . 9
6 ZJ180-300 Unit Dimensions Rear View . . . . . . . . . . . . . 10
7 ZJ180-300 Unit Dimensions Rain Hood . . . . . . . . . . . . . 11
8 ZJ180-300 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 Fixed Outdoor Air Damper . . . . . . . . . . . . . . . . . . . . . . . 13
10 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . 15
13 External Supply Connection External Shut-Off . . . . . . . 27
14 Bottom Supply Connection External Shut-Off . . . . . . . . 27
15 Vent and Combustion Air Hood . . . . . . . . . . . . . . . . . . . 29
TABLE OF CONTENTS
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Set Point Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . 36
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 47
Electric Heating Sequence Of Operations . . . . . . . . . . . . 49
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 49
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 50
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 51
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Basic Unit Control Board Navigation Examples: . . . . . . . . 56
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
LIST OF TABLES
15 Altitude/Temperature Correction Factors . . . . . . . . . . . . 37
16 Air Flow Performance - Side Duct Application . . . . . . . . 39
17 Air Flow Performance - Bottom Duct Application . . . . . . 42
18 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
19 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . 45
20 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 45
21 Limit Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
22 Electric Heat Anticipator Setpoint . . . . . . . . . . . . . . . . . . 50
23 Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . . . . . 51
24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 52
25 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 53
26 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . 58
27 4-Stage Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
LIST OF FIGURES
16 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 31
17 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
18 Altitude/Temperature Correction Factors . . . . . . . . . . . . 37
For All Unit Tonnages . . . . . . . . . . . . . . . . . . . . . . . . . . 46
20 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Gas Valve and Controls . . . . . . . . . . . . . . . . . . . . . . . . . 51
22 Proper Pilot Flame Adjustment . . . . . . . . . . . . . . . . . . . 54
23 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
24 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
25 ZJ180 (15 Ton) Charging Chart . . . . . . . . . . . . . . . . . . . 55
26 ZJ210 (17.5 Ton) Charging Chart . . . . . . . . . . . . . . . . . 55
27 ZJ240 (20 Ton) Charging Chart . . . . . . . . . . . . . . . . . . . 55
28 ZJ300 (25 Ton) Charging Chart . . . . . . . . . . . . . . . . . . . 55
29 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
30 4-Stage Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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Summary of Contents for York ZJ180
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Page 1: Table Of Contents
22 Proper Pilot Flame Adjustment ....54 8 ZJ180-300 Roof Curb ......12 9 Fixed Outdoor Air Damper . -
Page 2: General
1107662-YIM-B-1014 General ® YORK Model ZJ units are either single package air conditions equipped with optional factory installed electric heaters, or single Before performing service or maintenance operations on package gas-fired central heating furnaces with cooling unit. unit, turn off main power switch to unit. Electrical shock Both are designed for outdoor installation on a rooftop or slab. - Page 3 Reference Additional information is available in the following reference forms: • Technical Guide - ZJ180-300, 251934 This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be • General Installation - ZJ180-300, 1107662 used in this system.
- Page 4 Simplicity®Smart Equipment w/ BAS Option (BACnet, MS/TP) 300 = 25 Ton FDD (Fault Detecter Diagnostics) York Commercial Comfort System (YCCS) Rtu Controller Heat Type and Nominal Heat Capacity Hot Gas Bypass (Standard on VAV, Optional on CV) C00 = Cooling Only. No field installed...
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Page 5: Installation
1107662-YIM-B-1014 Installation Limitations These units must be installed in accordance with the following: Installation Safety Information In U.S.A.: Read these instructions before continuing this appliance National Electrical Code, ANSI/NFPA No. 70 - Latest installation. This is an outdoor combination heating and cooling Edition unit. -
Page 6: Zj180-300 Component Location
(Solid Core) Outdoor Fan #2 Outdoor Fan #1 Outdoor Fan #4 Outdoor Fan #3 Copper Tube/Aluminum Fin Condenser Coils Compressor #1 Compressor #4 Compressor #2 Compressor #3 High Efficiency Scroll Compressors Figure 1: ZJ180-300 Component Location Johnson Controls Unitary Products... -
Page 7: Location
1107662-YIM-B-1014 Table 1: ZJ180-300 Unit Limitations Unit Limitations Size Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°F) 208/230-3-60 460-3-60 (15) 575-3-60 208/230-3-60 460-3-60 (17.5) 575-3-60 208/230-3-60 460-3-60 (20) 575-3-60 208/230-3-60 460-3-60 (25) 575-3-60 Location Clearances All units require particular clearances for proper operation and Use the following guidelines to select a suitable location for service. -
Page 8: Weights And Dimensions
1107662-YIM-B-1014 Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly. Units may be moved or lifted with a forklift, from the side only, providing an accessory skid is used. LENGTH OF FORKS MUST BE A MINIMUM OF 90 INCHES. All panels must be secured in place when the unit is lifted. -
Page 9: Zj180-300 Unit Accessory Weights
ENTRY supply and return air duct connections. 46-5/8 9-1/4 9-3/4 Figure 5: ZJ180-300 Unit Dimensions Front View Table 5: Supply Fan VFD Weights, In Lbs. Table 4: Utilities Entry Supply Fan Motor 230V 460V... -
Page 10: Zj180-300 Unit Dimensions Rear View
Access Compartment Connector for Side Duct Flange Kit. Access Figure 6: ZJ180-300 Unit Dimensions Rear View NOTE: Units are shipped with the bottom duct openings covered. An accessory flange kit is available for connecting side ducts. For bottom duct applications:... -
Page 11: Zj180-300 Unit Clearances
Trapped) 5” 28-3/16” 92” Rear View LH View Detail “Y” Unit with Rain Hoods Figure 7: ZJ180-300 Unit Dimensions Rain Hood Table 6: ZJ180-300 Unit Clearances Direction Distance (in.) Direction Distance (in.) 72 With 36 Maximum Horizontal Overhang (For Right... -
Page 12: Ductwork
1107662-YIM-B-1014 25-1/4" Figure 8: ZJ180-300 Roof Curb Ductwork Gasketing and mounting screws are provided in a parts bag attached to the hood assembly. Apply gasketing to the three Ductwork should be designed and sized according to the flange surfaces on the hood prior to installing the hood. Extend... -
Page 13: Condensate Drain
1107662-YIM-B-1014 The compressor also uses a polyolester (POE oil), Mobil 3MA POE. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary Side Supply precautions to avoid exposure of the oil to the atmosphere. -
Page 14: Power And Control Wiring
A disconnect must be utilized for these units. Factory installed disconnects are available. If installing a disconnect (field ® supplied or York International supplied accessory), refer to Power Wiring Detail Figure 1 for the recommended mounting location. Units are factory wired for the voltage shown on the unit nameplate. -
Page 15: Control Wire Sizes
1107662-YIM-B-1014 Thermostat Wiring Space Sensor The thermostat should be located on an inside wall approximately The space sensor, if used, should be located on an inside wall 56 inch above the floor where it will not be subject to drafts, sun approximately 56 inches above the floor where it will not be exposure or heat from electrical fixtures or appliances. -
Page 16: Electrical Data
1107662-YIM-B-1014 Table 8: Electrical Data ZJ180-300 - Standard Drive Without Powered Convenience Outlet 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 MCC Model... - Page 17 1107662-YIM-B-1014 ZJ180-300 - Standard Drive Without Powered Convenience Outlet (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 MCC Model Stages Amps None 139.4...
- Page 18 1107662-YIM-B-1014 ZJ180-300 - Standard Drive With Powered Convenience Outlet 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 MCC Model Stages Amps None 90.1 13.5...
- Page 19 1107662-YIM-B-1014 ZJ180-300 - Standard Drive With Powered Convenience Outlet (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 MCC Model Stages Amps None 149.4...
- Page 20 1107662-YIM-B-1014 ZJ180-300 - High Static Drive Without Powered Convenience Outlet 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 MCC Model Stages Amps None 80.1...
- Page 21 1107662-YIM-B-1014 ZJ180-300 - High Static Drive Without Powered Convenience Outlet (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 MCC Model Stages Amps None 152.7...
- Page 22 1107662-YIM-B-1014 ZJ180-300 - High Static Drive With Powered Convenience Outlet 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 MCC Model Stages Amps None 90.1...
- Page 23 1107662-YIM-B-1014 ZJ180-300 - High Static Drive With Powered Convenience Outlet (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 MCC Model Stages Amps None 162.7...
- Page 24 1107662-YIM-B-1014 ZJ300 - Low Static Drive Without Powered Convenience Outlet 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 MCC Model Stages Amps None 130.0 13.5 37.5...
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Page 25: Zj180-300 Physical Data
1107662-YIM-B-1014 Table 9: ZJ180-300 Physical Data Models Component ZJ180 ZJ210 ZJ240 ZJ300 Nominal Tonnage 17.5 AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 181400 208000 255000 290000 AHRI net capacity (Btu) 172000 202000 240000 280000 12.2 12.1 11.0 10.5... -
Page 26: Optional Electric Heat
1107662-YIM-B-1014 Table 9: ZJ180-300 Physical Data (Continued) Models Component ZJ180 ZJ210 ZJ240 ZJ300 Nominal Tonnage 17.5 CONDENSER FAN DATA Quantity Fan diameter (Inch) Type Prop Prop Prop Prop Drive type Direct Direct Direct Direct No. speeds Number of motors Motor HP each... -
Page 27: Optional Gas Heat
1107662-YIM-B-1014 Optional Gas Heat These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition with proven pilot. Table 11: Gas Application Data Unit Input Temp Rise Output (MBH) Size Opt. (MBH) (°F) Main Manual 20-50 Shut-off 35-65 Valve... - Page 28 1107662-YIM-B-1014 Gas Connection The gas supply line can be routed within the space and roof curb, exiting through the unit’s basepan. Refer to Figure 5 for the gas The furnace and its individual shut-off valve must be piping inlet location. Typical supply piping arrangements are disconnected from the gas supply piping system during shown in Figures 13 and 14.
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Page 29: Options/Accessories
1107662-YIM-B-1014 Options/Accessories Check all connections for leaks when piping is completed using a soap solution. NEVER USE A FLAME. Electric Heat Electric heaters are available as a factory-installed option. These heaters mount in the heat compartment with the heating elements extending into the supply air chamber. All FIRE OR EXPLOSION HAZARD electric heaters are fused and intended for use with single Failure to follow the safety warning exactly could result... -
Page 30: Dual Enthalpy Changeover
1107662-YIM-B-1014 BTU/lb below the Economizer Outside Air Enthalpy Setpoint If at any time the economizer output drops below 100% the and the outside air temperature is no greater than the RAT plus timer stops and resets when the economizer output returns to 9°F. -
Page 31: Simplicity Se Economizer Board Details
1107662-YIM-B-1014 Figure 16: SE-ECO1001-0 Economizer Controller Table 14: Simplicity SE Economizer Board Details Cover Label Description Function & Comments Directional orientation: viewed with the center text of the cover label upright ANALOG INPUTS Terminal at left on upper edge of economizer board 24 VAC common/0-10 VDC negative for Connects through circuit trace to 24V~ IN pin COM economizer actuator position feedback... - Page 32 1107662-YIM-B-1014 Table 14: Simplicity SE Economizer Board Details (Continued) Cover Label Description Function & Comments SA BUS Pin connections at left on upper edge of economizer board EconCtrlr parameter reports UCB-to-economizer board SA bus communication status. Negative of the SA BUS communication Common for SA BUS power and circuit to the UCB.
- Page 33 1107662-YIM-B-1014 Table 14: Simplicity SE Economizer Board Details (Continued) Cover Label Description Function & Comments 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.
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Page 34: Optional Bas-Ready Economizer Power Exhaust Damper Set Point Adjustment
1107662-YIM-B-1014 Table 14: Simplicity SE Economizer Board Details (Continued) Cover Label Description Function & Comments 24 VAC common/0-10 VDC negative for the air Connects through circuit trace to 24V~ IN pin COM monitoring station sensor 24 VAC hot supplied for the building pressure 24V~ Connects through circuit trace to 24V~ IN pin HOT sensor... - Page 35 1107662-YIM-B-1014 Duct Static Pressure Transducer fan, the indoor blower motor will run at full-speed while in the bypass mode. A 0-5" WC pressure transducer, located in the control box compartment, is used to sense static (gauge) pressure in the supply air duct and convert this pressure measurement to a proportional 0-5 VDC electrical output.
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Page 36: Optional Hot Gas Bypass (Hgbp)
(C)* Phasing Figure 17: Belt Adjustment ® York Model ZJ units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the phasing of the... -
Page 37: Altitude/Temperature Correction Factors
1107662-YIM-B-1014 Table 15: Altitude/Temperature Correction Factors Altitude (Ft.) Temp. 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 1.060 1.022 0.986 0.950 0.916 0.882 0.849 0.818 0.788 0.758 0.729 1.039 1.002 0.966 0.931 0.898 0.864 0.832 0.802 0.772 0.743 0.715 1.019 0.982... - Page 38 1107662-YIM-B-1014 Drive Selection Determine side or bottom supply duct application. Determine desired airflow Calculate or measure the amount of external static pressure. Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table.
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Page 39: Air Flow Performance - Side Duct Application
1107662-YIM-B-1014 Table 16: Air Flow Performance - Side Duct Application ZJ180 (15 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP &... - Page 40 1107662-YIM-B-1014 ZJ240 (20 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP & Field Standard 5 HP &...
- Page 41 1107662-YIM-B-1014 ZJ300 (25 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Low Static 7.5 HP & Low Static 7.5 HP & Drive Field Supplied Drive 6600 760 2.51 793 3.11 824 3.68 856 4.23 887 4.74 919 5.23 950 5.70 983 6.15...
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Page 42: Air Flow Performance - Bottom Duct Application
1107662-YIM-B-1014 Table 17: Air Flow Performance - Bottom Duct Application ZJ180 (15 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP &... - Page 43 1107662-YIM-B-1014 ZJ240 (20 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP &...
- Page 44 1107662-YIM-B-1014 ZJ300 (25 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Low Static 7.5 HP & Field Low Static 7.5 HP & Drive Supplied Drive 6600...
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Page 45: Air Balance
1107662-YIM-B-1014 Table 18: RPM Selection Size Motor Blower 6 Turns 5 Turns 4 Turns 3 Turns 2 Turns 1 Turn Fully Model (Tons) Sheave Sheave Open Open Open Open Open Open Closed 5.75 1VP65 BK110 (15) 5.75 1VP65 BK090 1010 1055 1095 1135... -
Page 46: Pressure Drop Across A Dry Indoor Coil Vs. Supply Air Cfm For All Unit Tonnages
1107662-YIM-B-1014 Supply Air Drive Adjustment Pressure Drop Across A Dry Indoor Coil VS Supply Air CFM 0.45 The RPM of the supply air blower will depend on the required CFM, the unit accessories or options and the static resistances of both the supply and the return air duct systems. With this 0.35 information, the RPM for the supply air blower and the motor pulley adjustment (turns open) can be determined from the... -
Page 47: Sequence Of Operation
1107662-YIM-B-1014 Sequence of Operation For units with VFD and VAV control, the unit must first be put into the Occupied Mode to start operation. The default setting NOTE: For more in-depth sequence of operation of the for all VAV units is 'Unoccupied', therefore the installer must Simplicity®... - Page 48 1107662-YIM-B-1014 High-Pressure Limit Switch the thermostat is calling for cooling, the UCB will operate in the low ambient mode. During cooling operation, if a high-pressure limit switch opens, Low ambient mode operates the compressors in this manner: the UCB will de-energize the associated compressor, initiate 10 minutes on, 5 minutes off.
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Page 49: Electric Heating Sequence Of Operations
1107662-YIM-B-1014 Electric Heating Sequence Of Operations Safety Controls The UCB monitors the temperature limit switch of electric heat The following sequence describes the operation of the electric units. heat section. The control circuit includes the following safety controls: Temperature Limit Switch (TLs) Temperature Limit Switch (TLS 1, 2). -
Page 50: Gas Heating Sequence Of Operations
1107662-YIM-B-1014 If “IC1” fails to detect a pilot flame, it will continue to try for a Table 22: Electric Heat Anticipator Setpoint maximum of 85 seconds to ignite the pilot tube. If the pilot flame Setting, Amps Heater is not detected, then “IC1” will lock out first stage furnace Voltage operation for five minutes or until 24V power is removed from 0.29... -
Page 51: Gas Heating Operation Errors
1107662-YIM-B-1014 Gas Heating Operation Errors signal from the flame sensor indicating the pilot flame is properly ignited, then the main gas valve will not open. It will Temperature Limit continue to try and ignite the pilot for a maximum of 85 seconds, then if the pilot flame is not detected, the ignition control will If the UCB senses zero volts from the high temperature limit, lock out furnace operation until 24V power is removed from the... -
Page 52: Start-Up (Cooling)
1107662-YIM-B-1014 Start-Up (Gas Heat) Gas Heat Anticipator Setpoints It is important that the anticipator setpoint be correct. Too high Pre-Start Check List of a setting will result in longer heat cycles and a greater Complete the following checks before starting the unit. temperature swing in the conditioned space. -
Page 53: Checking Gas Heat Input
1107662-YIM-B-1014 units. If gas pressure is outside these limits, contact the Table 25: Gas Rate Cubic Feet Per Hour local gas utility or propane supplier for corrective action. Size of Test Dial Seconds for One Rev. 1/2 cu. ft. 1 cu. ft. Shut Down Set the thermostat to the lowest temperature setting. -
Page 54: Proper Pilot Flame Adjustment
1107662-YIM-B-1014 Adjustment Of Temperature Rise Burner Instruction The temperature rise (the difference of temperature between the To check or change burners, pilot or orifices, CLOSE MAIN return air and the heated air from the furnace) must lie within the MANUAL SHUT-OFF VALVE AND SHUT OFF ALL ELECTRIC range shown on the CSA rating plate and the data in Table 11. -
Page 55: Charging The Unit
110 115 120 125 130 135 140 145 150 155 160 165 170 156.15 507.95 Suction Pressure (psi) Suction Pressure (psig) Figure 25: ZJ180 (15 Ton) Charging Chart Figure 27: ZJ240 (20 Ton) Charging Chart 17.5 Ton Charging Chart 25 Ton Charging Chart Outdoor Temp (ºF) 115°F... -
Page 56: Simplicity™ Se (Smart Equipment) Firmware Version
1107662-YIM-B-1014 SIMPLICITY™ SE (SMART EQUIPMENT) FIRMWARE VE RSION 3. BASIC UNIT CONTROL BOARD NAVIGATION EXAMPLES: The following document details the navigation and viewing of navigate the basic status menu and how to change basic the LCD display screen equipped as a standard item on the configuration settings. - Page 57 1107662-YIM-B-1014 When the "Cancel" button is pressed multiple times to exit each menu level and the screen returns to the first "Status, Alarms" dis- play the next demonstration can begin. In this demonstration the information below steps through the "Commissioning" menu. Step 2- Once commission Step 1- Beginning at the status/alarm screen toggle the joystick down three times.
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Page 58: Simplicity Se Ucb Details
1107662-YIM-B-1014 THERMOSTAT WIRED HERE SD-24 Figure 29: Unit Control Board Table 26: Simplicity SE UCB Details Description Function & Comments Terminal Directional orientation: viewed with silkscreen labels upright Limit, 24 VAC power and shutdown connections from unit wiring harness at left on upper edge of UCB Monitored 24 VAC input through heat section limit If voltage is absent, indicating the heat section is over- LIMIT... - Page 59 1107662-YIM-B-1014 Table 26: Simplicity SE UCB Details (Continued) Description Function & Comments Terminal Thermostat connection strip on left edge of UCB 1st stage heating request, 24 VAC input switched Not effective for cooling-only units from R 2nd stage heating request, 24 VAC input switched Not effective for cooling-only units or units with single-stage from R heat sections...
- Page 60 1107662-YIM-B-1014 Table 26: Simplicity SE UCB Details (Continued) Description Function & Comments Input required for operation; 3.625 VDC reading RAT+ to RAT– Return Air Temperature sensor input from 10KΩ with open circuit. Used in return air enthalpy calculation. RAT+ @ 77°F, Type III negative temperature coefficient Substitutes for space temperature if no other space thermistor temperature input is present.
- Page 61 1107662-YIM-B-1014 Table 26: Simplicity SE UCB Details (Continued) Description Function & Comments The VFD alarm contact switches from R within the unit wiring 24 VAC hot input from the normally open VFD VFDFLT harness. 24 VAC input results in unit shutdown and a “VFD alarm contact fault”...
- Page 62 1107662-YIM-B-1014 Table 26: Simplicity SE UCB Details (Continued) Description Function & Comments HPS2 24 VAC hot out for refrigerant circuit 2 High Not effective for one stage compressor UCBs. Connects (right pin) Pressure Switch through circuit trace to the R terminal Not effective for one stage compressor UCBs.
- Page 63 1107662-YIM-B-1014 Table 26: Simplicity SE UCB Details (Continued) Description Function & Comments Item USB connector at right of UCB Used for backup, restoration, & copying of board parameters as Type A female Universal Serial Bus connector well as board software updating through a flash drive Optional communication sub-board at center of UCB Terminal FC BUS connections on left edge of the communication board Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts...
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Page 64: 27 4-Stage Board
1107662-YIM-B-1014 Figure 30: 4-Stage Board Table 27: 4-Stage Board Terminal Description Function and Comments Directional Orientation : Viewed with silkscreen labels upright C and R Terminals at left on upper edge of 4-Stage Board 24VAC common for 4-stage board power 24VAC hot for 4-stage board power Communication Terminals Sensor Actuator (SA) Bus Power for SA bus... - Page 65 1107662-YIM-B-1014 Table 27: 4-Stage Board (Continued) Terminal Description Function and Comments #4 refrigerant circuit Condenser Coil Input required for heat pump units, not required for A/C units; temperature sensor input from 10KΩ @ 77°F, CC4+ 3.625 VDC reading CC4+ to CC4– with open circuit. Used in Type III negative temperature coefficient heat pump demand defrost calculation.
- Page 66 1107662-YIM-B-1014 Table 27: 4-Stage Board (Continued) Terminal Description Function and Comments Input is only considered if C3 output is needed; input must be present to allow C3 output. Three HPS3 trips in a two hour 24 VAC hot return from refrigerant circuit 3 HPS3 (Left Pin) period cause a “High Pressure Switch 3 Lockout”...
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Page 67: Start-Up Sheet
Technical Services Department available. Therefore, some variation in the startup procedure will 5005 York Drive exist depending upon the products capacity, control system, Norman, OK 73069 options and accessories installed. - Page 68 1107662-YIM-B-1014 1034349-UCL-B-0814 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. must be observed at all times.
- Page 69 1107662-YIM-B-1014 1034349-UCL-B-0814 REFERENCE General Inspection Completed See Notes Unit inspected for shipping, storage, or rigging damage Unit installed with proper clearances Unit installed within slope limitations Refrigeration system checked for gross leaks (presence of oil) Terminal screws and wiring connections checked for tightness Filters installed correctly and clean Economizer hoods installed in operating position Condensate drain trapped properly, refer to Installation Manual...
- Page 70 1107662-YIM-B-1014 1034349-UCL-B-0814 Operating Measurements - Air Flow Fan operates with proper rotation ID Fans Exh. Fans Cond. Fans Pressure drop across dry evaporator coil (At maximum design CFM) External Static Pressure Return Static Pressure Supply Static Pressure Supply Air CFM Using Dry Coil Chart Final Adjusted Supply Air CFM 1.
- Page 71 1107662-YIM-B-1014 1034349-UCL-B-0814 OPERATING MEASUREMENTS - COOLING Discharge Discharge Liquid Line Suction Suction Stage Subcooling Superheat Pressure Temp. Temp. Pressure Temp. First ° ° ° ° ° Second (if equipped) ° ° ° ° ° Third (if equipped) ° ° ° °...
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Page 72: 1107662-Yim-B-1014
________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ ________________________________________________________________________________________________________ Subject to change without notice. Printed in U.S.A. 1107662-YIM-B-1014 Copyright © 2014 by Johnson Controls, Inc. All rights reserved. Supersedes: 1107662-YIM-A-0814 York International Corporation 5005 York Drive Norman, OK 73069...
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