Johnson Controls ZY Series Installation Manual
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Johnson Controls ZY Series Installation Manual

3-10 ton, 6 ton 60 hertz r-410a
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Installation Manual ZY Series 3 - 10 ton,
ZXA7 6 ton 60 Hertz R-410A
York International Corporation, 5005
6231824-UIM-E-0623
York Drive, Norman, OK 73069
www.johnsoncontrols.com
2023-06-19
Johnson Controls Ducted Systems

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  • Page 1 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A York International Corporation, 5005 6231824-UIM-E-0623 York Drive, Norman, OK 73069 www.johnsoncontrols.com 2023-06-19 Johnson Controls Ducted Systems...
  • Page 2 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 3: Table Of Contents

    ZXA7 side duct application (belt drive)... 86 Ignition control board on standby....118 ZY04 to 06 side duct application (direct Call for heat............118 drive)..............87 Combustion air proving........118 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 4 Start up for units equipped for fan energy rating................. 126 Troubleshooting..............128 Charging tables.............. 133 Smart Equipment™ Control board navigation components................139 Start-Up sheet..............140 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 5: General

    Refer to this manual for assistance or for additional information, consult a qualified contractor, installer, or service agency. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 6 Horizontal flow dry bulb economizer field Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the installed National Gas and Propane Installation Code, CSA B149.1. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 7: Renewal Parts

    CAUTION This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 8: Nomenclature

    G = E-Coat Indoor Coil & Standard Outdoor Coil w/Reheat* H = E-Coat Indoor & Outdoor Coils w/Reheat* *ZY04-12 units in power supply of 208/230/460/575-3-60 options only. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 9: Installation

    A fire or explosion may result causing property damage, personal injury or loss of life. Preceding installation About this task: Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 10 Use the excess wire available to its full length to drop or mount the RAT sensor in the duct. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 11: Limitations

    Air Conditioning Contractors of America (ACCA). This furnace is not to be used for temporary heating of buildings or structures under construction. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 12: Location

    Gas Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2, 7.3, or 7.4 of Gas Installation Codes, CSA- Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 13: Rigging And Handling

    All panels must be secured in place when the unit is lifted. The condenser coils should be protected from rigging cable damage with plywood or other suitable material. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 14: Zy04-12 Unit Weights

    A7 (6) 04 (3) 05 (4) 06 (5) A7 (6) 45.0 35.3 08 (7.5) 09 (8.5) 12 (10) 1013 1008 A7 (6) Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 15 Curb rigid 14 in. small footprint Curb rigid 14 in. large footprint Curb rigid 24 in. small footprint Curb rigid 24 in. large footprint Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 16 Figure 11: ZY04 unit dimensions Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 17 Figure 12: ZY05-06 and ZXA7 unit dimensions Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 18 Figure 13: ZYA7 unit dimensions Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 19 Figure 14: ZY08/09 unit dimensions Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 20 Figure 15: ZY12 unit dimensions Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 21 1TB0401 - through the base electrical and • ZY06 through the curb gas • ZXA7 1TB0403 - through the base electrical and gas Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 22 1TB0401 - through the base electrical and through the curb gas 1TB0403 - through the base electrical and gas Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 23: Ductwork

    When fastening ductwork to side duct flanges on unit, insert screws through duct flanges only. DO NOT insert screws through casing. Outdoor ductwork must be insulated and water-proofed. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 24: Condensate Drain

    R-410A compressor lubricants are known to cause long term damage to some synthetic roofing materials. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 25: Filters

    Table 1. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 26: Thermostat Wiring

    A or L1 and C or L3 only. Note: The maximum length is measured from the unit to the thermostat and back to the unit. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 27: Typical Field Power And Control Wiring

    Typical field power and control wiring Typical power wiring Figure 23: Everyday Thermostat Control (ETC) typical power wiring Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 28: High Altitude

    The 100,000 BTUH Ultra-Low NOx model is factory equipped to operate correctly at altitudes up to 5,400 ft above sea level, without a high altitude kit. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 29 92,000 4,001 to 4,500 54,600 91,000 4,501 to 5,000 54,000 90,000 5,001 to 5,400 53,500 89,200 above 5,400 not allowed not allowed Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 30: Electrical Data

    22.3 22.9 11446 16.8 26.6 None — — — 575-3-60 — — — — 11058 14.9 15.4 11458 13.8 13.3 20.4 20.9 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 31 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 32 39.7 54.1 55.4 14246 41.7 50.2 67.3 68.5 None — — — 15.3 16.1 575-3-60 — 11758 16.4 23.6 24.6 13458 32.7 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 33 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 34 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 35: Zy04 To 12 Standard Indoor Blower - With Powered Convenience Outlet

    11446 16.8 28.7 29.3 None — — — 11.4 11.8 575-3-60 — — — 11058 17.1 17.6 11458 13.8 13.3 22.6 23.1 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 36 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 37 39.7 56.8 58.1 14246 41.7 50.2 69.9 71.2 None — — — 17.8 575-3-60 11758 16.4 25.8 26.8 13458 32.7 46.2 47.2 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 38 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 39 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 40: Zy04 To 12 Medium Indoor Blower - Without Powered Convenience Outlet

    21.1 11446 16.8 24.3 24.9 None — — — 575-3-60 — — — — 11058 13.6 14.1 11458 13.8 13.3 19.1 19.6 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 41 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 42 39.7 54.1 55.4 14246 41.7 50.2 67.3 68.5 None — — — 15.3 16.1 575-3-60 — 11758 16.4 23.6 24.6 13458 32.7 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 43 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 44 Non-fused Disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 45: Zy04 To 12 Medium Indoor Blower - With Powered Convenience Outlet

    11446 16.8 26.9 27.6 None — — — 10.3 10.7 575-3-60 — — — 11058 15.8 16.3 11458 13.8 13.3 21.3 21.8 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 46 Non-fused Disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 47 39.7 56.8 58.1 14246 41.7 50.2 69.9 71.2 None — — — 17.8 575-3-60 11758 16.4 25.8 26.8 13458 32.7 46.2 47.2 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 48 Non-fused Disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 49 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 50: Zy04 To 12 High Indoor Blower - Without Powered Convenience Outlet

    Non-fused Disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 51 56.8 14246 41.7 50.2 68.6 69.9 None — — — 17.1 17.9 575-3-60 — 11758 16.4 25.9 26.9 13458 32.7 46.3 47.3 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 52 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 53 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 54: Zy04 To 12 High Indoor Blower - With Powered Convenience Outlet

    29.4 None — — — 12.3 12.7 575-3-60 5.1 39.5 — — — 11458 13.8 13.3 22.8 23.3 12358 22.1 33.8 34.3 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 55 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 56 13346 39.7 58.2 59.4 14246 41.7 50.2 71.3 72.6 None — — — 18.8 19.6 575-3-60 11758 16.4 13458 32.7 48.4 49.4 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 57 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 58 Non-fused disconnect. Verify on the unit nameplate that the disconnect is correctly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 59: Physical Data

    Face area (sq ft) 16.3 16.3 Rows Condenser coil data Fins per in. Tube diameter (in./mm) .63/16 .63/16 Circuitry type 2-pass Microchannel 2-pass Microchannel Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 60 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 2 in. throwaway, standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 61 2-pass Microchannel Face area (sq ft) Rows Fins per in. Evaporator coil data Tube diameter 0.375 0.375 Circuitry type Intertwined Intertwined Refrigerant control Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 62 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 2 in. throwaway, standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 63 2-pass Microchannel Face area (sq ft) Rows Fins per in. Evaporator coil data Tube diameter 0.375 0.375 Circuitry type Intertwined Intertwined Refrigerant control Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 64 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 65 Drive type Direct Direct Condenser fan data Quantity of motors Motor hp each No. speeds 1,085 1,085 Nominal total cfm 7,600 7,600 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 66 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 1st Stage 60% of 2nd Stage. 2 in. throwaway, standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 67 Drive type Direct Direct Condenser fan data Quantity of motors Motor hp each No. speeds 1,085 1,085 Nominal total cfm 8,200 8,200 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 68 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 2 in. Throwaway, Standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 69 Drive type Direct Direct Condenser fan data Quantity of motors Motor hp each No. speeds 1,085 1,085 Nominal total cfm 8,600 8,600 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 70 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 2 in. throwaway, standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 71 Condenser fan data Quantity of motors Motor hp each 1 1/2 1 1/2 No. speeds 1,140 1,140 Nominal total cfm 7,700 7,700 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 72 MagnaDRY reheat option is available in power supply of 208/230/460/575-3-60 options only. 2 in. throwaway, standard, MERV 4 (Minimum Efficiency Reporting Value). Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 73: Zxa7 Physical Data

    Quantity of motors Motor hp each Number of speeds 900 / 1,150 900 / 1,150 Nominal total cfm 3,600 / 4,600 3,600 / 4,600 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 74: Optional Gas Heat

    Low, ULN 1500 High, ULN 1050 1500 Note: Routing of gas piping must not interfere with the flue or heat compartment access. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 75: Gas Connection

    A fire or explosion may result causing property damage, personal injury or loss of life. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 76: Options And Accessories

    2. Horizontal flow application with barometric relief at the point of installation. standard. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 77: Power Exhaust

    A or L1 and C or L3 only. Blower rotation Check for correct supply air blower rotation. If the blower is rotating backwards, the line voltage at the Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 78: Belt Tension

    As the altitude or temperature increases, density correction factors are shown in Table 40 and the density of air decreases. In order to use the Figure 29. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 79 BHP requirement. Solution: As in the example above, no temperature information is given so 70°F is assumed. The 1.4 in. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 80 Select the appropriate drive if multiple drives are available for the chosen motor. 8. Determine turns open to obtain the required operation point. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 81: Airflow Performance

    0.46 — — — — 0.41 — 0.45 0.47 0.54 6000 0.28 0.50 — — — — 0.48 — 0.52 0.54 0.60 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 82: Zy04 To 12 Side Duct Application (Belt Drive)

    Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 83 Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 84 Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 85 Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 86: Zxa7 Side Duct Application (Belt Drive)

    Standard static option with motor rated at 2.4 hp Static option with motor rated at 2.9 hp Static option with motor rated at 3.7 hp Exceeds recommended blower speed Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 87: Zy04 To 06 Side Duct Application (Direct Drive)

    4 (Med/Hi) 2049 1969 1026 1902 1070 1808 1110 1637 1132 5 (Hi) 2218 1021 2138 1074 2007 1105 1846 1123 1671 1139 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 88: Zy04 To 12 Bottom Duct Application (Belt Drive)

    Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 89 Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 90 Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 91 Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 92: Zxa7 Bottom Duct Application (Belt Drive)

    Blower performance includes gas heat exchangers and 2 in. filters. See static resistance table for additional applications. Note: See rpm selection table to determine required motor sheave setting and to determine the maximum continuous bhp. kW = 0.929 x bhp Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 93: Zy04 To 06 Bottom Duct Application (Direct Drive)

    4 (Med/Hi) 1999 1932 1030 1860 1076 1753 1114 1598 1134 5 (Hi) 2170 1040 2091 1084 1965 1109 1798 1127 1618 1139 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 94: Rpm Selection

    1VP50 1000 1050 1100 Std. AK79 1VL44 12 (10) Med. AK79 1VP50 1027 H. Static 5.25 BK85 1VP56 1041 1085 1130 1174 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 95: Indoor Blower Specifications

    1725 0.84 1.15 56HZ 3.4 - 4.4 1VP50 AK79 H. Static 5.25 1725 0.84 1.15 145TY 4.3 - 5.3 1VP56 BK85 BX52 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 96: Supply Air Drive Adjustment

    Verify proper sheave alignment; tighten blower pulley and motor sheave set screws after these adjustments. Re-checking set screws and belt tension after 10-12 hrs. run time is recommended. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 97 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. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 98: Everyday Thermostat Control (Etc)

    Thermostat connection 24 VAC connection Thermostat connection No connection Thermostat connection 24 VAC common For internal use only No connection (For future use) Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 99 Shall be interlocked to the fan relay. (When LIMIT Limit switch power is interrupted from this input, the fan will be forced on by software) Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 100 2nd stage on output will energize. (heat/cool) 1st stage in Rapid flash ASCD (heat/cool) 1st stage on (heat/cool) Fan only (no Fast heartbeat heat/cool) Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 101 2 to 5 seconds: Clear anti-short cycle timers and Factory test mode Rapid flash Rapid flash reset any active lockouts • More than 5 seconds: Clear all fault history Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 102: Smart Equipment™ Unit Control Board

    SD-24 and R 24 VAC common for thermostat power Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 103 10KΩ at 77°F, type III negative temperature VDC reading EC2+ to EC2– with open circuit. Used in suction line temperature safety. coefficient thermistor Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 104 24 VAC hot output for compressor 2 allow compressor 2 operation; output with compressor cooling, comfort ventilation cooling or heat pump heating demands Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 105 Button for display menu acknowledgment and navigation Button for display menu navigation and zeroing of active compressor CANCEL ASCD timer 4-way Joystick for display menu navigation Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 106 Be sure the cable you use fits the modular jack housing. The preassembled cables that are available from Anixter (Part No. CBL-NETWORKxxx) use 24 gauge wire. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 107: Operation

    The energizes the compressor and condenser fan motor blower is energized after any specified delay only. associated with the operation. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 108 Should a freezestat open three times within two hours of operation, the UCB will lock-out the associated compressor and flash a code on the ETC. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 109: Space Humidity Sensing

    (authority). Priority #1: BAS override. BAS network overrides zone humidity Priority #2: Network space humidity sensor, communicating thermostat or sensor Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 110: Reheat Mode Sequence Of Operations For Smart Equipment™ Control Only

    3 (HGRH) and energizes SOL 1, engaging cooling circuit no. 1 resulting in circuit no. 1 cooling mode operation. The unit is now in first stage cooling without HGRH. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 111: Normal Reheat Mode

    Evaporator coil Reheat coil Open solenoid valve (SOL 1) Refrigerant flow Accumulator Check valve Compressor Condenser coil Closed solenoid valve (SOL 2) Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 112: Alternate Mode

    The call for cooling Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 113: Flashcodes Or Error Messages

    (Y2) temperature. This resets any pressure or freezestat lockouts. Smart Equipment™ economizer board details Figure 34: SE-ECO1001-1 economizer controller Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 114 24 V~ 24 VAC hot supplied for the outdoor air humidity sensor Connects through circuit trace to 24 V~ IN pin HOT Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 115 When wiring unit and other devices using the SA Bus and FC Bus, see Table "Cable for FC Buses and SA Buses in Order of Preference". Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 116: Indoor Air Quality (Iaq)

    The ICB begins a call for heat when W1 is energized at the Unit Control Board (UCB). The ICB ignores W2 until ignition has been established. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 117: Call For Heat

    If the pressure switch is lost during an ignition trial W2 is energized. The control energizes the high gas period, the control immediately de-energizes spark output. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 118: Post Purge

    Rollout switch lockout shall not reset automatically. Following the pressure sensor check, the draft inducer is set to the pre-purge pressure setting. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 119: Pre-Purge

    ICB keeps the main gas valve and control continues to monitor the gas valve circuit induced draft motor de-energized. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 120: Diagnostic Fault Code Storage And Retrieval

    10. Turn unit electrical power off. 11. If using a T-Stat, set the SE control to enable T- Stat. Operating instructions 1. Turn unit electrical power on. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 121: Post Start Checklist

    Turn ON electric power to unit. units operating on 60 Hz power only. If thermostat set temperature is above room temperature, the main burners will ignite. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 122: Manifold Gas Pressure Adjustment

    1/2 cu. ft. 1 cu. ft. 2. Using the outlet pressure port on the gas valve, connect a manometer to monitor the manifold pressure. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 123 High 9. Once pressure has been checked, replace the cover screws covering the HI and LO pressure adjustment screws. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 124: Adjustment Of Temperature Rise

    National Fuel Gas Code, ANSI Z223.1/NFPA 54 or National Standard of Canada, Natural Gas and Propane Installation Code, CSA B149.1. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 125 Figure 37: 3 ton through 5 ton, 1/2 in. single stage gas valve Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 126: Start Up For Units Equipped For Fan Energy Rating

    A red heating lead • A white, fan only lead Figure 38: 3 ton through 5 ton, 1/2 in. two stage gas valve Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 127 Figure 39: 6 ton through 12.5 ton 3/4 in. two stage gas valve Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 128: Troubleshooting

    FAN ONLY (NO HEAT/COOL) FAST HEARTBEAT NO ALARMS IN MEMORY 2 PULSES 2 PULSES NORMAL IDLE SLOW HEARTBEAT FACTORY TEST MODE RAPID FLASH RAPID FLASH Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 129 Verify that there are no conditioned air leaks or heat exchanger breaches to interfere with ignition or the burners. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 130 None required - normal operation Normal operation with a steady on green LED None required - normal operation call for heating operation Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 131 If it is open, the switch must be reset before operation can resume. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 132 ICB. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 133: Charging Tables

    300 Cfm/Ton 80/62 300 Cfm/Ton 80/67 300 Cfm/Ton 80/72 300 Cfm/Ton 75/62 400 Cfm/Ton 80/62 400 Cfm/Ton 80/67 400 Cfm/Ton 80/72 400 Cfm/Ton 75/62 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 134 400 Cfm/Ton 80/62 11.3 12.7 14.2 400 Cfm/Ton 80/67 11.2 12.7 14.2 400 Cfm/Ton 80/72 11.1 12.7 14.3 400 Cfm/Ton 75/62 11.2 12.7 14.1 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 135 300 Cfm/Ton 80/62 300 Cfm/Ton 80/67 300 Cfm/Ton 80/72 300 Cfm/Ton 75/62 400 Cfm/Ton 80/62 400 Cfm/Ton 80/67 400 Cfm/Ton 80/72 400 Cfm/Ton 75/62 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 136 300 Cfm/ton 80/62 300 Cfm/ton 80/67 300 Cfm/ton 80/72 300 Cfm/ton 75/62 400 Cfm/ton 80/62 400 Cfm/ton 80/67 400 Cfm/ton 80/72 400 Cfm/ton 75/62 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 137 10.7 12.1 400 Cfm/Ton 80/62 10.8 12.1 400 Cfm/Ton 80/67 10.8 12.1 400 Cfm/Ton 80/72 10.8 12.2 400 Cfm/Ton 75/62 10.8 12.1 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 138 10.6 12.0 400 Cfm/Ton 80/62 10.6 11.9 400 Cfm/Ton 80/67 10.7 12.0 400 Cfm/Ton 80/72 10.7 12.0 400 Cfm/Ton 75/62 10.7 12.0 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 139: Smart Equipment™ Control Board Navigation Components

    Note: For more in-depth sequence of operation of the Smart Equipment™ control, refer to the Smart Equipment™ Controls Sequence of Operation Overview LIT-12011950. Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...

  • Page 140: Start-Up Sheet

    Start-Up sheet Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 141 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 142 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 143 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 144 Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 145   Installation Manual ZY Series 3 - 10 ton, ZXA7 6 ton 60 Hertz R-410A Johnson Controls Ducted Systems...
  • Page 146 Subject to change without notice. Printed in U.S.A. Copyright © 2023 by Johnson Controls. All rights reserved. Supersedes: 6231824-UIM- D-0423 www.johnsoncontrols.com Johnson Controls Ducted Systems...

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