Johnson Controls ZL Series Installation Manual

7.5-12.5 ton 60 hertz r-410a

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Installation Manual ZL Series 7.5- 12.5 Ton

60 Hertz R-410A

York International Corporation, 5005

5830280-UIM-E-0123

York Drive, Norman, OK 73069

www.johnsoncontrols.com

2023-01-16

Johnson Controls Ducted Systems

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Summary of Contents for Johnson Controls ZL Series

Page 1 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A York International Corporation, 5005 5830280-UIM-E-0123 York Drive, Norman, OK 73069 www.johnsoncontrols.com 2023-01-16 Johnson Controls Ducted Systems...
Page 2 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 3 Gas heat ignition control board function.....67 Physical data............35 Ignition control board on standby....67 Optional gas heat............43 Call for heat............67 Gas piping............43 Pressure switch proving........68 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 4 Manifold gas pressure adjustment......71 Adjustment of temperature rise.......72 Burners/orifices inspection/servicing..... 72 Troubleshooting..............74 Flash codes............... 75 ZL08 to 14 charging tables..........77 Smart Equipment™ control board navigation components................79 Start-up sheet.................80 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 5 Refer to this manual for assistance or for additional information, consult a qualified contractor, installer or service agency. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 6 Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the National Gas and Propane Installation Code, CSA B149.1. Contact your local UP parts distribution center for authorized replacement parts. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 7 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 8 Nomenclature Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 9 Option are wired for 230 V power supply. Change tap on transformer for 208-3-60 operation. See unit wiring diagram. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 10 Figure 7. hold the RAT sensor in the return air stream. See Figure 4 for the factory RAT sensor location and Figure 5 for the sensor relocation. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 11 Air Conditioning Contractors of America (ACCA). This furnace is not to be used for temporary heating of buildings or structures under construction. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 12 Spreader bars, whose length exceeds the largest dimension across the unit, must be used across the top of the unit. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 13 Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 14 Operating 08 (7.5) 09 (8.5) 12 (10) 14 (12.5) 1003 08 (7.5) 1060 1055 09 (8.5) 1050 1045 12 (10) 1073 1068 14 (12.5) 1093 1088 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 15 Hail Guard kit large tall factory installed Flue extension kit (1FE0416) Curb rigid 14 in. large footprint Curb rigid 24 in. large footprint Figure 11: ZL 08 to ZL 09 unit dimensions Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 16 Units may be installed on combustible floors made from wood or class A, B, or C roof covering materials. Figure 12: ZL 12 to ZL 14 unit dimensions Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 17 The supply and return air duct systems should be designed for the CFM and static pressure requirements of the job. They should not be sized Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 18 Outdoor ductwork must be insulated and water-proofed. Figure 14: Side duct cover panels Note: Shown with duct connection cover panel as shipped. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 19 National Electrical Code (NEC), ANSI/NFPA No. 70 – Latest Edition (in U.S.A.), current Canadian Electrical Code C221, and/or local ordinances. The unit must be electrically grounded Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 20 Table 7: Control wire sizes Wire size Maximum length 18 AWG 150 ft From the unit to the thermostat and back to the unit. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 21 Typical field power and control wiring Typical power wiring Figure 18: Typical Smart Equipment™ control wiring Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 22 Figure 19: Field wiring disconnect Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 23 30.5 460-3-60 12846 27.8 33.4 46.3 47.5 13346 39.7 54.1 55.4 14246 41.7 50.2 67.3 68.5 None 15.1 15.9 575-3-60 11758 16.4 23.6 24.6 13458 32.7 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 24 Non-fused disconnect. Verify on the unit nameplate that the disconnect is properly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 25 12846 27.8 33.4 48.9 50.2 13346 39.7 56.8 58.1 14246 41.7 50.2 69.9 71.2 None 16.8 17.6 575-3-60 11758 16.4 25.8 26.8 13458 32.7 46.2 47.2 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 26 Non-fused disconnect. Verify on the unit nameplate that the disconnect is properly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 27 30.5 460-3-60 12846 27.8 33.4 46.3 47.5 13346 39.7 54.1 55.4 14246 41.7 50.2 67.3 68.5 None 15.1 15.9 575-3-60 11758 16.4 23.6 24.6 13458 32.7 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 28 Non-fused disconnect. Verify on the unit nameplate that the disconnect is properly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 29 12846 27.8 33.4 48.9 50.2 13346 39.7 56.8 58.1 14246 41.7 50.2 69.9 71.2 None 16.8 17.6 575-3-60 11758 16.4 25.8 26.8 13458 32.7 46.2 47.2 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 30 Non-fused disconnect. Verify on the unit nameplate that the disconnect is properly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 31 12846 27.8 33.4 47.6 48.9 13346 39.7 55.5 56.8 14246 41.7 50.2 68.6 69.9 None 16.9 17.7 575-3-60 11758 16.4 25.9 26.9 13458 32.7 46.3 47.3 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 32 Non-fused disconnect. Verify on the unit nameplate that the disconnect is properly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 33 34.6 460-3-60 12846 27.8 33.4 50.3 51.6 13346 39.7 58.2 59.4 14246 41.7 50.2 71.3 72.6 None 18.6 19.4 575-3-60 11758 16.4 13458 32.7 48.4 49.4 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 34 Non-fused disconnect. Verify on the unit nameplate that the disconnect is properly sized for the application. Units with field installed electric heat kits may exceed the factory installed disconnect amperage rating. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 35 Fan diameter (in.) Type Prop Prop 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 36 4 - (20 x 20 x 2) 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 37 Fan diameter (in.) Type Prop Prop 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 38 4 - (20 x 20 x 2) 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 39 Drive type Direct Direct Condenser fan data Quantity of motors Motor hp each 1 1/2 1 1/2 No. speeds 1,140 1,140 Nominal total cfm 9,700 9,700 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 40 4 - (20 x 20 x 2) 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 41 Drive type Direct Direct Condenser fan data Quantity of motors Motor hp each 1 1/2 1 1/2 No. speeds 1,140 1,140 Nominal total cfm 9,700 9,700 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 42 4 - (20 x 20 x 2) 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 43 Do not use a connector Length of pipe (ft) 3/4 in. 1 in. 1-1/4 in. which has previously serviced another gas 1050 appliance. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 44 The gas heat flue exhaust is routed from the unit through a field installed exhaust hood with screen Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 45 2550 4250 outdoor air hood to complete the assembly. Field ZL12 (10) 3000 5000 installed economizer accessories include complete ZL14 (12.5) 3750 6000 instructions for installation. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 46 0.758 0.730 0.702 0.676 0.964 0.929 0.897 0.864 0.833 0.802 0.772 0.744 0.716 0.689 0.663 0.946 0.912 0.880 0.848 0.817 0.787 0.758 0.730 0.703 0.676 0.651 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 47 Select the appropriate pressure to equivalent sea level conditions. motor and, or drive. Sea level static pressure = 1.4 in. / .832 = 1.68 in. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 48 1039 rpm is within the range of the 3 hp drives. Using the 3 hp motor and drive, 1.5 turns open will achieve 1,039 rpm. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 49 High static 5.25 BK85 1VP56 1041 1085 1130 1174 Standard AK79 1VL44 14 (12.5) Medium AK79 1VP50 1027 High static 5.25 BK85 1VP56 1041 1085 1130 1174 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 50 AK79 14 (12.5) Medium 1750 0.90 1.15 184TZ 3.4 - 4.4 1VP50 AK79 High static 5.25 1750 0.90 1.15 184TZ 4.3 - 5.3 1VP56 BK85 BX52 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 51 High static option with motor rated at 3.7 hp Bold Field-supplied BK95 x 1 fixed pulley (p/n 9381) with motor rated at 3.7 hp Exceeds recommended blower speed Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 52 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 Exceeds recommended blower speed Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 53 High static option with motor rated at 3.7 hp Bold Field-supplied BK95 x 1 fixed pulley (p/n 9381) with Motor rated at 3.7 hp Exceeds recommended blower speed Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 54 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 Exceeds recommended blower speed Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 55 Use Table 35 to locate the DD nearest to 2.48 in. Close the sheave to 2 turn open. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 56 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 than0.25 IWG, the unit will deliver less CFM during full economizer operation. Figure 25: Unit control board Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 57 Type III negative temperature coefficient thermistor cooling changeover, outside air enthalpy calculation, economizer loading operation, heat pump demand defrost calculation. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 58 Pin Refrigerant circuit safety switch and indoor blower overload connections at center on lower edge of UCB HPS1(right pin) 24 VAC hot out for refrigerant circuit 1 High Pressure Switch Connects through circuit trace to the R terminal Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 59 0.25 V lower than +) FC bus BACnet MSTP communication circuit Common for the FC (Field Connected) Negative of the VDC FC bus BACnet MSTP communication circuit BUS BACnet MSTP communication circuit Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 60 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 61 The dampers modulate to maintain a constant supply air temperature as monitored by the discharge air sensor. If the outdoor air enthalpy is above the setpoint, Y1 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 62 If the call for cooling Local LCD on Unit Control Board. is still present at the conclusion of the ASCD, the UCB re-energizes the halted compressor. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 63 The refrigeration systems are which is priority #1. independently monitored and controlled. On any fault, only the associated system is affected by any safety or preventive action. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 64 When the UCB detects a need for dehumidification through the field installed return/space humidity sensor and there is not a call for cooling, the UCB energizes solenoids SOL 3 (HGRH), SOL 2 and the reheat relay Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 65 Reheat valve (SOL 3) Evaporator coil Reheat coil Open solenoid valve (SOL 1) Refrigerant flow Accumulator Check valve Compressor Condenser coil Closed solenoid valve (SOL 2) Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 66 When there is a call for second stage cooling, the energizes. UCB de-energizes the HGR, which de-energizes SOL 3 and SOL 2, and energizes SOL 1. Both circuits now Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 67 When the pressure switch is sensed as open, the ICB begins pressure switch proving period. If the call for heat is lost, the ICB goes back to Standby. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 68 If a flame is not detected in 2 seconds, the prove open pressure switch before continuing with main valve is de-energized and a retry operation the heat cycle. begins. The flame stabilization period lasts 10 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 69 ICB will enter lockout. The control will turn on the inducer blower while the flame is present. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 70 60 Hz power only. as the supply piping. To determine the rate of gas flow (Second Stage). Turn off all other gas appliances connected to the gas meter. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 71 1/2 cu. ft. 1 cu. ft. to the LO marking on the valve (See Figure 29). Manifold pressure adjustment procedure. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 72 Physical data. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 73 National Fuel Gas Code, ANSI Z223.1/NFPA 54 or National Standard of Canada, Natural Gas and Propane Installation Code, CSA B149.1. Figure 29: Typical two stage gas valve Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 74 Caution should be used at all times as the supply air blower may energize regardless of the room thermostat fan switch position. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 75 Verify that there are no conditioned air leaks or heat exchanger breaches to interfere with ignition or the burners. Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 76 1 second at the 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 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 77 400 Cfm/ 400 Cfm/ Ton 80/67 Ton 80/67 10.0 400 Cfm/ 400 Cfm/ Ton 80/72 Ton 80/72 10.0 400 Cfm/ 400 Cfm/ Ton 75/62 Ton 75/62 10.0 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 78 11.6 400 Cfm/ 400 Cfm/ 10.8 13.3 Ton 80/72 Ton 80/72 12.1 14.9 11.6 400 Cfm/ 400 Cfm/ 10.7 13.2 Ton 75/62 Ton 75/62 12.0 14.7 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 79 Equipment™ Quick Start Guide. 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 ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 80 Start-up sheet Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 81 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 82 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 83 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 84 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 85 Installation Manual ZL Series 7.5- 12.5 Ton 60 Hertz R-410A Johnson Controls Ducted Systems...
Page 86 Supersedes: D-0722 www.johnsoncontrols.com Johnson Controls Ducted Systems...

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