Table of Contents
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R-410A
ZJ SERIES W/SMART EQUIPMENT™
3 - 5 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 31
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 31
1 ZJ037-061 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZJ037-061 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8
4 ZJ037-061 Unit Physical Dimensions . . . . . . . . . . . . . . . 11
5 ZJ037-061 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 27
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 28
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 29
14 Smart Equipment™ Economizer Board Details . . . . . . . 33
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16 Altitude/Temperature Correction Factors . . . . . . . . . . . . 37
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Component Location (ZJ037 Shown) . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZJ037 - 049 Physical Dimensions . . . . . . . . . . . . . . . . . . 9
9 ZJ061 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 10
10 ZJ037-061 Unit Bottom Duct Openings . . . . . . . . . . . . . 12
11 ZJ037-061 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13
12 ZJ037-061 Unit Side Duct Openings . . . . . . . . . . . . . . . 13
13 ZJ037-061 Unit Left/End Duct Opening . . . . . . . . . . . . . 14
14 ZJ037-061 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZJ037-061 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15
16 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 15
TABLE OF CONTENTS
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 46
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 46
Electric Heating Sequence Of Operations . . . . . . . . . . . . 47
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 48
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 49
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 49
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Control Board Navigation Components . . . . . . . . . . . . . . . . . 54
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LIST OF TABLES
17 Airflow Performance - Side Duct Application . . . . . . . . . 40
18 Airflow Performance - Bottom Duct Application . . . . . . . 41
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . 42
21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 42
22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 44
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 45
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 48
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 48
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 50
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 52
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . 55
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . 60
LIST OF FIGURES
17 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 16
18 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . 16
19 Save Side Panels For Economizer Hood Tops . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19
23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 28
25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 33
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . 38
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
29 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
30 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . 53
31 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . 54
32 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Table of Contents
Related Manuals for York ZJ061
Summarization of Contents
General Unit Information and Safety
Safety Considerations
Explains the safety alert symbol, signal words DANGER, WARNING, CAUTION.
Installation Safety Warnings
Improper installation, adjustment, or maintenance can cause injury or damage.
Refrigerant Safety
R-410A refrigerant system; use compatible servicing equipment.
Gas Safety Precautions
Fire or explosion hazard if manual is not followed; gas safety.
Installation Requirements and Limitations
Unit Inspection and Preparation
Inspect unit for transit damage and note any evident damage.
Installation Compliance
Strict compliance with instructions and codes required for installation.
Gas Piping Pressure Testing
Disconnect gas piping during pressure testing above 1/2 PSIG.
Installation Procedures
Installation Safety Information
Read instructions, check rating plate, test for leaks safely, and install within specified ranges.
Fire and Explosion Hazard Warning
FIRE OR EXPLOSION HAZARD. Never test for gas leaks with an open flame.
Preceding Installation Steps
Steps to prepare for unit installation, like removing brackets.
Convenience Outlet Voltage Adjustment
Voltage conversion for convenience outlet option requires transformer tap adjustment.
Installation Limitations and Guidelines
Applicable Codes and Standards
Lists codes and standards for unit installation in the US and Canada.
Smart Equipment Control Board Operation
Smart Equipment control board operates cooling down to 0°F.
Unit Location and Rigging
Location Selection Guidelines
Guidelines for selecting a suitable outdoor installation location.
Combustion Air Obstruction Warning
Do not obstruct condenser air discharge or combustion air inlet.
Rigging and Handling Instructions
Instructions for safe rigging and handling of the unit.
Roof Curb Gasketing Caution
Gasketing required for non-York roof curbs.
Rigging Cable Load Distribution
Ensure rigging cables distribute unit weight equally.
Unit Weights and Dimensions
Unit Weights and Load Locations
Provides weights and load locations for ZJ037-061 units.
Accessory Weights
Lists shipping and operating weights for common accessories.
Physical Dimensions
ZJ037-049 Physical Dimensions
Diagram showing physical dimensions for ZJ037 and ZJ049 units.
Unit Clearances and Dimensions
Physical Dimensions Table
Table detailing physical dimensions A through F for ZJ037-061 models.
Required Unit Clearances
Specifies required clearances for top, front, rear, left, and right sides.
Duct Openings
Bottom Duct Openings
Diagram illustrating bottom duct opening locations and dimensions.
Electrical and Side Duct Details
Unit Electrical Entry Points
Diagram showing electrical entry points and conduit sizes.
Side Duct Openings
Diagram illustrating side duct opening locations.
Side Duct Dimensions
Table providing side duct opening dimensions for ZJ037-061 models.
Left/End Duct and Roof Curb Details
Left/End Duct Opening Diagram
Diagram showing left/end duct opening dimensions.
Left/End Duct Dimensions Table
Table detailing left/end duct opening dimensions for ZJ037-061 models.
Roof Curb Diagram
Diagram illustrating the ZJ037-061 roof curb dimensions.
Ductwork and Covers
Transition Roof Curb Diagram
Diagram showing dimensions for the transition roof curb.
Ductwork Design Guidelines
Guidelines for designing and sizing ductwork according to ACCA and ASHRAE standards.
Ductwork Fastening Caution
Fasten ductwork to flanges only, not casing; insulate outdoor ductwork.
Use of Duct Covers
Information on using factory-provided duct covers for side openings.
Component Details and Safety
Return Downflow Plenum Diagram
Image of the return downflow plenum.
Condensate Drain Installation
Instructions for condensate drain installation and protection.
Side Panels for Economizer Hoods
Notes on saving side panels for economizer hood tops.
Compressor Information and Safety
Details on compressor, R-410A refrigerant, and POE oil safety.
Filters and Wiring
Filter Installation and Maintenance
Information on filter types, installation, and maintenance.
Panel Latch Airtight Seal Caution
Ensure panel latches are properly positioned for an airtight seal.
Power and Control Wiring Guidelines
Guidelines for field wiring, fuses, and disconnects per NEC/CEC.
Voltage Transformer Tap Adjustment
Transformer tap adjustment for voltage compatibility.
Disconnect Mounting Caution
Avoid damage to internal components when drilling for disconnect mounting.
Waterproof Connectors Caution
Use waterproof connectors for electrical wiring to prevent moisture ingress.
Wiring Diagrams
Power Wiring Detail
Illustrates power wiring connection to the terminal block and disconnect.
Field Wiring Disconnect Diagram
Diagram showing field wiring to a disconnect switch.
Thermostat and Control Wiring
Thermostat Location and Wiring
Guidance on thermostat location and wiring to the unit.
Typical Control Wiring Diagram
Diagram showing typical thermostat wiring connections.
R-OCC Jumper Function
Explains the R-OCC jumper and its function for occupancy mode control.
Electrical Data Tables
Electrical Data (No Convenience Outlet)
Electrical data for ZJ037-061 units without powered convenience outlet.
Electrical Data Continuation
Electrical Data (No Convenience Outlet) Cont.
Electrical data for ZJ037-061 units without powered convenience outlet.
Electrical Data with Convenience Outlet
Electrical Data (With Convenience Outlet)
Electrical data for ZJ037-061 units with powered convenience outlet.
Electrical Data with Convenience Outlet Continuation
Electrical Data (With Convenience Outlet) Cont.
Electrical data for ZJ037-061 units with powered convenience outlet.
Physical Data
Single Stage Gas Heat Physical Data
Provides physical and performance data for single stage gas heat models.
Physical Data Continuation
Single Stage Gas Heat Physical Data Cont.
Continued physical data including fan specifications and filters.
Two Stage Gas Heat Physical Data Continuation
Two Stage Gas Heat Physical Data Cont.
Continued physical data including fan specs and filter sizes.
Optional Electric Heat Information
Information on factory-installed electric heaters and their power requirements.
Electric Heat Minimum Supply Air
Minimum supply air (CFM) required for various electric heat kW sizes.
Gas Heat and Piping
Optional Gas Heat Details
Details on gas-fired heaters, heat exchangers, and spark ignition.
Gas Piping Installation Guidelines
Guidelines for gas piping sizing and installation based on codes.
Gas Pipe Sizing Table
Table showing gas pipe capacity based on length and nominal iron pipe size.
Gas Connection and LP Conversion
Gas Heat Minimum Supply Air Table
Minimum supply air (CFM) required for gas heat models.
Gas Supply Line Connection
Instructions for routing and connecting the gas supply line.
Propane Gas Solvent Warning
Propane gas solvent warning; use special pipe dope resistant to solvents.
Gas Leak Testing Hazard Warning
FIRE OR EXPLOSION HAZARD. Never test for gas leaks with an open flame.
Pressure Testing Caution
Disconnect gas piping during pressure testing above 1/2 PSIG.
LP Gas Piping Compound Warning
Use sealing compound resistant to liquefied petroleum gases; do not use Teflon tape.
LP Gas Unit Conversion
Information on converting units for LP gas and safety standards.
Options and Accessories
Vent and Combustion Air
Notes on venting slots and flue exhaust for heating compartment.
Electric Heat Option Details
Details on electric heaters, their mounting, and power supply.
Smoke Detector Information
Information on factory-installed smoke detectors, their limitations, and maintenance.
Smoke Detector Limitation Warning
Smoke detector limitation warning; refer to NFPA.
Smoke Detector Temperature Warning
Smoke detector temperature warning; subject to extreme temperatures.
Smoke Detector Airflow Caution
Ensure adequate airflow to the smoke detector sensor.
Economizer and Damper Operation
Motorized Outdoor Damper
Information on factory or field installed motorized outdoor dampers.
Economizer Options
Describes economizer options and installation requirements.
Economizer Minimum Position
Setting the economizer minimum position for occupied mode.
Power Exhaust Installation
Details on factory or field installed power exhaust options.
Rain Hood Components
Notes on packaging of hood components for installation.
Economizer Sequence Functions
Describes economizer functions like minimum position and free cooling.
Free Cooling Types
Details on Dry Bulb, Single Enthalpy, Dual Enthalpy, and Auto free cooling.
Free Cooling Operation Logic
First stage of cooling is always free cooling when suitable.
Control Board Operation and Settings
Thermostat Interaction with Economizer
How the thermostat interacts with economizer and cooling controls.
Power Exhaust Setpoints and Operation
Details on power exhaust setpoints and operation.
Power Exhaust Inputs and Outputs
Describes control inputs and outputs for power exhaust.
Power Exhaust Operation Details
Details operation of economizer and power exhaust interaction.
Economizer Controller Board
Economizer Controller Diagram
Image of the Smart Equipment Economizer Controller board.
Economizer Board Analog Inputs and LEDs
Details of Analog Inputs and LEDs on the economizer board.
Economizer Board Details Continuation
Economizer Board Analog and Binary Outputs
Details of Analog Outputs and Binary Outputs on the economizer board.
Economizer Board Sensor Inputs
Economizer Board Analog Sensor Inputs
Details of Analog Inputs for various sensors on the economizer board.
Economizer Board Binary Inputs and Phasing
Economizer Board Binary Inputs
Details of Binary Inputs and connections on the economizer board.
Indoor Air Quality (IAQ) Sensor
Describes connection and operation of the Indoor Air Quality sensor.
Compressor Rotation Safety
Scroll compressors require correct rotation; do not change internal wiring.
Blower Rotation and Phasing
How to check for correct blower rotation and identify phasing issues.
Supply Air Limitations
Minimum and maximum supply air limitations (CFM) by unit size.
Belt Tension and Airflow Corrections
Belt Tension Adjustment Procedure
Instructions for adjusting belt tension on blower motors.
Belt Drive Blower Adjustment Caution
Belt drive blowers require specific static/CFM adjustment; verify alignment.
Altitude and Temperature Corrections
How altitude and temperature affect airflow and power requirements.
Altitude/Temperature Correction Factors Table
Table of correction factors for altitude and temperature.
Altitude Correction Examples
Altitude/Temperature Correction Factors Graph
Graph showing altitude/temperature correction factors.
Altitude Correction Example 1
Example calculation for corrected static pressure and BHP at altitude.
Altitude Correction Example 2
Example calculation for selecting blower speed based on altitude conditions.
Drive Selection
Drive Selection Steps
Step-by-step guide for selecting the correct motor drive and settings.
Supply Air Blower Performance Example
Sample blower performance data table for drive selection.
RPM Selection Table
Table correlating unit size, HP, RPM, and sheave settings.
Airflow Performance Tables
Airflow Performance - Side Duct Application
Airflow performance data for side duct applications.
Blower and Airflow Adjustments
RPM Selection Table
Table for selecting motor RPM based on unit size and static pressure.
Indoor Blower Specifications
Details on indoor blower motor, sheave, and belt specifications.
Power Exhaust Specifications
Specifications for power exhaust motors and associated data.
Air Balance Procedure
Procedures for balancing supply and return air distribution.
Belt Drive Blower Adjustment Caution
Belt drive blowers require specific static/CFM adjustment; verify alignment.
Checking Air Quantity Method One
Procedure for checking air quantity using manometer and tubing.
Compressor Deactivation Note
Important note regarding compressor de-activation for dry coil testing.
Air Quantity Measurement and Drive Adjustment
System Air Quantity Warning
Failure to adjust system air quantity can result in blower damage.
Checking Air Quantity Method Two
Alternative procedure for checking air quantity using manometer.
Dry Coil Delta P Graph
Graph showing dry coil delta P vs. airflow.
Supply Air Drive Adjustment
Blower Speed Change Caution
Review installation for errors before changing blower speed.
Motor Sheave Adjustment Example
Example calculation for determining required DD for motor sheave.
Motor Sheave Datum Diameters Table
Table for motor sheave datum diameters based on turns open.
Belt Drive Blower Adjustment Caution
Belt drive blowers require adjustment for static and CFM requirements.
Operation Sequences
Cooling Sequence of Operation
Describes how the UCB controls cooling based on thermostat inputs.
Blower Operation Modes
How the fan operates in continuous and intermittent modes.
Economizer Cooling Modes
Details on economizer operation with single/dual enthalpy and power exhaust.
Motorized Outdoor Air Damper Operation
Operation of motorized outdoor air dampers.
Cooling Operation Error Handling
Monitoring and handling of cooling system operational errors.
Compressor Limit Switch Operation
How the high-pressure limit switch affects compressor operation.
System Safety Controls and Heating Operation
Low-Pressure Limit Switch Operation
How the low-pressure limit switch affects compressor operation.
Evaporator Low Limit Sensor
How the evaporator low limit sensor affects compressor operation.
Low Ambient Cooling Operation
Operation in low ambient conditions and defrost cycle.
Unit Safety Controls Overview
Lists safety controls monitored by the unit control board.
Compressor Protection Features
Internal compressor protection and Anti-Short Cycle Delay.
Electric Heating Sequence of Operations
Details the operation sequence for electric heating.
Electric Heat Controls and Settings
Electric Heat Operation Errors
Errors related to electric heat operation, particularly temperature limits.
Temperature Limit Function
How the temperature limit switch affects blower operation.
Electric Heat Safety Controls
Lists safety controls for electric heat units.
Limit Switch (LS) Function
Description and function of the electric heat limit switch.
Auxiliary Limit Switch (ALS)
Description and function of the auxiliary limit switch.
Electric Heat Anticipator Setpoints
Guidelines for setting electric heat anticipators.
Gas Heating Sequences and Safety
Gas Heating Sequence of Operations
Details the sequence of operations for gas heating.
First Stage Heating Operation
Describes the ignition and operation sequence for first stage heating.
Retry Operation
How the system handles flame loss and retry attempts.
Recycle Operation
How the system handles flame loss after stabilization period.
Gas Heating Operation Errors
Errors encountered during gas heating operation, including lock-out.
Temperature Limit in Gas Heating
How temperature limits affect blower operation and potential lock-on.
Flame Sensing Operation
Operation and monitoring of the flame sensing system.
Gas Valve Monitoring
Monitoring and operation of the gas valve.
Gas Heating Safety Controls and Start-Up
Gas Heat Safety Controls
Lists safety controls for gas heat units including limit, auxiliary limit, pressure, and roll-out switches.
Limit Switch (LS) Function
Operation of the gas heat compartment limit switch.
Auxiliary Limit Switch (ALS)
Operation of the auxiliary limit switch in series with the limit switch.
Pressure Switch (PS) Operation
Operation of the pressure switch during ignition sequence.
Roll-out Switch (ROS) Operation
Operation of the roll-out switch in series with the pressure switch.
Internal Microprocessor Failure
Actions taken by ICB upon detecting internal failure.
Ignition Control Flash Codes
How the ICB initiates flash codes for system errors.
Resetting Flash Codes
How to reset flash codes by lowering thermostat setting.
Gas Heat Anticipator Setpoints
Importance of correct setpoints for anticipators.
Cooling Start-Up Checklist
Pre-start checklist and operating instructions for cooling start-up.
Gas Heat Start-Up and Input Adjustment
Gas Heat Start-Up Procedures
Pre-start checklist and operating instructions for gas heat start-up.
Gas Leak Testing Hazard Warning
FIRE OR EXPLOSION HAZARD. Never test gas leaks with open flame.
Pilot Lighting Caution
Furnace has automatic re-ignition; do not manually light pilot.
Main Burner Lighting Procedure
Steps for lighting the main burners.
Gas Heat Post Start Checklist
Checks to perform after heating section is operating.
Unit Shut Down Procedure
Procedures for shutting down the unit.
Gas Heat Input Checking
Procedure to determine gas flow rate for heat stages.
Gas Flow Rate and Manifold Pressure
Determining Gas Flow Rate (First Stage)
Steps to determine gas flow rate for first stage heating.
Gas Rate Cubic Feet Per Hour Table
Table for calculating gas rate based on test dial revolutions.
Manifold Gas Pressure Adjustment
Procedure for adjusting gas valve manifold pressure.
Gas Heat Stages and Temperature Rise
Gas Heat Stages Table
Table detailing gas heat stages, input, and output.
Temperature Rise Adjustment
Procedure for adjusting temperature rise and calculating CFM.
Burner and Orifice Servicing
Steps for inspecting and servicing burners and orifices.
Typical Flame Diagram
Diagram showing a typical gas burner flame.
Typical Two Stage Gas Valve Diagram
Diagram of a typical two-stage gas valve.
Control Board Navigation and Charging
Control Board Navigation Components
Identifies components for accessing Smart Equipment™™ control points.
Typical Single Stage Gas Valve Diagram
Diagram of a typical single-stage gas valve.
Unit Charging Procedure
Instructions for charging the unit with refrigerant.
Unit Control Board Diagram
Image of the Smart Equipment™™ Unit Control Board.
Smart Equipment UCB Terminal Details
UCB Limit, Power, and Detector Terminals
UCB terminals for limit, power, and smoke detector connections.
Smart Equipment UCB Terminal Details Continuation
UCB Temperature Sensor Terminals
UCB terminals for temperature sensors.
Smart Equipment UCB Terminal Details Continuation 2
UCB VFD, Output, and Fan/Compressor Terminals
UCB terminals for VFD, outputs, and fan/compressor connections.
Smart Equipment UCB Terminal Details Continuation 3
UCB Safety Switch and Blower Overload Terminals
UCB terminals for safety switches and blower overload connections.
Smart Equipment UCB Terminal Details Continuation 4
UCB SA BUS, Communication, and LEDs
UCB terminals for SA BUS, communication, and LEDs.
Communication Cable Specifications
Cable for FC and SA Buses
Recommended cable types for FC and SA bus communication.
Ignition Control Flash Codes
Table of ignition control flash codes and their meanings.
Start-Up and Service Data
Start-Up & Service Data Instructions
Instructions and checklist for unit start-up and service data.
Warranty Statement
Details Johnson Controls warranty coverage for new equipment start-up failures.
Equipment Start-Up Procedure
Instructions on using LCD or MAP Gateway for startup.
Safety Warnings and Application Information
General Safety Warnings
General safety warnings regarding lethal voltages and moving parts during start-up.
Lethal Voltage Warning
Lethal voltages present during start-up checks; use extreme caution.
Moving Parts Warning
Moving parts may be exposed during start-up checks; use extreme caution.
Design Application Information
Information on obtaining design CFM and application data.
Inspection Checklist
General Inspection Checklist
Checklist items for general unit inspection.
Air Moving Inspection Checklist
Checklist items for inspecting air moving components.
Exhaust Inspection Checklist
Checklist items for inspecting exhaust components.
Economizer Inspection Checklist
Checklist items for inspecting economizer functions.
Operating Measurements
Air Flow Measurements
Procedures for measuring and recording airflow data.
Electrical Data Recording
Section to record electrical data for various unit components.
Operating Measurements - Cooling and Heating
Cooling Operating Measurements
Section for recording cooling operating measurements.
Refrigerant Safeties Checklist
Checklist for verifying refrigerant safety controls.
Gas Heating Operating Measurements
Section for recording gas heating operating measurements.
Final Operational Checks
Staging Controls Verification
Steps to verify proper operation of heating/cooling staging controls.
Variable Frequency Drive Verification
Steps to verify VFD operation.
Final Inspection Checklist
Final checks before concluding installation.
Observed Product Deficiencies
Space to record any observed issues or concerns.
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