Johnson Controls J ZB Series Installation Manual Download

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R-410A

J**ZB SERIES W/SMART EQUIPMENT™

6.5 - 12.5 Ton
60 Hertz

5808011-JIM-A-0320

Table of contents

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 44

Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Cooling operation 2 fan cooling operation . . . . . . . . . . . . . . . . . . 60

Cooling operation 4 fan cooling operation . . . . . . . . . . . . . . . . . . 60

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Electric heating sequence of operations . . . . . . . . . . . . . . . . . 62

Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 62

Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 63

Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 63

Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Navigation components for the Smart Equipment™ control board . . 67

Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 68

Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

List of tables

1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 J06-12ZB unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 J06-12ZB standard unit weights . . . . . . . . . . . . . . . . . . . . . . 11

4 J06-12ZB unit accessory weights . . . . . . . . . . . . . . . . . . . . . 11

5 J06-12ZB unit physical dimensions . . . . . . . . . . . . . . . . . . . . 13

6 J06-12ZB unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 J06-10ZB side duct dimensions . . . . . . . . . . . . . . . . . . . . . . 16

8 J12ZB side duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 17

9 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

10 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

11 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

12 Physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

13 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 36

14 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 37

15 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 37

16 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

17 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 49

18 Airflow performance - side duct application . . . . . . . . . . . . . . 51

19 Airflow performance - bottom duct application . . . . . . . . . . . 54

20 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

21 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 56

22 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 56

23 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 58

24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

25 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 63

26 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 64

27 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 66

28 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

29 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 67

30 Cable for FC buses and SA buses in order of preference . . 74

31 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 74

32 J06ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 75

33 J06ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 75

34 J07ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 76

35 J07ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 76

36 J08ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 77

37 J08ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 77

38 J10ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 78

39 J10ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 78

40 J12ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 79

41 J12ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 79

List of figures

1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Barometric relief hood - shipping location . . . . . . . . . . . . . . . 5

3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 4 point and 6 point load weight for J12ZB units . . . . . . . . . . 10

6 4 point and 6 point load weight for J06-10ZB units . . . . . . . 10

7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8 J06-10ZB physical dimensions . . . . . . . . . . . . . . . . . . . . . . . 12

9 J12ZB physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 13

10 J06-12ZB unit bottom duct openings . . . . . . . . . . . . . . . . . . 15

11 J06-12ZB unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . . 16

12 J06-12ZB unit left/end duct opening . . . . . . . . . . . . . . . . . . . 17

13 J06-12ZB roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

14 J06-12ZB transition roof curb . . . . . . . . . . . . . . . . . . . . . . . . 18

15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 19

16 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 19

17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 20

19 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

20 Field wiring disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

21 Typical control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

22 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

23 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

24 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 44

26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 49

28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

29 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

30 Typical two stage gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 67

31 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Summary of Contents for J ZB Series

Page 1: ...ce bottom duct application 54 20 RPM selection 55 21 Indoor blower specifications 56 22 Power exhaust specifications 56 23 Motor sheave datum diameters 58 24 Electric Heat Limit Setting 62 25 Electric heat anticipator setpoints 63 26 Gas heat anticipator setpoints 64 27 Gas rate cubic feet per hour 66 28 Gas heat stages 66 29 Gas heat limit control settings 67 30 Cable for FC buses and SA buses in...

Page 2: ... 1 latest edition Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available during brazing operations Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assist...

Page 3: ...ombustible flooring or in the U S on wood flooring or Class A Class B or Class C roof covering materials For use with natural gas The unit can be converted to LP with a kit This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes The furnace...

Page 4: ...G A Std Cabinet E SSD SST Drain Pan R Reverse Drain Pan A No Economizer B Economizer w Barometric RLF D Economizer w Power EXH H Motorized Damper Outdoor Air Option 1 No Service Options 2 DSC Disconnect Switch 3 NCO Non PWR Conv Outlet 4 PCO Powered Conv Outlet 5 DSC NCO 6 DSC PCO A No Sensors B PHM Phase Monitor C DFS Dirty Filter Switch D SSD Supply Air Smoke DET E RSD Return Air Smoke DET F PHM...

Page 5: ...et air and combustion air intake hoods The unit must be operated under thermostatic control Return and supply air ducts must be sealed to the unit Air filters in place The unit furnace input rate and temperature rise must be set according to the rating plate marking The return air temperature must be maintained between 55ºF 13ºC and 80ºF 27ºC When the construction phase is completed and before for...

Page 6: ...tain a temperature rise within the range specified on the unit rating plate If components are added to a unit to meet local codes they are installed at the dealer s and or customer s expense The size of the unit for the proposed installation must be based on a heat loss heat gain calculation made according to the methods of the Air Conditioning Contractors of America ACCA This furnace is not to be...

Page 7: ... or 4 in filter options O Compressor 1 access E Filter drier solid core P Side entry power and control knockouts F Micro channel aluminum tube aluminum fin condenser Q Toolless door latch G Slide out motor and blower assembly for easy adjustment and service R Roof curbs in eight inch and fourteen inch heights1 1 Roof curbs for transitioning from York Sunline footprint to the ZB Series footprints a...

Page 8: ...U S A or Sections 7 2 7 3 or 7 4 of Gas Installation Codes CSA B149 1 in Canada Latest Edition and or applicable provisions of the local building codes Refer to Table 6 for the clearances required for combustible construction servicing and proper unit operation Table 2 J06 12ZB unit limitations Size tons Model Unit voltage SCCR kVA Unit limitations Applied voltage Outdoor DB temp Minimum Maximum M...

Page 9: ...in the base rails are provided for this purpose THE LENGTH OF THE FORKS MUST BE A MINIMUM OF 60 INCHES Do not permit overhanging structures or shrubs to obstruct the condenser air discharge outlet combustion air inlet or vent outlets If a unit is installed on a roof curb other than a Johnson Controls roof curb you must apply gasketing to all surfaces that come in contact with the unit underside Be...

Page 10: ...ystems Figure 5 4 point and 6 point load weight for J12ZB units Figure 6 4 point and 6 point load weight for J06 10ZB units Figure 7 Center of gravity A LEFT D C FRONT B A LEFT B C D FRONT E F D A C B LEFT FRONT D A C B E F LEFT FRONT X Y LEFT FRONT ...

Page 11: ...5 171 142 121 180 212 255 J08 8 5 ZB 1089 1084 38 4 24 4 255 193 274 361 178 147 123 175 208 252 J10 10 ZB 1090 1085 38 8 24 8 257 199 274 355 179 150 127 175 207 247 J12 12 5 ZB 1285 1280 49 6 24 1 231 291 422 335 149 172 202 292 249 215 Table 4 J06 12ZB unit accessory weights Unit accessory Weight lbs Shipping Operating Economizer 90 85 Power exhaust 40 35 Electric heat1 49 49 Gas heat2 110 110 ...

Page 12: ...hnson Controls Ducted Systems Figure 8 J06 10ZB physical dimensions LEFT A 59 00 C D E F 4 19 27 31 89 00 21 19 11 38 15 38 59 00 15 38 29 69 15 25 FRONT SEE DETAIL B FOR DRAIN LOCATION SEE DETAIL A FOR GAS INLET B 2X Ø 24 38 ...

Page 13: ...t model number Dimension in A B C D E F J06 07 08 10ZB 50 3 4 89 30 3 16 24 3 16 17 3 16 6 3 16 J12ZB 50 3 4 119 1 2 30 3 16 24 3 16 17 3 16 6 3 16 15 23 29 03 14 85 29 03 14 85 15 23 28 86 29 66 44 09 Ø 24 58 TYP 4 PL FRONT See detail B for drain location See detail A for gas inlet C D E F B 4 3 16 27 5 16 89 21 3 16 11 3 8 A LEFT 59 ...

Page 14: ...FPT Table 6 J06 12ZB unit clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Make sure that overhanging structures or shrubs do not obscure the condenser air discharge outlet 72 Right 12 Front 36 Left 36 Rear 36 Bottom2 2 Units may be installed on combustable floors made from wood or class A B or C roof covering materials 0 ...

Page 15: ... bottom duct openings Bottom condensate drain Bottom gas supply entry FRONT RETURN AIR SUPPLY AIR RIGHT LEFT 20 1 8 19 1 8 17 1 8 6 13 16 6 13 16 32 11 16 14 1 2 16 3 8 18 1 16 25 9 16 12 5 16 27 1 2 24 21 18 89 Ø 2 469 3X Ø 0 875 Bottom power control and convenience outlet wiring entry ...

Page 16: ...nect Swith Cover Power Entry Ø 2 1 2 Control Entry Ø 7 8 Power Entry Ø 2 1 2 Convenience Outlet Cover Convenience Outlet Power Entry Ø 7 8 FRONT Table 7 J06 10ZB side duct dimensions Unit model number Dimension in A B C D J06 07 08 10ZB 28 1 4 18 1 16 28 1 4 18 1 4 Dot Plugs 5 5 32 31 11 16 2 31 32 18 1 4 Return Air Supply Air A B C D ...

Page 17: ... end duct opening Table 8 J12ZB side duct dimensions Unit model number Dimension in A B C D J12ZB 28 1 4 18 1 16 28 1 4 18 1 4 Table 9 Left end duct dimensions Unit model number Dimension in A B C J06 07 08 10ZB 30 358 22 580 22 330 J12ZB 30 358 22 580 22 330 Dot Plugs 2 7 8 5 5 32 D C 31 5 8 18 1 4 B A 4 5 16 A C B ...

Page 18: ...f curb Figure 14 J06 12ZB transition roof curb 8 or 14 50 1 2 30 20 20 80 5 8 6 2 TYP INSULATED DECK UNDER COMPRESSOR SECTION INSULATED DECK UNDER CONDENSER SECTION FRONT RIGHT SUPPLY RETURN 76 5 8 94 50 1 2 30 1 2 64 1 4 59 1 4 10 23 4 26 80 5 8 2 TYP FRONT RIGHT SUPPLY RETURN ...

Page 19: ...he following steps 1 Remove the side duct covers 2 Orient the supply panel with the painted surface up 3 Slide the supply panel between the heat exchanger and the unit bottom The painted surface must face the heat exchanger The space is narrow but there is adequate room to install the panel 4 Secure the supply panel with the factory installed bracket and two screws 5 Orient the return panel with t...

Page 20: ... times as much water as other oils designed for HCFC and CFC refrigerants Take all the necessary precautions to avoid exposure of the oil to the atmosphere POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials Procedures that risk oil leakage include but are not limited to the following Compressor replacement Repairing refrigerant leaks Repla...

Page 21: ...ed replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be used for these units Factory installed disconnects are available If you install a disconnect you must use a field supplied or York International supplied accessory See Figure 4 for the recommended mounting location Note Not all local codes allow the installation ...

Page 22: ...nit nameplate See Table 11 Electrical data on page 24 to size power wiring fuses and the disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the curb Figure 20 Field wiring disconnect THREE PHASE POWER SUPPLY FACTORY OR FIELD SUPPLIED DISCONNECT GROUND LUG TERMINAL BLOCK TB1 ...

Page 23: ... BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 2 4 Second stage heating not required on single stage heĂƟŶg units Jumper is required if there is no Smoke Detector circuit Jumper is required for any combination of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied ĐŽŶĚŝƟon X is an input to the thermostat to display Error Status conditions 3 W2 Y1 G OCC Y2 X R ...

Page 24: ... 25 4 25 30 E09 9 1 10 8 23 2 25 5 25 30 E18 18 2 21 7 36 4 39 1 40 40 E24 24 2 28 9 45 4 48 1 50 50 E36 34 2 40 9 60 4 63 1 70 70 575 3 60 3 2 26 5 1 35 2 1 1 8 20 None 18 1 19 9 20 20 E09 9 1 8 7 18 5 20 8 20 25 E18 18 2 17 3 29 3 31 5 30 35 E24 24 2 23 1 36 5 38 8 40 40 E36 34 2 32 7 48 5 50 8 50 60 J07 7 5 208 3 60 14 83 1 22 3 03 4 9 5 5 20 None 52 1 57 6 60 70 E09 6 8 1 18 9 52 1 57 6 60 70 ...

Page 25: ... 1 70 6 80 80 E18 13 5 2 37 5 67 9 74 8 80 80 E24 18 2 50 83 5 90 4 90 100 E36 25 5 2 70 8 109 5 116 4 110 125 E54 40 6 2 112 7 161 9 168 8 175 175 230 3 60 16 2 110 25 3 03 6 8 5 5 20 None 65 1 70 6 80 80 E18 18 2 43 3 75 1 82 80 90 E24 24 2 57 7 93 1 100 100 100 E36 34 2 81 8 123 3 130 1 125 150 E54 54 2 129 9 150 9 157 8 175 175 460 3 60 7 6 52 12 1 6 3 4 2 2 20 None 31 4 33 6 35 40 E18 18 2 21...

Page 26: ... 18 2 21 7 39 3 42 45 45 E24 24 2 28 9 48 3 51 50 60 E36 34 2 40 9 63 3 66 70 70 E54 54 2 65 77 1 79 9 90 90 575 3 60 7 1 56 11 0 66 3 2 1 8 20 None 26 5 28 3 30 35 E18 18 2 17 3 30 6 32 9 35 35 E24 24 2 23 1 37 9 40 1 40 45 E36 34 2 32 7 49 9 52 1 50 60 E54 54 2 52 61 63 3 70 70 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J06 12ZB Standard Indoor Blower With Powe...

Page 27: ... 25 E09 9 1 10 8 18 2 20 4 20 25 E18 18 2 21 7 30 1 32 9 35 35 E24 24 2 28 9 39 1 41 9 40 45 E36 34 2 40 9 54 1 56 9 60 60 575 3 60 3 2 26 5 1 35 2 1 1 8 None 14 1 15 9 15 20 E09 9 1 8 7 14 1 15 9 15 20 E18 18 2 17 3 24 3 26 5 25 30 E24 24 2 23 1 31 5 33 8 35 35 E36 34 2 32 7 43 5 45 8 45 50 J07 7 5 208 3 60 14 83 1 22 3 03 4 9 5 5 None 42 1 47 6 50 60 E09 6 8 1 18 9 42 1 47 6 50 60 E18 13 5 2 37 ...

Page 28: ...5 1 60 6 70 70 E18 13 5 2 37 5 55 4 62 3 70 70 E24 18 2 50 71 77 9 80 80 E36 25 5 2 70 8 97 103 9 100 110 E54 40 6 2 112 7 149 4 156 3 150 175 230 3 60 16 2 110 25 3 03 6 8 5 5 None 55 1 60 6 70 70 E18 18 2 43 3 62 6 69 5 70 70 E24 24 2 57 7 80 6 87 5 90 90 E36 34 2 81 8 110 8 117 6 125 125 E54 54 2 129 9 138 4 145 3 150 175 460 3 60 7 6 52 12 1 6 3 4 2 2 None 26 4 28 6 30 35 E18 18 2 21 7 31 4 34...

Page 29: ... 2 21 7 33 35 8 40 40 E24 24 2 28 9 42 44 8 45 45 E36 34 2 40 9 57 59 8 60 60 E54 54 2 65 70 9 73 6 80 80 575 3 60 7 1 56 11 0 66 3 2 1 8 None 22 5 24 3 30 30 E18 18 2 17 3 25 6 27 9 30 30 E24 24 2 23 1 32 9 35 1 35 40 E36 34 2 32 7 44 9 47 1 45 50 E54 54 2 52 56 58 3 60 70 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J06 12ZB Standard Indoor Blower Without Powered...

Page 30: ...46 8 52 3 60 60 E09 6 8 1 18 9 46 8 52 3 60 60 E18 13 5 2 37 5 58 9 65 8 60 70 E24 18 2 50 74 5 81 4 80 90 E36 25 5 2 70 8 100 5 107 4 110 110 230 3 60 14 83 1 22 3 03 9 6 5 5 None 46 8 52 3 60 60 E09 9 1 21 7 46 8 52 3 60 60 E18 18 2 43 3 66 1 73 70 80 E24 24 2 57 7 84 1 91 90 100 E36 34 2 81 8 114 3 121 1 125 125 460 3 60 6 4 41 10 1 6 4 7 2 2 None 22 24 2 25 30 E09 9 1 10 8 22 24 2 25 30 E18 18...

Page 31: ...74 5 90 90 E24 18 2 50 80 86 9 90 90 E36 25 5 2 70 8 106 112 9 110 125 E54 40 6 2 112 7 158 4 165 3 175 175 230 3 60 18 6 149 29 2 1 14 5 5 None 69 74 5 90 90 E18 18 2 43 3 71 6 78 5 90 90 E24 24 2 57 7 89 6 96 5 90 100 E36 34 2 81 8 119 8 126 6 125 150 E54 54 2 129 9 147 4 154 3 175 175 460 3 60 9 60 9 14 1 26 6 6 2 2 None 33 9 36 1 40 45 E18 18 2 21 7 35 4 38 1 40 45 E24 24 2 28 9 44 4 47 1 45 5...

Page 32: ... 3 70 70 E09 6 8 1 18 9 56 8 62 3 70 70 E18 13 5 2 37 5 71 4 78 3 80 80 E24 18 2 50 87 93 9 90 100 E36 25 5 2 70 8 113 119 9 125 125 230 3 60 14 83 1 22 3 03 9 6 5 5 20 None 56 8 62 3 70 70 E09 9 1 21 7 56 8 62 3 70 70 E18 18 2 43 3 78 6 85 5 80 90 E24 24 2 57 7 96 6 103 5 100 110 E36 34 2 81 8 126 8 133 6 150 150 460 3 60 6 4 41 10 1 6 4 7 2 2 20 None 27 29 2 30 35 E09 9 1 10 8 27 29 2 30 35 E18 ...

Page 33: ...9 29 2 1 14 5 5 20 None 79 84 5 100 100 E18 18 2 43 3 84 1 91 100 100 E24 24 2 57 7 102 1 109 110 110 E36 34 2 81 8 132 3 139 1 150 150 E54 54 2 129 9 159 9 166 8 175 175 460 3 60 9 60 9 14 1 26 6 6 2 2 20 None 38 9 41 1 45 50 E18 18 2 21 7 41 6 44 4 45 50 E24 24 2 28 9 50 6 53 4 60 60 E36 34 2 40 9 65 6 68 4 70 70 E54 54 2 65 79 5 82 3 90 90 575 3 60 7 1 56 11 0 66 5 2 1 8 20 None 28 5 30 3 35 35...

Page 34: ...ners 4 6 4 6 4 6 6 8 6 8 No stages 23 23 23 23 23 23 23 23 23 23 Temperature Rise Range ºF 20 50 35 65 15 45 30 60 10 40 25 55 20 50 35 65 10 40 25 55 Gas Limit Setting ºF 165 165 165 165 215 195 195 160 195 160 Gas piping connection in 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 DIMENSIONS inches Length 89 89 89 89 119 1 2 Width 59 59 59 59 59 Height 50 3 4 50 3 4 50 3 4 50 3 4 50 3 4 OPERATING WT lb...

Page 35: ...69 AK89 AK74 AK84 AK74 AK74 BK77 Belt A53 A54 A52 A54 A56 A54 A56 A54 A54 BX56 Motor HP each 1 1 2 2 1 1 2 3 2 3 2 3 3 5 RPM 1725 1725 1725 1725 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56 56 56 56 56 56 184T FILTERS Quantity Size 4 24 x 20 x 2 5 6 4 24 x 20 x 2 5 6 4 24 x 20 x 2 5 6 4 24 x 20 x 2 5 6 4 24 x 20 x 2 5 6 4 24 x 20 x 4 7 4 24 x 20 x 4 7 4 24 x 20 x 4 7 4 24 x 20 x 4 7 4 24 x...

Page 36: ...ollow the National Fuel Gas Code Z223 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada in all cases unless they are superseded by local codes or gas utility requirements See Table 14 Gas pipe sizing capacity of pipe on page 37 The heating value of the gas may vary by locality You must check the value with the local gas utility Figure 22 Side entry gas piping Table 13 Electric ...

Page 37: ...e dope sparingly to male threads only Clean all piping of dirt and scale Hammer on the outside of the pipe and blow out loose particles Before initial start up make sure that all gas lines external to the unit are purged of air The gas supply must be a separate line and installed in accordance with all safety codes as prescribed under Limitations OPTIONAL COIL GUARD SHOWN Table 14 Gas pipe sizing ...

Page 38: ...heat Electric heaters are available as factory installed options or field installed accessories Refer to the electric heat instructions for installation These heaters mount in the heat compartment with the heating elements extending into the supply air chamber All electric heaters are fused and intended for use with single point power supply Fire or explosion hazard Failure to follow the safety wa...

Page 39: ...re are two field installed power exhaust accessories 1 Down flow application 2 Horizontal flow application that requires the purchase of a barometric relief hood Rain hood For factory installed options all of the hood components including the filters the gasketing and the hardware for assembling are packaged and located between the condenser coil section and the main unit cabinet For field install...

Page 40: ...er minimum position low speed fan When the VFD output is between the fan high speed and fan low speed settings the economizer damper is position proportionally between the economizer minimum position setpoint and the economizer damper minimum position low speed fan Note To disable the VAV economizer minimum position reset set the economizer minimum position setpoint and the economizer damper minim...

Page 41: ... economizer outside air dampers close until the supply air temperature rises above 49 F but does not go below the current economizer operating minimum position The economizer then modulates to control the supply air temperature at 50 F Note The exception to this rule occurs when hydronic heat enable and SAT tempering with hydronic heat enable 40 F default are both on Hydronic heat is used to contr...

Page 42: ...age 3 cooling demand Y3 input a second compressor output energizes When each cooling demand is removed the compressor outputs de energize in reverse order without time delays When only a Y1 input remains the economizer controls the SAT to the upper SAT setpoint 5 F Note If the SAT limit for cooling enabled is turned on the 20 minute timer reapplies when appropriate to re energize the compressor ou...

Page 43: ...ting VAV SAT setpoint 5 F the last energized compressor turns off If it remains at the minimum position or the SAT remains lower than the operating VAV SAT setpoint 5 F the compressors de energize every 5 minutes until all the compressors are off If all compressor outputs de engerize the economizer modulates to control to operating VAV SAT Setpoint 0 5 F When the cooling demand ends the compressor...

Page 44: ...ects through circuit trace to 24V IN pin HOT C COM Mixed air temperature sensor input from 10KΩ 77 F Type III negative temperature coefficient thermistor The MAT parameter reports input status F C 3 65 VDC reading MAT to COM with open circuit Read only use in current control revision IN1 MAT H R 24V 24 VAC hot supplied for the outdoor air humidity sensor Connects through circuit trace to 24V IN pi...

Page 45: ...station sensor MOA Range parameter sets the cubic feet per minute liters per second measured by the air monitoring station sensor when it outputs 10 VDC Fr Air parameter reports input status 0 50000CFM 23595lps Used for economizer minimum position reset in speed controlled indoor blower applications C COM 24 VAC common 0 10 VDC negative for the air monitoring station sensor Connects through circui...

Page 46: ...to the 4 stage board and or fault detection diagnostics board 1 When wiring the unit and other devices using the SA Bus and FC Bus see Table 30 Smart Equipment economizer board analog outputs Location Board label Cover label Description Function and comments D J4 EX VFD 2 10 VDC positive output for the modulating power Exhaust fan Variable Frequency Drive discharge damper modulating power exhaust ...

Page 47: ... economizer actuator Connects through circuit trace to 24V IN pin COM EX FAN 24 VAC hot output to energize power exhaust fan contactor coil VFD enable relay coil ExFan parameter reports output status Off On when ExFType selection is Non Modulating Modulating Damper or Variable Frequency Fan Used to turn on enable the power exhaust fan motor COM 24 VAC common 0 10 VDC negative for economizer actuat...

Page 48: ...ection force recommended for the belt section 5 Re tighten the belt nuts Figure 26 Belt adjustment CFM static pressure and power altitude and temperature corrections Use the information below to assist in the application of the product at altitudes at or exceeding 1000 feet above sea level The air flow rates listed in the standard blower performance tables are based on standard air at sea level As...

Page 49: ... given is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 0 6 832 0 72 in Enter the blower table at 1 400 sCFM and static pressure of 0 72 in The RPM listed is the same RPM needed at 5 000 ft Suppose that the corresponding BHP listed in the table is 0 7 This value must be corrected for elevation BHP at 5 000...

Page 50: ... 5 1 62 BHP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1230 RPM is within the range of the 2 HP drives 7 Using the 2 HP motor and drive 5 turns open achieves 1230 RPM Example supply air blower performance Air flow CFM Available external static pressure IWG 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP...

Page 51: ...31 1 86 885 2 05 937 2 22 991 2 38 1045 2 54 1104 2 71 1166 2 89 1235 3 09 3800 736 1 63 796 1 86 853 2 06 907 2 24 960 2 41 1013 2 58 1068 2 74 1126 2 91 1189 3 09 1258 3 29 3 HP Field Supplied Drive J07ZB 7 5 Ton Side Duct Air Flow CFM Available External Static Pressure IWG1 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 ...

Page 52: ...06 2 17 953 2 36 999 2 54 1044 2 72 1087 2 89 1129 3 06 1171 3 23 1211 3 41 3 HP Field Supplied Drive J10ZB 10 Ton Side Duct Air Flow CFM Available External Static Pressure IWG1 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum conti...

Page 53: ...4 1 96 932 2 15 978 2 33 1022 2 50 1066 2 67 1108 2 84 1149 3 02 1190 3 19 4200 805 1 77 856 1 98 906 2 17 953 2 36 999 2 54 1044 2 72 1087 2 89 1129 3 06 1171 3 23 1211 3 41 4400 828 2 00 879 2 21 929 2 41 976 2 59 1022 2 77 1067 2 95 1110 3 12 1152 3 29 1194 3 46 1235 3 64 4600 852 2 25 904 2 46 953 2 66 1001 2 85 1047 3 03 1092 3 20 1135 3 37 1177 3 54 1219 3 72 1259 3 89 4800 879 2 52 930 2 73...

Page 54: ...1 2 09 2200 666 0 26 720 0 53 777 0 77 836 1 00 896 1 21 956 1 41 1012 1 61 1065 1 81 1113 2 02 1153 2 24 2400 689 0 42 743 0 69 800 0 93 859 1 16 919 1 37 978 1 57 1035 1 77 1088 1 97 1135 2 18 1176 2 40 2600 712 0 60 766 0 87 823 1 11 882 1 34 942 1 55 1002 1 75 1058 1 95 1111 2 15 1159 2 36 1199 2 58 2800 736 0 80 790 1 06 847 1 31 906 1 53 967 1 74 1026 1 94 1082 2 14 1135 2 34 1183 2 55 1223 ...

Page 55: ...P RPM BHP Field Supplied Drive Standard 3 HP Drive Hi Static 5 HP Drive 3200 797 1 32 851 1 46 903 1 60 953 1 74 1001 1 86 1048 1 99 1093 2 11 1138 2 23 1181 2 35 1224 2 48 3400 828 1 52 882 1 67 934 1 81 983 1 94 1032 2 07 1078 2 19 1124 2 32 1168 2 44 1212 2 56 1254 2 68 3600 861 1 75 915 1 90 967 2 04 1017 2 17 1065 2 30 1112 2 42 1157 2 54 1201 2 67 1245 2 79 1287 2 91 3800 897 2 00 951 2 15 1...

Page 56: ...ir duct as close to the outlet of the unit as possible 2 Using the hole drilled in step 1 insert eight inches of 1 4 inch metal tubing into the airflow of the return and supply air ducts of the unit Note You must insert the tubes and hold them in a position perpendicular to the air flow so that velocity pressure does not affect the static pressure readings Table 21 Indoor blower specifications Siz...

Page 57: ...able external static pressure and the number of turns the variable motor sheave is open 7 To adjust measured CFM to required CFM see Supply air drive adjustment on page 58 8 After you note the reading remove the tubes and seal the holes 9 Tighten the blower pulley and motor sheave set screws after any adjustments Re check the set screws after 10 12 hours run time Note You must repeat this procedur...

Page 58: ... in blower speed can result in substantial changes in static pressure and BHP BHP and AMP draw of the blower motor increase by the cube of the blower speed Static pressure increases by the square of the blower speed Only qualified personnel can make blower speed changes strictly adhering to the fan laws 1 700 CFM 1 400 CFM 1 88 in 2 28 in Table 23 Motor sheave datum diameters 1VL34x7 8 1 1 2 HP mo...

Page 59: ...2 0 25 0 26 0 31 4300 0 28 0 65 0 35 0 23 0 24 0 28 0 29 0 34 4500 0 30 0 69 0 38 0 25 0 26 0 30 0 31 0 37 4700 0 33 0 74 0 41 0 28 0 29 0 33 0 34 0 40 4900 0 36 0 78 0 44 0 30 0 31 0 35 0 37 0 43 5100 0 39 0 82 0 47 0 33 0 34 0 38 0 40 0 46 5300 0 42 0 86 0 51 0 35 0 37 0 41 0 43 0 49 5500 0 45 0 89 0 55 0 38 0 40 0 44 0 46 0 53 5700 0 48 0 93 0 58 0 41 0 43 0 47 0 49 0 56 5900 0 52 0 96 0 62 0 4...

Page 60: ...relay This starts compressor 2 and also energizes cond fan 3 and cond fan 4 on The UCB energizes the VFD equipped blower at the second stage speed as set in the Smart Equipment control If a Y3 call is present it is passed to the UCB The UCB then determines whether the requested operation is available and if so which components to energize With a Y3 call for third stage cooling the UCB determines i...

Page 61: ...the halted compressor If a high pressure switch opens three times within two hours of operation the UCB locks out the compressor Low pressure limit switch The low pressure limit switch is not monitored during the initial 30 seconds of a cooling system s operation For the following 30 seconds the UCB monitors the low pressure switch to ensure that it closes If the low pressure switch fails to close...

Page 62: ...ng the UCB energizes the blower motor If the second stage of heat is required heater relay RB is energized After completing the specified fan on delay for heating the UCB energizes the blower motor b The thermostat cycles the electric heat to satisfy the heating requirements of the conditioned space Electric heat operation errors Temperature limit If the UCB senses zero volts from the high tempera...

Page 63: ...or one hour The furnace is monitored during this one hour period for unsafe conditions Recycle operation When a flame is lost after the flame stabilization period a recy cle operation occurs If the unit fails after five recycle attempts the furnace is locked out for one hour Gas heating operation errors Lockout A one hour lockout occurs following three retries or five recycles During the one hour ...

Page 64: ...ies with the pressure switch As such the ICB cannot distinguish the roll out switch operation from that of the pressure switch Consequently the control only responds in the same manner as outlined in Pressure switch on page 64 An open roll out inhibits the gas valve from actuating Internal microprocessor failure If the ICB detects an internal failure it ceases all outputs ignores inputs and displa...

Page 65: ...g down the unit 1 Set the thermostat to the lowest temperature setting 2 Turn off electrical power to unit 3 Open the gas heat access panel 4 Turn the gas valve clockwise to the OFF position see Figure 30 Checking gas heat input This unit has two stages of gas heat The first stage is 60 of the full fire input and is considered the minimum input for the furnace The intended input for each furnace i...

Page 66: ...djustment screw is adjacent to the HI marking on the valve The first stage 60 input adjustment screw is located adjacent to the LO marking on the valve see Figure 30 Adjust the second stage 100 input pressure first then adjust first stage 60 input pressure 1 Turn off electrical power to the unit 2 Using the outlet pressure port on the gas valve connect a manometer to monitor the manifold pressure ...

Page 67: ...ve procedure to replace the assemblies Verify that burners are level and seated at the rear of the gas orifice Figure 29 Typical flame Figure 30 Typical two stage gas valve Navigation components for the Smart Equipment control board The following components are needed to access the control points in the Smart Equipment control Installation and operation guides are available from your equipment dea...

Page 68: ...re also effective for economizer free cooling supply air temperature reset when the ClgStgs parameter is set for 1 or more G Continuous indoor blower request 24 VAC input switched from R OCC Occupancy request 24 VAC input switched from R Must have the OccMode parameter set for External to be effective X Hard lockout indicator 24 volt output to a light thermostat LED R 24 VAC hot for thermostat swi...

Page 69: ...inate temporary occupancy COM Common for ST and SSO inputs Negative of VDC circuit for ST and SSO inputs SSO Space Sensor Offset input from 0 to 20KΩ potentiometer Positive of VDC circuit 3 625 VDC reading to COM with open circuit 10KΩ 2 5 VDC is 0 F offset 0Ω 0 VDC is maximum above offset and 20KΩ 3 4 VDC is maximum below offset from active space temperature setpoint Smart Equipment UCB temperatu...

Page 70: ...AC hot return from Air Proving Switch When this optional input is enabled the air proving switch must close within 30 seconds of initiation of indoor blower operation and not open for greater than 10 seconds during indoor blower operation to allow heat cool operation and prevent an APS open alarm the air proving switch must open within 30 seconds of termination of indoor blower operation to preven...

Page 71: ...entilation cooling reheat or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage compressor UCBs If demand is present and permissions allow compressor 2 operation output with compressor cooling comfort ventilation cooling or heat pump heating demands Smart Equipment UCB refrigerant circuit safety switch and indoor blower overload connections Location Label D...

Page 72: ...of the 15 VDC reading to C circuit for powering an optional netstat and or Multi Touch gateway C Common for SA BUS power and communication circuits Also incorporated in the J8 6 pin phone jack connector at the left center of the board Negative of the SA BUS circuits Communication for SA BUS devices Also incorporated in the J8 6 pin phone jack connector at the left center of the board Positive of t...

Page 73: ... than FC bus BACnet MSTP communication circuit FC FC Field Connected BUS BACnet MSTP communication Positive of the VDC typically a fluctuating 1 5 to 3 5 volts reading to COM at least 0 25 volts lower than FC bus BACnet MSTP communication circuit COM Common for the FC Field Connected BUS BACnet MSTP communication circuit Negative of the VDC FC bus BACnet MSTP communication circuit SHLD Shield for ...

Page 74: ...22 AWG stranded shielded cable A 22 gauge cable offers the best performance for various baud rates cable distances and number of trunk devices primarily due to lower conductor to conductor capacitance Shielded cable offers better overall electrical noise immunity than non shielded cable Observe the shield grounding requirements 2 We recommend 26 AWG solid 6 wire 3 twisted pairs cable as the best f...

Page 75: ... 0 95 158 66 353 104 20 7 7 400 Cfm Ton 80 72 75 149 68 265 82 23 6 3 85 157 68 309 94 21 7 0 95 164 69 354 106 18 7 7 400 Cfm Ton 75 62 75 146 66 269 81 19 6 3 85 147 64 311 91 19 7 0 95 148 61 352 102 19 7 7 Air flow Indoor Db Wb Outdoor DB Suction pressure Suction temp Discharge pressure Liquid temp Delta T Db Entering evap Db 300 Cfm Ton 80 62 75 140 66 278 86 25 7 0 85 141 65 321 96 25 7 9 95...

Page 76: ...4 98 20 8 3 95 158 68 382 108 18 9 2 400 Cfm Ton 75 62 75 140 65 284 86 20 7 3 85 141 64 331 95 19 8 3 95 143 62 379 105 19 9 2 Table 35 J07ZB charging table system 2 Air flow Indoor Db Wb Outdoor DB Suction pressure Suction temp Discharge pressure Liquid temp Delta T Db Entering evap Db 300 Cfm Ton 80 62 75 140 67 279 87 25 6 8 85 138 64 323 96 26 7 6 95 137 61 367 106 26 8 5 300 Cfm Ton 79 89 67...

Page 77: ...16 21 8 4 95 156 64 364 364 20 9 3 400 Cfm Ton 75 62 75 144 62 268 268 20 7 4 85 145 60 315 315 20 8 3 95 146 59 363 363 19 9 2 Table 37 J08ZB charging table system 2 Air flow Indoor Db Wb Outdoor DB Suction pressure Suction temp Discharge pressure Liquid temp Delta T Db Entering evap Db 300 Cfm Ton 80 62 75 143 467 277 83 25 7 1 85 143 467 321 91 26 7 9 95 144 468 365 99 26 8 7 300 Cfm Ton 79 82 ...

Page 78: ... 21 10 6 95 152 66 376 102 19 11 6 400 Cfm Ton 75 62 75 137 63 280 82 20 9 4 85 139 62 327 91 20 10 5 95 141 61 374 101 19 11 6 Table 39 J10ZB charging table system 2 Air flow Indoor Db Wb Outdoor DB Suction pressure Suction temp Discharge pressure Liquid temp Delta T Db Entering evap Db 300 Cfm Ton 80 62 75 142 59 285 86 25 9 3 85 142 57 334 94 26 10 4 95 141 56 382 102 26 11 5 300 Cfm Ton 79 97 ...

Page 79: ... 9 95 152 63 370 99 19 13 6 400 Cfm Ton 75 62 75 137 63 272 78 21 10 4 85 139 61 319 89 20 11 9 95 142 59 366 99 19 13 4 Table 41 J12ZB charging table system 2 Air flow Indoor Db Wb Outdoor DB Suction pressure Suction temp Discharge pressure Liquid temp Delta T Db Entering evap Db 300 Cfm Ton 80 62 75 128 68 267 78 25 12 6 85 131 63 311 120 26 14 1 95 133 58 354 163 26 15 6 300 Cfm Ton 80 01 67 11...

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Johnson Controls J ZB Series, Installation Manual

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