Johnson Controls TempMaster ZD Series Installation Manual Download

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R-410A

ZD SERIES

3 - 6 Ton
60 Hertz

5742640-TIM-A-0419

TABLE OF CONTENTS

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

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

Installation Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . 15

Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Typical Cool/Heat Control Wiring (Smart Equipment™ ZDT03

through TA6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34

Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . . 35

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 50

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 51

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 52

Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 56

Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 57

Smart Equipment™ Control Board Navigation Components . . . . 65

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

LIST OF TABLES

1 ZDT03 through TA6 Unit Limitations . . . . . . . . . . . . . . . . . . . . 6

2 ZDT03 through TA6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZDT03 through TA6 Unit Accessory Weights . . . . . . . . . . . . . 8

4 ZDT03 through TA6 Unit Clearances . . . . . . . . . . . . . . . . . . 10

5 ZDT03 through TA6 Utilities Entry . . . . . . . . . . . . . . . . . . . . . 11

6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Electrical data: single-phase gas heat, belt drive . . . . . . . . . 28

9 ZDT03 through TA6 Physical Data . . . . . . . . . . . . . . . . . . . . 29

10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31

11 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31

12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32

13 Smart Equipment™ Economizer Board Details . . . . . . . . . . 37

14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 41

15 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 44

16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 45

17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 47

19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 47

20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 48

21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 51

23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 53

24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 53

25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 53

26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56

27 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

28 ZDT03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59

29 ZDT04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59

30 ZDT05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60

31 ZDTA6 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60

32 Simplicity Lite Unit Control Board Flash Codes . . . . . . . . . . 65

33 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 65

34 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 66

35 Cable for FC Buses and SA Buses in Order of Preference . 71

LIST OF FIGURES

1 ZDT03 through TA6 Component Location . . . . . . . . . . . . . . . 6

2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 ZDT03 through TA6 Cooling Only/Electric Heat Front View

Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 ZDT03 through TA6 Cooling Only/Gas Heat Front View

Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 ZDT03 through TA6 Fixed Outdoor Air Motorized Damper Rain

Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8 ZDT03 through TA6 Disconnect Location . . . . . . . . . . . . . . 10

9 ZDT03 through TA6 Unit Side Duct Openings . . . . . . . . . . . 11

10 ZDT03 through TA6 Roof Curb . . . . . . . . . . . . . . . . . . . . . . 11

11 Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13

13 Typical Smart Equipment™ Control Wiring . . . . . . . . . . . . . 15

14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 34

17 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . 34

18 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 37

19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

20 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42

21 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 48

22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

23 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 54

24 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 54

25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 55

26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 55

27 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 65

28 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 66

Summary of Contents for TempMaster ZD Series

Page 1: ...rection Factors 41 15 ZD Blower Performance Side Duct 44 16 ZD Blower Performance Bottom Duct 45 17 Belt Drive RPM Selection 47 18 Indoor Blower Specifications Belt Drive 47 19 Power Exhaust Specifications 47 20 Additional Static Resistance 48 21 Electric Heat Limit Setting 51 22 Electric Heat Anticipator Setpoints 51 23 Single Stage Gas Heat Limit Control Setting 53 24 2 Stage Gas Heat Limit Cont...

Page 2: ...practices and hazards involving only property damage 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 assistance or for additional information consult a qualified contractor installer or service...

Page 3: ...s Design certified by CSA as follows 1 For use as a cooling only unit cooling unit with supplemental electric heat or a forced air furnace 2 For outdoor installation only 3 For installation on combustible material 4 For use with natural gas convertible to LP with kit This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and n...

Page 4: ...art Equipment C BACnet MSTP Modbus N2 COM Card F FDD H Hnywll Excel 10 Ctrl DFS APS N Novar UCM Ctrl DFS APS P CPC Control DFS APS M Verasys Single Zone N Verasys Change Over Bypass Control Options 1 2 Throwaway Filters 2 2 Pleated Filters Merv 8 Additional Options A No Options B Phase Monitor PM C Coil Guard CG D Dirty Filter Switch DFS E PM CG F PM DFS G CG DFS H PM CG DFS J Hinged Filter Door T...

Page 5: ...ding codes and 5 Local gas utility requirements In Canada 1 Canadian Electrical Code CSA C22 1 2 Installation Codes CSA B149 1 3 Local plumbing and waste water codes and 4 Other applicable local codes Refer to unit application data found in this document After installation gas fired units must be adjusted to obtain a temperature rise within the range specified on the unit rating plate If component...

Page 6: ...e Aluminized Steel Tubular Heat Exchanger Belt Drive Or Direct Drive Blower HACR Breaker Economizer Hood Knockout For Side Power Entry Slide In Economizer Table 1 ZDT03 through TA6 Unit Limitations Size Tons Unit Voltage SCCR kVA Unit Limitations Applied Voltage Outdoor DB Temp Min Max Max F ZDT03 3 0 208 230 1 60 5 187 252 125 208 230 3 60 5 187 252 125 460 3 60 5 432 504 125 575 3 60 5 540 630 1...

Page 7: ...operation Rigging And Handling Exercise care when moving the unit Do not remove any packaging until the unit is near the place of installation Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails Spreader bars whose length exceeds the largest dimension across the unit MUST be used across the top of the unit Units may be moved or lifted with a forklift Slo...

Page 8: ...03 3 475 470 34 5 18 25 111 80 117 162 78 62 51 74 91 114 T04 4 603 598 36 18 5 139 108 154 198 96 81 69 98 116 137 T05 5 637 632 37 5 18 2 139 117 171 204 96 85 76 111 124 140 TA6 6 670 665 35 5 17 75 150 114 173 228 104 86 72 111 132 160 Table 3 ZDT03 through TA6 Unit Accessory Weights Unit Accessory Weight lbs Shipping Operating Economizer 55 50 Power Exhaust 55 50 Electric Heat1 28 28 Gas Heat...

Page 9: ...TIM A 0419 Johnson Controls Ducted Systems 9 Figure 5 ZDT03 through TA6 Cooling Only Electric Heat Front View Physical Dimensions Figure 6 ZDT03 through TA6 Cooling Only Gas Heat Front View Physical Dimensions ...

Page 10: ...ar 12 Less Economizer 36 With Economizer or Fixed Air Motorized Damper Left Side Filter Access 24 Less Economizer 36 With Economizer Right Side Cond Coil 24 Below Unit1 1 Units may be installed on combustible floors made from wood or class A B or C roof covering material 0 Above Unit2 2 Units must be installed outdoors Overhanging structures or shrubs should not obstruct condenser air discharge ou...

Page 11: ...A6 Roof Curb Table 5 ZDT03 through TA6 Utilities Entry Hole Opening Size Dia Used For A 7 8 KO1 1 Opening in the bottom to the unit can be located by the slice in the insulation Control Wiring2 2 Do not remove the 2 knockout ring Side Bottom B 2 KO1 Power Wiring Side Bottom C 1 5 8 KO Gas Piping Front D 1 1 2 KO Gas Piping Bottom ...

Page 12: ...re 11 Condensate Drain Compressors The scroll compressor used in this product is specifically designed to operate with R 410A Refrigerant and cannot be interchanged The compressor also uses a polyolester POE oil Mobil 3MA POE This oil is extremely hygroscopic meaning it absorbs water readily POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all nec...

Page 13: ...placement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be utilized for these units Factory installed disconnects are available NOTE Since not all local codes allow the mounting of a disconnect on the unit please confirm compliance with local code before mounting a disconnect on the unit Electrical line must be sized properly...

Page 14: ...ostat to the unit Refer to Table 6 for control wire sizing and maximum length When installing equipment in a facility with a 3 phase high leg delta power supply care must be taken to ensure that the high leg conductor is not attached to either of the two legs of the single phase direct drive X13 or ECM motors Failure to do so can result in the motor acting erratically or not running at all Check f...

Page 15: ...cuit Jumper is required for any coŵďŝŶĂƟŽŶ 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 condiƟons 3 W2 Y1 G OCC Y2 X R SD 24 C W1 2 24V C 24 VAC Class 2 SD 24 Jumper Located on Harness Smoke Detector SD R 24V Output R If No Smoke Detector If Smoke Detector Is Used R Occ Jumper Smart Equipment Contro...

Page 16: ...2 2 51 69 1 70 460 3 60 5 8 38 9 1 3 2 1 0 NONE 10 6 15 E07 6 8 1 8 2 12 8 15 E10 10 1 1 12 1 17 8 20 E15 13 6 2 16 4 23 1 25 E20 19 5 2 23 5 31 9 35 575 3 60 4 2 36 5 5 9 1 3 1 9 0 NONE 8 2 15 E10 10 6 1 10 2 15 1 20 E15 15 9 2 15 3 21 5 25 E20 21 2 2 20 4 27 9 30 T04 4 0 208 1 604 19 6 130 30 5 2 3 6 7 0 NONE 33 5 45 E05 4 1 19 2 33 5 45 E07 5 6 1 26 9 42 50 E10 8 1 38 5 56 5 60 E15 11 9 2 57 2 ...

Page 17: ... E10 10 6 1 10 2 15 1 20 E15 15 9 2 15 3 21 5 25 E20 21 2 2 20 4 27 9 30 E30 30 4 2 29 3 38 9 40 TA6 6 0 208 3 60 19 6 136 27 4 4 4 3 None 33 2 45 E05 4 1 11 1 33 2 45 E07 5 6 1 15 5 33 2 45 E10 8 1 22 2 33 2 45 E15 11 9 1 33 46 6 50 E20 15 9 2 44 1 60 5 70 E30 22 2 2 61 6 82 4 90 230 3 60 19 6 136 27 4 4 4 3 None 33 2 45 E05 5 3 1 12 7 33 2 45 E07 7 5 1 18 33 2 45 E10 10 6 1 25 5 37 3 50 E15 15 9...

Page 18: ... 69 1 70 460 3 60 5 8 38 9 1 3 2 1 0 NONE 10 6 15 E07 6 8 1 8 2 12 8 15 E10 10 1 1 12 1 17 8 20 E15 13 6 2 16 4 23 1 25 E20 19 5 2 23 5 31 9 35 575 3 60 4 2 36 5 5 9 1 3 1 9 0 NONE 8 2 15 E10 10 6 1 10 2 15 1 20 E15 15 9 2 15 3 21 5 25 E20 21 2 2 20 4 27 9 30 T04 4 0 208 1 604 19 6 130 30 5 2 3 6 7 0 NONE 33 5 45 E05 4 1 19 2 33 5 45 E07 5 6 1 26 9 42 50 E10 8 1 38 5 56 5 60 E15 11 9 2 57 2 79 9 8...

Page 19: ... 37 2 50 E10 8 1 22 2 38 1 50 E15 11 9 1 33 51 6 60 E20 15 9 2 44 1 65 5 70 E30 22 2 2 61 6 87 4 90 230 3 60 19 6 136 27 4 4 8 3 None 37 2 50 E05 5 3 1 12 7 37 2 50 E07 7 5 1 18 37 2 50 E10 10 6 1 25 5 42 3 50 E15 15 9 1 38 2 58 1 60 E20 21 2 2 51 74 1 80 E30 29 6 2 71 2 99 4 100 460 3 60 9 4 66 1 13 2 4 4 1 None 18 3 25 E07 6 8 1 8 2 18 3 25 E10 10 1 1 12 1 20 3 25 E15 13 6 1 16 4 25 6 30 E20 19 ...

Page 20: ...1 4 30 E07 5 6 1 15 5 26 9 30 E10 8 1 22 2 35 3 40 E15 11 9 2 33 48 8 50 E20 15 9 2 44 1 62 7 70 230 3 60 10 4 73 16 3 2 3 6 0 NONE 21 3 30 E05 5 3 1 12 7 23 4 30 E07 7 5 1 18 30 1 35 E10 10 6 1 25 5 39 4 40 E15 15 9 2 38 2 55 3 60 E20 21 2 2 51 71 2 80 T04 4 0 208 1 60 19 6 130 30 5 2 3 7 6 0 NONE 34 4 45 E05 4 1 19 2 34 4 45 E07 5 6 1 26 9 43 2 50 E10 8 1 38 5 57 6 60 E15 11 9 2 57 2 81 90 E20 1...

Page 21: ...6 0 NONE 32 40 E05 4 1 11 1 32 40 E07 5 6 1 15 5 32 40 E10 8 1 22 2 37 3 45 E15 11 9 2 33 50 8 60 E20 15 9 2 44 1 64 7 70 E30 22 2 2 61 6 86 5 90 230 3 60 16 110 24 9 4 4 7 6 0 NONE 32 40 E05 5 3 1 12 7 32 40 E07 7 5 1 18 32 1 40 E10 10 6 1 25 5 41 4 45 E15 15 9 2 38 2 57 3 60 E20 21 2 2 51 73 2 80 E30 29 6 2 71 2 98 5 100 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per N...

Page 22: ... 460 3 60 5 8 38 9 1 3 2 1 5 NONE 15 6 20 E07 6 8 1 8 2 19 1 20 E10 10 1 1 12 1 24 1 25 E15 13 6 2 16 4 29 3 30 E20 19 5 2 23 5 38 2 40 575 3 60 4 2 36 5 5 9 1 3 1 9 4 NONE 12 2 15 E10 10 6 1 10 2 20 1 25 E15 15 9 2 15 3 26 5 30 E20 21 2 2 20 4 32 9 35 T04 4 0 208 1 604 19 6 130 30 5 2 3 6 7 10 NONE 43 5 60 E05 4 1 19 2 44 9 60 E07 5 6 1 26 9 54 5 60 E10 8 1 38 5 69 70 E15 11 9 2 57 2 92 4 100 E20...

Page 23: ... 10 6 1 10 2 20 1 25 E15 15 9 2 15 3 26 5 30 E20 21 2 2 20 4 32 9 35 E30 30 4 2 29 3 43 9 45 TA6 6 0 208 3 60 19 6 136 27 4 4 4 3 20 None 43 2 60 E05 4 1 11 1 43 2 60 E07 5 6 1 15 5 43 2 60 E10 8 1 22 2 45 6 60 E15 11 9 1 33 59 1 60 E20 15 9 2 44 1 73 80 E30 22 2 2 61 6 94 9 100 230 3 60 19 6 136 27 4 4 4 3 20 None 43 2 60 E05 5 3 1 12 7 43 2 60 E07 7 5 1 18 43 2 60 E10 10 6 1 25 5 49 8 60 E15 15 ...

Page 24: ...1 6 90 460 3 60 5 8 38 9 1 3 2 1 5 NONE 15 6 20 E07 6 8 1 8 2 19 1 20 E10 10 1 1 12 1 24 1 25 E15 13 6 2 16 4 29 3 30 E20 19 5 2 23 5 38 2 40 575 3 60 4 2 36 5 5 9 1 3 1 9 4 NONE 12 2 15 E10 10 6 1 10 2 20 1 25 E15 15 9 2 15 3 26 5 30 E20 21 2 2 20 4 32 9 35 T04 4 0 208 1 604 19 6 130 30 5 2 3 6 7 10 NONE 43 5 60 E05 4 1 19 2 44 9 60 E07 5 6 1 26 9 54 5 60 E10 8 1 38 5 69 70 E15 11 9 2 57 2 92 4 1...

Page 25: ...47 2 60 E10 8 1 22 2 50 6 60 E15 11 9 1 33 64 1 70 E20 15 9 2 44 1 78 80 E30 22 2 2 61 6 99 9 100 230 3 60 19 6 136 27 4 4 8 3 20 None 47 2 60 E05 5 3 1 12 7 47 2 60 E07 7 5 1 18 47 2 60 E10 10 6 1 25 5 54 8 60 E15 15 9 1 38 2 70 6 80 E20 21 2 2 51 86 6 90 E30 29 6 2 71 2 111 9 125 460 3 60 9 4 66 1 13 2 4 4 1 20 None 23 3 30 E07 6 8 1 8 2 23 3 30 E10 10 1 1 12 1 26 5 30 E15 13 6 1 16 4 31 9 35 E2...

Page 26: ... 40 E07 5 6 1 15 5 39 4 40 E10 8 1 22 2 47 8 50 E15 11 9 2 33 61 3 70 E20 15 9 2 44 1 75 2 80 230 3 60 10 4 73 16 3 2 3 6 10 NONE 31 3 40 E05 5 3 1 12 7 35 9 40 E07 7 5 1 18 42 6 45 E10 10 6 1 25 5 51 9 60 E15 15 9 2 38 2 67 8 70 E20 21 2 2 51 83 7 90 T04 4 0 208 1 60 19 6 130 30 5 2 3 7 6 10 NONE 44 4 60 E05 4 1 19 2 46 60 E07 5 6 1 26 9 55 7 60 E10 8 1 38 5 70 1 80 E15 11 9 2 57 2 93 5 100 E20 1...

Page 27: ... 4 7 6 10 NONE 42 50 E05 4 1 11 1 42 50 E07 5 6 1 15 5 42 50 E10 8 1 22 2 49 8 50 E15 11 9 2 33 63 3 70 E20 15 9 2 44 1 77 2 80 E30 22 2 2 61 6 99 100 230 3 60 16 110 24 9 4 4 7 6 10 NONE 42 50 E05 5 3 1 12 7 42 50 E07 7 5 1 18 44 6 50 E10 10 6 1 25 5 53 9 60 E15 15 9 2 38 2 69 8 70 E20 21 2 2 51 85 7 90 E30 29 6 2 71 2 111 125 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type ...

Page 28: ... 38 4 4 17 4 None 52 3 70 230 1 60 24 4 144 2 38 4 4 17 4 None 52 3 70 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC ZDT03 through T05 With Powered Convenience Outlet Belt Drive Single Phase Gas Heat Size Tons Volt Compressors each OD Fan Motors each Supply Blower Motor Pwr Conv Outlet Electric Heat Option MCA1 Amps Max Fuse2 Breaker3 Size Amps RLA LRA MCC FLA FLA F...

Page 29: ...s Yes FER Compliant Belt Drive Single Phase Gas Heat Only 3 Yes Yes Yes Yes No Yes Steady state efficiency 3 Phase Only 80 80 81 1 80 2 80 80 81 1 80 5 80 80 81 1 80 5 80 0 80 0 81 1 80 5 No burners 2 4 3 5 3 5 3 5 4 5 3 5 4 5 3 5 No stages 1 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2 Temperature Rise Range ºF 15 45 45 75 35 70 55 90 25 70 45 75 25 70 45 75 25 55 35 75 20 55 35 75 25 55 30 75 15 45 30 75 Gas L...

Page 30: ... 1VL44 1VP56 1VL44 1VP56 VL44 1VP56 Blower Sheave AK64 AK66 AK56 AK61 AK56 AK56 AK56 AK56 Belt A37 A39 A36 A38 A36 A38 A36 A38 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 1 1 2 3 RPM 1740 1740 1740 1740 Frame size 56 56 56 56 DIRECT DRIVE EVAP FAN DATA5 Quantity 1 1 1 Fan Size Inch 11 x 10 11 x 10 11 x 10 Type Centrifugal Centrifugal Centrifugal Motor HP each 3 4 1 1 RPM 1050 1050 1050 FILTERS 1...

Page 31: ...an be converted to L P with Kit Model No 1NP0440 or 1NP0485 2 Stage All furnaces meet the latest California seasonal efficiency requirements 1 Based on 1075 Btu Ft 3 2 The air flow must be adjusted to obtain a temperature rise within the range shown Table 10 Electric Heat Minimum Supply Air Size Tons Voltage Minimum Supply Air CFM Heater kW 5 7 10 15 20 30 T03 3 0 208 230 1 60 900 900 900 900 900 ...

Page 32: ...d joint union must be installed in the gas piping 2 Where required by local codes a manual shut off valve must be installed outside of the unit 3 Use wrought iron or steel pipe for all gas lines Pipe dope should be applied sparingly to male threads only 4 All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out loose particles Before initial start up b...

Page 33: ...t and Combustion Air Hood Figure 16 The vent hood is installed by inserting the top flange of the hood into the slotted opening in the access panel and securing in place The products of combustion are discharged horizontally through this screened hooded vent opening on the gas heat access panel FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury dea...

Page 34: ...ew Units with Simplicity Lite Controls will have a field installed RRS Economizer Kit Offered This section describes how to use the Economizer s user interface for Keypad and menu navigation Settings and parameter changes Menu structure and selection User Interface The user interface consists of an LCD display and a 4 button keypad on the front of the economizer module Figure 17 RRS Economizer LCD...

Page 35: ...ts should be set to the same value Free Cooling Four types of free cooling options are available dry bulb changeover single enthalpy dual enthalpy changeover and Auto Dry Bulb Changeover For dry bulb economizer operation the outside air is suitable for free cooling if the outside air temperature is 1 F below the Economizer OAT Enable Setpoint and 1 F below the Return Air Temperature Free cooling i...

Page 36: ...ompressor output be turned ON if the economizer output is less than 100 even if the differential between zone or return temperature and the current cooling setpoint is great enough to demand more than one stage of cooling If the economizer output goes to minimum position and the SAT is less than Economizer Setpoint 1 F the control starts a 12 minute timer to de energize a compressor output If at a...

Page 37: ...nomizer actuator position feedback Connects 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 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 LEDs at left on upper edge of economizer board POWER POWER Green UCB pow...

Page 38: ...er Used to ramp the power exhaust fan VFD position the discharge damper actuator COM 24 VAC common 0 10 VDC negative for the power exhaust variable frequency drive discharge damper modulating power exhaust actuator Connects through circuit trace to 24V IN pin COM 24V 24 VAC hot supplied for the discharge damper modulating power exhaust actuator and economizer actuator Connects through circuit trac...

Page 39: ...nge parameter sets the CO2 parts per million measured by the indoor air quality sensor when it outputs 10 VDC IAQ parameter reports input status 0 5000ppm Used for demand ventilation functions if the NetIAQ parameter indicates Unrel C COM 24 VAC common 0 10 VDC negative for the indoor air quality sensor Connects through circuit trace to 24V IN pin COM R 24V 24 VAC hot supplied for the outdoor air ...

Page 40: ...5 VDC negative for the building pressure sensor Connects through circuit trace to 24V IN pin COM BINARY INPUTS at right on lower edge of economizer board IN9 PURGE 24 VAC hot input from the PURGE dry contact Purge parameter reports input status False with 0 VAC input True with 24 VAC input When Purge status is True heating and cooling operation is prevented the indoor blower and power exhaust fan ...

Page 41: ...e shown in Table 14 and Figure 20 Never Loosen A C B Span Length Defl Force Procedure for adjusting belt tension 1 Loosen six nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown Deflection distance of 4mm 5 32 is obtained To determine the deflection distance from normal position...

Page 42: ...2 0 56 Example 2 A system located at 5 000 feet of elevation is to deliver 1 400 CFM at a static pressure of 1 5 Use the unit blower tables to select the blower speed and the BHP requirement Solution As in the example above no temperature information is given so 70 F is assumed The 1 5 static pressure given is at an elevation of 5 000 ft The first step is to convert this static pressure to equival...

Page 43: ...elow Size X and Model Y is found 5 1 82 BHP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1478 RPM is within the range of the 2 HP drive 7 Using the 2 HP motor and drive 2 5 turns open will achieve 1478 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 RP...

Page 44: ...0 49 942 0 58 1016 0 67 1087 0 76 1155 0 85 1221 0 96 1284 1 05 1345 1 16 1200 733 0 33 817 0 47 896 0 56 973 0 64 1047 0 73 1118 0 82 1186 0 92 1252 1 01 1315 1 11 1376 1 21 1400 770 0 42 853 0 56 933 0 63 1010 0 73 1083 0 81 1154 0 90 1222 1 00 1288 1 10 1352 1 19 1413 1 30 1600 811 0 55 895 0 67 974 0 76 1051 0 84 1125 0 94 1196 1 02 1264 1 12 1330 1 22 1393 1 32 1454 1 42 1800 857 0 73 940 0 8...

Page 45: ...1451 363 1411 376 1374 390 1331 403 1292 417 1249 430 4 MED HI 1480 263 1433 276 1389 290 1347 303 1303 316 1257 329 1208 343 1153 358 1080 374 3 MED 1332 208 1286 221 1241 234 1195 246 1146 258 1097 272 1031 288 962 303 919 313 2 MED LOW 1227 171 1178 183 1129 195 1076 207 1021 220 953 235 891 248 1 LOW 1075 130 992 134 930 145 858 158 43 5 HI 2067 696 2027 714 1991 734 1953 749 1910 764 1860 769...

Page 46: ...48 852 0 56 939 0 64 1022 0 73 1103 0 81 1180 0 89 1254 0 99 1326 1 08 1395 1 19 1462 1 29 1600 807 0 61 897 0 68 984 0 76 1068 0 84 1148 0 93 1225 1 02 1300 1 12 1371 1 21 1440 1 31 1507 1 40 1800 856 0 77 947 0 84 1034 0 93 1118 1 00 1198 1 10 1275 1 18 1349 1 28 1421 1 37 1490 1 47 1557 1 57 2000 910 0 97 1001 1 04 1088 1 13 1172 1 21 1252 1 30 1329 1 39 1403 1 48 1475 1 57 1544 1 68 1611 1 77 ...

Page 47: ...4 715 1802 730 1759 740 1722 756 1657 748 2 MED LOW 1688 413 1645 432 1611 451 1575 468 1534 479 1498 497 1461 513 1 LOW 1509 327 1477 339 Table 17 Belt Drive RPM Selection Size Tons Model HP Max BHP Motor Sheave Blower Sheave 5 Turns Open 4 Turns Open 3 Turns Open 2 Turns Open 1 Turn Open Fully Closed T03 3 ZD 1 5 1 73 1VL44 AK64 805 865 920 980 1035 1095 1 5 1 73 1VP56 AK66 1115 1170 1225 1280 1...

Page 48: ...determine the pressure drop across a dry evaporator coil Since the moisture on an evaporator coil may vary greatly measuring the pressure drop across a wet coil under field conditions would be inaccurate To assure a dry coil the compressors should be deactivated while the test is being run 4 Knowing the pressure drop across a dry coil the actual CFM through the unit can be determined from the curv...

Page 49: ... the elapse of the fan off delay for cooling To be available a compressor must not be locked out due to a high or low pressure switch or Evaporator Low Limit sensor EC1 detecting a temperature below 26 F Smart Equipment Control and the anti short cycle delay ASCD must have elapsed Economizer With Dry Bulb Sensor Smart Equipment When the room thermostat calls for cooling the low voltage control cir...

Page 50: ... the UCB will operate in the low ambient mode Low ambient mode operates the compressors in this manner 10 minutes on 5 minutes off The indoor blower is operated throughout the cycle The 5 minute off period is necessary to defrost the indoor coil Low ambient mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor operation The off cycle will beg...

Page 51: ...Equipment Control Safety Controls The UCB monitors the temperature limit switch of electric heat units The control circuit includes the following safety controls Temperature Limit Switch TLS This control is located inside the heater compartment and is set to open at the temperature indicated in the Electric Heat Limit Setting Table 21 It resets automatically The limit switch operates when a high t...

Page 52: ...een satisfied Gas Heat Operation Errors During furnace operation the ICB monitors the flame sense circuit the centrifugal switch the primary limit switch and the roll out switch If a signal from any of the inputs moves to a fault state then the ICB immediately closes the pilot and main gas valves The ICB will determine the device that is signaling a fault and flash a code for that device A primary...

Page 53: ...ability If the pilot flame is unstable or lost completely then the ICB will immediately close both the pilot and main gas valves The ICB will retry the purging and ignition sequence If the flame is unstable or lost more than 16 times during the same call for heat then the ICB will lock out furnace operation for 5 minutes Error Messages The UCB will initiate an error message to the LCD Smart Equipm...

Page 54: ... knob of gas valve while turning to off position or position the switch to the off position Post Start Check List Gas After the entire control circuit has been energized and the heating section is operating make the following checks 1 Check for gas leaks in the unit piping as well as the supply piping 2 Check for correct manifold gas pressures See Checking Gas Input on page 55 3 Check the supply g...

Page 55: ...al shut off valve 3 Remove the gas piping closure panel 4 Disconnect wiring to the gas valves and spark ignitors Remove the manifold burner gas valve assembly by lifting up and pulling back Figure 26 Typical Flame Appearance Burners are now accessible for service Reverse the above procedure to replace the assemblies Make sure that burners are level and seat at the rear of the heat exchanger Burner...

Page 56: ... specific applications as factory defaults may not always be suitable To make airflow changes adjust the variable pitch sheave pulley If pulley adjustments fail to achieve the required airflow you may need to adjust the factory default speed settings for the Smart Equipment control see Adjusting the fan speed percentages NOTE During installation the speed chosen for the heating speed must produce ...

Page 57: ...n of the economizer blades If the blades are open the economizer is providing free cooling and the compressors will not immediately operate If both stages of cooling are requested simultaneously and the economizer provides free cooling following a short delay the compressor will be energized unless it is locked out unless this option has been disabled through computer communications 2 If no econom...

Page 58: ...al If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug the jumper in the Mate N Lock plug and in the wiring from the Mate N Lock plug to the Y1 ECON terminal 13 For units with economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal t...

Page 59: ...95 159 70 364 97 15 80 65 11 400 Cfm Ton 75 63 75 130 60 256 76 21 75 54 8 85 135 57 299 88 20 75 55 9 95 140 52 348 100 19 75 56 10 Table 29 ZDT04 4 0 Ton Operating Pressures Air Flow Indoor Db Wb Indoor DB WB Outdoor DB Suction Pressure Suction Temp Liquid Pressure Liquid Temp Delta T Db Entering Evap Db Leaving Evap Db Compressor Amps 300 Cfm Ton 80 62 75 123 62 276 79 30 80 50 11 85 127 55 324...

Page 60: ...5 63 75 132 56 287 77 20 75 55 14 85 134 57 334 85 20 75 55 17 95 138 58 386 94 19 75 56 19 Table 31 ZDTA6 6 0 Ton Operating Pressures Air Flow Indoor Db Wb Indoor DB WB Outdoor DB Suction Pressure Suction Temp Liquid Pressure Liquid Temp Delta T Db Entering Evap Db Leaving Evap Db Compressor Amps 300 Cfm Ton 80 62 75 129 58 304 137 24 80 56 12 0 85 128 54 352 148 24 80 56 13 4 95 128 50 399 159 2...

Page 61: ...eck the power and common wires between the unit control box and the ICB and repair as necessary If the control voltage is present then verify the cleanliness of the harness and the ICB connector clean if necessary and reconnect the wiring harness to the ICB and observe ICB LED If it now flashes the heartbeat then the fault was a bad connection between the harness connector and the ICB connector or...

Page 62: ...f not clean then clean reinstall and adjust pilot per the start up procedures 2 If the flame is weak or unstable in the flame sensor area then verify the gas inlet pressure If gas inlet pressure is above the minimum inlet pressure stated on unit data label then adjust the pilot pressure per the start up procedures If the pilot cannot be adjusted to obtain a strong and stable flame in the flame sen...

Page 63: ... board may need to be replaced Symptomatic Troubleshooting On calls for heating the draft motor operates and the furnace lights but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in AUTO position 1 Place the thermostat fan switch in the ON position If the supply air blower motor energizes go to Step 10 2 If the supply air blower motor does not e...

Page 64: ...e igniter continues to spark and the main burners do not ignite 1 Make the same checks and adjustment as described in PILOT CHECKOUT on page 55 2 Check the supply pressure as described in POST START CHECK LIST on page 54 Make adjustments as necessary 3 Make sure that the pilot burner is not bent or damaged 4 Make sure that the ground connections at the pilot burner gas valve and ignition control a...

Page 65: ...h Not Applicable 2 Flashes Control waiting ASCD1 1 These flash codes do not represent alarms 3 Flashes HPS1 Compressor Lock out 5 Flashes LPS1 Compressor Lock out 7 Flashes FS1 Compressor Lock out 9 Flashes Ignition Control Locked Out Ignition Control Failure Limit Switch Trip No Jumper Plug in Heat Section 10 Flashes Compressors Locked Out On Low Outdoor Air Temperature1 11 Flashes Compressors Lo...

Page 66: ...s the UCB microprocessor connects through circuit trace to the SD 24 terminal SD 24 24 VAC hot out for factory accessory smoke detector condensate overflow and or user shutdown relay switching in series Connects through circuit trace to thermostat connection strip SD 24 A wiring harness jumper plug connecting SD 24 to SD R is in place if factory accessories for unit shutdown are not used this jump...

Page 67: ...indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout networking error and firmware error indicator 1 2 second on off flashing indicates one or more alarm is currently active 1 10th second on off flashing indicates a networking error polarity addressing etc or a firmware error likely correctable with re loading from USB flash drive SA BUS Green UCB SA bus communication transmis...

Page 68: ... VDC reading EC2 to EC2 with open circuit Used in suction line temperature safety Pinned connections on right edge of UCB RAH Return Air Humidity input from 0 10 VDC 0 100 RH sensor Input required for reheat units optional in all other units may be a communicated value Used in return air enthalpy calculation temperature humidity setpoint reset reheat operation DCT PRS Supply Duct Pressure input fr...

Page 69: ...put for indoor blower contactor coil indoor blower VFD enable relay coil Output with heat cool operation G input or schedule demand C1 24 VAC hot output for compressor 1 If demand is present and permissions allow compressor 1 operation output with compressor cooling comfort ventilation cooling reheat or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage com...

Page 70: ...ter of the board Positive 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 ...

Page 71: ...t indicates the UCB is supplying power to the communication sub board 1 When wiring unit and other devices using the SA Bus and FC Bus see Table 31 Table 35 Cable for FC Buses and SA Buses in Order of Preference Bus and Cable Type Non Plenum Applications Plenum Applications Part Number O D Part Number O D FC Bus 22 AWG Stranded 3 Wire Twisted Shielded Cable1 1 We strongly recommend 3 wire for FC b...

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