Johnson Controls ZJ SERIES Installation Manual Download

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R-410A
SERIES 20 J**ZJ

15 - 25 Ton

60 Hertz

349218-JIM-F-0512

TABLE OF CONTENTS

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 45

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 46

Electric Heating Sequence Of Operations. . . . . . . . . . . . . 48

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 48

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 49

Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 50

Start-Up (Cooling)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Start-Up (Gas Heat)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Checking Gas Heat Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Charging The Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Unit Control Board Option Setup

. . . . . . . . . . . . . . . . . . . . . . 62

Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   62
Heat Delay Setup  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   62
Optional VAV Control Board Flash Codes  . . . . . . . . . . . .   62

LIST OF TABLES

1 J15 thru 25 ZJ Unit Limitations

. . . . . . . . . . . . . . . . . . . . . 7

2 Weights and Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . 8

3 J15 thru 25 ZJ Unit Accessory Weights

. . . . . . . . . . . . . . 9

4 Utilities Entry

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Supply Fan VFD Weights, In Lbs.

. . . . . . . . . . . . . . . . . . . 9

6 J15 thru 25 ZJ Unit Clearances

. . . . . . . . . . . . . . . . . . . . 11

7 Control Wire Sizes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8 Electrical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9 J15 thru 25 ZJ Physical Data

. . . . . . . . . . . . . . . . . . . . . 25

10 Electric Heat Minimum Supply Air

. . . . . . . . . . . . . . . . . . 26

11 Gas Application Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . 27

12 Gas Pipe Sizing - CapacIty of Pipe

. . . . . . . . . . . . . . . . . 27

13 Gas Heat Minimum Supply Air

. . . . . . . . . . . . . . . . . . . . 27

14 Altitude/Temperature Correction Factors

. . . . . . . . . . . . 35

15 Air Flow Performance - Side Duct Application

. . . . . . . . 37

16 Air Flow Performance - Bottom Duct Application

. . . . . . 40

17 RPM Selection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

18 Indoor Blower Specifications

. . . . . . . . . . . . . . . . . . . . . . 43

19 Power Exhaust Specifications

. . . . . . . . . . . . . . . . . . . . . 43

20 Limit Control Setting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

21 Electric Heat Anticipator Setpoint

. . . . . . . . . . . . . . . . . . 49

22 Gas Heat Limit Control Setting

. . . . . . . . . . . . . . . . . . . . 50

23 Gas Heat Anticipator Setpoints

. . . . . . . . . . . . . . . . . . . . 51

24 Gas Rate Cubic Feet Per Hour

. . . . . . . . . . . . . . . . . . . . 52

25 Unit Control Board Flash Codes

. . . . . . . . . . . . . . . . . . . 61

26 Heat Delay

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

27 VAV Control Board Flash Codes

. . . . . . . . . . . . . . . . . . 62

LIST OF FIGURES

1 J15 thru 25 ZJ Component Location

. . . . . . . . . . . . . . . . 6

2 Unit 4 Point Load Weight

. . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Unit 6 Point Load Weight

. . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Center of Gravity

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 J15 thru 25 ZJ Unit Dimensions Front View

. . . . . . . . . . . 9

6 J15 thru 25 ZJ Unit Dimensions Rear View

. . . . . . . . . . 10

7 J15 thru 25 ZJ Unit Dimensions Rain Hood

. . . . . . . . . . 11

8 J15 thru 25 ZJ Roof Curb

. . . . . . . . . . . . . . . . . . . . . . . . 12

9 Fixed Outdoor Air Damper

. . . . . . . . . . . . . . . . . . . . . . . 13

10 Condensate Drain

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

11 Field Wiring Disconnect - Cooling Unit With/

Without Electric Heat

. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

12 Typical Field Wiring 24 Volt Thermostat

. . . . . . . . . . . . 15

13 External Supply Connection External Shut-Off

. . . . . . . 27

14 Bottom Supply Connection External Shut-Off

. . . . . . . . 27

15 Vent and Combustion Air Hood

. . . . . . . . . . . . . . . . . . . 29

16 Enthalpy Set Point Chart

. . . . . . . . . . . . . . . . . . . . . . . . 33

17 Economizer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
18 Belt Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

19 Altitude/Temperature Correction Factors

. . . . . . . . . . . . 35

20 Pressure Drop Across A Dry Indoor Coil Vs. Supply

Air CFM For All Unit Tonnages

. . . . . . . . . . . . . . . . . . . 44

21 Gas Valve Piping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

22 Gas Valve and Controls

. . . . . . . . . . . . . . . . . . . . . . . . . 51

23 Proper Pilot Flame Adjustment

. . . . . . . . . . . . . . . . . . . 53

24 Typical Flame

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

25 Typical Gas Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

26 J15ZJ (15 Ton) Charging Chart

. . . . . . . . . . . . . . . . . . . 54

27 J18ZJ (17.5 Ton) Charging Chart

. . . . . . . . . . . . . . . . . 54

28 J20ZJ (20 Ton) Charging Chart

. . . . . . . . . . . . . . . . . . . 54

29 J25ZJ (25 Ton) Charging Chart

. . . . . . . . . . . . . . . . . . . 54

30 Unit Control Board

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Summary of Contents for ZJ SERIES

Page 1: ... 27 14 Altitude Temperature Correction Factors 35 15 Air Flow Performance Side Duct Application 37 16 Air Flow Performance Bottom Duct Application 40 17 RPM Selection 43 18 Indoor Blower Specifications 43 19 Power Exhaust Specifications 43 20 Limit Control Setting 48 21 Electric Heat Anticipator Setpoint 49 22 Gas Heat Limit Control Setting 50 23 Gas Heat Anticipator Setpoints 51 24 Gas Rate Cubic...

Page 2: ...intenance functions of cleaning coils and filters and replacing filters Observe all precautions in the literature labels and tags accompanying the equipment whenever working on air conditioning equipment Be sure to follow all other applicable safety precautions and codes including ANSI Z223 1 or CSA B149 1 latest edition Improper installation may create a condition where the operation of the produ...

Page 3: ...e 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 and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1 2 PSIG Pressures greater than 1 2 PSIG will ca...

Page 4: ...4 J Options 1 2 3 K Options 1 2 4 L Options 1 3 4 M Options 1 2 3 4 1 Disconnect 2 Non Pwr d Conv Outlet 3 Smoke Detector S A 4 Smoke Detector R A 5 Pwr d Conv Outlet Options N Options 2 3 P Options 2 4 Q Options 2 3 4 R Options 3 4 S Option 5 T Options 1 5 U Options 1 3 5 V Options 1 4 5 W Options 1 3 4 5 X Options 3 5 Y Options 4 5 Z Options 3 4 5 SS Drain Pan Configuration Options not required ...

Page 5: ...on 4 Local building 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 pla...

Page 6: ...ric Electric Units Belt Drive Blower Motor 14 Gauge Base Rails with Lifting Holes Filter Drier Solid Core Thermal Expansion Valve Copper Tube Aluminum Fin Evaporator Coils 2 Disposable Filters 4 Filters Optional Slide In Plug In Internal Economizer Optional 1 NPT Condensate Drain Location of VFD Optional Location of VFD Bypass Optional High Efficiency Scroll Compressors Copper Tube Aluminum Fin Co...

Page 7: ...nit 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 Table 1 J15 thru 25 ZJ Unit Limitations Size...

Page 8: ...be secured in place when the unit is lifted The condenser coils should be protected from rigging cable damage with plywood or other suitable material A D B C A D E C F B X Y LEFT FRONT Table 2 Weights and Dimensions Size Tons Weight lbs Center of Gravity 4 Point Load Location lbs 6 Point Load Location lbs Shipping Operating X Y A B C D A B C D E F J15ZJ 15 2614 2609 85 25 44 467 781 852 510 287 39...

Page 9: ...s BLOWER ACCESS Location of Optional VFD 52 5 8 180 19 32 COMPRESSOR ACCESS DISCONNECT SWITCH LOCATION ECONOMIZER MOTORIZED DAMPER FIXED OUTDOOR INTAKE AIR AND POWER EXHAUST RAIN HOODS See detail Y 92 46 5 8 35 1 4 33 2 3 4 3 3 4 B POWER WIRING ENTRY BOTTOM SUPPLY AND RETURN AIR OPENINGS See Note A CONTROL WIRING ENTRY 21 1 2 11 1 8 D GAS SUPPLY ENTRY UNIT BASE RAILS Shown separately to illustrate...

Page 10: ...pt when the unit includes a power exhaust option The covering consists of a heavy black paper composition 3 Replace the side supply and return air compartment panels For side duct applications 1 Replace the side panels on the supply and return air compartments with the accessory flange kit panels 2 Connect ductwork to the flanges on those panels Outdoor Air Supply Air Return Air 40 1 2 39 5 8 Outd...

Page 11: ...J15 thru 25 ZJ Unit Clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser air discharge outlet 72 With 36 Maximum Horizontal Overhang For Condenser Air Discharge Right 36 Front 36 Bottom2 2 Units may be installed on combustable floors made from wood or class A B or C roof covering materials 0 Rea...

Page 12: ...izer or a motorized damper option Refer to the Fixed Outdoor Damper Figure 9 Gasketing and mounting screws are provided in a parts bag attached to the hood assembly Apply gasketing to the three flange surfaces on the hood prior to installing the hood Extend gasketing 1 4 inch beyond the top and bottom of the two side flanges to insure adequate sealing Adjusting the damper to the desired air flow m...

Page 13: ...tering device or coil Units are shipped with compressor mountings which are factory adjusted and ready for operation Filters Two inch filters are supplied with each unit but units can be converted easily to four inch filters Filters must always be installed ahead of the evaporator coil and must be kept clean or replaced with same size and type Dirty filters will reduce the capacity of the unit and...

Page 14: ...ompliance with local code before mounting a disconnect on the unit Electrical line must be sized properly to carry the load USE COPPER CONDUCTORS ONLY Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused Refer to Figures 11 and 12 for typical field wiring and to the appropriate unit wiring diagram mounted inside control doors for control circu...

Page 15: ...r general installation procedure Figure 12 Typical Field Wiring 24 Volt Thermostat Table 7 Control Wire Sizes Wire Size Maximum Length1 1 From the unit to the thermostat and back to the unit 18 AWG 150 Feet OCC C RC G Y2 Y1 W2 W1 X R THERMOSTAT TERMINALS CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 2 4 Second stage heating not required on single stage heating units J...

Page 16: ...15 4 0 0 None 94 8 110 E18 13 5 1 37 5 94 8 110 E36 27 0 2 74 9 112 9 125 E54 40 6 2 112 7 160 1 175 E72 54 1 2 150 2 169 4 200 230 3 60 16 7 120 26 0 2 1 14 4 0 0 None 93 8 110 E18 18 0 1 43 3 93 8 110 E36 36 0 2 86 6 126 3 150 E54 54 0 2 129 9 147 9 175 E72 72 0 2 173 2 191 2 225 460 3 60 8 7 60 15 5 1 1 7 2 0 0 None 48 6 50 E18 18 0 1 21 7 48 6 50 E36 36 0 2 43 3 63 1 70 E54 54 0 2 65 0 74 0 90...

Page 17: ... 0 0 0 None 72 7 80 E18 18 0 1 21 7 72 7 80 E36 36 0 2 43 3 72 7 80 E54 54 0 2 65 0 81 2 90 E72 72 0 2 86 6 102 9 110 575 3 60 8 7 62 13 5 1 5 10 3 0 0 None 53 7 60 E18 18 0 1 17 3 53 7 60 E36 36 0 2 34 6 56 2 60 E54 54 0 2 52 0 64 8 70 E72 72 0 2 69 3 82 2 90 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J15 thru 25 ZJ Standard Drive Without Powered Convenience Out...

Page 18: ...04 8 110 E18 13 5 1 37 5 104 8 110 E36 27 0 2 74 9 125 4 150 E54 40 6 2 112 7 172 6 175 E72 54 1 2 150 2 181 9 200 230 3 60 16 7 120 26 0 2 1 14 4 10 0 None 103 8 110 E18 18 0 1 43 3 103 8 110 E36 36 0 2 86 6 138 8 150 E54 54 0 2 129 9 160 4 175 E72 72 0 2 173 2 203 7 225 460 3 60 8 7 60 15 5 1 1 7 2 5 0 None 53 6 60 E18 18 0 1 21 7 53 6 60 E36 36 0 2 43 3 69 4 70 E54 54 0 2 65 0 80 2 90 E72 72 0 ...

Page 19: ... 13 0 5 0 None 77 7 90 E18 18 0 1 21 7 77 7 90 E36 36 0 2 43 3 77 7 90 E54 54 0 2 65 0 87 5 90 E72 72 0 2 86 6 109 1 110 575 3 60 8 7 62 13 5 1 5 10 3 4 0 None 57 7 60 E18 18 0 1 17 3 57 7 60 E36 36 0 2 34 6 61 2 70 E54 54 0 2 52 0 69 8 70 E72 72 0 2 69 3 87 2 90 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J15 thru 25 ZJ Standard Drive With Powered Convenience Out...

Page 20: ... 100 2 110 E18 13 5 1 37 5 100 2 110 E36 27 0 2 74 9 118 7 125 E54 40 6 2 112 7 165 9 175 E72 54 1 2 150 2 175 2 200 230 3 60 16 7 120 26 0 2 1 20 0 0 0 None 100 2 110 E18 18 0 1 43 3 100 2 110 E36 36 0 2 86 6 133 3 150 E54 54 0 2 129 9 154 9 175 E72 72 0 2 173 2 198 2 225 460 3 60 8 7 60 15 5 1 1 10 0 0 0 None 51 7 60 E18 18 0 1 21 7 51 7 60 E36 36 0 2 43 3 66 6 70 E54 54 0 2 65 0 77 5 90 E72 72 ...

Page 21: ... 0 0 None 80 5 90 E18 18 0 1 21 7 80 5 90 E36 36 0 2 43 3 80 5 90 E54 54 0 2 65 0 89 1 100 E72 72 0 2 86 6 110 7 125 575 3 60 8 7 62 13 5 1 5 15 4 0 0 None 60 1 70 E18 18 0 1 17 3 60 1 70 E36 36 0 2 34 6 62 6 70 E54 54 0 2 52 0 71 2 80 E72 72 0 2 69 3 88 5 100 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J15 thru 25 ZJ High Static Drive Without Powered Convenience ...

Page 22: ...110 2 125 E18 13 5 1 37 5 110 2 125 E36 27 0 2 74 9 131 2 150 E54 40 6 2 112 7 178 4 200 E72 54 1 2 150 2 187 7 200 230 3 60 16 7 120 26 0 2 1 20 0 10 0 None 110 2 125 E18 18 0 1 43 3 110 2 125 E36 36 0 2 86 6 145 8 150 E54 54 0 2 129 9 167 4 175 E72 72 0 2 173 2 210 7 225 460 3 60 8 7 60 15 5 1 1 10 0 5 0 None 56 7 60 E18 18 0 1 21 7 56 7 60 E36 36 0 2 43 3 72 9 80 E54 54 0 2 65 0 83 7 90 E72 72 ...

Page 23: ...3 5 0 None 85 5 100 E18 18 0 1 21 7 85 5 100 E36 36 0 2 43 3 85 5 100 E54 54 0 2 65 0 95 3 110 E72 72 0 2 86 6 117 0 125 575 3 60 8 7 62 13 5 1 5 15 4 4 0 None 64 1 70 E18 18 0 1 17 3 64 1 70 E36 36 0 2 34 6 67 6 70 E54 54 0 2 52 0 76 2 90 E72 72 0 2 69 3 93 5 100 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC J15 thru 25 ZJ High Static Drive With Powered Convenience...

Page 24: ...62 13 5 1 5 8 2 0 0 None 51 2 60 E18 18 0 1 17 3 51 2 60 E36 36 0 2 34 6 53 6 60 E54 54 0 2 52 0 62 2 70 E72 72 0 2 69 3 79 5 90 J25ZJ Low Static Drive With Powered Convenience Outlet Size Tons Volt Compressors each OD Fan Motors each Supply Blower Motor Pwr Conv Outlet Electric Heat Option MCA1 Amps 1 Minimum Circuit Ampacity Max Fuse2 Breaker3 Size Amps 2 Dual Element Time Delay Type 3 HACR type...

Page 25: ...240 320 240 320 240 320 240 320 AFUE Steady state efficiency 80 80 80 80 80 80 80 80 No burners 6 8 6 8 6 8 6 8 No stages 2 2 2 2 2 2 2 2 Temperature Rise Range ºF 20 50 30 60 20 50 30 60 20 50 30 60 20 50 30 60 Gas Limit Setting ºF 195 195 195 195 195 195 195 195 Gas piping connection in 1 1 1 1 1 1 1 1 DIMENSIONS inches Length 180 19 32 Width 92 Height 52 5 8 OPERATING WT lbs 2609 2665 2697 2783...

Page 26: ...K110 BK090 BK110 BK090 BK110 BK090 1B5V94 1B5V110 1B5V94 Belt BX85 BX81 BX78 BX75 BX78 BX75 BX78 5VX840 5VX860 Motor HP each 5 5 5 7 5 5 7 5 7 5 10 15 RPM 1725 1725 1725 1725 1725 1725 1725 1725 1725 Frame size 184T 184T 184T 213T 184T 213T 213T 215T 254T FILTERS Quantity Size 12 12 x 24 x 2 1 2 12 12 x 24 x 2 1 2 12 12 x 24 x 2 1 2 12 12 x 24 x 2 1 2 2 20 x 24 x 4 4 24 x 24 x 4 3 2 20 x 24 x 4 4 ...

Page 27: ...onnection External Shut Off NOTE Maximum capacity of pipe in cubic feet of gas per hour based upon a pressure drop of 0 3 inch W C and 0 6 specific gravity gas Table 11 Gas Application Data Unit Input MBH Output MBH Temp Rise F 1 1 On VAV units individual VAV boxes must be full open in heating mode to insure airflow falls within temperature rise range Size Opt J15ZJ 24 300 240 20 50 32 400 320 30 ...

Page 28: ...pressure regulation Two stage regulation is recommended 3 The pressure drop in the lines between regulators and between the second stage regulator and the appliance Pipe size required will depend on the length of the pipe run and the total load of all appliances Complete information regarding tank sizing for vaporization recommended regulator settings and pipe sizing is available from most regulat...

Page 29: ... outdoor and return air divider baffles and all the control sensors are factory mounted as part of the Factory installed economizer option Power Exhaust Barometric Relief Damper and Rain Hood The instructions for the power exhaust barometric relief damper and rain hood can be found in the rain hood kit The exhaust fan all supporting brackets angles and the wiring are factory installed as part of t...

Page 30: ...Variable Air Volume VAV A variable air volume VAV option using a variable frequency drive VFD is available for applications requiring a constant supply duct static pressure A differential pressure transducer is used to monitor supply duct static pressure and return a speed reference signal to the VFD to control the output of the indoor blower motor Duct Static Pressure Transducer A 0 5 WC pressure...

Page 31: ...he factory default setting of 4 5 WC If the duct static pressure reaches the high limit set point then the supply fan motor will be shutdown NOTE Either of the set points described above can be changed through the unit control board UCB with the use of a USB to RS485 converter personal computer or PDA and a down loaded copy of the Simplicity software available at the UPGnet Commercial Product Cata...

Page 32: ... x 8 W x 8 D If the drive will not fit in the allotted space then it will need to be mounted elsewhere either within the building on a perpendicular wall which is not subjected to excessive temperature vibration humidity dust corrosive gas explosive gas etc or within an appropriate enclosure rated for outside installation to safeguard against moisture dust and excessive heat The power leads to the...

Page 33: ...05 41 110 43 APPROXIMATE DRY BULB TEMPERATURE 0 F 0 C D D C C B B A A CONTROL CURVE CONTROL POINT APPROX 0 F 0 C AT 50 RH A D C B 63 17 73 23 70 21 67 19 N1 N P1 P EXH Set EXH Min Pos IAQ Max IAQ IAQ Min Free Cool T T1 AQ1 AQ SO SO SR SR A B C D TR TR1 24 Vac HOT 24 Vac COM EF EF1 2 3 4 5 1 Exhaust Air Adjustment Screw Exhaust Air LED Damper Min Position Screw Indoor Air Quality Max Adjustment Scr...

Page 34: ...ir decreases In order to use the indoor blower tables for high altitude applications certain corrections are necessary A centrifugal fan is a constant volume device This means that if the rpm remains constant the CFM delivered is the same regardless of the density of the air However since the air at high altitude is less dense less static pressure will be generated and less power will be required ...

Page 35: ...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 1 5 832 1 80 Enter the blower table at 6000 sCFM and static pressure of 1 8 The rpm listed will be the same rpm needed at 5 000 ft Suppose that the corresponding BHP listed in the table is 3 2 This value must be corrected for elevation BHP at 5 000 ft ...

Page 36: ... 5 0 HP motor The 7 5 HP motor is required 6 1020 RPM is within the range of the 7 5 HP drives 7 Using the 7 5 HP motor and drive 3 5 turns open will achieve 1020 RPM Example Supply Air Blower Performance Air Flow CFM Available External Static Pressure IWG 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP...

Page 37: ...ormance 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 continuous BHP 3 kW BHP x 0 838 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP Field ...

Page 38: ... 4 85 6000 699 2 11 735 2 60 772 3 06 808 3 49 844 3 88 879 4 24 913 4 55 946 4 80 977 5 01 1007 5 15 1036 5 24 1062 5 25 6400 719 2 55 756 3 03 792 3 49 828 3 92 864 4 32 899 4 67 933 4 98 966 5 24 998 5 45 1028 5 59 1056 5 67 1083 5 68 6800 742 3 02 778 3 51 814 3 97 850 4 40 886 4 79 921 5 15 955 5 46 988 5 72 1020 5 92 1050 6 07 1078 6 15 1105 6 16 7200 765 3 54 802 4 03 838 4 49 874 4 92 910 ...

Page 39: ...97 14 35 1129 14 92 1160 15 47 1192 15 98 1223 16 47 1255 16 94 High Static 15 HP Drive 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 continuous BHP 3 kW BHP x 0 82 2 0 2 2 2 4...

Page 40: ...ance 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 continuous BHP 3 kW BHP x 0 838 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 2 6 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 5 HP Field Sup...

Page 41: ... 53 1017 4 67 1045 4 74 1071 4 75 6000 734 2 25 770 2 70 806 3 13 841 3 53 877 3 90 911 4 23 944 4 52 977 4 77 1008 4 96 1038 5 09 1066 5 17 1092 5 18 6400 757 2 71 793 3 17 829 3 60 864 4 00 899 4 37 934 4 70 967 4 99 1000 5 23 1031 5 42 1060 5 56 1088 5 64 1114 5 65 6800 781 3 22 817 3 68 853 4 11 888 4 51 923 4 88 958 5 21 991 5 50 1024 5 74 1055 5 94 1085 6 07 1112 6 15 1139 6 16 7200 807 3 78...

Page 42: ... 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 continuous BHP 3 kW BHP x 0 82 1 8 2 0 2 2 2 4 2 6 2 8 3 0 3 2 3 4 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Standard 10 HP Drive High Static 15 HP Drive 6600 1006 6 07 1039...

Page 43: ...110 730 765 800 835 870 905 N A 7 5 8 63 1VP60 BK090 905 950 990 1035 1075 1120 N A J20 20 ZJ 5 5 75 1VP60 BK110 730 765 800 835 870 905 N A 7 5 8 63 1VP60 BK090 905 950 990 1035 1075 1120 N A J25 25 ZJ 7 5 8 63 1VP60 1B5V94 810 850 885 920 960 1000 N A 10 11 50 1VP75X 1B5V110 975 1005 1040 1070 1100 1135 1165 15 17 25 1VP75X 1B5V94 1140 1180 1215 1255 1290 1330 1365 Table 18 Indoor Blower Specifi...

Page 44: ...t Figure 18 4 Tighten blower pulley and motor sheave set screws after any adjustments Re check set screws after 10 12 hours run time recommended Failure to properly adjust the total system air quantity can result in extensive blower damage Pressure Drop Across A Dry Indoor Coil VS Supply Air CFM 0 0 05 0 1 0 15 0 2 0 25 0 3 0 35 0 4 0 45 4000 5000 6000 7000 8000 9000 10000 11000 12000 Nominal Air ...

Page 45: ...to put the unit into Occupied Mode Additionally the unit can be switched between Unoccupied Occupied mode through network communications with Simplicity PC and other BAS control systems Figure 21 Occupied Jumper Once placed into the Occupied Mode the speed of the indoor blower motor is controlled by duct static pressure The Duct Static set point default 1 5 is the pressure that the VFD drive will ...

Page 46: ...low the set point of the enthalpy controller previously determined Y1 energizes the economizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enthalpy is above the set point Y1 energizes compressor 1 When the thermostat calls for second stage cooling the low voltage control circuit from R to Y2 is completed The UC...

Page 47: ...ition of the economizer actuator s auxiliary switch adjustment screw The adjustment screw represents the outdoor damper position at which to activate power exhaust and can be set between 25 to 85 degrees open The outlet pressure of the power exhaust fan forces the barometric relief dampers open gravity closes the dampers when the exhaust fan is off Motorized Outdoor Air Dampers This system operati...

Page 48: ...ly the associated system will be affected by any safety preventive action The other refrigerant system will continue in operation unless it is affected by the fault as well The unit control board monitors the temperature limit switch of electric heat units and the temperature limit switch and the gas valve of gas furnace units Compressor Protection In addition to the external pressure switches the...

Page 49: ...rature indicated in the Limit Control Setting Table 20 It is a manual reset limit These limit switches will de energize the heaters should the primary limit fail to open or the contactors fail to open in a failure mode Flash Codes The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 25 Reset Remove the call for heating by lowerin...

Page 50: ... then IC2 will lock out first stage furnace operation for five minutes or until 24V power is removed from the module either at the unit or by resetting the room thermostat NOTE That the second stage furnace can operate even if first stage has locked out When the thermostat satisfies de energizing the RW2 and RW1 thus opening all gas valves The blower motor will continue to run after the furnace is...

Page 51: ... lock out furnace operation until 24V power is removed from the module either at the unit or by resetting the room thermostat Rollout Switch This switch is located above the main burners in the control compartment which in the event of a sustained main burner rollout shuts off and locks out both ignition controls closing both gas valves The ignition controls lock out furnace operation until 24V po...

Page 52: ...est setting 3 Turn gas valve knob or switch to ON position See Figure 26 4 Turn ON electric power to unit 5 Set room thermostat to desired temperature If thermostat set temperature is above room temperature pilot burner ignition will occur and after an interval to prove pilot flame main burners will ignite Post Start Checklist After the entire control circuit has been energized and the heating sec...

Page 53: ...table above headed 1 Cubic Foot where you will see that 278 cubic feet of gas per hour are consumed by the furnace at that rate Multiply 278 x 1050 the Btu rating of the gas obtained from the local gas company The result is 292 425 Btuh which is close to the 300 000 Btuh rating of the furnace Manifold Gas Pressure Adjustment Small adjustments to the high fire gas flow may be made by turning the pr...

Page 54: ... sure all controls function properly Burner Instruction To check or change burners pilot or orifices CLOSE MAIN MANUAL SHUT OFF VALVE AND SHUT OFF ALL ELECTRIC POWER TO THE UNIT 1 Remove the screws holding either end of the manifold to the burner supports 2 Open the union fitting in the gas supply line just upstream of the unit gas valve and downstream from the main manual shut off valve 3 Remove ...

Page 55: ...0 340 360 380 400 420 440 460 480 500 110 115 120 125 130 135 140 145 150 155 160 165 170 Suction Pressure psig Discharge Pressure psig 95 F Outdoor 85 F Outdoor 75 F Outdoor 65 F Outdoor 105 F Outdoor 115 F Outdoor 20 Ton Charging Chart 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 110 115 120 125 130 135 140 145 150 155 160 165 170 Suction Pressure psig Discharge Pressure psig ...

Page 56: ...e thermostat and the UCB i e that the thermostat G terminal is connected to the G terminal of the UCB and for loose wiring 9 If the thermostat and UCB are properly wired replace the UCB On calls for cooling the supply air blower motor is operating but compressor 1 is not the room thermostat fan switch is in the AUTO position 1 If installed check the position of the economizer blades If the blades ...

Page 57: ...te N Lock plug to the economizer back to the Mate N Lock plug and from the Mate N Lock plug to the Y1 ECON terminal If nothing is found the economizer control may have faulted and is failing to return the 24 volt call to the Y1 ECON terminal even though the economizer is not providing free cooling To test disconnect the Mate N Locks and jumper between the WHITE and YELLOW wires of the UCB s Mate N...

Page 58: ...unavailable for cooling calls Check the UCB for alarms indicating that compressor 1 is locked out Press and release the ALARMS button if the LED is not flashing an alarm 2 Check for line voltage at the compressor contactor M1 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor 3 If M1 is pulled in and voltage is supplied at M1 lightly touch the compr...

Page 59: ...oubleshooting Guide 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 9 2 If the supply air blower motor does not energize when the fan switch is set to ON...

Page 60: ... problem and correct 2 Check all 24 volt connections from the relay board to and in the gas heat section Check low voltage connections to the ETD located in the control box 3 If the furnace is hot it may be out on an over temperature condition wait for limit reset 4 If the furnace is cold check for 24 volts at wire 241 attached to the electrical time delay ETD located in the main control box If 24...

Page 61: ...page 54 2 Check the main burner orifices for obstruction and alignment Removal procedure is described in BURNER INSTRUCTIONS page 54 Clean or replace burner orifices and burners as needed Unit Control Board Flash Codes Various flash codes are utilized by the unit control board UCB to aid in troubleshooting Flash codes are distinguished by the short on and off cycle used approximately 200ms on and ...

Page 62: ...Flashes Compressors Locked Out on Low Outdoor Air Temperature1 Flashing On Off On Off 11 Flashes Compressors locked out because the Economizer is using free Cooling1 Flashing On Off On On 12 Flashes Unit Locked Out due to Fan Overload Switch Failure Off On On Off Off 13 Flashes Compressor Held Off due to Low Voltage1 Flashing On On Off On 14 Flashes EEPROM Storage Failure Off On On On Off 15 Flash...

Page 63: ...layed value push the OPTION SETUP STORE button and hold it for at least 2 seconds When the value is saved the red LED will flash a few times and then normal display will resume NOTE While in either Setup mode if no buttons are pushed for 60 seconds the display will revert to its normal display exiting the Option Setup mode When saving the control board only saves the parameters for the currently d...

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Johnson Controls ZJ SERIES, Installation Manual

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