Johnson Controls ZY Series Installation Manual Download

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5943357-UIM-A-1020

York International Corporation, 5005

York Drive, Norman, OK 73069

2020-10-01

Johnson Controls Ducted Systems

INSTALLATION MANUAL ZY SERIES

3 - 10 ton 60 Hertz R-410A

Summary of Contents for ZY Series

Page 1: ...5943357 UIM A 1020 York International Corporation 5005 York Drive Norman OK 73069 2020 10 01 Johnson Controls Ducted Systems INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A ...

Page 2: ...2 INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A Johnson Controls Ducted Systems ...

Page 3: ...er Specifications 97 Everyday Thermostat Control ETC 100 Smart Equipment unit control board 104 Operation 109 Cooling sequence of operation 109 Electric Heating Sequence of Operations 112 Electric Heat Operating Errors 112 Gas Heating Sequence of Operations 112 Gas Heat Operation Errors 113 Indoor Air Quality AQ 118 Gas Heating Operation 118 Gas Heat Ignition Control Board Function 119 Ignition Co...

Page 4: ...roubleshooting 129 Charging Tables 132 Smart Equipment Control Board Navigation Components 138 Start Up Sheet 139 INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 4 Johnson Controls Ducted Systems ...

Page 5: ... compliance with the installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes WARNING Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury Improper installation adjustment alteration service or maintenance can cause injury o...

Page 6: ... damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing CAUTION 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...

Page 7: ... 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 WARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage CAUTION This system uses R 410A Refrigerant which ope...

Page 8: ...Nomenclature INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 8 Johnson Controls Ducted Systems ...

Page 9: ...s under construction WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life P...

Page 10: ...e sensor relocation Figure 3 Supply air temperature sensor 6 For units equipped with an economizer or motorized OD air damper you must move the return air temperature RAT sensor to the working position to ensure proper RAT readings See Item B in Figure 5 a Move the RAT sensor to the inside of the return air duct verifying that the sensor is at least 6 in below the unit duct opening The sensor must...

Page 11: ... sensor C Flex tube in the working position Limitations These units must be installed in accordance with the following In U S A National Electrical Code ANSI NFPA No 70 Latest Edition National Fuel Gas Code ANSI Z223 1 Latest Edition Gas Fired Central Furnace Standard ANSI Z21 47a Latest Edition Local building codes and Local gas utility requirements In Canada Canadian Electrical Code CSA C22 1 In...

Page 12: ...7 252 125 460 3 60 5 432 504 125 ZY 04 3 575 3 60 5 540 630 125 208 230 1 60 5 187 252 125 208 230 3 60 5 187 252 125 460 3 60 5 432 504 125 ZY 05 4 575 3 60 5 540 630 125 208 230 1 60 5 187 252 125 208 230 3 60 5 187 252 125 460 3 60 5 432 504 125 ZY 06 5 575 3 60 5 540 630 125 208 230 3 60 5 187 252 125 460 3 60 5 432 504 125 ZY 07 6 575 3 60 5 540 630 125 208 230 3 60 5 187 252 125 460 3 60 5 4...

Page 13: ...ust make provisions for adequate combustion and ventilation air in accordance with section 5 3 of Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 Latest Edition in 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 4 and Table 5 for clearances required fo...

Page 14: ...ZYE 08 7 5 873 868 46 36 236 268 193 171 154 167 182 132 121 111 ZYE 09 8 5 878 878 46 36 241 265 195 177 158 168 180 132 124 116 ZYE 12 10 907 902 47 36 239 278 207 178 155 171 190 142 128 116 ZYG 04 3 532 527 36 27 147 136 117 126 99 94 90 77 81 85 ZYG 05 4 623 618 36 26 167 156 142 152 113 108 103 94 98 103 ZYG 06 5 641 636 35 26 174 159 144 159 118 111 104 95 101 108 ZYG 07 6 800 795 43 37 237...

Page 15: ...t 55 Power Exhaust Vert Flow Large Footprint 75 Power Exhaust Horiz Flow Small Footprint 40 Power Exhaust Horiz Flow Large Footprint 80 Hail Guard Kit Small Short Factory Installed 18 Hail Guard Kit Small Tall Factory Installed 23 Hail Guard Kit Large Short Factory Installed 36 Hail Guard Kit Large Tall Factory Installed 44 Flue Extension Kit 1FE0414 15 Flue Extension Kit 1FE0415 17 Flue Extension...

Page 16: ...Figure 11 ZY04 Unit Dimensions INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 16 Johnson Controls Ducted Systems ...

Page 17: ...Figure 12 ZY05 06 Unit Dimensions INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 17 Johnson Controls Ducted Systems ...

Page 18: ...Figure 13 ZY07 and ZYA7 Unit Dimensions INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 18 Johnson Controls Ducted Systems ...

Page 19: ...Figure 14 ZY08 09 Unit Dimensions INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 19 Johnson Controls Ducted Systems ...

Page 20: ...Figure 15 ZY12 Unit Dimensions INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 20 Johnson Controls Ducted Systems ...

Page 21: ... 4 1 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser air discharge outlet 2 Units without economizer or power exhaust 3 Units equipped with an Economizer or Power Exhaust Flue products must not be discharged within 10 Feet of the rear of the unit 4 Units may be installed on combustible floors made from wood or class A B or C roof covering materials ...

Page 22: ... required through the base of the unit or through the roof curb the following field installed accessories can be purchased through your dealer or contractor 1TB0401 through the base electrical and through the curb gas 1TB0403 through the base electrical and gas INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 22 Johnson Controls Ducted Systems ...

Page 23: ...r changes are necessary For side duct application remove the side duct covers and install over the bottom duct openings The panels removed from the side duct connections are designed to be reused by securing each panel to its respective bottom duct opening But keep in mind that the supply and return panels are installed with the painted surface DOWN facing the bottom duct opening The gasket must b...

Page 24: ...imes as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere CAUTION Do not leave the system open to the atmosphere Unit damage could occur due to moisture being absorbed by the refrigerant in the system This type of oil is highly susceptible to moisture absorption R 410A compressor lubricants are known to cau...

Page 25: ... 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 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 CAUTION When connecting electrical power and control wiring to the unit...

Page 26: ... Wire size Maximum length ft 1 20 AWG 150 18 AWG 150 to 250 16 AWG 250 to 500 Note 1 From the unit to the thermostat and back to the unit INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 26 Johnson Controls Ducted Systems ...

Page 27: ...al field power and control wiring Typical Power Wiring Figure 22 Everyday Thermostat Control ETC typical power wiring INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 27 Johnson Controls Ducted Systems ...

Page 28: ...Figure 23 Typical Smart Equipment Control Wiring INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 28 Johnson Controls Ducted Systems ...

Page 29: ...5 12 43 10646 6 1 7 2 13 15 15 12 42 13 6 15 15 13 43 11146 11 5 1 13 8 21 3 25 25 20 42 21 9 25 25 20 43 460 3 60 5 8 38 9 0 8 3 2 0 5 11446 14 1 16 8 25 25 25 23 42 25 6 30 30 24 43 None 7 8 15 15 8 39 8 2 15 15 8 40 11058 9 2 1 8 9 14 1 15 15 13 39 14 6 15 15 13 40 04 3 575 3 60 3 8 36 5 6 0 6 6 0 4 11458 13 8 1 13 3 19 6 20 20 18 39 20 1 25 25 19 40 None 37 1 40 50 36 122 38 6 40 60 38 126 106...

Page 30: ...1 39 5 8 1 1 7 6 0 4 12358 23 1 22 1 31 4 35 35 29 43 31 9 35 35 29 44 None 33 6 35 50 33 165 35 8 40 50 36 175 10725 4 9 1 13 6 33 6 35 50 33 165 35 8 40 50 36 175 11725 12 1 33 3 48 1 50 50 44 165 50 9 60 60 47 175 208 3 60 19 123 30 2 3 5 2 1 1 12525 18 6 1 51 6 71 80 80 65 165 73 8 80 80 68 175 None 33 6 35 50 33 168 35 6 40 50 35 163 10725 6 5 1 15 6 33 6 35 50 33 168 35 6 40 50 35 163 11725 ...

Page 31: ...46 33 1 39 7 52 9 60 60 49 106 54 1 60 60 50 103 460 3 60 6 1 41 10 6 1 41 10 1 3 2 6 0 5 14246 41 7 2 50 2 66 70 70 61 106 67 3 70 70 62 103 None 13 7 15 15 14 85 14 5 15 15 15 83 11758 17 1 16 4 23 25 25 21 85 24 25 25 22 83 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 0 4 13458 34 1 32 7 43 4 45 45 40 85 44 4 45 45 41 83 None 40 6 45 50 43 208 42 8 45 50 45 218 11725 12 1 33 3 48 1 50 50 44 208 50 9...

Page 32: ...19 8 28 30 30 26 128 29 3 30 30 27 130 12846 27 8 1 33 4 45 45 45 41 128 46 3 50 50 43 130 13346 33 1 39 7 52 9 60 60 49 128 54 1 60 60 50 130 460 3 60 7 8 52 12 7 8 52 12 2 9 2 6 0 5 14246 41 7 2 50 2 66 70 70 61 128 67 3 70 70 62 130 None 17 20 20 18 99 17 8 20 20 19 101 11758 17 1 16 4 23 25 25 21 99 24 25 25 22 101 12 10 575 3 60 5 7 38 9 9 5 7 38 9 9 2 2 2 0 4 13458 34 1 32 7 43 4 45 45 40 99...

Page 33: ...3 1 39 7 54 1 60 60 50 125 55 4 60 60 51 121 460 3 60 6 1 41 10 6 1 41 10 1 3 3 6 0 5 14246 41 7 2 50 2 67 3 70 70 62 125 68 5 70 70 63 121 None 14 2 15 15 15 93 15 15 15 16 90 11758 17 1 16 4 23 6 25 25 22 93 24 6 25 25 23 90 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 5 0 4 13458 34 1 32 7 44 45 45 40 93 45 45 45 41 90 None 42 4 45 50 45 246 44 6 45 50 47 256 11725 12 1 33 3 50 4 60 60 46 246 53 1 6...

Page 34: ...301 59 6 60 60 55 305 12525 24 8 1 59 7 83 6 90 90 77 301 86 1 90 90 79 305 13225 32 1 77 105 3 110 110 97 301 107 8 110 110 99 305 230 3 60 16 110 25 16 110 25 5 2 7 2 1 14225 42 4 2 102 136 5 150 150 126 301 139 150 150 128 305 None 24 1 25 30 25 146 25 1 30 30 27 148 11746 16 5 1 19 8 29 3 30 30 27 146 30 5 35 35 28 148 12846 27 8 1 33 4 46 3 50 50 43 146 47 5 50 50 44 148 13346 33 1 39 7 54 1 ...

Page 35: ...0 14 44 16 3 20 20 15 45 11146 11 5 1 13 8 23 9 25 25 22 44 24 6 25 25 23 45 460 3 60 5 8 38 9 0 8 3 2 0 5 8 6 11446 14 1 16 8 27 7 30 30 25 44 28 3 30 30 26 45 None 9 5 15 15 10 41 9 9 15 15 10 41 11058 9 2 1 8 9 16 3 20 20 15 41 16 8 20 20 15 41 04 3 575 3 60 3 8 36 5 6 0 6 6 0 4 8 6 11458 13 8 1 13 3 21 8 25 25 20 41 22 3 25 25 20 41 None 41 4 45 60 41 127 42 9 45 60 43 130 10625 4 9 1 23 6 45 ...

Page 36: ... 1 1 7 6 0 4 8 6 12358 23 1 22 1 33 6 35 35 31 44 34 1 35 35 31 45 None 37 9 40 50 38 169 40 1 45 50 41 179 10725 4 9 1 13 6 37 9 40 50 38 169 40 1 45 50 41 179 11725 12 1 33 3 53 5 60 60 49 169 56 3 60 60 52 179 208 3 60 19 123 30 2 3 5 2 1 1 8 6 12525 18 6 1 51 6 76 4 80 80 70 169 79 1 80 80 73 179 None 37 9 40 50 38 172 39 9 40 50 40 167 10725 6 5 1 15 6 37 9 40 50 38 172 39 9 40 50 40 167 1172...

Page 37: ...6 60 60 51 108 56 8 60 60 52 105 460 3 60 6 1 41 10 6 1 41 10 1 3 2 6 0 5 8 6 14246 41 7 2 50 2 68 7 70 70 63 108 69 9 70 70 64 105 None 15 4 20 20 16 87 16 2 20 20 17 84 11758 17 1 16 4 25 2 30 30 23 87 26 2 30 30 24 84 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 0 4 8 6 13458 34 1 32 7 45 5 50 50 42 87 46 5 50 50 43 84 None 44 9 45 50 48 212 47 1 50 50 50 222 11725 12 1 33 3 53 5 60 60 49 212 56 3 6...

Page 38: ...35 28 130 31 9 35 35 29 132 12846 27 8 1 33 4 47 7 50 50 44 130 48 9 50 50 45 132 13346 33 1 39 7 55 6 60 60 51 130 56 8 60 60 52 132 460 3 60 7 8 52 12 7 8 52 12 2 9 2 6 0 5 8 6 14246 41 7 2 50 2 68 7 70 70 63 130 69 9 70 70 64 132 None 18 7 20 20 20 101 19 5 20 20 21 103 11758 17 1 16 4 25 2 30 30 23 101 26 2 30 30 24 103 12 10 575 3 60 5 7 38 9 9 5 7 38 9 9 2 2 2 0 4 8 6 13458 34 1 32 7 45 5 50...

Page 39: ... 60 60 52 127 58 1 60 60 53 123 460 3 60 6 1 41 10 6 1 41 10 1 3 3 6 0 5 8 6 14246 41 7 2 50 2 69 9 70 70 64 127 71 2 80 80 65 123 None 15 9 20 20 17 95 16 7 20 20 18 92 11758 17 1 16 4 25 8 30 30 24 95 26 8 30 30 25 92 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 5 0 4 8 6 13458 34 1 32 7 46 2 50 50 42 95 47 2 50 50 43 92 None 46 7 50 60 50 250 48 9 50 60 52 260 11725 12 1 33 3 55 8 60 60 51 250 58 5 ...

Page 40: ...65 70 70 60 310 12525 24 8 1 59 7 89 90 90 82 305 91 5 100 100 84 310 13225 32 1 77 110 6 125 125 102 305 113 1 125 125 104 310 230 3 60 16 110 25 16 110 25 5 2 7 2 1 8 6 14225 42 4 2 102 141 9 150 150 131 305 144 4 150 150 133 310 None 26 3 30 30 28 148 27 3 30 30 29 150 11746 16 5 1 19 8 31 9 35 35 29 148 33 2 35 35 31 150 12846 27 8 1 33 4 48 9 50 50 45 148 50 2 60 60 46 150 13346 33 1 39 7 56 ...

Page 41: ...4 10646 6 1 7 2 12 3 15 15 11 52 12 9 15 15 12 54 11146 11 5 1 13 8 20 5 25 25 19 52 21 1 25 25 19 54 460 3 60 5 8 38 9 0 8 2 6 0 5 11446 14 1 16 8 24 3 25 25 22 52 24 9 25 25 23 54 None 7 4 15 15 7 48 7 8 15 15 8 49 11058 9 2 1 8 9 13 6 15 15 13 48 14 1 15 15 13 49 04 3 575 3 60 3 8 36 5 6 0 6 2 0 4 11458 13 8 1 13 3 19 1 20 20 18 48 19 6 20 20 18 49 None 36 3 40 50 35 153 37 8 40 50 37 157 10625...

Page 42: ... 39 5 8 1 1 2 5 0 4 12358 23 1 22 1 30 8 35 35 28 60 31 3 35 35 29 60 None 35 9 40 50 36 191 38 1 40 50 38 201 10725 4 9 1 13 6 35 9 40 50 36 191 38 1 40 50 38 201 11725 12 1 33 3 51 60 60 47 191 53 8 60 60 49 201 208 3 60 19 123 30 2 3 7 5 1 1 12525 18 6 1 51 6 73 9 80 80 68 191 76 6 80 80 70 201 None 35 9 40 50 36 198 37 9 40 50 38 193 10725 6 5 1 15 6 35 9 40 50 36 198 37 9 40 50 38 193 11725 1...

Page 43: ...46 33 1 39 7 52 9 60 60 49 106 54 1 60 60 50 103 460 3 60 6 1 41 10 6 1 41 10 1 3 2 6 0 5 14246 41 7 2 50 2 66 70 70 61 106 67 3 70 70 62 103 None 13 7 15 15 14 85 14 5 15 15 15 83 11758 17 1 16 4 23 25 25 21 85 24 25 25 22 83 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 0 4 13458 34 1 32 7 43 4 45 45 40 85 44 4 45 45 41 83 None 40 6 45 50 43 208 42 8 45 50 45 218 11725 12 1 33 3 48 1 50 50 44 208 50 9...

Page 44: ...8 35 35 28 150 32 35 35 29 152 12846 27 8 1 33 4 47 8 50 50 44 150 49 50 50 45 152 13346 33 1 39 7 55 6 60 60 51 150 56 9 60 60 52 152 460 3 60 7 8 52 12 7 8 52 12 2 9 4 8 0 5 14246 41 7 2 50 2 68 8 70 70 63 150 70 70 70 64 152 None 18 4 20 20 20 117 19 2 20 20 20 119 11758 17 1 16 4 24 8 25 25 23 117 25 8 30 30 24 119 12 10 575 3 60 5 7 38 9 9 5 7 38 9 9 2 2 3 4 0 4 13458 34 1 32 7 45 1 50 50 42 ...

Page 45: ...3 1 39 7 54 1 60 60 50 125 55 4 60 60 51 121 460 3 60 6 1 41 10 6 1 41 10 1 3 3 6 0 5 14246 41 7 2 50 2 67 3 70 70 62 125 68 5 70 70 63 121 None 14 2 15 15 15 93 15 15 15 16 90 11758 17 1 16 4 23 6 25 25 22 93 24 6 25 25 23 90 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 5 0 4 13458 34 1 32 7 44 45 45 40 93 45 45 45 41 90 None 42 4 45 50 45 246 44 6 45 50 47 256 11725 12 1 33 3 50 4 60 60 46 246 53 1 6...

Page 46: ...320 62 4 70 70 57 324 12525 24 8 1 59 7 86 4 90 90 79 320 88 9 90 90 82 324 13225 32 1 77 108 110 110 99 320 110 5 125 125 102 324 230 3 60 16 110 25 16 110 25 5 2 9 4 1 14225 42 4 2 102 139 3 150 150 128 320 141 8 150 150 130 324 None 25 2 30 30 27 155 26 2 30 30 28 158 11746 16 5 1 19 8 30 6 35 35 28 155 31 9 35 35 29 158 12846 27 8 1 33 4 47 6 50 50 44 155 48 9 50 50 45 158 13346 33 1 39 7 55 5...

Page 47: ...1 7 2 14 9 15 15 14 55 15 6 20 20 14 56 11146 11 5 1 13 8 23 2 25 25 21 55 23 8 25 25 22 56 460 3 60 5 8 38 9 0 8 2 6 0 5 8 6 11446 14 1 16 8 26 9 30 30 25 55 27 6 30 30 25 56 None 9 1 15 15 9 50 9 5 15 15 10 51 11058 9 2 1 8 9 15 8 20 20 15 50 16 3 20 20 15 51 04 3 575 3 60 3 8 36 5 6 0 6 2 0 4 8 6 11458 13 8 1 13 3 21 3 25 25 20 50 21 8 25 25 20 51 None 40 6 45 60 40 158 42 1 45 60 42 161 10625 ...

Page 48: ...358 23 1 22 1 32 9 35 35 30 61 33 4 35 35 31 62 None 40 2 45 50 41 195 42 4 45 60 43 205 10725 4 9 1 13 6 40 2 45 50 41 195 42 4 45 60 43 205 11725 12 1 33 3 56 4 60 60 52 195 59 1 60 60 54 205 208 3 60 19 123 30 2 3 7 5 1 1 8 6 12525 18 6 1 51 6 79 3 80 80 73 195 82 90 90 75 205 None 40 2 45 50 41 202 42 2 45 60 43 197 10725 6 5 1 15 6 40 2 45 50 41 202 42 2 45 60 43 197 11725 16 1 38 5 62 9 70 7...

Page 49: ... 60 60 51 108 56 8 60 60 52 105 460 3 60 6 1 41 10 6 1 41 10 1 3 2 6 0 5 8 6 14246 41 7 2 50 2 68 7 70 70 63 108 69 9 70 70 64 105 None 15 4 20 20 16 87 16 2 20 20 17 84 11758 17 1 16 4 25 2 30 30 23 87 26 2 30 30 24 84 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 0 4 8 6 13458 34 1 32 7 45 5 50 50 42 87 46 5 50 50 43 84 None 44 9 45 50 48 212 47 1 50 50 50 222 11725 12 1 33 3 53 5 60 60 49 212 56 3 60...

Page 50: ... 35 35 31 152 34 7 35 35 32 154 12846 27 8 1 33 4 50 4 60 60 46 152 51 7 60 60 48 154 13346 33 1 39 7 58 3 60 60 54 152 59 6 60 60 55 154 460 3 60 7 8 52 12 7 8 52 12 2 9 4 8 0 5 8 6 14246 41 7 2 50 2 71 4 80 80 66 152 72 7 80 80 67 154 None 20 1 25 25 22 118 20 9 25 25 22 120 11758 17 1 16 4 26 9 30 30 25 118 27 9 30 30 26 120 12 10 575 3 60 5 7 38 9 9 5 7 38 9 9 2 2 3 4 0 4 8 6 13458 34 1 32 7 4...

Page 51: ...60 60 52 127 58 1 60 60 53 123 460 3 60 6 1 41 10 6 1 41 10 1 3 3 6 0 5 8 6 14246 41 7 2 50 2 69 9 70 70 64 127 71 2 80 80 65 123 None 15 9 20 20 17 95 16 7 20 20 18 92 11758 17 1 16 4 25 8 30 30 24 95 26 8 30 30 25 92 08 7 5 575 3 60 4 2 33 7 4 2 33 7 1 1 2 5 0 4 8 6 13458 34 1 32 7 46 2 50 50 42 95 47 2 50 50 43 92 None 46 7 50 60 50 250 48 9 50 60 52 260 11725 12 1 33 3 55 8 60 60 51 250 58 5 6...

Page 52: ...8 70 70 62 329 12525 24 8 1 59 7 91 8 100 100 84 324 94 3 100 100 87 329 13225 32 1 77 113 4 125 125 104 324 115 9 125 125 107 329 230 3 60 16 110 25 16 110 25 5 2 9 4 1 8 6 14225 42 4 2 102 144 6 150 150 133 324 147 1 150 150 135 329 None 27 4 30 35 29 157 28 4 30 35 30 160 11746 16 5 1 19 8 33 3 35 35 31 157 34 6 35 35 32 160 12846 27 8 1 33 4 50 3 60 60 46 157 51 6 60 60 47 160 13346 33 1 39 7 ...

Page 53: ...7 8 30 40 27 137 11125 7 9 1 21 9 36 8 40 40 34 135 38 1 40 40 35 137 208 3 60 13 7 83 1 21 1 4 7 5 1 1 11625 12 1 33 3 51 60 60 47 135 52 4 60 60 48 137 None 26 30 35 26 141 27 30 40 27 144 10625 6 5 1 15 6 28 9 30 35 27 141 30 1 35 40 28 144 11125 10 5 1 25 3 41 45 45 38 141 42 3 45 45 39 144 230 3 60 13 7 83 1 21 1 4 7 5 1 11625 16 1 38 5 57 5 60 60 53 141 58 8 60 60 54 144 None 12 15 15 12 70 ...

Page 54: ...one 36 8 40 50 37 215 38 8 40 50 40 220 10725 6 5 1 15 6 36 8 40 50 37 215 38 8 40 50 40 220 11725 16 1 38 5 60 9 70 70 56 215 63 4 70 70 58 220 230 3 60 17 6 136 27 2 3 10 2 1 12525 24 8 1 59 7 87 4 90 90 80 215 89 9 90 90 83 220 None 18 20 25 18 106 19 20 25 19 109 10746 6 1 7 2 18 20 25 14 106 19 20 25 15 109 11746 16 5 1 19 8 30 8 35 35 28 106 32 35 35 29 109 460 3 60 8 5 66 1 13 1 3 4 8 0 5 1...

Page 55: ...7 103 17 2 20 20 18 100 11758 17 1 16 4 24 8 25 25 23 103 25 8 30 30 24 100 09 8 5 575 3 60 4 8 33 8 4 8 33 8 1 1 3 4 0 4 13458 34 1 32 7 45 1 50 50 42 103 46 1 50 50 42 100 None 56 7 60 70 61 323 58 9 60 70 63 333 11725 12 1 33 3 60 3 70 70 61 323 63 70 70 63 333 12525 18 6 1 51 6 83 1 90 90 76 323 85 9 90 90 79 333 13225 24 1 66 6 101 9 110 110 94 323 104 6 110 110 96 333 208 3 60 16 110 25 16 1...

Page 56: ... 45 41 112 45 5 50 50 42 114 None 14 4 15 20 15 100 15 2 20 20 16 102 11758 17 1 16 4 25 9 30 30 24 100 26 9 30 30 25 102 A7 6 575 3 60 6 3 55 3 10 1 1 4 3 0 4 12658 25 7 1 24 7 36 3 40 40 33 100 37 3 40 40 34 102 None 45 1 50 50 48 258 47 3 50 50 50 268 11725 12 1 33 3 54 60 60 50 258 56 8 60 60 52 268 12525 18 6 1 51 6 76 9 80 80 71 258 79 6 80 80 73 268 13225 24 1 66 6 95 6 100 100 88 258 98 4 ...

Page 57: ...0 19 115 18 1 20 20 19 113 11758 17 1 16 4 25 9 30 30 24 115 26 9 30 30 25 113 09 8 5 575 3 60 4 8 33 8 4 8 33 8 1 1 4 3 0 4 13458 34 1 32 7 46 3 50 50 43 115 47 3 50 50 43 113 None 55 3 60 70 59 345 57 5 60 70 62 355 11725 12 1 33 3 58 5 60 70 59 345 61 3 70 70 62 355 12525 18 6 1 51 6 81 4 90 90 75 345 84 1 90 90 77 355 13225 24 1 66 6 100 1 110 110 92 345 102 9 110 110 95 355 208 3 60 16 110 25...

Page 58: ...42 11125 7 9 1 21 9 42 1 45 45 39 139 43 5 45 45 40 142 208 3 60 13 7 83 1 21 1 4 7 5 1 1 8 6 11625 12 1 33 3 56 4 60 60 52 139 57 8 60 60 53 142 None 30 3 35 40 31 146 31 3 35 45 32 148 10625 6 5 1 15 6 34 3 35 40 32 146 35 5 40 45 33 148 11125 10 5 1 25 3 46 4 50 50 43 146 47 6 50 50 44 148 230 3 60 13 7 83 1 21 1 4 7 5 1 8 6 11625 16 1 38 5 62 9 70 70 58 146 64 1 70 70 59 148 None 14 2 15 20 14...

Page 59: ... 42 219 43 1 45 60 45 224 10725 6 5 1 15 6 41 1 45 50 42 219 43 1 45 60 45 224 11725 16 1 38 5 66 3 70 70 61 219 68 8 70 70 63 224 230 3 60 17 6 136 27 2 3 10 2 1 8 6 12525 24 8 1 59 7 92 8 100 100 85 219 95 3 100 100 88 224 None 20 2 25 25 21 109 21 2 25 25 22 111 10746 6 1 7 2 20 2 25 25 16 109 21 2 25 25 17 111 11746 16 5 1 19 8 33 4 35 35 31 109 34 7 35 35 32 111 460 3 60 8 5 66 1 13 1 3 4 8 0...

Page 60: ...9 105 18 9 20 20 20 102 11758 17 1 16 4 26 9 30 30 25 105 27 9 30 30 26 102 09 8 5 575 3 60 4 8 33 8 4 8 33 8 1 1 3 4 0 4 8 6 13458 34 1 32 7 47 3 50 50 43 105 48 3 50 50 44 102 None 61 70 70 66 328 63 2 70 70 68 338 11725 12 1 33 3 65 6 70 70 66 328 68 4 70 70 68 338 12525 18 6 1 51 6 88 5 90 90 81 328 91 3 100 100 84 338 13225 24 1 66 6 107 3 110 110 99 328 110 125 125 101 338 208 3 60 16 110 25...

Page 61: ...43 114 48 2 50 50 44 117 None 16 1 20 20 17 102 16 9 20 20 18 104 11758 17 1 16 4 28 30 30 26 102 29 30 30 27 104 A7 6 575 3 60 6 3 55 3 10 1 1 4 3 0 4 8 6 12658 25 7 1 24 7 38 4 40 40 35 102 39 4 40 40 36 104 None 49 4 50 60 53 262 51 6 60 60 55 272 11725 12 1 33 3 59 4 60 60 55 262 62 1 70 70 57 272 12525 18 6 1 51 6 82 3 90 90 76 262 85 90 90 78 272 13225 24 1 66 6 101 110 110 93 262 103 8 110 ...

Page 62: ... 117 19 8 20 20 21 114 11758 17 1 16 4 28 30 30 26 117 29 30 30 27 114 09 8 5 575 3 60 4 8 33 8 4 8 33 8 1 1 4 3 0 4 8 6 13458 34 1 32 7 48 4 50 50 45 117 49 4 50 50 45 114 None 59 6 60 70 64 349 61 8 70 70 66 359 11725 12 1 33 3 63 9 70 70 64 349 66 6 70 70 66 359 12525 18 6 1 51 6 86 8 90 90 80 349 89 5 90 90 82 359 13225 24 1 66 6 105 5 110 110 97 349 108 3 110 110 100 359 208 3 60 16 110 25 16...

Page 63: ...Heating Option L D M E Heating model Low Low NOx Low Med Low NOx Med 1st Stage Heat input K Btu 49 82 2nd Stage Heat input K Btu 56 70 90 112 1st Stage Heat output K Btu 39 66 2nd Stage Heat output K Btu 45 56 72 90 Steady state efficiency 80 80 80 80 No burners 2 2 3 3 No stages 1 2 1 2 Temperature Rise Range ºF 28 46 35 58 44 74 55 78 Gas Limit Setting ºF 150 150 140 140 AHRI HEATING PERFORMANCE...

Page 64: ...FAN DATA DIRECT DRIVE RPM 1050 1050 Airflow Option B C B C Quantity 1 1 1 1 Fan Size in 10 x 10 10 x 10 10 x 10 10 x 10 Type Centrifugal Centrifugal Motor Sheave 1VL34 1VL44 1VL34 1VL44 Blower Sheave AK46 AK46 AK46 AK46 Belt A39 A40 A39 A40 Motor Hp 1 Phase 1 5 1 5 Motor Max Bhp 3 Phase 2 4 2 4 2 4 2 4 RPM 1725 1725 1725 1725 EVAP FAN DATA BELT DRIVE Frame size 56Y 56Y 56Y 56Y FILTERS Quantity Siz...

Page 65: ...F Heating model Low Low NOx Low Med Low NOx Med High Low NOx High 1st Stage Heat input K Btu 49 82 100 2nd Stage Heat input K Btu 56 70 90 112 118 145 1st Stage Heat output K Btu 39 66 80 2nd Stage Heat output K Btu 45 56 72 90 94 116 Steady state efficiency 80 80 80 80 80 80 No burners 2 2 3 3 3 3 No stages 1 2 1 2 1 2 Temperature Rise Range ºF 21 35 26 43 33 56 41 69 44 73 49 77 Gas Limit Settin...

Page 66: ... DATA DIRECT DRIVE RPM 1050 1050 Airflow Option B C B C Quantity 1 1 1 1 Fan Size in 10 x 10 10 x 10 10 x 10 10 x 10 Type Centrifugal Centrifugal Motor Sheave 1VL34 1VL44 1VL44 1VL44 Blower Sheave AK46 AK46 AK46 AK46 Belt A39 A40 A39 A40 Motor Hp 1 Phase 1 5 1 5 Motor Max Bhp 3 Phase 2 4 2 9 2 4 2 9 RPM 1725 1725 1725 1725 EVAP FAN DATA BELT DRIVE Frame size 56Y 56Y 56Y 56Y FILTERS Quantity Size 1...

Page 67: ... F Heating model Low Low NOx Low Med Low NOx Med High Low NOx High 1st Stage Heat input K Btu 49 82 100 2nd Stage Heat input K Btu 56 70 90 112 118 145 1st Stage Heat output K Btu 39 66 80 2nd Stage Heat output K Btu 45 56 72 90 94 116 Steady state efficiency 80 80 80 80 80 80 No burners 2 2 3 3 3 3 No stages 1 2 1 2 1 2 Temperature Rise Range ºF 17 28 21 35 27 44 33 55 35 58 43 72 Gas Limit Setti...

Page 68: ... DATA DIRECT DRIVE RPM 1050 1050 Airflow Option B C B C Quantity 1 1 1 1 Fan Size in 11 x 10 11 x 10 11 x 10 11 x 10 Type Centrifugal Centrifugal Motor Sheave 1VL34 1VL44 1VL34 1VL44 Blower Sheave AK46 AK46 AK46 AK46 Belt A37 A39 A37 A39 Motor Hp 1 Phase 1 5 1 5 Motor Max Bhp 3 Phase 2 4 2 9 2 4 2 9 RPM 1750 1750 1750 1750 EVAP FAN DATA BELT DRIVE Frame size 56HZ 56Z 56HZ 56Z FILTERS Quantity Size...

Page 69: ... Gas Limit Setting ºF 140 140 160 AHRI HEATING PERFORMANCE Gas piping connection in 1 2 3 4 3 4 Length 87 2 87 2 Width 61 7 61 7 DIMENSIONS in Height 40 6 40 6 OPERATING WT lb 795 725 Type Scroll Scroll Quantity 1 1 COMPRESSORS Unit Capacity Steps 100 100 Face area Sq Ft 21 1 21 1 Rows 1 1 Fins per inch 23 23 Tube diameter in MM 1 20 1 20 CONDENSER COIL DATA Circuitry Type 2 pass Microchannel 2 pa...

Page 70: ...1VL34 1VL44 1VP50 Blower Sheave AK74 AK74 AK74 AK74 AK74 AK74 Belt A47 A48 A48 A47 A48 A48 Motor Max Bhp 3 Phase 2 4 2 9 3 7 2 4 2 9 3 7 RPM 1725 1725 1725 1725 1725 1725 EVAP FAN DATA BELT DRIVE Frame size 56Y 56Y 56HZ 56Y 56Y 56HZ FILTERS Quantity Size 1 4 16 x 20 x 2 1 4 16 x 20 x 2 1 1 2 in Throwaway Standard MERV 4 Minimum Efficiency Reporting Value INSTALLATION MANUAL ZY SERIES 3 10 ton 60 H...

Page 71: ...Gas Limit Setting ºF 140 140 160 AHRI HEATING PERFORMANCE 1 1 Gas piping connection in 1 2 3 4 3 4 Length 87 2 87 2 Width 61 7 61 7 DIMENSIONS in Height 40 6 40 6 OPERATING WT lb 899 829 Type Scroll Scroll Quantity 1 1 COMPRESSORS Unit Capacity Steps 67 100 67 100 Face area Sq Ft 21 1 21 1 Rows 1 1 Fins per inch 23 23 Tube diameter in MM 1 25 1 25 CONDENSER COIL DATA Circuitry Type 2 pass Microcha...

Page 72: ...P50 Blower Sheave AK74 AK74 AK74 AK74 AK74 AK74 Belt A47 A48 A48 A47 A48 A48 Motor Max Bhp 3 Phase 2 4 2 9 3 7 2 4 2 9 3 7 RPM 1725 1725 1725 1725 1725 1725 EVAP FAN DATA BELT DRIVE Frame size 56Y 56Y 56HZ 56Y 56Y 56HZ FILTERS Quantity Size 2 4 16 x 20 x 2 2 4 16 x 20 x 2 2 1 1st Stage 60 of 2nd Stage 2 2 in Throwaway Standard MERV 4 Minimum Efficiency Reporting Value INSTALLATION MANUAL ZY SERIES...

Page 73: ...2 Gas Limit Setting ºF 140 150 140 AHRI HEATING PERFORMANCE THREE PHASE Gas piping connection in 3 4 3 4 3 4 Length 87 2 87 2 Width 61 7 61 7 DIMENSIONS in Height 48 6 48 6 OPERATING WT lb 970 868 Type Scroll Scroll Quantity 2 2 COMPRESSORS Unit Capacity Steps 50 100 50 100 Face area Sq Ft 25 5 25 5 Rows 1 1 Fins per inch 23 23 Tube diameter in MM 79 20 79 20 CONDENSER COIL DATA Circuitry Type 2 p...

Page 74: ...50 1VL34 1VL44 1VP50 Blower Sheave AK74 AK74 AK74 AK74 AK74 AK74 Belt A47 A48 A50 A47 A48 A50 Motor Max Bhp 3 Phase 2 4 2 4 3 7 2 4 2 4 3 7 RPM 1725 1725 1725 1725 1725 1725 EVAP FAN DATA BELT DRIVE Frame size 56Y 56Y 56HZ 56Y 56Y 56HZ FILTERS Quantity Size 1 4 20 x 20 x 2 1 4 20 x 20 x 2 1 1 2 in Throwaway Standard MERV 4 Minimum Efficiency Reporting Value INSTALLATION MANUAL ZY SERIES 3 10 ton 6...

Page 75: ...1 52 38 64 Gas Limit Setting ºF 140 150 140 AHRI HEATING PERFORMANCE Gas piping connection in 3 4 3 4 3 4 Length 87 2 87 2 Width 61 7 61 7 DIMENSIONS in Height 48 6 48 6 OPERATING WT lb 980 878 Type Scroll Scroll Quantity 2 2 COMPRESSORS Unit Capacity Steps 50 100 50 100 Face area Sq Ft 25 5 25 5 Rows 1 1 Fins per inch 23 23 Tube diameter in MM 1 25 1 25 CONDENSER COIL DATA Circuitry Type 2 pass M...

Page 76: ...0 1VL34 1VL44 1VP50 Blower Sheave AK74 AK74 AK74 AK74 AK74 AK74 Belt A47 A48 A50 A47 A48 A50 Motor Max Bhp 3 Phase 2 4 2 4 3 7 2 4 2 4 3 7 RPM 1725 1725 1725 1725 1725 1725 EVAP FAN DATA BELT DRIVE Frame size 56Y 56Y 56HZ 56Y 56Y 56HZ FILTERS Quantity Size 1 4 20 x 20 x 2 1 4 20 x 20 x 2 1 1 2 in Throwaway Standard MERV 4 Minimum Efficiency Reporting Value INSTALLATION MANUAL ZY SERIES 3 10 ton 60...

Page 77: ...4 37 62 Gas Limit Setting ºF 150 140 160 AHRI HEATING PERFORMANCE Gas piping connection in 3 4 3 4 3 4 Length 87 2 87 2 Width 61 7 61 7 DIMENSIONS in Height 55 3 55 3 OPERATING WT lb 1008 902 Type Scroll Scroll Quantity 2 2 COMPRESSORS Unit Capacity Steps 50 100 50 100 Face area Sq Ft 24 9 24 9 Rows 1 1 Fins per inch 21 21 Tube diameter in MM 1 26 32 1 26 32 CONDENSER COIL DATA Circuitry Type 2 pa...

Page 78: ... 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada should be followed in all cases unless superseded by local codes or gas utility requirements Refer to Table 25 The heating value of the gas may differ with locality The value should be checked with the local gas utility Figure 24 Side Entry Gas Piping Note Routing of gas piping must not interfere with the flue or heat compartme...

Page 79: ...connector which has previously serviced another gas appliance WARNING Natural gas may contain some propane Propane is an excellent solvent and will quickly dissolve white lead and most standard commercial compounds A special pipe dope must be used when assembling wrought iron or steel pipe Shellac based compounds such as Gaskolac or Stalastic and compounds such as Rectorseal 5 Clydes s or John Cra...

Page 80: ...ially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life Combustion air and flue exhaust Venting slots in the heating compartment access panel remove the need for a combustion air hood The gas heat flue exhaust is routed from the unit through a field installed exhaust h...

Page 81: ...t 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 for the high leg conductor by checking voltage of each phase to ground Example A or L1 phase to ground ...

Page 82: ...e tighten nuts A B and C Altitude and temperature correction for CFM static pressure and power The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 ft above sea level The air flow rates listed in the standard blower performance tables are based on standard air at sea level As the altitude or temperature increases the density ...

Page 83: ...r the Altitude correction must be used to determine the static pressure and BHP Since no temperature data is given we will assume an Air Temperature of 70 F The Altitude Temperature Factors show the correction factor to be 0 832 Corrected static pressure 1 4 x 0 832 1 16 IWC Corrected BHP 2 0 x 0 832 1 66 Example 2 A system located at 5 000 ft of elevation is to deliver 3 000 CFM at a static press...

Page 84: ... for the motor options available Select the appropriate drive if multiple drives are available for the chosen motor 8 Determine turns open to obtain the desired operation point Example 1 3400 CFM 2 1 6 iwg 3 Using the airflow performance table below the following data point was located 1039 RPM and 2 52 BHP 4 Using the RPM selection table below Model ZY and Size 08 Tons 7 5 is found 5 2 59 BHP exc...

Page 85: ...on with Motor rated at 3 7 hp Exceeds recommended blower speed 1 Blower performance includes gas heat exchangers and 2 in filters See STATIC RESISTANCE table for additional applications Note See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP kW 0 929 x BHP Table 30 Example RPM Selection Model Size Tons Airflow Option Phase Max BHP Blower S...

Page 86: ...29 x BHP Table 33 ZY05 4 0 Ton Side Duct 1 AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1200 840 0 30 927 0 41 1012 0 53 1096 0 65 1177 0 77 1257 0 89 1334 1 01 1411 1 12 1485 1 22 1558 1 31 1300 857 0 35 944 0 47 1029 0 59 1112 0 71 1194 0 83 1273 0 95 1351 1 07 1427 1 18 1502 1...

Page 87: ... AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1800 521 0 27 583 0 44 644 0 63 703 0 81 759 0 99 814 1 17 866 1 34 916 1 51 964 1 67 1010 1 83 1900 529 0 31 591 0 49 651 0 67 710 0 85 767 1 03 821 1 21 874 1 39 924 1 56 972 1 72 1017 1 87 2000 536 0 36 598 0 54 659 0 72 718 0 90 7...

Page 88: ...wer speed 1 Blower performance includes gas heat exchangers and 2 in filters See STATIC RESISTANCE table for additional applications Note See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP kW 0 929 x BHP Table 37 ZY08 7 5 Ton Side Duct 1 AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RP...

Page 89: ...esired motor sheave setting and to determine the maximum continuous BHP kW 0 929 x BHP Table 39 ZY12 10 Ton Side Duct 1 AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 3000 653 0 79 706 1 02 758 1 25 808 1 49 858 1 72 907 1 95 955 2 18 1003 2 40 1049 2 62 1095 2 82 3200 667 0 94 720...

Page 90: ...316 812 892 2240 861 954 2181 894 1000 2113 938 1045 2003 946 1093 Table 41 ZY04 to 06 Side Duct Gas Heat Available External Static 0 2 0 4 0 6 0 8 1 0 Unit Ton Motor Speed CFM WATTS RPM CFM WATTS RPM CFM WATTS RPM CFM WATTS RPM CFM WATTS RPM 1 LOW 978 125 684 853 149 797 734 172 906 596 190 998 445 203 1068 2 MED LOW 1078 153 721 962 175 817 846 200 922 726 226 1026 599 241 1098 3 MED 1153 178 74...

Page 91: ...s BHP kW 0 929 x BHP Table 43 ZY05 4 0 Ton Bottom Duct 1 AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1200 840 0 37 929 0 46 1016 0 56 1101 0 68 1184 0 80 1265 0 93 1345 1 04 1423 1 14 1500 1 22 1576 1 28 1300 858 0 43 947 0 52 1035 0 62 1120 0 74 1203 0 86 1284 0 99 1364 1 10 14...

Page 92: ...ttom Duct 1 AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1800 525 0 31 590 0 48 653 0 65 713 0 82 770 0 98 825 1 15 878 1 31 928 1 48 976 1 65 1022 1 83 1900 534 0 36 599 0 53 661 0 71 721 0 87 779 1 03 834 1 20 886 1 36 936 1 53 984 1 70 1030 1 88 2000 542 0 41 607 0 59 670 0 76...

Page 93: ...1 Blower performance includes gas heat exchangers and 2 in filters See STATIC RESISTANCE table for additional applications Note See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP kW 0 929 x BHP Table 47 ZY08 7 5 Ton Bottom Duct 1 AVAILABLE EXTERNAL STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RP...

Page 94: ... STATIC PRESSURE IWG 1 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 CFM RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 2600 626 0 50 679 0 73 731 0 97 782 1 20 831 1 44 880 1 67 928 1 90 976 2 12 1022 2 33 1068 2 53 2800 639 0 64 692 0 87 744 1 11 795 1 34 845 1 58 894 1 81 942 2 04 989 2 26 1036 2 47 1082 2 67 3000 653 0 79 706 1 02 758 1 25 808 1 49 858 1 72 907 1 95 ...

Page 95: ...2 1100 3 MED 1135 182 769 1041 208 858 919 229 952 805 254 1045 681 275 1127 4 MED HI 1310 256 842 1225 279 917 1123 307 1001 1029 334 1083 863 335 1155 ZY04 3 5 HI 1680 501 997 1622 526 1056 1538 546 1119 1296 485 1153 939 374 1176 1 LOW 1277 228 801 1196 251 878 1096 278 967 983 305 1062 873 329 1156 2 MED LOW 1382 278 847 1307 302 916 1217 327 994 1108 355 1083 949 359 1164 3 MED 1486 331 888 1...

Page 96: ...Y A7 6 H Static 3 3 7 AK74 1VP50 N A 850 900 950 1000 1050 1100 Std 3 2 4 AK74 1VL34 N A 475 525 575 625 675 725 Med 3 2 4 AK74 1VL44 N A 700 750 800 850 900 950 ZY 08 7 5 H Static 3 3 7 AK74 1VP50 N A 850 900 950 1000 1050 1100 Std 3 2 4 AK74 1VL34 N A 475 525 575 625 675 725 Med 3 2 4 AK74 1VL44 N A 700 750 800 850 900 950 ZY 9 8 5 H Static 3 3 7 AK74 1VP50 N A 850 900 950 1000 1050 1100 Std 3 2...

Page 97: ... 3 2 4 1725 0 80 1 15 56Y 1 9 2 9 5 8 1VL34 7 0 1 AK74 A47 Med 3 2 9 1725 0 81 1 15 56Y 2 8 3 8 7 8 1VL44 7 0 1 AK74 A48 ZY 07 6 H Static 3 3 7 1725 0 84 1 15 56HZ 3 4 4 4 7 8 1VP50 7 0 1 AK74 A48 Std 3 2 4 1725 0 80 1 15 56Y 1 9 2 9 5 8 1VL34 7 0 1 AK74 A47 Med 3 2 9 1725 0 81 1 15 56Y 2 8 3 8 7 8 1VL44 7 0 1 AK74 A48 ZY A7 6 H Static 3 3 7 1725 0 84 1 15 56HZ 3 4 4 4 7 8 1VP50 7 0 1 AK74 A48 Std...

Page 98: ...sheave Use Table 54 to locate the DD nearest to 2 48 in Close the sheave to 2 turn open EXAMPLE NEW BHP Speed increase 3 Original BHP New BHP Speed increase 3 BHP at 1 350 CFM EXAMPLE NEW MOTOR AMPS Speed increase 3 Original Amps New Amps Speed increase 3 Amps at 1 350 CFM Table 54 Motor Sheave Datum Diameters 1VL34 1VL44 1VP50 1VP56 Turns Open Datum Diameter Turns Open Datum Diameter Turns Open D...

Page 99: ...0 21 0 07 0 08 0 1 2600 0 38 0 24 0 08 0 09 0 11 2800 0 41 0 29 0 09 0 10 0 12 07 6 0 3000 0 45 0 35 0 11 0 12 0 14 1800 0 23 0 13 0 03 0 05 0 06 2000 0 28 0 15 0 04 0 06 0 07 2200 0 32 0 18 0 06 0 07 0 09 2400 0 37 0 21 0 07 0 08 0 1 2600 0 38 0 24 0 08 0 09 0 11 2800 0 41 0 29 0 09 0 10 0 12 A7 6 0 3000 0 45 0 35 0 11 0 12 0 14 2200 0 04 0 18 0 07 0 09 0 10 0 12 2600 0 06 0 24 0 09 0 11 0 12 0 1...

Page 100: ...tion 2nd Stage Heat Command Y1 Thermostat Connection 1st Stage Cool Command G Thermostat Connection Indoor Fan Command Y2 Thermostat Connection 2nd Stage Cool Command X Thermostat Connection Alarm Indication 24VAC Rectified R Thermostat Connection 24VAC Connection 24V Thermostat Connection No Connection A C Thermostat Connection 24VAC Common ConnectionLimit B P4 For Internal Use Only C J10 No Conn...

Page 101: ...nits only H2 H2 Output Stage 2 Gas Electric Heat ContactorFor F H1 H1 Output Stage 1 Gas Electric Heat Contactor VFD G C VFD Output For use with Intellispeed OptionH1 FS1 Evaporator Freeze Stat For low evaporator temperature Set for 26 F H FS2 Evaporator Freeze Stat For low evaporator temperature Set for 26 F only used for dual compressor operation I PB1 Push Button Reset Clears alarms and the sto...

Page 102: ...pply Fan Speed Control Type Fan Output Single Stage Cool Y1 7 3 7 4VDC 67 10VDC 100 1 Two Stage Cool Y1 Y2 7 3 7 4VDC 67 10 VDC 100 Single Stage Heat W1 10VDC 100 Two Stage Heat W1 W2 10VDC 100 Fan only 6 VDC 50 1 10VDC signal is provided with FAN2 output only when Y2 is energized VFD Operation The VFD output is a 2 10VDC signal with a minimum off time between fan cycles of 10 seconds and a minimu...

Page 103: ...ow heartbeat 24 Factory test mode Rapid flash Rapid flash Push Button Hold down for 0 to 2 seconds 5 most recent error codes in the history will flash on the LEDs 2 to 5 seconds clear anti short cycle timers and reset any active lockouts 5 seconds clear all fault history INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 103 Johnson Controls Ducted Systems ...

Page 104: ...ter 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 switching and power If field added external accessories for unit shutdown are used 24 VAC hot return ...

Page 105: ... UCB temperature sensor connections Location Label Description Function and comments SAT Supply Air Temperature sensor input from 10KΩ 77 F Type III negative temperature coefficient thermistor Input required for operation 3 625 VDC reading SAT to SAT with open circuit Used in heat cool staging cutouts free cooling operation demand ventilation operation comfort ventilation operation economizer load...

Page 106: ...flash drive F J15 Factory wired SA Bus connector Table 65 Smart Equipment UCB 24 V terminal Location Label Description Function and comments G 24 V FOR OUTPUTS 24 VAC hot for H1 H2 CN FAN AUX HGR FAN C1 and C2 output relay contact switching Output relay circuitry is isolated from other UCB components and the 24 VAC hot source may be from a second transformer in the unit Table 66 Smart Equipment UC...

Page 107: ...ircuit trace to the R terminal J FAN OVR left pin 24 VAC hot return from indoor blower FAN Overload relay contact motor protector switch Input is only considered if FAN output is needed input must be present to allow FAN output and unit operation One FAN OVR trip lasting longer than 5 minutes or three FAN OVR trips in a two hour period cause a Fan Overload Lockout and unit operation is then preven...

Page 108: ...ON P FC BUS Green FC bus communication transmission indicator Lit flickering indicates outgoing UCB FC bus communication is currently active off indicates the UCB is awaiting incoming FC bus communication R ISO PWR Green communication board Isolated Power indicator Lit indicates the UCB is supplying power to the communication sub board Table 73 Cable for FC Buses and SA Buses in Order of Preferenc...

Page 109: ...ngs the blower is energized whenever a cooling or heating operation is requested The blower is energized after any specified delay associated with the operation When energized the indoor blower has a minimum run time of 30 seconds Additionally the indoor blower has a minimum off delay of 10 seconds No Outdoor Air Options When the thermostat calls for cooling the low voltage control circuit from R ...

Page 110: ... minimum run times for compressors High Pressure Limit Switch During cooling operation if a high pressure limit switch opens the UCB will de energize the compressor initiate the ASCD Anti short cycle delay and stop the condenser fan If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the compressor Should a high pressure switch open three times within tw...

Page 111: ...lowing inputs for each cooling system 1 For the ETC a suction line freezestat will protect against low evaporator temperatures due to a low airflow or a low return air temperature opens at 26 5 F and resets at 38 5 F For Smart Equipment an evaporator low limit sensor EC1 Located on the Suction Line at the Evaporator Coil will protect against low evaporator temperatures due to a low airflow or a lo...

Page 112: ...mes within one hour the UCB will lock on the indoor blower motor and will initiate a flash code on the ETC or send an error message to the LCD Display on Smart Equipment 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...

Page 113: ...ture sensitive switch can sense the temperature of the heat exchanger tubes On single or two stage models the limit is mounted just above the inlet of the heat exchanger tubes on the right side If a primary limit LS fault occurs the primary limit opens due to excessive heat exchanger temperature then the ICB will flash the appropriate code see Table 74 and monitor the primary limit The UCB will en...

Page 114: ...e surrounds the tip of the sensor On a call for heat the ICB checks for the flame sense circuit to be open If open then the ICB initiates the purging and ignition sequence Once the pilot flame is present the ICB monitors the flame sense circuit for pilot flame stability If the pilot flame is unstable or lost completely then the ICB will immediately close both the pilot and main gas valves The ICB ...

Page 115: ...rmware error likely correctable with re loading from USB flash drive SA BUS SA BUS Green UCB SA bus communication transmission indicator Lit flickering indicates UCB to economizer board SA bus communication is currently active off indicates the economizer board is awaiting SA bus communication 1 SA BUS Pin connections at left on upper edge of economizer board C COM Common for SA BUS power and comm...

Page 116: ...NALOG INPUTS Terminal on lower edge of economizer board R 24V 24 VAC hot supplied for the outdoor air humidity sensor Connects through circuit trace to 24V IN pin HOT IN3 OAH 0 10 VDC positive input from the Outdoor Air Humidity sensor OAH parameter reports input status 0 100 H Used in outdoor air enthalpy calculation for dual enthalpy economizer free cooling changeover C COM 24 VAC common 0 10 VD...

Page 117: ...eating and cooling operation is prevented the indoor blower and power exhaust fan operate the economizer actuator is positioned to 100 IN9 24V 24 VAC hot supplied for the purge dry contact Connects through circuit trace to 24V IN pin HOT EX VFD FLT 24 VAC hot input from the power Exhaust Variable Frequency Drive Fault contact ExFanVFDFlt parameter reports input status Normal with 0 VAC input Alarm...

Page 118: ...energizes the gas valve and provides a 24 V input to the MV terminal on the UCB 3 The FAN ON HEAT DELAY timer starts as soon as 24 V is present on MV terminal When the timer expires the FAN output for the indoor fan operation energizes If 24 V is not received on the MV terminal within 6 minutes an alarm appears and the fan output energizes immediately and remains On until the alarm clears 4 When t...

Page 119: ...ximum number of ignition trials The ICB has a maximum number of 3 ignition trials If the control has attempted the maximum number of ignition trials within the same call for heat without flame the control will lockout flashing 4 on the LED If the control has attempted less than maximum ignition trials it begins an inter purge period before attempting another ignition trial If the call for heat is ...

Page 120: ... has failed and the control shall enter a hard lockout and flash a 9 on the LED During the hard lockout the control will continue to run the inducer as long as the limit switch is open If the limit switch recloses in this hard lockout condition the inducer will run a post purge and then shutoff The control shall remain locked out until power is removed and shall not reset automatically Roll out sw...

Page 121: ...he unit supply air CFM 7 Measure evaporator fan motor s amp draw 8 Set the room thermostat fan switch to off 9 Turn unit electrical power off Operating instructions 1 Turn unit electrical power on Note Prior to each cooling season the crankcase heaters where equipment must be energized at least 10 hours before the system is put into operation 2 Set the room thermostat setting to lower than the roo...

Page 122: ...WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury death or property damage Never test for gas leaks with an open flame use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life 2 Check for correct ma...

Page 123: ...e the time needed for one revolution of the hand on the lowest increment dial on the meter A typical gas meter has a 1 2 or a 1 cubic foot test dial 5 Using the number of seconds it takes for one revolution of the dial calculate the cubic feet of gas consumed per hour See example below 6 If necessary adjust the low pressure regulator as discussed in the section Manifold Gas Pressure Adjustment Be ...

Page 124: ...st first stage pressure refer to Table 77 for input value 1 Turn off all power to the unit 2 Using the outlet pressure port on the gas valve connect a manometer to monitor the manifold pressure 3 Remove cover screws covering HI and LO pressure adjustment screws 4 Turn on power to the unit 5 Set thermostat to call for second stage heat and start furnace 6 If necessary using a screwdriver turn these...

Page 125: ... CLOSE MAIN MANUAL SHUT OFF VALVE AND SHUT OFF ALL POWER TO THE UNIT 1 Open the union fitting just upstream of the unit gas valve and downstream from the main manual shut off valve in the gas supply line 2 Remove the screws holding each end of the manifold to the manifold supports 3 Disconnect wiring to the gas valve Remove the manifold and gas valve assembly Orifices can now be inspected and or r...

Page 126: ...Figure 34 3 ton through 5 Ton 1 2 in Single Stage Gas Valve INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 126 Johnson Controls Ducted Systems ...

Page 127: ...et on default taps from the factory See the wiring diagrams for details on factory default speeds During installation you may need to move the leads to different taps depending on the airflow and static requirements of the application Note During installation the tap chosen for the heating speed must produce a temperature rise that lies within the rise range stated on the rating plate and the phys...

Page 128: ...Figure 36 6 ton through 12 5 ton 3 4 in Two Stage Gas Valve INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 128 Johnson Controls Ducted Systems ...

Page 129: ... Caution should be used at all times as the supply air blower may energize regardless of the room thermostat fan switch position Table 78 Everyday Thermostat Controls fault codes SR No Condition Red LED Green LED 1 POWER FAILURE OFF OFF 2 CONTROL FAILURE ON OFF 3 BLACKOUT CONDITION 7 PULSES OFF 4 BROWNOUT CONDITION 6 PULSES OFF 5 LIMIT SWITCH FAULT 8 PULSES OFF 6 DUAL HPS FAULTS 3 PULSES 3 PULSES ...

Page 130: ...ify that the ignition control s L1 to IND contacts are not stuck or welded closed causing the induced draft motor to run continuously Verify that the wiring from the ignition control s P1 3 pin through the induced draft pressure switch to the ignition control s pressure switch input P1 8 pin is not shorted The output relay contacts open so inducer and gas valve operation is not permitted Opening o...

Page 131: ...s been sensed for longer than 2 seconds when the first stage gas valve output is off Verify that the gas valve is not slow to shut off leaks by or otherwise does not completely shut off gas flow when de energized Verify the gas valve wiring to is intact and not shorted in a manner that would improperly allow 24 VAC from another circuit to be applied to the gas valve The gas valve output relay cont...

Page 132: ... 86 20 9 2 400 Cfm Ton 75 62 95 139 58 365 96 20 10 4 Table 81 ZY05 Charging Table Air Flow Indoor Db Wb Outdoor DB Suction P Suction Temp Liquid P Liquid Temp Delta T Db Compr amps 75 134 57 285 80 26 11 1 85 133 56 333 89 27 12 8 300 Cfm Ton 80 62 95 133 56 381 98 28 14 4 75 134 56 284 79 26 11 1 85 137 57 331 88 26 12 7 300 Cfm Ton 80 67 95 140 58 377 96 25 14 3 75 133 56 283 78 27 11 2 85 140 ...

Page 133: ...329 91 20 14 9 400 Cfm Ton 75 62 95 142 64 380 100 19 16 8 Table 83 ZY07 Charging Table Air Flow Indoor Db Wb Outdoor DB Suction P Suction Temp Liquid P Liquid Temp Delta T Db Compr amps 75 135 60 269 75 26 17 7 85 135 59 317 85 26 19 7 300 Cfm Ton 80 62 95 135 58 365 95 26 21 6 75 134 58 268 75 26 17 8 85 138 59 318 85 25 19 7 300 Cfm Ton 80 67 95 141 61 368 95 24 21 7 75 134 57 267 75 27 17 8 85...

Page 134: ...0 305 86 20 12 0 400 Cfm Ton 75 62 95 136 60 350 96 19 13 3 Table 85 ZY08 Charging Table System 1 Air Flow Indoor Db Wb Outdoor DB Suction P Suction Temp Liquid P Liquid Temp Delta T Db Compr amps 75 139 60 271 83 25 7 0 85 138 58 319 91 26 7 9 300 Cfm Ton 80 62 95 137 57 367 98 27 8 8 75 139 60 270 85 25 7 0 85 143 59 318 94 24 7 9 300 Cfm Ton 80 67 95 146 58 365 103 23 8 8 75 140 59 269 87 25 7 ...

Page 135: ...8 317 89 20 7 9 400 Cfm Ton 75 62 95 144 58 369 98 19 8 9 Table 87 ZY09 Charging Table System 1 Air Flow Indoor Db Wb Outdoor DB Suction P Suction Temp Liquid P Liquid Temp Delta T Db Compr amps 75 138 63 278 79 26 7 7 85 138 61 325 89 27 8 5 300 Cfm Ton 80 62 95 137 59 371 98 27 9 3 75 137 62 277 80 26 7 6 85 141 62 325 89 25 8 5 300 Cfm Ton 80 67 95 144 62 374 98 24 9 3 75 137 61 275 80 27 7 6 8...

Page 136: ... 1 400 Cfm Ton 75 62 95 142 61 373 98 20 9 0 Table 89 ZY12 Charging Table System 1 Air Flow Indoor Db Wb Outdoor DB Suction P Suction Temp Liquid P Liquid Temp Delta T Db Compr amps 75 135 59 284 81 26 8 9 85 135 58 332 90 26 10 0 300 Cfm Ton 80 62 95 135 58 380 98 27 11 0 75 134 59 285 81 26 9 1 85 138 59 334 91 25 10 1 300 Cfm Ton 80 67 95 142 60 383 100 24 11 0 75 132 58 285 81 26 9 3 85 141 60...

Page 137: ...n 80 72 95 150 62 385 99 20 10 5 75 128 57 278 78 23 8 4 85 130 57 328 88 23 9 4 300 Cfm Ton 75 62 95 132 57 377 98 23 10 4 75 139 62 278 80 23 8 4 85 141 62 328 89 23 9 3 400 Cfm Ton 80 62 95 143 61 378 99 23 10 2 75 141 62 280 79 22 8 6 85 144 62 331 89 22 9 5 400 Cfm Ton 80 67 95 147 63 381 98 21 10 4 75 142 62 282 78 22 8 7 85 147 63 333 88 20 9 6 400 Cfm Ton 80 72 95 152 64 385 98 19 10 5 75 ...

Page 138: ...teway Portable Source 1 P N S1 JC MAP1810 OP 3 MAP Gateway Quick Start Guide P N 24 10737 16 4 MAP Gateway Instruction P N 24 10737 8 For more information on the Smart Equipment unit control board navigation refer to the Smart Equipment Quick Start Guide Note For more in depth sequence of operation of the Smart Equipment control refer to the Smart Equipment Controls Sequence of Operation Overview ...

Page 139: ...Start Up Sheet INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 139 Johnson Controls Ducted Systems ...

Page 140: ...INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 140 Johnson Controls Ducted Systems ...

Page 141: ...INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 141 Johnson Controls Ducted Systems ...

Page 142: ...INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 142 Johnson Controls Ducted Systems ...

Page 143: ...INSTALLATION MANUAL ZY SERIES 3 10 ton 60 Hertz R 410A 143 Johnson Controls Ducted Systems ...

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Johnson Controls ZY Series, Installation Manual

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Summary of Contents for ZY Series

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