Johnson Controls ZZ Series Installation Manual Download Page 1

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R-410A

ZZ SERIES

6 - 12.5 Ton
60 Hertz (Export Only)

5834853-YIM-B-0320

TABLE OF CONTENTS

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

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

Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

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

ZZ07-14 Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 16

Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . 18

Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Blower Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . 47

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

IntelliSpeed Supply Fan Control . . . . . . . . . . . . . . . . . . . . 53

Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 53

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 53

Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Smart Equipment™ Control Board Navigation Components 63

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

LIST OF TABLES

1 ZZ07-14 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 ZZE07-14 Corner Weights . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZZE07-14 Unit Accessory Weights . . . . . . . . . . . . . . . . . . 9

4 ZZ07-14 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Unit Models used with 1RC0456, 1RC0458 Roof Curb . 13

6 Unit Models used with 1RC0457, 1RC0459 Roof Curb . 14

7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

10 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

11 Altitude/Temperature Correction Factors . . . . . . . . . . . . 38

12 ZZ07-14 Side Duct Application (Belt Drive) . . . . . . . . . . 40

13 ZZ07-14 Bottom Duct Application (Belt Drive) . . . . . . . . 42

14 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 45

15 Additional Static Resistance - ZZ08-14 . . . . . . . . . . . . . 46

16 Additional Static Resistance - ZZ07 . . . . . . . . . . . . . . . . 46

17 Cable for FC Buses and SA Buses in Order of Preference . 52

18 Smart Equipment™ Economizer Board Details . . . . . . . 55

19 ZZ07 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

20 ZZ08 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

21 ZZ09 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 60

22 ZZ09 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 61

23 ZZ12 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 61

24 ZZ12 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 62

25 ZZ14 Charging Table System 1 . . . . . . . . . . . . . . . . . . . 62

26 ZZ14 Charging Table System 2 . . . . . . . . . . . . . . . . . . . 63

LIST OF FIGURES

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

2 Protective condenser covering. . . . . . . . . . . . . . . . . . . . . 5

3 Factory-mounted return air temperature sensor . . . . . . . 6

4 Supply and return air ducts . . . . . . . . . . . . . . . . . . . . . . . 6

5 Return air smoke detector - shipped position . . . . . . . . . 6

6 Return air smoke detector - working position . . . . . . . . . . 6

7 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

9 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 ZZE07-08 Unit Dimension . . . . . . . . . . . . . . . . . . . . . . . 10

11 ZZ09-12 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . 11

12 ZZ14 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 12

13 1RC0456, 1RC0458 Roof Curb Dimensions . . . . . . . . . 13

14 1RC0457, 1RC0459 Roof Curb Dimensions . . . . . . . . . 14

15 Side Duct Cover Panels . . . . . . . . . . . . . . . . . . . . . . . . . 15

16 Bottom Return Opening For Side Duct Conversion . . . . 15

17 Bottom Supply Opening For Side Duct Conversion . . . . 15

18 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

19 Typical Smart Equipment™ Control Wiring . . . . . . . . . . 18

20 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

21 Altitude/Temperature Correction Factors . . . . . . . . . . . . 38

22 Unit control board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

23 SE-ECO1001-1 Economizer Controller . . . . . . . . . . . . . 55

Summary of Contents for ZZ Series

Page 1: ...s 38 12 ZZ07 14 Side Duct Application Belt Drive 40 13 ZZ07 14 Bottom Duct Application Belt Drive 42 14 Motor Sheave Datum Diameters 45 15 Additional Static Resistance ZZ08 14 46 16 Additional Static...

Page 2: ...or service agency This product must be installed in strict compliance with the installation instructions and any applicable local state and national codes including but not limited to building electri...

Page 3: ...or outdoor installation only 3 For installation on combustible material and may be installed directly on combustible flooring or in the U S on wood flooring or Class A Class B or Class C roof covering...

Page 4: ...on Units 1 L Product Generation 1 First Generation Special Options Country L Latin America 1 None 2 Louvered Panels Installed 3 Hinged Cabinet Doors 4 Hinged Cabinet Doors Louvered Panels 1 None 2 Non...

Page 5: ...ective condenser covering 4 If a factory option convenience outlet is installed you must install the weatherproof outlet cover in the field The cover is located behind the filter access panel a Remove...

Page 6: ...ns These units must be installed in accordance with the following In U S A 1 National Electrical Code ANSI NFPA No 70 Latest Edition 2 National Fuel Gas Code ANSI Z223 1 Latest Edition 3 Gas Fired Cen...

Page 7: ...visions of the local building codes Refer to Table 4 for clearances required for combustible construction servicing and proper unit operation Rigging And Handling Exercise care when moving the unit Do...

Page 8: ...FRONT LEFT D C A F FRONT LEFT E B LEFT FRONT Y X Table 2 ZZE07 14 Corner Weights Model Size Tons Weight lbs Center of Gravity 4 Point Load Location lbs 6 Point Load Location lbs Shipping Operating X Y...

Page 9: ...w Dry Bulb Economizer Large Footprint Short 79 Horizontal Flow Dry Bulb Economizer Large Footprint Tall 82 Power Exhaust Vert Flow Large Footprint 75 Power Exhaust Horiz Flow Large Footprint 80 Hail G...

Page 10: ...5834853 YIM B 0320 10 Johnson Controls Ducted Systems Figure 10 ZZE07 08 Unit Dimension...

Page 11: ...5834853 YIM B 0320 Johnson Controls Ducted Systems 11 Figure 11 ZZ09 12 Unit Dimensions...

Page 12: ...5834853 YIM B 0320 12 Johnson Controls Ducted Systems Figure 12 ZZ14 Unit Dimensions...

Page 13: ...hould 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...

Page 14: ...as 1TB0403 1TB0404 Thru the base electrical and gas 26 000 X 81 746 84 000 O D O D 53 500 53 496 11 417 6 043 24 813 4 173 34 313 I D 50 000 78 250 I D 40 188 15 469 3 000 15 813 31 531 81 750 O D R E...

Page 15: ...g for all other models no other 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...

Page 16: ...ty of the unit and result in frosted coils or safety shutdown Refer to physical data tables for the number and size of filters needed for the unit The unit should not be operated without filters prope...

Page 17: ...e to internal components if drilling holes for disconnect mounting When connecting electrical power and control wiring to the unit water proof connectors must be used so that water or moisture cannot...

Page 18: ...of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied on X is an input to the thermostat to display Error Status condi ons 3 W2 Y1 G OCC Y2 X R SD 24 C W1 2 24V C 24 VAC Cla...

Page 19: ...20 3 25 25 19 79 20 8 25 25 19 80 10646 6 1 7 2 20 3 25 25 19 79 20 8 25 25 19 80 11146 11 5 1 13 8 19 9 20 20 11 79 20 4 25 25 19 80 11446 14 1 16 8 23 6 25 25 22 79 24 1 25 25 19 80 09 8 5 208 3 60...

Page 20: ...1 35 35 29 180 12846 27 8 1 33 4 46 9 50 50 43 178 48 1 50 50 44 180 13346 33 1 39 7 54 8 60 60 50 178 56 60 60 52 180 14246 41 7 2 50 2 67 9 70 70 62 178 69 1 70 70 64 180 1 Minimum Circuit Ampacity...

Page 21: ...30 27 153 10646 6 1 7 2 25 9 30 30 27 128 26 4 30 30 27 153 11146 11 5 1 13 8 28 5 30 30 27 128 29 0 30 30 27 153 11446 14 1 16 8 32 2 35 50 31 158 32 7 35 50 32 163 09 8 5 208 3 60 14 5 98 23 14 5 9...

Page 22: ...30 180 33 8 35 35 31 182 12846 27 8 1 33 4 49 6 50 50 46 180 50 8 60 60 47 182 13346 33 1 39 7 57 4 60 60 53 180 58 7 60 60 54 182 14246 41 7 2 50 2 70 6 80 80 65 180 71 8 80 80 66 182 1 Minimum Circ...

Page 23: ...25 25 23 97 10646 6 1 7 2 21 1 25 25 20 94 21 6 25 25 23 97 11146 11 5 1 13 8 20 7 25 25 20 94 21 2 25 25 23 97 11446 14 1 16 8 24 4 25 25 20 94 24 9 25 25 23 97 09 8 5 208 3 60 14 5 98 23 14 5 98 23...

Page 24: ...9 35 35 29 186 12846 27 8 1 33 4 47 6 50 50 44 184 48 9 50 50 45 186 13346 33 1 39 7 55 5 60 60 51 184 56 8 60 60 52 186 14246 41 7 2 50 2 68 6 70 70 63 184 69 9 70 70 64 186 1 Minimum Circuit Ampacit...

Page 25: ...30 26 97 10646 6 1 7 2 26 7 30 30 26 96 27 2 30 30 26 97 11146 11 5 1 13 8 29 3 30 30 26 96 29 8 30 30 26 97 11446 14 1 16 8 33 0 35 35 31 127 33 5 35 35 31 127 09 8 5 208 3 60 14 5 98 23 14 5 98 23...

Page 26: ...31 186 34 6 35 35 32 188 12846 27 8 1 33 4 50 3 60 60 46 186 51 6 60 60 47 188 13346 33 1 39 7 58 2 60 60 54 186 59 4 60 60 55 188 14246 41 7 2 50 2 71 3 80 80 66 186 72 6 80 80 67 188 1 Minimum Circu...

Page 27: ...25 25 22 102 10646 6 1 7 2 22 5 25 25 21 101 23 0 25 25 22 102 11146 11 5 1 13 8 22 1 25 25 21 101 22 6 25 25 22 102 11446 14 1 16 8 25 8 30 30 25 101 26 3 30 30 25 102 09 8 5 208 3 60 14 5 98 23 14...

Page 28: ...194 34 4 35 35 32 196 12846 27 8 1 33 4 50 1 60 60 46 194 51 4 60 60 47 196 13346 33 1 39 7 58 60 60 53 194 59 3 60 60 55 196 14246 41 7 2 50 2 71 1 80 80 65 194 72 4 80 80 67 196 1 Minimum Circuit A...

Page 29: ...104 10646 6 1 7 2 28 1 30 30 27 103 28 6 30 30 24 104 11146 11 5 1 13 8 30 7 35 35 28 104 31 2 35 35 28 104 11446 14 1 16 8 34 4 35 35 28 104 34 9 35 35 28 104 09 8 5 208 3 60 14 5 98 23 14 5 98 23 2...

Page 30: ...0 40 33 196 37 1 40 40 34 199 12846 27 8 1 33 4 52 8 60 60 49 196 54 1 60 60 50 199 13346 33 1 39 7 60 7 70 70 56 196 61 9 70 70 57 199 14246 41 7 2 50 2 73 8 80 80 68 196 75 1 80 80 69 199 1 Minimum...

Page 31: ...diameter in MM 79 20 Circuitry Type 2 pass Microchannel EVAPORATOR COIL DATA Face area Sq Ft 7 3 Rows 4 Fins per inch 15 Tube diameter 0 375 Circuitry Type Intertwined Refrigerant control TXV CONDENSE...

Page 32: ...er in MM 79 20 Circuit Type 2 pass Microchannel EVAPORATOR COIL DATA Face area Sq Ft 7 3 Rows 4 Fins per inch 15 Tube diameter 0 375 Circuit Type Intertwined Refrigerant control TXV CONDENSER FAN DATA...

Page 33: ...meter in MM 1 25 Circuitry Type 2 pass Microchannel EVAPORATOR COIL DATA Face area Sq Ft 11 1 Rows 3 Fins per inch 15 Tube diameter 0 375 Circuitry Type Intertwined Refrigerant control Orifice CONDENS...

Page 34: ...eter in MM 1 25 Circuitry Type 2 pass Microchannel EVAPORATOR COIL DATA Face area Sq Ft 11 1 Rows 4 Fins per inch 15 Tube diameter 0 375 Circuitry Type Intertwined Refrigerant control Orifice CONDENSE...

Page 35: ...eter in MM 1 26 32 Circuitry Type 2 pass Microchannel EVAPORATOR COIL DATA Face area Sq Ft 11 1 Rows 4 Fins per inch 15 Tube diameter 0 375 Circuitry Type Intertwined Refrigerant control TXV CONDENSER...

Page 36: ...operly phased at the factory Check for proper blower rotation If the blower rotates in the wrong direction at start up the electrical connection to the unit is misphased Change the phasing of the Fiel...

Page 37: ...will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Table 11 and Figure 21 Belt Tightening Slots 1 4 X 1 2 Span Lengt...

Page 38: ...ssure 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 4 832 1 68 Enter the Supply Air Blower Perfo...

Page 39: ...PM BHP RPM BHP 2250 577 0 50 636 0 68 693 0 86 749 1 03 803 1 21 856 1 39 908 1 57 959 1 74 1009 1 91 1059 2 07 2400 591 0 59 650 0 77 707 0 95 763 1 13 817 1 31 870 1 48 922 1 66 973 1 83 1023 2 00 1...

Page 40: ...1 42 1200 1 56 1253 1 69 1306 1 82 1357 1 96 1407 2 09 1457 2 22 2600 1015 1 29 1076 1 42 1135 1 55 1192 1 68 1247 1 81 1301 1 94 1353 2 07 1404 2 21 1455 2 34 1504 2 48 2800 1070 1 59 1131 1 71 1190...

Page 41: ...tatic Option with Motor rated at 5 25 hp Exceeds recommended Blower speed ZZ14 12 5 Ton Side Duct CFM Available External Static 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP...

Page 42: ...080 1 33 1138 1 48 1196 1 61 1254 1 74 1311 1 87 1368 2 00 1422 2 14 1473 2 30 1522 2 49 2600 1080 1 41 1137 1 58 1194 1 73 1253 1 87 1311 1 99 1368 2 12 1424 2 25 1479 2 39 1530 2 56 1579 2 75 2800 1...

Page 43: ...2 Standard Static Option with Motor rated at 2 4 hp Medium Static Option with Motor rated at 3 7 hp High Static Option with Motor rated at 5 25 hp ZX14 12 5 Ton Bottom Duct CFM Available External Stat...

Page 44: ...56 953 997 1041 1085 1130 1174 N A Indoor Blower Specifications Model Size Tons Airflow Option Motor Motor Sheave Blower Sheave Belt Phase HP RPM Eff SF Frame Datum Dia in Bore in Model Datum Dia in B...

Page 45: ...ven small changes in blower speed can result in substantial changes in static pressure and BHP BHP and AMP draw of the blower motor will increase by the cube of the blower speed Static pressure will i...

Page 46: ...s greater for 100 outdoor air than for 100 return air If the resistance of the return air duct is less than 0 25 IWG the unit will deliver less CFM during full economizer operation Table 16 Additional...

Page 47: ...e also effective for economizer free cooling supply air temperature reset when the ClgStgs parameter is set for 1 or more G Continuous indoor blower request 24 VAC input switched from R OCC Occupancy...

Page 48: ...erminate temporary occupancy COM Common for ST and SSO inputs Negative of VDC circuit for ST and SSO inputs SSO Space Sensor Offset input from 0 to 20K potentiometer Positive of VDC circuit 3 625 VDC...

Page 49: ...hot return from Air Proving Switch When this optional input is enabled the air proving switch must close within 30 seconds of initiation of indoor blower operation and not open for greater than 10 se...

Page 50: ...ntilation cooling reheat or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage compressor UCBs If demand is present and permissions allow compressor 2 operatio...

Page 51: ...f 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 connecto...

Page 52: ...P EOL Green End Of Line indicator Lit indicates the EOL switch is selected ON FC BUS Green FC bus communication transmission indicator Lit flickering indicates outgoing UCB FC bus communication is cur...

Page 53: ...ccupied One Stage of Cool Command Economizer Sequences Several functions can drive the economizer including minimum position free cooling economizer loading and minimum outdoor air supply Economizer M...

Page 54: ...tput returns to 100 Once a compressor output is turned ON the economizer dampers continue to modulate to control the supply air temperature to the Economizer Setpoint At no time will a compressor outp...

Page 55: ...mistor 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...

Page 56: ...power exhaust actuator and economizer actuator Connects through circuit trace to 24V IN pin HOT ECON 2 10 VDC output for the Economizer actuator Econ parameter reports output status 0 100 Used to posi...

Page 57: ...atus 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 2...

Page 58: ...tions 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...

Page 59: ...y air blower motor until the high temperature limit has reset Caution should be used at all times as the supply air blower may energize regardless of the room thermostat fan switch position Table 19 Z...

Page 60: ...374 95 18 20 0 95 147 53 420 106 17 21 6 400 Cfm Ton 75 62 75 125 43 312 86 21 17 7 85 130 48 361 97 20 19 4 95 134 52 410 108 19 21 1 Table 21 ZZ09 Charging Table System 1 Air Flow Indoor Db Wb Outdo...

Page 61: ...5 95 143 66 387 99 19 10 4 400 Cfm Ton 75 62 75 126 64 292 79 19 8 7 85 131 60 335 89 19 9 5 95 135 56 377 98 19 10 3 Table 23 ZZ12 Charging Table System 1 Air Flow Indoor Db Wb Outdoor DB Suction P...

Page 62: ...0 7 95 151 74 401 104 19 11 8 400 Cfm Ton 75 62 75 132 70 292 82 20 9 3 85 136 70 339 93 20 10 4 95 140 69 386 105 19 11 5 Table 25 ZZ14 Charging Table System 1 Air Flow Indoor Db Wb Outdoor DB Suctio...

Page 63: ...ence of Operation Overview LIT 12011950 Table 26 ZZ14 Charging Table System 2 Air Flow Indoor Db Wb Outdoor DB Suction P Suction Temp Liquid P Liquid Temp Delta T Db Compr amps 300 Cfm Ton 80 62 75 13...

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