York International ZK Series Installation Manual Download Page 1

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R-410A
ZK SERIES

3 - 5 Ton

60 Hertz

5121817-TIM-A-0515

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

Typical Reheat Control Wiring (Simplicity S E ZKT03 Thru

T05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Economizer And Power Exhaust Set Point Adjustments . . . . . 29

Economizer Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Sequence Of Operations Overview . . . . . . . . . . . . . . . . . . . . . 42

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 42

Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . . . . 42

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 44

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 44

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 45

Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Simplicity SE Control Board Navigation Components . . . . . . . . . 52

Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic

Unit Control Board Navigation Examples: . . . . . . . . . . . . . . . . 53

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

LIST OF TABLES

1 ZKT03 Thru T05 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . 6

2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZKT03 Thru T05 Unit Accessory Weights . . . . . . . . . . . . . . . . 8

4 ZKT03 Thru T05 Unit Clearances . . . . . . . . . . . . . . . . . . . . . 10

5 ZKT03 Thru T05 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

8 ZKT03 Thru T05 Physical Data . . . . . . . . . . . . . . . . . . . . . . . 24

9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 26

10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 26

11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 27

12 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . . . 31

13 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 35

14 ZK Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 38

15 ZK Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 39

16 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

17 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 40

18 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 41

19 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 42

20 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

21 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 45

22 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 47

23 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 47

24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 47

25 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 49

26 ZKT03 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

27 ZKT04 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

28 ZKT05 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

29 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 60

LIST OF FIGURES

1 ZKT03 Thru T05 Component Location . . . . . . . . . . . . . . . . . . 6

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

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

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

5 ZKT03 Thru T05 Cooling Only/Electric Heat Front View

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

6 ZKT03 Thru T05 Cooling Only/Gas Heat Front View Physical

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 ZKT03 Thru T05 Fixed Outdoor Air Motorized Damper Rain

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

8 ZKT03 Thru T05 Disconnect Location . . . . . . . . . . . . . . . . . 10

9 ZKT03 Thru T05 Unit Side Duct Openings . . . . . . . . . . . . . . 11

10 ZKT03 Thru T05 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

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

14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 29

17 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 31

18 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

19 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 36

20 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 41

21 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

22 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 48

23 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 48

24 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 49

25 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 49

Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Summary of Contents for ZK Series

Page 1: ...y Air 26 10 Gas Heat Application Data 26 11 Gas Pipe Sizing Capacity of Pipe 27 12 Simplicity SE Economizer Board Details 31 13 Altitude Temperature Correction Factors 35 14 ZK Blower Performance Side Duct 38 15 ZK Blower Performance Bottom Duct 39 16 Belt Drive RPM Selection 40 17 Indoor Blower Specifications Belt Drive 40 18 Power Exhaust Specifications 41 19 Additional Static Resistance 42 20 E...

Page 2: ...ng 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 Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available during brazing operations Improper installa...

Page 3: ...s 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 cause gas valve damage resulting in a hazardous condition If it is subjected ...

Page 4: ...4 5 X Options 3 5 Y Options 4 5 Z Options 3 4 5 1 Disconnect 2 Non Pwr d Conv Outlet 3 Smoke Detector S A 4 Smoke Detector R A 5 Pwr d Conv Outlet Options 1 Bottom Drain Composite 3 SS Drain Pan Configuration Options A None C BACnet MSTP Modbus N2 COM Card F FDD H Hnywll Excel 10 Ctrl DFS APS N Novar UCM Ctrl DFS APS P CPC Control DFS APS R Commercial Control System CCS Single Zone S Commercial Co...

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

Page 6: ...nel Aluminum Tube Aluminum Fin Condenser High Efficiency Compressor Power Ventor Motor With Post Purge Cycle 20 Gauge Aluminized Steel Tubular Heat Exchanger Belt Drive Or Direct Drive Blower HACR Breaker Economizer Hood Knockout For Side Power Entry Slide In Economizer Table 1 ZKT03 Thru T05 Unit Limitations Size Tons Unit Voltage Unit Limitations Applied Voltage Outdoor DB Temp Min Max Max F T03...

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

Page 8: ...pping Operating X Y A B C D A B C D E F T03 3 0 580 575 40 20 132 125 155 164 89 85 82 102 106 110 T04 4 0 590 585 40 20 134 127 158 167 90 87 84 104 108 112 T05 5 0 595 590 40 20 135 128 159 168 91 88 84 105 109 113 Table 3 ZKT03 Thru T05 Unit Accessory Weights Unit Accessory Weight lbs Shipping Operating Economizer 55 50 Power Exhaust 55 50 Electric Heat1 28 28 Gas Heat2 70 70 1 Weight given is ...

Page 9: ...7 TIM A 0515 Johnson Controls Unitary Products 9 Figure 5 ZKT03 Thru T05 Cooling Only Electric Heat Front View Physical Dimensions Figure 6 ZKT03 Thru T05 Cooling Only Gas Heat Front View Physical Dimensions ...

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

Page 11: ...05 Roof Curb Table 5 ZKT03 Thru T05 Utilities Entry Hole Opening Size Dia Used For A 7 8 KO1 1 Opening in the bottom to the unit can be located by the slice in the insulation Control Wiring2 2 Do not remove the 2 knockout ring Side Bottom B 2 KO1 Power Wiring Side Bottom C 1 5 8 KO Gas Piping Front D 1 1 2 KO Gas Piping Bottom ...

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

Page 13: ...nd the same minimum gauge as the replaced wire A disconnect must be utilized for these units Factory installed disconnects are available If installing a disconnect field supplied or York International supplied accessory refer to Figure 8 for the recommended mounting location NOTE Since not all local codes allow the mounting of a disconnect on the unit please confirm compliance with local code befo...

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

Page 15: ...TED NUMBER OF THERMOSTATS 1 4 3 1 4 Second stage ŚĞĂƟŶŐ Ŷot required on single stage heĂƟŶg units Jumper is required for any coŵďŝŶĂƟŽŶ of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied ĐŽŶĚŝƟon X is an input to the thermostat to display Error Status condiƟons 3 W2 Y1 G OCC Y2 X R SD 24 C W1 24V COM OUT Return or Space Humidity Sensor 0 10VDC TB 1 823 R RAH DCT PRS P4...

Page 16: ...0 21 2 2 51 70 2 80 460 3 60 5 8 38 9 1 3 2 6 0 NONE 11 1 15 E07 6 8 1 8 2 13 5 15 E10 10 1 1 12 1 18 4 20 E15 13 6 2 16 4 23 7 25 E20 19 5 2 23 5 32 6 35 575 3 60 3 8 36 5 5 9 1 3 2 0 NONE 7 8 15 E10 10 6 1 10 2 15 2 20 E15 15 9 2 15 3 21 6 25 E20 21 2 2 20 4 28 30 T04 4 0 208 3 60 13 7 83 1 21 4 2 3 5 2 0 NONE 24 6 30 E05 4 1 11 1 24 6 30 E07 5 6 1 15 5 25 9 35 E10 8 1 22 2 34 3 35 E15 11 9 2 33...

Page 17: ...60 7 8 52 12 1 1 3 2 6 0 NONE 13 6 20 E07 6 8 1 8 2 13 6 20 E10 10 1 1 12 1 18 4 20 E15 13 6 2 16 4 23 7 25 E20 19 5 2 23 5 32 6 35 E30 28 8 2 34 6 46 6 50 575 3 60 5 7 38 9 8 9 1 3 2 0 NONE 10 2 15 E10 10 6 1 10 2 15 2 20 E15 15 9 2 15 3 21 6 25 E20 21 2 2 20 4 28 30 E30 30 4 2 29 3 39 1 40 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC ZKT03 Thru T05 Without Powere...

Page 18: ... 2 51 70 2 80 460 3 60 5 8 38 9 1 3 2 6 0 NONE 11 1 15 E07 6 8 1 8 2 13 5 15 E10 10 1 1 12 1 18 4 20 E15 13 6 2 16 4 23 7 25 E20 19 5 2 23 5 32 6 35 575 3 60 3 8 36 5 5 9 1 3 2 0 NONE 7 8 15 E10 10 6 1 10 2 15 2 20 E15 15 9 2 15 3 21 6 25 E20 21 2 2 20 4 28 30 T04 4 0 208 3 60 13 7 83 1 21 4 2 3 5 2 0 NONE 24 6 30 E05 4 1 11 1 24 6 30 E07 5 6 1 15 5 25 9 35 E10 8 1 22 2 34 3 35 E15 11 9 2 33 47 8 ...

Page 19: ...2 12 1 1 3 3 4 0 NONE 14 5 20 E07 6 8 1 8 2 14 5 20 E10 10 1 1 12 1 19 4 20 E15 13 6 2 16 4 24 7 25 E20 19 5 2 23 5 33 6 35 E30 28 8 2 34 6 47 6 50 575 3 60 5 7 38 9 8 9 1 3 2 4 0 NONE 10 6 15 E10 10 6 1 10 2 15 7 20 E15 15 9 2 15 3 22 1 25 E20 21 2 2 20 4 28 5 30 E30 30 4 2 29 3 39 6 40 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC ZKT03 Thru T05 Without Powered Co...

Page 20: ... 5 3 1 12 7 23 4 30 E07 7 5 1 18 30 1 35 E10 10 6 1 25 5 39 4 40 E15 15 9 2 38 2 55 3 60 E20 21 2 2 51 71 2 80 T04 4 0 208 3 60 13 7 83 1 21 4 2 3 7 6 0 NONE 27 35 E05 4 1 11 1 27 35 E07 5 6 1 15 5 28 9 35 E10 8 1 22 2 37 3 40 E15 11 9 2 33 50 8 60 E20 15 9 2 44 1 64 7 70 230 3 60 13 7 83 1 21 4 2 3 7 6 0 NONE 27 35 E05 5 3 1 12 7 27 35 E07 7 5 1 18 32 1 40 E10 10 6 1 25 5 41 4 45 E15 15 9 2 38 2 ...

Page 21: ...e 34 6 45 E05 4 0 1 11 1 34 6 45 E07 5 6 1 15 5 38 4 45 E10 8 0 1 22 2 46 8 50 E15 11 9 2 33 0 60 3 70 E20 15 9 2 44 1 74 2 80 230 3 60 13 7 83 1 21 4 2 3 5 2 10 0 None 34 6 45 E05 5 3 1 12 7 34 9 45 E07 7 5 1 18 0 41 6 45 E10 10 6 1 25 5 50 9 60 E15 15 9 2 38 2 66 8 70 E20 21 2 2 51 0 82 7 90 460 3 60 6 2 41 9 7 1 3 2 6 5 0 None 16 6 20 E07 6 8 1 8 2 19 7 20 E10 10 1 1 12 1 24 7 25 E15 13 6 2 16 ...

Page 22: ...2 10 NONE 34 6 45 E05 4 1 11 1 34 6 45 E07 5 6 1 15 5 38 4 45 E10 8 1 22 2 46 8 50 E15 11 9 2 33 60 3 70 E20 15 9 2 44 1 74 2 80 230 3 60 13 7 83 1 21 4 2 3 5 2 10 NONE 34 6 45 E05 5 3 1 12 7 34 9 45 E07 7 5 1 18 41 6 45 E10 10 6 1 25 5 50 9 60 E15 15 9 2 38 2 66 8 70 E20 21 2 2 51 82 7 90 460 3 60 6 2 41 9 7 1 3 2 6 5 NONE 16 6 20 E07 6 8 1 8 2 19 7 20 E10 10 1 1 12 1 24 7 25 E15 13 6 2 16 4 29 9...

Page 23: ...3 1 12 7 35 9 40 E07 7 5 1 18 42 6 45 E10 10 6 1 25 5 51 9 60 E15 15 9 2 38 2 67 8 70 E20 21 2 2 51 83 7 90 T04 4 0 208 3 60 13 7 83 1 21 4 2 3 7 6 10 NONE 37 45 E05 4 1 11 1 37 45 E07 5 6 1 15 5 41 4 50 E10 8 1 22 2 49 8 50 E15 11 9 2 33 63 3 70 E20 15 9 2 44 1 77 2 80 230 3 60 13 7 83 1 21 4 2 3 7 6 10 NONE 37 45 E05 5 3 1 12 7 37 9 50 E07 7 5 1 18 44 6 50 E10 10 6 1 25 5 53 9 60 E15 15 9 2 38 2...

Page 24: ...ners 2 4 3 5 3 5 3 5 4 5 3 5 No stages 1 1 2 2 1 1 2 2 1 1 2 2 Temperature Rise Range ºF 15 45 45 75 35 70 55 90 25 70 45 75 25 70 45 75 25 55 35 75 20 55 35 75 Gas Limit Setting ºF Direct Drive 240 170 210 200 210 165 210 165 170 165 210 165 Gas Limit Setting ºF Belt Drive 240 210 240 200 240 210 240 210 210 210 210 210 Gas piping connection in 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 DIME...

Page 25: ...gal Motor Sheave 1VL44 1VP56 1VL44 1VP56 1VL44 1VP56 Blower Sheave AK64 AK66 AK56 AK61 AK56 AK56 Belt A37 A39 A36 A38 A36 A38 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 RPM 1725 1725 1725 Frame size 56 56 56 DIRECT DRIVE EVAP FAN DATA Quantity 1 1 1 Fan Size Inch 11 x 10 11 x 10 11 x 10 Type Centrifugal Centrifugal Centrifugal Motor HP each 1 2 1 1 RPM 1050 1050 1050 FILTERS 15 x 20 x 1 or 2 2 ...

Page 26: ...sions Accessory model 1LN0406 must be used NOTE Gas Heaters are shipped available for natural gas but can be converted to L P with Kit Model No 1NP0440 or 1NP0485 2 Stage All furnaces meet the latest California seasonal efficiency requirements 1 Based on 1075 Btu Ft 3 2 The air flow must be adjusted to obtain a temperature rise within the range shown Table 9 Electric Heat Minimum Supply Air Size T...

Page 27: ...nt union must be installed in the gas piping 2 Where required by local codes a manual shut off valve must be installed outside of the unit 3 Use wrought iron or steel pipe for all gas lines Pipe dope should be applied sparingly to male threads only 4 All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out loose particles Before initial start up be sur...

Page 28: ...nt and Combustion Air Hood Figure 16 The vent hood is installed by inserting the top flange of the hood into the slotted opening in the access panel and securing in place The products of combustion are discharged horizontally through this screened hooded vent opening on the gas heat access panel FIRE OR EXPLOSION HAZARD Failure to follow the safety warning exactly could result in serious injury de...

Page 29: ... R to G With the thermostat set to the indoor fan ON position or terminals R to G energized turn the Minimum Position Adjusting screw located on the damper control module counterclockwise until the desired minimum damper position has been attained installation comes in the accessory Economizer Sequences Several functions can drive the economizer including minimum position free cooling economizer l...

Page 30: ...zone return sensor for the first stage of cooling the dampers modulate to control the supply air temperature to the Economizer Setpoint 1 F If the economizer output is at 100 and the SAT is greater than the Economizer setpoint 1 F the control starts a 12 minute timer to energize a compressor output If at any time the economizer output drops below 100 the timer stops and resets when the economizer ...

Page 31: ...r actuator position feedback Connects through circuit trace to 24V IN pin HOT C COM Mixed Air Temperature sensor input from 10KΩ 77 F Type III negative temperature coefficient thermistor MAT parameter reports input status F C 3 65 VDC reading MAT to COM with open circuit Read only use in current control revision IN1 MAT LEDs at left on upper edge of economizer board POWER POWER Green UCB power ind...

Page 32: ...xFType selection is Modulating Damper Used to ramp the power exhaust fan VFD position the discharge damper actuator COM 24 VAC common 0 10 VDC negative for the power exhaust variable frequency drive discharge damper modulating power exhaust actuator Connects through circuit trace to 24V IN pin COM 24V 24 VAC hot supplied for the discharge damper modulating power exhaust actuator and economizer act...

Page 33: ...he Indoor Air Quality sensor IAQRange parameter sets the CO2 parts per million measured by the indoor air quality sensor when it outputs 10 VDC IAQ parameter reports input status 0 5000ppm Used for demand ventilation functions if the NetIAQ parameter indicates Unrel C COM 24 VAC common 0 10 VDC negative for the indoor air quality sensor Connects through circuit trace to 24V IN pin COM R 24V 24 VAC...

Page 34: ...harge pressures or producing a high noise level the scroll is misphased R 24V 24 VAC hot supplied for the building pressure sensor Connects through circuit trace to 24V IN pin HOT IN8 BLDG PRES 0 5 VDC positive input from the Building Pressure sensor BldgPres parameter reports input status 250 250 w 062 062kPa Used for modulating power exhaust functions when ExFType selection is Modulating Damper ...

Page 35: ...ase to ground Example A or L1 phase to ground voltage reading is 120V B or L2 phase to ground voltage reading is 195 to 208V C or L3 phase to ground voltage reading is 120V Therefore B or L2 phase is the high Leg The high should always be wired to the center or B or L2 tap Note Check all three phase motors and compressors for proper rotation after making a change If it is necessary to change 3 pha...

Page 36: ...re 19 Altitude Temperature Correction Factors 0 600 0 650 0 700 0 750 0 800 0 850 0 900 0 950 1 000 1 050 1 100 40 50 60 70 80 90 100 Air Temperature ºF Correction Factor Sea Level 1000 ft 2000 ft 3000 ft 4000 ft 6000 ft 7000 ft 8000 ft 9000 ft 10000 ft 5000 ft ...

Page 37: ...s point on the appropriate supply air blower performance table Linear interpolation may be necessary 5 Noting the RPM and BHP from step 4 locate the appropriate motor and or drive on the RPM selection table 6 Review the BHP compared to the motor options available Select the appropriate motor and or drive 7 Review the RPM range for the motor options available Select the appropriate drive if multipl...

Page 38: ...9 786 0 47 866 0 54 942 0 62 1016 0 71 1087 0 79 1155 0 88 1221 0 98 1284 1 07 1345 1 17 1200 733 0 44 817 0 52 896 0 60 973 0 68 1047 0 76 1118 0 85 1186 0 94 1252 1 03 1315 1 12 1376 1 22 1400 770 0 52 853 0 60 933 0 67 1010 0 76 1083 0 84 1154 0 93 1222 1 02 1288 1 11 1352 1 20 1413 1 30 1600 811 0 64 895 0 71 974 0 79 1051 0 87 1125 0 96 1196 1 04 1264 1 13 1330 1 23 1393 1 32 1454 1 42 1800 8...

Page 39: ...SISTANCE 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 0 932 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard Drive Option HIgh Static Drive Option 800 613 0 35 724 0 40 826 0 46 920 0 53 ...

Page 40: ...5 1438 349 1401 363 1363 376 1327 390 1286 403 1248 417 1207 430 4 MED HI 1430 263 1384 276 1342 290 1302 303 1259 316 1215 329 1168 343 1114 358 1044 374 3 MED 1287 208 1242 221 1199 234 1155 246 1108 258 1060 272 997 288 930 303 889 313 2 MED LOW 1185 171 1138 183 1091 195 1041 207 987 220 921 235 862 248 1 LOW 1040 130 959 134 900 145 43 5 HI 1995 696 1957 714 1922 734 1885 749 1844 764 1795 76...

Page 41: ...ill not affect the static pressure readings 3 Using an inclined manometer determine the pressure drop across a dry evaporator coil Since the moisture on an evaporator coil may vary greatly measuring the pressure drop across a wet coil under field conditions would be inaccurate To assure a dry coil the compressors should be deactivated while the test is being run 4 Knowing the pressure drop across ...

Page 42: ... has satisfied its minimum run time the compressor and condenser fan de energize Otherwise the unit operates the cooling system until the minimum run time for the compressor has been completed After the compressor de energizes the blower is stopped following the elapse of the fan off delay for cooling To be available a compressor must not be locked out due to a high or low pressure switch or Evapo...

Page 43: ...rate As always the R to G connection provides minimum position but does not provide power exhaust operation Motorized Outdoor Air Dampers This system operation is the same as the units with no outdoor air options with one exception When the R to G circuit is complete the motorized damper drives open to a position set by the thumbwheel on the damper motor When the R to G circuit is opened the dampe...

Page 44: ...y compressor reset or lock out Error Message The UCB will initiate an error message associated with errors within the system Refer to UNIT CONTROL BOARD error messages Reset Remove the call for cooling by raising thermostat setting higher than the conditioned space temperature This resets any pressure or freezestat error messages Electric Heating Sequence Of Operations The following sequence descr...

Page 45: ...tch located on the end of the draft motor closes After the centrifugal switch closes a 15 second heat exchanger purging period is completed After this purging period the ICB will simultaneously energize the pilot gas valve and the ignition coil Once the flame sensor senses a pilot flame is present the ignition coil is de energized The ICB checks for pilot flame stability and once the ICB is satisf...

Page 46: ...f the excessive heat has been high enough to cause the auxiliary limit AUX to open then the ICB will flash the primary limit code but the furnace will not retry ignition during the same call for heat The auxiliary limit is of the manual reset type and is mounted in the upper right hand corner of the panel between the burner manifold and the flue gas collector box just behind the draft motor If the...

Page 47: ...4 Set the room thermostat fan switch to on 5 Check indoor blower rotation If blower rotation is in the wrong direction Refer to Phasing Section in general information section Check blower drive belt tension 6 Check the unit supply air CFM See CHECKING SUPPLY AIR CFM on page 41 7 Measure evaporator fan motor s amp draw 8 Set the room thermostat fan switch to off 9 Turn unit electrical power off Ope...

Page 48: ...de these limits contact the local gas utility for corrective action Figure 22 Typical Single Stage Gas Valves Figure 23 Typical 2 Stage Gas Valves Manifold Gas Pressure Adjustment Adjustments to the high fire and low fire 2 stage gas flow may be made by turning the pressure regulator adjusting screws on the automatic gas valve Adjust as follows 1 Remove the adjustment screw cap s on the regulator ...

Page 49: ... flame is observed in the heat exchanger tubes Checking Gas Input Natural Gas 1 Turn off all other gas appliances connected to the gas meter 2 With the furnace turned on measure the time needed for one revolution of the hand on the smallest dial on the meter A typical gas meter usually has a 1 2 or a 1 cubic foot test dial 3 Using the number of seconds for each revolution and the size of the test ...

Page 50: ...u will see that 95 cubic feet of gas per hour are consumed by the furnace at that rate Multiply 95 X 1050 the Btu rating of the gas obtained from the local gas company The result is 99 750 Btuh which is close to the 100 000 Btuh rating of the furnace CFM Btuh Input x 0 8 108 x F Temp Rise o Air Flow Indoor Db Wb Outdoor DB Suction Pressure Suction Temp Discharge Pressure Pressure Liquid Temp Delta...

Page 51: ...80 56 8 2 95 132 52 300 88 26 80 54 9 1 400 Cfm Ton 75 63 75 157 65 353 100 10 75 65 7 5 85 152 63 268 79 12 75 63 8 2 95 140 58 264 79 17 75 58 9 0 Air Flow Indoor Db Wb Outdoor DB Suction Pressure Suction Temp Discharge Pressure Pressure Liquid Temp Delta T Db Entering Evap Db Leaving Evap Db Compressor Amps 300 Cfm Ton 80 62 75 121 54 288 81 29 80 51 10 0 85 123 55 332 90 28 80 52 10 8 95 126 5...

Page 52: ... Center Equipment Catalog Commercial Products Zoning Systems and Controls 1 Local LCD on Unit Control Board 2 Mobile Access Portal MAP Gateway 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 NOTE For more in depth sequence of operation of the Simplicity SE control please refer to LIT 12011950 on www upgnet com under Pr...

Page 53: ... the cursor is on the top Status line hit the ENTER button This action steps the LCD display into the status mode Hit ENTER to view the status menu Press Enter Step 2 Scroll down to DVent Mode This is the demand ventila tion mode ENTER CANCEL JOY C PWR 7 7 77 DVent Mode OprST Press Enter Step 3 When the cursor is on the DVent Mode hit ENTER to view the status of this mode In this case a CO2 sensor...

Page 54: ...aged ENTER CANCEL JOY C PWR 7 7 77 Clg Engaged LeadLag Engaged Press Enter Joy Stick Down 2 Step 6 By toggling down 4 times the screen reaches the ClgOcc SP screen or Cooling Occupied Set Point ENTER CANCEL JOY C PWR 7 7 77 LeadLag Engaged ClgOcc SP Press Enter T Step 8 In order to change set points push the toggle switch left or right Note The screen ÀDVKHV HIW GHFUHDVHV WKH YDOXH ULJKW increases...

Page 55: ...B microprocessor connects through circuit trace to the SD 24 terminal SD 24 24 VAC hot out for factory accessory smoke detector condensate overflow and or user shutdown relay switching in series Connects through circuit trace to thermostat connection strip SD 24 A wiring harness jumper plug connecting SD 24 to SD R is in place if factory accessories for unit shutdown are not used this jumper plug ...

Page 56: ...t indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout networking error and firmware error indicator 1 2 second on off flashing indicates one or more alarm is currently active 1 10th second on off flashing indicates a networking error polarity addressing etc or a firmware error likely correctable with re loading from USB flash drive SA BUS Green UCB SA bus communication transm...

Page 57: ...rmistor Input required for operation of 2 compressor units not active for 1 compressor units 3 625 VDC reading EC2 to EC2 with open circuit Used in suction line temperature safety Pinned connections on right edge of UCB RAH Return Air Humidity input from 0 10 VDC 0 100 RH sensor Input required for reheat units optional in all other units may be a communicated value Used in return air enthalpy calc...

Page 58: ...s reheat components Effective only for reheat units output with reheat operation FAN 24 VAC hot output for indoor blower contactor coil indoor blower VFD enable relay coil Output with heat cool operation G input or schedule demand C1 24 VAC hot output for compressor 1 If demand is present and permissions allow compressor 1 operation output with compressor cooling comfort ventilation cooling reheat...

Page 59: ...enter of the board Positive of the 15 VDC reading to C circuit for powering an optional netstat and or Multi Touch gateway C Common for SA BUS power and communication circuits Also incorporated in the J8 6 pin phone jack connector at the left center of the board Negative of the SA BUS circuits Communication for SA BUS devices Also incorporated in the J8 6 pin phone jack connector at the left cente...

Page 60: ...r switch for the FC BUS BACnet MSTP communication circuit ON selected only for the UCB that is the terminus of the FC bus BACnet MSTP communication cable to prevent signal bounce back LEDs on the communication board 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 commun...

Page 61: ...This confidence is supported by the 30 day dealer protection coverage portion of our standard warranty policy which states that Johnson Controls UPG will cover parts and labor on new equipment start up failures that are caused by a defect in factory workmanship or material for a period of 30 days from installation Refer to current standard warranty policy and warranty manual found on UPGnet for de...

Page 62: ...ull open position and the frequency drive is operating at 60 HZ Do not proceed with the equipment start up without the design CFM information Design Supply Air CFM __________________________ Design Return Air CFM ______________________________________ Design Outdoor Air CFM At Minimum Position ________________________________________________________ Total External Static Pressure _________________...

Page 63: ... and control complete Air Moving Inspection Completed See Notes Alignment of drive components Belt tension adjusted properly Blower pulleys tight on shaft bearing set screws tight wheel tight to shaft Pressure switch or transducer tubing installed properly Exhaust Inspection Powered Barometric Relief Completed See Notes Check hub for tightness Check fan blade for clearance Check for proper rotatio...

Page 64: ...y to increase of decrease the airflow to meet the design conditions If the motor pulley size was changed measure the outside diameters of the motor and blower pulleys and record those diameters here Blower Motor HP _______________________________ FLA________ RPM________ Pulley Pitch Diameter ______________Turns Out________ Final Turns Out________ Blower Pulley Pitch Diameter ________________ Fixed...

Page 65: ... Return Air Temperature ________________ F db ________________ F wb ________________ RH Mixed Air Temperature ________________ F db ________________ F wb ________________ RH Supply Air Temperature ________________ F db ________________ F wb ________________ RH Action Completed See Notes Prove Compressor Rotation 3 phase only by gauge pressure Prove High Pressure Safety All Systems Prove Low Pressu...

Page 66: ...______________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _________________________...

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