York International ZQ Series Installation Manual Download Page 79

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Burners/Orifices Inspection/
Servicing

About this task:

Before checking or changing burners or orifices,

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 & gas valve assembly. Orifices

can now be inspected and/or replaced.

To service burners, complete step 4.

4. Remove the heat shield on top of the manifold

supports. Burners are now accessible for

inspection and/or replacement.

Note:

Reverse the above procedure to

replace the assemblies.

Make sure that burners are level and seat at the

rear of the gas orifice.

Figure 29: Typical Flame

Note:

installation of this furnace at

altitudes above 2000 ft (610 m) shall be

in accordance with local codes, or in

the absence of local codes, the National

Fuel Gas Code, ANSI Z223.1/NFPA 54 or

National Standard of Canada, Natural Gas

and Propane Installation Code, CSA B149.1.

Figure 30: 3 Thru 5 Ton, 1/2” Single Stage Gas Valve

INSTALLATION MANUAL ZQ SERIES 3 - 5 ton 60 Hertz R-410A

Johnson Controls Ducted Systems

Summary of Contents for ZQ Series

Page 1: ...5943355 UIM A 1020 York International Corporation 5005 York Drive Norman OK 73069 2020 10 01 Johnson Controls Ducted Systems INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A ...

Page 2: ...2 INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A Johnson Controls Ducted Systems ...

Page 3: ...ptions Accessories 42 Economizer 42 Power Exhaust 42 Rain Hood 42 Blower Phasing 42 Blower Rotation 43 Belt Tension 44 Altitude and Temperature Correction for CFM Static Pressure and Power 44 Airflow Performance 46 ZQ04 06 Side Duct Application Belt Drive 47 ZQ04 06 Side Duct Application Direct Drive 48 ZQ04 06 Bottom Duct Application Belt Drive 49 ZQ04 06 Bottom Duct Application Direct Drive 50 R...

Page 4: ...s Heat Input 76 Single Stage Gas Heat 76 Two Stage Gas Heat 76 Manifold Gas Pressure Adjustment 77 Single Stage 77 Two Stage 77 Adjustment Of Temperature Rise 78 Burners Orifices Inspection Servicing 79 Start up for Units Equipped for FER 80 Direct Drive 80 Troubleshooting 81 Charging Tables 84 Control Board Navigation Components 86 Start Up Sheet 87 INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz ...

Page 5: ...mpliance 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 or p...

Page 6: ...ght 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 furnace and its individual shut off valve must be disconnected from the gas supp...

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 ZQ SERIES 3 5 ton 60 Hertz R 410A 8 Johnson Controls Ducted Systems ...

Page 9: ...eath 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 Preceding Installation 1 Remove the two screws that hold the brackets in the forklift slots on the side of the unit Figure 1 Unit sh...

Page 10: ...m 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 read the return air temperature not mixed return air and outdoor air temperatures b Use the excess wire available to its full length to drop or mount the RAT sensor in the duct c You can use the shipping bracket to hold the RAT sensor in ...

Page 11: ... at the dealer s and or customer s expense Size of unit for proposed installation should be based on heat loss heat gain calculation made according to the methods of Air Conditioning Contractors of America ACCA This furnace is not to be used for temporary heating of buildings or structures under construction Table 1 ZQ04 06 Unit Limitations Unit Limitations Applied Voltage Outdoor DB Temp Model Si...

Page 12: ...SI 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 for clearances required for combustible construction servicing and proper unit operation WARNING Do not permit overhanging structures or shrubs to obstruct condenser air discharge outlet combustion air i...

Page 13: ... 154 144 123 131 104 99 95 81 85 89 ZQG 06 5 639 610 36 26 165 157 141 147 111 107 104 93 96 99 Table 3 ZQ04 06 Unit Accessory Weights Unit Accessory Weights lb Vertical Flow Dry Bulb Economizer Small Footprint 55 Horizontal Flow Dry Bulb Economizer Small Footprint Short 74 Horizontal Flow Dry Bulb Economizer Small Footprint Tall 76 Power Exhaust Vert Flow Small Footprint 55 Power Exhaust Horiz Fl...

Page 14: ...Figure 11 ZQ04 05 Unit Dimensions INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 14 Johnson Controls Ducted Systems ...

Page 15: ...Figure 12 ZQ06 Unit Dimensions INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 15 Johnson Controls Ducted Systems ...

Page 16: ... the roof curb the following field installed accessories can be purchased thru your dealer or contractor 1TB0401 Thru the base electrical and thru the curb gas 1TB0403 Thru the base electrical and gas Ductwork Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of America ACCA or as recommended by any other recognized authority such as ASH...

Page 17: ... removed from original panel location Seals around duct openings must be tight CAUTION When fastening ductwork to side duct flanges on unit insert screws through duct flanges only DO NOT insert screws through casing Outdoor ductwork must be insulated and water proofed Figure 14 Side Duct Cover Panels Note Shown with duct connection cover panel as shipped Figure 15 Bottom Return Opening For Side Du...

Page 18: ...imited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch metering device or coil Units are shipped with compressor mountings which are factory adjusted and ready for operation CAUTION Do not loosen compressor mounting bolts Filters Two inch filters are supplied with each unit Four inch filters may be used with no modificatio...

Page 19: ...nstalling a field supplied disconnect switch CAUTION 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...

Page 20: ...al Field Power and Control Wiring Typical Power Wiring Figure 18 Everyday Thermostat Control ETC typical power wiring INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 20 Johnson Controls Ducted Systems ...

Page 21: ...Figure 19 Typical Smart Equipment Control Wiring INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 21 Johnson Controls Ducted Systems ...

Page 22: ...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 34 3 35 50 34 135 35 8 40 50 36 139 106...

Page 23: ... 31 8 35 45 32 119 11125 7 9 1 21 9 37 9 40 45 35 117 39 3 40 45 36 119 208 3 60 16 110 25 2 3 8 4 1 1 11625 12 1 33 3 52 1 60 60 48 117 53 5 60 60 49 119 None 29 9 30 45 30 117 30 9 35 45 31 119 10625 6 5 1 15 6 29 9 30 45 30 117 30 9 35 45 31 119 11125 10 5 1 25 3 41 1 45 45 38 117 42 4 45 45 39 119 230 3 60 16 110 25 2 3 7 6 1 11625 16 1 38 5 57 6 60 60 53 117 58 9 60 60 54 119 None 15 1 20 20 ...

Page 24: ...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 38 6 40 50 39 140 40 1 45 50 40 143 10625 4 9 1 23 6 45 ...

Page 25: ...40 50 37 124 11125 7 9 1 21 9 43 3 45 50 40 121 44 6 45 50 41 124 208 3 60 16 110 25 2 3 8 4 1 1 8 6 11625 12 1 33 3 57 5 60 60 53 121 58 9 60 60 54 124 None 34 2 35 50 35 121 35 2 40 50 36 124 10625 6 5 1 15 6 34 4 35 50 35 121 35 6 40 50 36 124 11125 10 5 1 25 3 46 5 50 50 43 121 47 8 50 50 44 124 230 3 60 16 110 25 2 3 7 6 1 8 6 11625 16 1 38 5 63 70 70 58 121 64 3 70 70 59 124 None 17 3 20 25 ...

Page 26: ...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 33 5 35 50 33 166 35 35 50 35 170 10625 4...

Page 27: ...8 6 30 40 28 140 11125 7 9 1 21 9 33 9 35 40 31 137 35 3 40 40 32 140 208 3 60 16 110 25 2 3 5 2 1 1 11625 12 1 33 3 48 1 50 50 44 137 49 5 50 50 46 140 None 27 5 30 40 27 140 28 5 30 40 28 142 10625 6 5 1 15 6 27 5 30 40 27 140 28 5 30 40 28 142 11125 10 5 1 25 3 38 1 40 40 35 140 39 4 40 40 36 142 230 3 60 16 110 25 2 3 5 2 1 11625 16 1 38 5 54 6 60 60 50 140 55 9 60 60 51 142 None 13 7 15 20 13...

Page 28: ... 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 37 8 40 50 38 171 39 3 40 50 40 174 10625 4...

Page 29: ...35 45 33 144 11125 7 9 1 21 9 39 3 40 45 36 142 40 6 45 45 37 144 208 3 60 16 110 25 2 3 5 2 1 1 8 6 11625 12 1 33 3 53 5 60 60 49 142 54 9 60 60 50 144 None 31 8 35 45 32 144 32 8 35 45 33 147 10625 6 5 1 15 6 31 8 35 45 32 144 32 8 35 45 33 147 11125 10 5 1 25 3 43 5 45 45 40 144 44 8 45 45 41 147 230 3 60 16 110 25 2 3 5 2 1 8 6 11625 16 1 38 5 60 60 60 55 144 61 3 70 70 56 147 None 15 9 20 20 ...

Page 30: ... 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 23 7 25 35 23 109 24 8 25 35 25 111 10625 4 9 1 13 6 23 7 25 35 23 109 24 9 25 35 25 111 11125 7 9 1 21 9 33 9 35 35 31 109 35 3 40 40 32 111 208 3 60 13 7 83 1 21 1 4 5 2 1 1 11625 12 1 33 3...

Page 31: ...70 30 8 35 45 31 172 10625 6 5 1 15 6 29 8 30 45 30 170 30 8 35 45 31 172 11125 10 5 1 25 3 41 45 45 38 170 42 3 45 45 39 172 230 3 60 16 110 25 2 3 7 5 1 11625 16 1 38 5 57 5 60 60 53 170 58 8 60 60 54 172 None 14 5 15 20 14 82 15 15 20 15 84 10646 6 1 7 2 14 5 15 20 12 82 15 15 20 13 84 11146 11 5 1 13 8 21 5 25 25 20 82 22 1 25 25 20 84 460 3 60 7 8 52 12 1 3 3 4 0 5 11446 14 1 16 8 25 3 30 30 ...

Page 32: ...0 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 28 30 40 28 113 29 1 30 40 30 116 10625 4 9 1 13 6 28 9 30 40 28 113 30 3 35 40 30 116 11125 7 9 1 21 9 39 3 40 40 36 113 40 6 45 45 37 116 208 3 60 13 7 83 1 21 1 4 5 2 1 1 8 6 11625 12 1 33 3...

Page 33: ...0 50 36 177 10625 6 5 1 15 6 34 3 35 50 35 174 35 5 40 50 36 177 11125 10 5 1 25 3 46 4 50 50 43 174 47 6 50 50 44 177 230 3 60 16 110 25 2 3 7 5 1 8 6 11625 16 1 38 5 62 9 70 70 58 174 64 1 70 70 59 177 None 16 7 20 20 17 85 17 2 20 20 17 86 10646 6 1 7 2 16 7 20 20 15 85 17 2 20 20 15 86 11146 11 5 1 13 8 24 2 25 25 22 85 24 8 25 25 23 86 460 3 60 7 8 52 12 1 3 3 4 0 5 8 6 11446 14 1 16 8 27 9 3...

Page 34: ...ING PERFORMANCE SINGLE PHASE Gas piping connection in 1 2 1 2 1 2 1 2 Heating Option L D M E Heating Model Low Low NOx Low Med Low NOx Med 1st Stage Heat input K Btu 82 2nd Stage Heat input K Btu 56 70 90 112 1st Stage Heat output K Btu 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 1 1 2 Temperature Rise Range ºF 28 46 35 58 44 74 55 ...

Page 35: ... x 10 Type Centrifugal Centrifugal Motor HP 3 4 3 4 EVAP FAN DATA DIRECT DRIVE Motor 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 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 Frame size 1 phase 56HZ 56HZ Motor HP 3 phase 2...

Page 36: ...PHASE Gas piping connection in 1 2 1 2 1 2 1 2 1 2 1 2 Heating Option L D M E N F Heating Model Low Low NOx Low Med Low NOx Med High Low NOx High 1st Stage Heat input K Btu 100 2nd Stage Heat input K Btu 56 70 90 112 118 145 1st Stage Heat output K Btu 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 1 1 1 1 2 Temperatur...

Page 37: ...10 x 10 Type Centrifugal Centrifugal Motor HP 1 1 EVAP FAN DATA DIRECT DRIVE Motor 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 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 Frame size 1 phase 56HZ 56HZ Motor HP 3 phase 2 4...

Page 38: ...NGLE PHASE Gas piping connection in 1 2 1 2 1 2 1 2 1 2 1 2 Heating Option L D M E N F Heating Model Low Low NOx Low Med Low NOx Med High Low NOx High 1st Stage Heat input K Btu 100 2nd Stage Heat input K Btu 56 70 90 112 118 145 1st Stage Heat output K Btu 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 1 1 1 1 2 Tempe...

Page 39: ... 1 1 Fan Size Inch 11 x 10 11 x 10 Type Centrifugal Centrifugal Motor HP 1 1 EVAP FAN DATA DIRECT DRIVE Motor RPM 1050 1050 Airflow Option B C B Quantity 1 1 1 Fan Size Inch 11 x 10 11 x 10 11 x 10 Type Centrifugal Centrifugal Centrifugal Motor Sheave 1VL34 1VL44 1VL34 Blower Sheave AK46 AK46 AK46 Belt A37 A39 A37 Motor HP 1 phase 1 5 1 5 Frame size 1 phase 56HZ 56HZ Motor HP 3 phase 2 4 2 9 2 4 F...

Page 40: ...ts require either a 1 2 or 3 4 inch pipe connection at the entrance fitting Line should not be sized smaller than the entrance fitting size Table 19 Gas Heat Supply Air Supply Air CFM Heating Model Size Gas Heat Description Opt Min Max Low NOx L 900 1480 Low D 890 1480 Med NOx M 900 1520 ZQ04 3 Med E 1060 1510 Low NOx L 1190 1980 Low D 1210 1990 Med NOx M 1190 2020 Med E 1200 2020 High NOx N 1200 ...

Page 41: ...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 to a pressure greater than 1 2 PSIG the gas valve must be replaced The furnace must be isolated from the gas supply piping system by c...

Page 42: ...s 1 Down Flow application 2 Horizontal Flow application that requires the purchase of a barometric relief hood Table 20 Supply Air Limitations Supply Air CFM Model Size Minimum Maximum ZQ04 3 900 1500 ZQ05 4 1200 2000 ZQ06 5 1500 2500 Rain Hood All of the hood components including the mist eliminators the gasketing and the hardware for assembling are packaged and located between the condenser coil...

Page 43: ...20V 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 phase motor rotation swap A or L1 and C or L3 only Blower Rotation Ch...

Page 44: ...ased on standard air at sea level As the altitude or temperature increases the density of air decreases In order to use the indoor blower tables for high altitude applications certain corrections are necessary A centrifugal fan is a constant volume device This means that if the rpm remains constant the CFM delivered is the same regardless of the density of the air However since the air at high alt...

Page 45: ...on is given so 70 F is assumed The 1 5 in static pressure 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 0 6 832 0 72 in Enter the blower table at 1 400 sCFM and static pressure of 0 72 in The rpm listed will be the same rpm needed at 5 000 ft Suppose that the corresponding BHP listed in the table ...

Page 46: ...1 1136 0 91 1214 1 01 1287 1 11 1356 1 20 1425 1 29 1494 1 39 1566 1 48 1644 1 57 1900 1091 0 91 1176 1 02 1254 1 12 1327 1 21 1397 1 31 1465 1 40 1534 1 49 1607 1 58 2000 1136 1 02 1222 1 13 1300 1 23 1372 1 32 1442 1 42 1510 1 51 1580 1 60 Medium Static Option with Motor rated at 2 4 hp High Static Option with Motor rated at 2 4 hp Field supplied AK41 x 3 4 fixed blower pulley with Motor rated a...

Page 47: ...AL 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 893 0 37 976 0 46 1054 0 56 1128 0 66 1199 0 75 1268 0 85 1336 0 94 1404 1 03 1474 1 12 1545 1 20 1300 910 0 43 993 0 52 1071 0 62 1144 0 72 1216 0 81 1285 0 91 1353 1 00 1421 1 09 1491 1 18 1562 1 26 1400 931 0 49 1014 0 59 1092 0 69 1166 0 78 1...

Page 48: ... 988 181 787 901 203 891 800 226 987 682 247 1071 2 MED LOW 1214 175 683 1094 206 810 965 232 896 898 258 1003 794 276 1084 3 MED 1402 234 735 1324 264 835 1161 302 947 1074 329 1034 986 351 1114 4 MED HI 1570 310 791 1512 348 884 1429 381 977 1253 420 1079 1130 423 1148 ZQ04 3 5 HI 1825 448 866 1769 487 946 1705 521 1023 1610 559 1107 1229 472 1159 1 LOW 1412 261 793 1322 290 884 1244 321 966 110...

Page 49: ...nce includes gas heat exchangers and 2 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 31 ZQ05 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 BH...

Page 50: ...hangers and 2 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 ZQ04 06 Bottom Duct Application Direct Drive Table 33 ZQ04 06 Bottom Duct Cooling 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 C...

Page 51: ... Motor Sheave 6 Turns Open 5 Turns Open 4 Turns Open 3 Turns Open 2 Turns Open 1 Turns Open Fully Closed Std Direct Drive Med 1 1 5 AK46 1VL34 N A 792 875 958 1042 1125 1208 Med 3 2 4 AK46 1VL34 N A 792 875 958 1042 1125 1208 ZQ 04 3 H Static 3 2 4 AK46 1VL44 N A 1167 1250 1333 1417 1500 1593 Std Direct Drive Med 1 1 5 AK46 1VL34 N A 792 875 958 1042 1125 1208 Med 3 2 4 AK46 1VL34 N A 792 875 958 ...

Page 52: ... CFM The variable pitch motor sheave is set at 4 turns open Use the equation to determine the required DD for the new motor sheave Use Table 37 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 Ta...

Page 53: ...0 36 0 95 0 06 0 06 0 08 0 09 2300 0 41 1 03 0 06 0 06 0 09 0 10 2400 0 45 1 10 0 07 0 07 0 10 0 11 04 3 0 05 4 0 2500 0 50 1 17 0 08 0 08 0 11 0 12 1800 0 23 0 66 0 03 0 03 0 05 0 06 2000 0 28 0 81 0 04 0 04 0 07 0 08 2200 0 32 0 95 0 06 0 06 0 08 0 09 ZQ 06 5 0 2400 0 37 1 10 0 07 0 07 0 10 0 11 1 Add these values to the available static resistance in the respective Blower Performance Tables 2 D...

Page 54: ...ction 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 Con...

Page 55: ...units 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 st...

Page 56: ... is energized with a call for fan on the ETC 24VAC will be applied to FAN1 output and 6VDC will be applied to VFD output to produce 50 fan speed Table 41 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 7 HPS1 fault ...

Page 57: ...eter 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 58: ...t 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 loa...

Page 59: ... flash drive F J15 Factory wired SA Bus connector Table 48 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 49 Smart Equipment U...

Page 60: ...circuit 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 preve...

Page 61: ... 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 56 Cable for FC Buses and SA Buses in Order of Preferen...

Page 62: ...ergized Otherwise the unit operates until the minimum run has been completed Upon the compressor de energizing the blower is stopped following the elapse of the fan off delay for cooling The call is passed to the Unit Control Board UCB which then determines whether the requested operation is available and if so which components to energize If at any time a call for both heating and cooling are pre...

Page 63: ...ergized 45 seconds after the actuator position exceeds the exhaust fan set point on the economizer control When the power exhaust is operating the second stage of mechanical cooling will not operate 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 o...

Page 64: ...rost the indoor coil Low ambient mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor operation The off cycle will begin immediately following the elapse of the minimum run time When operating in low ambient mode an Evaporator Low Limit Sensor EC1 temperature below 26oF will de energize the compressor If the call for cooling is still present...

Page 65: ... will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space Electric Heat Operating Errors Temperature Limit If the UCB senses zero volts from the high temperature limit the indoor blower motor is immediately energized This limit is monito...

Page 66: ...g a single stage thermostat cut the 440 GY wire that runs from pin 2 of the S3 connector on the UCB unit control board to P2 4 on the ignition control board Cut the wire 1 2 in from the S3 mate n lock connector Wire nut or tape off the 1 2 in wire Attach the other end of the 440 GY wire to the R terminal on the UCB or to the TB1 power strip The unit will operate the same as a W1 only call for heat...

Page 67: ... out into the burner manifold area the roll out switch will open the ICB will close both the main and pilot gas valves and flash a code see Table 57 The ICB will not retry the ignition sequence during the same call for heat Flame Sense Circuit The flame sensor is mounted on the left hand side of the burner assembly and is positioned such that the pilot flame surrounds the tip of the sensor On a ca...

Page 68: ...irmware 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 com...

Page 69: ...ANALOG 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 V...

Page 70: ...ality AQ Indoor Air Quality indoor sensor input Terminal AQ accepts a 2 to 10 VDC signal with respect to the AQ1 terminal When the signal is below it s set point the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs When the AQ signal exceeds it s set point setting and there is no call for free cooling the actuator is proportionately modulated fro...

Page 71: ...is present again on the MV terminal Note If 24 V is present on the MV terminal without a call for heat an alarm appears and the fan output energizes If this condition occurs for 6 minutes an alarm appears and remains until the alarm condition is cleared 5 At any time if 24 V is lost on the LIMIT terminal the FAN output for indoor fan operation is energized If 24 V is lost on the LIMIT input 3 time...

Page 72: ...aximum 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 73: ...r 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 s...

Page 74: ...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 Cooling 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 th...

Page 75: ...ping 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 corre...

Page 76: ...st dial 4 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 5 If necessary adjust the high pressure regulator as discussed in the section Manifold Gas Pressure Adjustment Be sure not to over fire the furnace on second stage If in doubt it is better to leave the second stage of the furnace slightly under fired Rep...

Page 77: ...screw covering the pressure adjustment screw 4 Turn on power to the unit 5 Set thermostat to call for heat and start furnace 6 If necessary using a screwdriver turn the adjustment screw clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure 7 Once pressure has been checked replace the plastic cap covering the pressure adjustment screw Two Stage About this task Th...

Page 78: ...6 Low D 2 70 70 Med NOx M 3 90 90 Med E 3 112 112 High NOx N 3 116 116 ZQ06 5 Single Phase High F 3 142 142 Low NOx L 2 56 56 Low D 2 70 70 Med NOx M 3 90 90 Med E 3 112 112 High NOx N 3 118 118 ZQ06 5 Three Phase High F 3 100 145 145 Adjustment Of Temperature Rise The temperature rise the difference of temperature between the return air and the heated air from the furnace must lie within the rang...

Page 79: ...vice burners complete step 4 4 Remove the heat shield on top of the manifold supports Burners are now accessible for inspection and or replacement Note Reverse the above procedure to replace the assemblies Make sure that burners are level and seat at the rear of the gas orifice Figure 29 Typical Flame Note installation of this furnace at altitudes above 2000 ft 610 m shall be in accordance with lo...

Page 80: ...e motor and provides different speeds The leads are set 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 t...

Page 81: ...AST HEARTBEAT 22 NO ALARMS IN MEMORY 2 PULSES 2 PULSES 23 NORMAL IDLE OFF SLOW HEARTBEAT 24 FACTORY TEST MODE RAPID FLASH RAPID FLASH Table 62 Flash Codes for the Gas Heat Ignition Control Board Flash Code Description Technician Corrective Action Ignition Control Response to Flash Code Method for Reset Heartbeat Normal Operation no status or error information currently needs to be displayed None A...

Page 82: ...ening and adjusted to provide proper manifold pressure Verify that the wiring to the gas valve is intact Verify that there is no wind rain or snow entering the heat compartment to interfere with ignition or the burners Verify that there are no conditioned air leaks or heat exchanger breaches to interfere with ignition or the burners Immediately after the third ignition trial the gas valve output r...

Page 83: ...s been lost to the control s limit switch input P1 9 pin for a duration of more than 6 minutes with 24 VAC present at the control s W1 input P2 3 pin Correct the no extremely low indoor airflow condition Verify filters indoor coil and blower wheel are clean Verify that the blower belt is intact properly maintained and adjusted the blower motor fuses are intact contactor and motor are operable and ...

Page 84: ... 89 19 9 0 400 Cfm Ton 75 62 95 136 59 357 101 19 10 1 Table 64 ZQ05 Charging Table Air Flow Indoor Db Wb Outdoor DB F Suction P psig Suction Temp F Liquid P psig Liquid Temp F Delta T Db F Compr amps 75 128 57 277 82 27 10 8 85 129 54 320 94 28 12 3 300 Cfm Ton 80 62 95 131 50 363 106 28 13 8 75 132 64 277 81 25 10 8 85 137 61 323 92 24 12 4 300 Cfm Ton 80 67 95 143 59 368 103 23 13 9 75 137 70 2...

Page 85: ...m Ton 80 72 95 150 70 376 98 21 18 1 75 130 63 279 78 23 14 0 85 132 61 321 88 23 15 8 300 Cfm Ton 75 62 95 135 60 363 99 23 17 7 75 138 70 285 77 23 14 3 85 141 69 328 88 23 16 2 400 Cfm Ton 80 62 95 144 68 371 98 23 18 1 75 139 70 286 77 22 14 4 85 144 70 330 87 21 16 2 400 Cfm Ton 80 67 95 148 70 374 98 21 18 1 75 140 70 287 77 22 14 4 85 146 71 332 87 20 16 3 400 Cfm Ton 80 72 95 151 72 377 97...

Page 86: ...ortable 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 LIT 120...

Page 87: ...Start Up Sheet INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 87 Johnson Controls Ducted Systems ...

Page 88: ... INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 88 Johnson Controls Ducted Systems ...

Page 89: ... INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 89 Johnson Controls Ducted Systems ...

Page 90: ... INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 90 Johnson Controls Ducted Systems ...

Page 91: ... INSTALLATION MANUAL ZQ SERIES 3 5 ton 60 Hertz R 410A 91 Johnson Controls Ducted Systems ...

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