York ZD Series Installation Manual Download Page 1

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R-410A
ZD SERIES

3 - 5 Ton

60 Hertz

5188236-BIM-A-0316

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 Cool/Heat Control Wiring (Simplicity Lite ZD-03 Thru -05)

Typical Cool/Heat Control Wiring (Simplicity S E ZD-03 Thru -05)

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Economizer And Power Exhaust Set Point Adjustments . . . . . 34

Jade Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34

Simplicity SE Economizer Sequences . . . . . . . . . . . . . . . . . . . 36

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 50

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 52

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53

Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 55

Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Simplicity SE Control Board Navigation Components . . . . . . . . . 67

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

Unit Control Board Navigation Examples: . . . . . . . . . . . . . . . . 68

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

LIST OF TABLES

1 ZD-03 Thru -05 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . 6

2 ZD-03 Thru -05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZD-03 Thru -05 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8

4 ZD-03 Thru -05 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10

5 ZD-03 Thru -05 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . 11

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

7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 ZD-03 Thru -05 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 29

9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31

10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31

11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32

12 Single Enthalpy and Dual Enthalpy High Limit Curves. . . . . . 36

13 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . . . 38

14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42

15 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45

16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 47

17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48

19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 48

20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 50

21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53

23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 55

24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 55

25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 55

26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 58

27 ZD-03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61

28 ZD-04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61

29 ZD-05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 62

30 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 67

31 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 67

Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

LIST OF FIGURES

1 ZD-03 thru -05 Component Location . . . . . . . . . . . . . . . . . . . 6

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

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

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

5 ZD-03 Thru -05 Cooling Only/Electric Heat Front View Physical

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

6 ZD-03 Thru -05 Cooling Only/Gas Heat Front View Physical

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

7 ZD-03 Thru -05 Fixed Outdoor Air Motorized Damper Rain

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

8 ZD-03 Thru -05 Disconnect Location . . . . . . . . . . . . . . . . . . 10

9 ZD-03 Thru -05 Unit Side Duct Openings . . . . . . . . . . . . . . . 11

10 ZD-03 Thru -05 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

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

14 Typical Simplicity SE Control Wiring . . . . . . . . . . . . . . . . . . 16

15 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

17 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 34

18 Economizer LCD and Keypad Layout. . . . . . . . . . . . . . . . . . 34

19 Single Enthalpy Curve And Boundaries . . . . . . . . . . . . . . . . 35

20 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38

21 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

22 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43

23 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 49

24 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

25 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 56

26 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 56

27 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 57

28 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 57

29 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Summary of Contents for ZD Series

Page 1: ... and Dual Enthalpy High Limit Curves 36 13 Simplicity SE Economizer Board Details 38 14 Altitude Temperature Correction Factors 42 15 ZD Blower Performance Side Duct 45 16 ZD Blower Performance Bottom Duct 47 17 Belt Drive RPM Selection 48 18 Indoor Blower Specifications Belt Drive 48 19 Power Exhaust Specifications 48 20 Additional Static Resistance 50 21 Electric Heat Limit Setting 53 22 Electri...

Page 2: ...ctices and hazards involving only property damage Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified contractor installer or service ag...

Page 3: ...certified by CSA as follows 1 For use as a cooling only unit cooling unit with supplemental electric heat or a forced air furnace 2 For outdoor installation only 3 For installation on combustible material 4 For use with natural gas convertible to LP with kit This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national c...

Page 4: ...binet B HDF HingedFLTR Tooless DR E SSD SST Drain Pan F SSD HFD A No Economizer C Economizer w o Barometric RLF F Econ BAS Rdy w o Barometric RLF H Motorized Damper Outdoor Air Option 1 No Service Options 2 DSC Disconnect Switch 3 NCO Non PWR Conv Outlet 4 PCO Powered Conv Outlet 5 DSC NCO 6 DSC PCO A No Sensors B PHM Phase Monitor C DFS Dirty Filter Switch D SSD Supply Air Smoke DET E RSD Return ...

Page 5: ...s 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 to a un...

Page 6: ...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 ZD 03 Thru 05 Unit Limitations Size Tons Unit Voltage Unit Limitations Applied Voltage Outdoor DB Temp Min Max Max F ZD 03 3 0 208 230 1 60 187 252 125 208 230 3 ...

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: ...perating X Y A B C D A B C D E F 03 3 475 470 34 5 18 25 111 80 117 162 78 62 51 74 91 114 04 4 603 598 36 18 5 139 108 154 198 96 81 69 98 116 137 05 5 637 632 37 5 18 2 139 117 171 204 96 85 76 111 124 140 Table 3 ZD 03 Thru 05 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 for the ma...

Page 9: ...36 BIM A 0316 Johnson Controls Unitary Products 9 Figure 5 ZD 03 Thru 05 Cooling Only Electric Heat Front View Physical Dimensions Figure 6 ZD 03 Thru 05 Cooling Only Gas Heat Front View Physical Dimensions ...

Page 10: ... 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 outlet ...

Page 11: ...5 Roof Curb Table 5 ZD 03 Thru 05 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: ...mostat to the unit Refer to Table 6 for control wire sizing and 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 ...

Page 15: ...N AND WIRING OCC C RC G Y2 Y1 W2 W1 X R THERMOSTAT TERMINALS CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 2 4 Second stage ŚĞĂƟŶŐ Ŷot required on single stage heĂƟŶg units Jumper is required if there is no Smoke Detector circuit 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...

Page 16: ...3 1 2 4 Second stage ŚĞĂƟŶŐ Ŷot required on single stage heĂƟŶg units Jumper is required if there is no Smoke Detector circuit 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 2 24V C 24 VAC Class 2 SD 24 Jumper Located on H...

Page 17: ...2 51 69 1 70 460 3 60 5 8 38 9 1 3 2 1 0 NONE 10 6 15 E07 6 8 1 8 2 12 8 15 E10 10 1 1 12 1 17 8 20 E15 13 6 2 16 4 23 1 25 E20 19 5 2 23 5 31 9 35 575 3 60 4 2 36 5 5 9 1 3 1 9 0 NONE 8 2 15 E10 10 6 1 10 2 15 1 20 E15 15 9 2 15 3 21 5 25 E20 21 2 2 20 4 27 9 30 04 4 0 208 1 60 19 6 130 30 5 2 3 6 7 0 NONE 33 5 45 E05 4 1 19 2 33 5 45 E07 5 6 1 26 9 42 50 E10 8 1 38 5 56 5 60 E15 11 9 2 57 2 79 9...

Page 18: ...30 3 60 16 110 24 9 4 4 4 3 0 NONE 28 7 35 E05 5 3 1 12 7 28 7 35 E07 7 5 1 18 28 7 35 E10 10 6 1 25 5 37 2 40 E15 15 9 2 38 2 53 2 60 E20 21 2 2 51 69 1 70 E30 29 6 2 71 2 94 4 100 460 3 60 7 8 52 12 1 4 4 2 1 0 NONE 14 1 20 E07 6 8 1 8 2 14 1 20 E10 10 1 1 12 1 17 8 20 E15 13 6 2 16 4 23 1 25 E20 19 5 2 23 5 31 9 35 E30 28 8 2 34 6 45 9 50 575 3 60 5 7 38 9 8 9 4 4 1 9 0 NONE 10 8 15 E10 10 6 1 ...

Page 19: ...9 1 70 460 3 60 5 8 38 9 1 3 2 1 0 NONE 10 6 15 E07 6 8 1 8 2 12 8 15 E10 10 1 1 12 1 17 8 20 E15 13 6 2 16 4 23 1 25 E20 19 5 2 23 5 31 9 35 575 3 60 4 2 36 5 5 9 1 3 1 9 0 NONE 8 2 15 E10 10 6 1 10 2 15 1 20 E15 15 9 2 15 3 21 5 25 E20 21 2 2 20 4 27 9 30 04 4 0 208 1 60 19 6 130 30 5 2 3 6 7 0 NONE 33 5 45 E05 4 1 19 2 33 5 45 E07 5 6 1 26 9 42 50 E10 8 1 38 5 56 5 60 E15 11 9 2 57 2 79 9 80 E2...

Page 20: ...2 12 1 4 4 3 15 0 NONE 15 1 20 E07 6 8 1 8 2 15 1 20 E10 10 1 1 12 1 19 1 20 E15 13 6 2 16 4 24 4 25 E20 19 5 2 23 5 33 3 35 E30 28 8 2 34 6 47 2 50 575 3 60 5 7 38 9 8 9 4 4 2 2 0 NONE 11 1 15 E10 10 6 1 10 2 15 5 20 E15 15 9 2 15 3 21 9 25 E20 21 2 2 20 4 28 2 30 E30 30 4 2 29 3 39 3 40 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC ZD 03 Thru 05 Without Powered Co...

Page 21: ... 4 30 E07 5 6 1 15 5 26 9 30 E10 8 1 22 2 35 3 40 E15 11 9 2 33 48 8 50 E20 15 9 2 44 1 62 7 70 230 3 60 10 4 73 16 3 2 3 6 0 NONE 21 3 30 E05 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 04 4 0 208 1 60 19 6 130 30 5 2 3 7 6 0 NONE 34 4 45 E05 4 1 19 2 34 4 45 E07 5 6 1 26 9 43 2 50 E10 8 1 38 5 57 6 60 E15 11 9 2 57 2 81 90 E20 15 ...

Page 22: ... 7 6 0 NONE 32 40 E05 4 1 11 1 32 40 E07 5 6 1 15 5 32 40 E10 8 1 22 2 37 3 45 E15 11 9 2 33 50 8 60 E20 15 9 2 44 1 64 7 70 E30 22 2 2 61 6 86 5 90 230 3 60 16 110 24 9 4 4 7 6 0 NONE 32 40 E05 5 3 1 12 7 32 40 E07 7 5 1 18 32 1 40 E10 10 6 1 25 5 41 4 45 E15 15 9 2 38 2 57 3 60 E20 21 2 2 51 73 2 80 E30 29 6 2 71 2 98 5 100 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type pe...

Page 23: ...60 3 60 5 8 38 9 1 3 2 1 5 NONE 15 6 20 E07 6 8 1 8 2 19 1 20 E10 10 1 1 12 1 24 1 25 E15 13 6 2 16 4 29 3 30 E20 19 5 2 23 5 38 2 40 575 3 60 4 2 36 5 5 9 1 3 1 9 4 NONE 12 2 15 E10 10 6 1 10 2 20 1 25 E15 15 9 2 15 3 26 5 30 E20 21 2 2 20 4 32 9 35 04 4 0 208 1 60 19 6 130 30 5 2 3 6 7 10 NONE 43 5 60 E05 4 1 19 2 44 9 60 E07 5 6 1 26 9 54 5 60 E10 8 1 38 5 69 70 E15 11 9 2 57 2 92 4 100 E20 15 ...

Page 24: ...0 230 3 60 16 110 24 9 4 4 4 3 10 NONE 38 7 50 E05 5 3 1 12 7 38 7 50 E07 7 5 1 18 40 4 50 E10 10 6 1 25 5 49 7 50 E15 15 9 2 38 2 65 7 70 E20 21 2 2 51 81 6 90 E30 29 6 2 71 2 106 9 110 460 3 60 7 8 52 12 1 4 4 2 1 5 NONE 19 25 E07 6 8 1 8 2 19 1 25 E10 10 1 1 12 1 24 1 25 E15 13 6 2 16 4 29 3 30 E20 19 5 2 23 5 38 2 40 E30 28 8 2 34 6 52 2 60 575 3 60 5 7 38 9 8 9 4 4 1 9 4 NONE 14 8 15 E10 10 6...

Page 25: ...6 90 460 3 60 5 8 38 9 1 3 2 1 5 NONE 15 6 20 E07 6 8 1 8 2 19 1 20 E10 10 1 1 12 1 24 1 25 E15 13 6 2 16 4 29 3 30 E20 19 5 2 23 5 38 2 40 575 3 60 4 2 36 5 5 9 1 3 1 9 4 NONE 12 2 15 E10 10 6 1 10 2 20 1 25 E15 15 9 2 15 3 26 5 30 E20 21 2 2 20 4 32 9 35 04 4 0 208 1 60 19 6 130 30 5 2 3 6 7 10 NONE 43 5 60 E05 4 1 19 2 44 9 60 E07 5 6 1 26 9 54 5 60 E10 8 1 38 5 69 70 E15 11 9 2 57 2 92 4 100 E...

Page 26: ...52 12 1 4 4 3 15 5 NONE 20 1 25 E07 6 8 1 8 2 20 4 25 E10 10 1 1 12 1 25 4 30 E15 13 6 2 16 4 30 6 35 E20 19 5 2 23 5 39 5 40 E30 28 8 2 34 6 53 5 60 575 3 60 5 7 38 9 8 9 4 4 2 2 4 NONE 15 1 20 E10 10 6 1 10 2 20 5 25 E15 15 9 2 15 3 26 9 30 E20 21 2 2 20 4 33 2 35 E30 30 4 2 29 3 44 3 45 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR type per NEC ZD 03 Thru 05 With Powered Conv...

Page 27: ...40 E07 5 6 1 15 5 39 4 40 E10 8 1 22 2 47 8 50 E15 11 9 2 33 61 3 70 E20 15 9 2 44 1 75 2 80 230 3 60 10 4 73 16 3 2 3 6 10 NONE 31 3 40 E05 5 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 04 4 0 208 1 60 19 6 130 30 5 2 3 7 6 10 NONE 44 4 60 E05 4 1 19 2 46 60 E07 5 6 1 26 9 55 7 60 E10 8 1 38 5 70 1 80 E15 11 9 2 57 2 93 5 100 E20 15 ...

Page 28: ... 4 4 7 6 10 NONE 42 50 E05 4 1 11 1 42 50 E07 5 6 1 15 5 42 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 E30 22 2 2 61 6 99 100 230 3 60 16 110 24 9 4 4 7 6 10 NONE 42 50 E05 5 3 1 12 7 42 50 E07 7 5 1 18 44 6 50 E10 10 6 1 25 5 53 9 60 E15 15 9 2 38 2 69 8 70 E20 21 2 2 51 85 7 90 E30 29 6 2 71 2 111 125 1 Minimum Circuit Ampacity 2 Dual Element Time Delay Type 3 HACR typ...

Page 29: ...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 DIMENSIONS inches Length 82 1 4...

Page 30: ... 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 1740 1740 1740 Frame size 56 56 56 DIRECT DRIVE EVAP FAN DATA2 Quantity 1 1 1 Fan Size Inch 11 x 10 11 x 10 11 x 10 Type Centrifugal Centrifugal Centrifugal Motor HP each 3 4 1 1 RPM 1050 1050 1050 FILTERS 15 x 20 x 1 or 2 2 2 2 14 x 25 x 1 or 2 ...

Page 31: ...t 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 Tons Voltage Minimum Supply Air CF...

Page 32: ...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 33: ...nt and Combustion Air Hood Figure 17 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 34: ...te the economizer control module where the following adjustments will be made Minimum Position Adjustment Check that the damper blades move smoothly without binding carefully turn the Minimum Position Adjust screw found on the damper control module fully clockwise and then set the thermostat indoor fan switch to the ON position and then OFF or energize and de energize terminals R to G With the the...

Page 35: ...s the button MenuUp Exit to return to the previous menu Menu Structure The Menus in display order are STATUS SETPOINTS SYSTEM SETUP ADVANCED SETUP CHECKOUT ALARMS NOTE Your menu parameters will be different depending on your configuration See the JADE Economizer Module accessory instruction P N 1150208 UAI A 0514 included in this instruction packet for additional menu information Economizer Setup ...

Page 36: ... both set points should be set to the same value Free Cooling Four types of free cooling options are available dry bulb changeover single enthalpy dual enthalpy changeover and Auto Dry Bulb Changeover For dry bulb economizer operation the outside air is suitable for free cooling if the outside air temperature is 1 F below the Economizer OAT Enable Setpoint and 1 F below the Return Air Temperature ...

Page 37: ...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 output be turned ON if the economizer output is less than 100 even if the differential between zone or return temperature and the current cooling setpoint is great enough to demand more than one stage of cooling If the economizer...

Page 38: ...ermistor 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 indicator Lit indicates 24 VAC is present at 24V IN COM and HOT pins FAULT FAULT Red networking error and firmware error indicator 1 10th second on off flashing indicates a networki...

Page 39: ...ng 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 position the economizer actuator for minimum position free cooling demand ventilation cooling economizer loading and purge functions COM 24 VAC common 0 10 VDC negative for economizer actuator Connects...

Page 40: ...C negative for the indoor air quality sensor Connects through circuit trace to 24V IN pin COM R 24V 24 VAC hot supplied for the outdoor air quality sensor Connects through circuit trace to 24V IN pin HOT IN6 OAQ 0 10 VDC positive input from the Outdoor Air Quality sensor OAQRange parameter sets the CO2 parts per million measured by the outdoor air quality sensor when it outputs 10 VDC OAQ paramete...

Page 41: ... as shown in Figure 20 C COM 24 VAC common 0 5 VDC negative for the building pressure sensor Connects through circuit trace to 24V IN pin COM BINARY INPUTS at right on lower edge of economizer board IN9 PURGE 24 VAC hot input from the PURGE dry contact Purge parameter reports input status False with 0 VAC input True with 24 VAC input When Purge status is True heating and cooling operation is preve...

Page 42: ...B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown Deflection distance of 4mm 5 32 is obtained To determine the deflection distance from normal position use a straight edge from sheave to sheave as reference line The recommended deflection force is as follows Tension new belts at the max deflection force recommended fo...

Page 43: ...32 0 56 Example 2 A system located at 5 000 feet of elevation is to deliver 1 400 CFM at a static pressure of 1 5 Use the unit blower tables to select the blower speed and the BHP requirement Solution As in the example above no temperature information is given so 70 F is assumed The 1 5 static pressure given is at an elevation of 5 000 ft The first step is to convert this static pressure to equiva...

Page 44: ...below Size X and Model Y is found 5 1 82 BHP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1478 RPM is within the range of the 2 HP drive 7 Using the 2 HP motor and drive 2 5 turns open will achieve 1478 RPM Example Supply Air Blower Performance Air Flow CFM Available External Static Pressure IWG 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP R...

Page 45: ... 0 49 942 0 58 1016 0 67 1087 0 76 1155 0 85 1221 0 96 1284 1 05 1345 1 16 1200 733 0 33 817 0 47 896 0 56 973 0 64 1047 0 73 1118 0 82 1186 0 92 1252 1 01 1315 1 11 1376 1 21 1400 770 0 42 853 0 56 933 0 63 1010 0 73 1083 0 81 1154 0 90 1222 1 00 1288 1 10 1352 1 19 1413 1 30 1600 811 0 55 895 0 67 974 0 76 1051 0 84 1125 0 94 1196 1 02 1264 1 12 1330 1 22 1393 1 32 1454 1 42 1800 857 0 73 940 0 ...

Page 46: ...146 258 1097 272 1031 288 962 303 919 313 2 MED LOW 1227 171 1178 183 1129 195 1076 207 1021 220 953 235 891 248 1 LOW 1075 130 992 134 930 145 858 158 43 5 HI 2067 696 2027 714 1991 734 1953 749 1910 764 1860 769 1770 743 1621 685 4 MED HI 1913 539 1877 557 1839 571 1798 585 1764 602 1721 619 1677 638 1621 653 1545 639 3 MED 1722 408 1682 426 1634 438 1597 455 1554 472 1506 490 1450 505 1404 521 ...

Page 47: ...029 0 67 1107 0 77 1181 0 85 1253 0 95 1322 1 05 1388 1 15 1200 722 0 40 812 0 48 899 0 56 983 0 64 1063 0 73 1140 0 82 1215 0 90 1286 1 01 1355 1 11 1422 1 20 1400 761 0 48 852 0 56 939 0 64 1022 0 73 1103 0 81 1180 0 89 1254 0 99 1326 1 08 1395 1 19 1462 1 29 1600 807 0 61 897 0 68 984 0 76 1068 0 84 1148 0 93 1225 1 02 1300 1 12 1371 1 21 1440 1 31 1507 1 40 1800 856 0 77 947 0 84 1034 0 93 111...

Page 48: ...3 1363 440 1312 455 1279 469 1235 485 1 LOW 1287 223 1246 237 1190 247 53 5 HI 2166 883 2169 931 2158 950 2134 964 2095 979 2040 971 1963 940 1881 898 1791 854 4 MED HI 2060 771 2042 784 2035 808 2006 826 1970 844 1934 859 1888 861 1821 843 1730 806 3 MED 1940 637 1920 656 1907 675 1870 696 1834 715 1802 730 1759 740 1722 756 1657 748 2 MED LOW 1688 413 1645 432 1611 451 1575 468 1534 479 1498 497...

Page 49: ... penetration into the air flow on both sides of the indoor coil NOTE The tubes must be inserted and held in a position perpendicular to the air flow so that velocity pressure will 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 ...

Page 50: ...ng 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 freezestat trip Simplicity Lite Control or Evaporator Low Limit sensor EC1 detecting a temperature below 26 F Simplicity SE Control and the anti short cycle delay ASCD must have elapsed Economizer With Single Enthalpy Sensor Simplicity Lite or Economizer With D...

Page 51: ...nser fan Once the low pressure switch has been proven closed during the 30 second monitor period described above the UCB will monitor the low pressure limit switch for any openings If the low pressure switch opens for greater than 5 seconds the UCB will de energize the compressor initiate the ASCD and stop the condenser fan If the call for cooling is still present at the conclusion of the ASCD the...

Page 52: ... is an abnormal temperature rise in a compressor the protector will open to shut down the compressor The UCB incorporates features to minimize compressor wear and damage An Anti Short Cycle Delay ASCD is utilized to prevent operation of a compressor too soon after its previous run Additionally a minimum run time is imposed any time a compressor is energized The ASCD is initiated on unit start up a...

Page 53: ...ut switch the centrifugal switch and the primary auxiliary temperature limit switch circuit If they are in the expected state then the ICB energizes the draft motor and verifies that the centrifugal switch 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 ener...

Page 54: ...irst control If 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 draf...

Page 55: ...e sure that it is the same as listed on the unit nameplate 2 Set the room thermostat to the off position 3 Turn unit electrical power on 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 ...

Page 56: ...de these limits contact the local gas utility for corrective action Figure 25 Typical Single Stage Gas Valves Figure 26 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 57: ...cedure to replace the assemblies Make sure that burners are level and seat at the rear of the heat exchanger Burner Air Shutter Adjustment Adjust burner shutters so no yellow 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 o...

Page 58: ...cool 5 If M2 is not pulled in check for 24 volts at the M2 coil If 24 volts are present at M2 but M2 is not pulled in replace the contactor 6 Failing the above if there is line voltage supplied at M2 M2 is pulled in and the supply air blower motor still does not operate replace the motor 7 If 24 volts is not present at M2 check that 24 volts is present at the UCB supply air blower motor terminal F...

Page 59: ... Y1 terminal the compressor may be out due to an open high pressure switch low pressure switch or freezestat Check for 24 volts at the HPS1 LPS1 and FS1 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals 9 If 24 volts is present at the UCB Y1 terminal and none ...

Page 60: ...ammed to lock out compressor operation when the LAS set point is reached For units without factory installed or with field installed economizers the UCB allows compressor operation all the time This programming can be checked or changed by the local distributor 15 If none of the above correct the error replace the UCB ...

Page 61: ... 95 159 70 364 97 15 80 65 11 400 Cfm Ton 75 63 75 130 60 256 76 21 75 54 8 85 135 57 299 88 20 75 55 9 95 140 52 348 100 19 75 56 10 Table 28 ZD 04 4 0 Ton Operating Pressures Air Flow Indoor Db Wb Indoor DB WB Outdoor DB Suction Pressure Suction Temp Liquid Pressure Liquid Temp Delta T Db Entering Evap Db Leaving Evap Db Compressor Amps 300 Cfm Ton 80 62 75 123 62 276 79 30 80 50 11 85 127 55 32...

Page 62: ... 381 94 27 80 53 19 300 Cfm Ton 80 67 75 135 58 289 79 24 80 56 14 85 138 58 335 86 24 80 56 17 95 143 60 387 95 22 80 58 19 300 Cfm Ton 80 72 75 147 64 294 80 19 80 61 15 85 150 64 340 88 19 80 61 17 95 153 66 392 95 18 80 62 19 300 Cfm Ton 75 63 75 124 54 283 76 24 75 51 14 85 128 55 329 84 23 75 52 16 95 132 56 382 94 22 75 53 19 400 Cfm Ton 80 62 75 130 56 285 78 26 80 54 14 85 133 57 331 86 2...

Page 63: ...ds white and red on single stage models and white and black on two stage models If it is less than 177 volts then check and repair the power circuit to the draft motor If the voltage is greater than 176 volts and the draft motor is not turning then disconnect power and draft motor power leads Measure the resistance of the draft motor windings If an open circuit exists in the motor then replace the...

Page 64: ...ficient or the gas input rate to the furnace exceeds the recommended rate Verify both conditions are within the published ranges 4 Cracked heat exchanger tube s If a heat exchanger tube or tubes is cracked then the flow through the heat exchanger is restricted and the flame will either roll out of the tube inlet or heat will build to an abnormal level in the burner area This can usually be determi...

Page 65: ...ot the device indicated by the fault code If not then remove power to the unit for more than 20 seconds If upon restoring the power to the unit the draft motor does not start with a call for heat then verify that terminal L1 of the ICB has a minimum of 120 volts to ground on 230 and 460 volt models or a minimum of 18 volts to ground on 575 volt models If terminal L1 does not have the minimum volta...

Page 66: ... alarm is shown last When pressed and released twice within a five second span the fault history is cleared TEST RESET When this button is pressed and released one time within five seconds any anti short cycle delays ASCD is by passed for one cycle When this button is pressed twice within five seconds any active lockouts are reset COMM SET UP If the board is to be networked with other units this b...

Page 67: ...al Operation 1 Flash Not Applicable 2 Flashes Control waiting ASCD1 1 These flash codes do not represent alarms 3 Flashes HPS1 Compressor Lock out 5 Flashes LPS1 Compressor Lock out 7 Flashes FS1 Compressor Lock out 9 Flashes Ignition Control Locked Out Ignition Control Failure Limit Switch Trip No Jumper Plug in Heat Section 10 Flashes Compressors Locked Out On Low Outdoor Air Temperature1 11 Fla...

Page 68: ... 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 7KH UVW LWHP XQGHU WKH status menu is DVent Mode This is the demand ventilation 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...

Page 69: ...ER CANCEL JOY C PWR 7 7 77 Clg Engaged LeadLag Engaged Press Enter Joy Stick Down 2 Step 6 By toggling down twice 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 In this d...

Page 70: ...mostat connection strip C and indoor blower VFD pin C 24V 24 VAC 75 VA transformer hot Powers the UCB 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 connecti...

Page 71: ...ing in series Unit wiring harness jumper plug for factory shutdown accessories must be removed if the switching of field added external accessories for unit shutdown are wired between thermo stat connection strip SD 24 and R C 24 VAC common for thermostat power LEDs on left edge of UCB POWER Green UCB power indicator Lit indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout net...

Page 72: ...input from 10KΩ 77 F Type III negative temperature coefficient thermistor Input required for 2 compressor heat pump units not required for 2 compressor A C units not active for 1 compressor units 3 625 VDC reading CC2 to CC2 with open circuit Used in heat pump demand defrost calculation EC2 2 refrigerant circuit Evaporator Coil temperature sensor input from 10KΩ 77 F Type III negative temperature ...

Page 73: ...er no input within 5 minutes from initiation of H1 output initiates an Ignition Failure alarm input for longer than 5 minutes without H1 output initiates a Gas Valve Mis wire alarm Pin Cooling and fan output connections at right on lower edge of UCB CN FAN 24 VAC hot output for the condenser fan contactor coil Output with either C1 or C2 output interrupted during defrost cycle for heat pump units ...

Page 74: ...utput 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 prevented until alarm reset Terminal SA BUS connections on at left on lower edge and center of UCB PWR Power for SA Sensor Actuator BUS devices Also incorporated in the J8 6 pi...

Page 75: ...bus BACnet MSTP communication circuit COM Common for the FC Field Connected BUS BACnet MSTP communication circuit Negative of the VDC FC bus BACnet MSTP communication circuit SHLD Shield for the FC Field Connected BUS BACnet MSTP communication circuit Earth ground reference of the cable to prevent interference on the FC bus BACnet MSTP communication circuit Item Selector in red housing at left on ...

Page 76: ...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 77: ...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 78: ... 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 79: ...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 80: ... 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 81: ...___________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ____________________...

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