York ZE036 Installation Manual Download Page 1

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R-410A
ZE SERIES

3 - 5 Ton

60 Hertz

5188235-YIM-B-1016

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 ZE036-060). 15

Typical Cool/Heat Control Wiring (Smart Equipment™ ZE036-

060) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34

Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . . 35

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Jade Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 40

Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 51

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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

Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 53

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54

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

Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 56

Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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

Smart Equipment™ Control Board Navigation Components . . . . 67

Smart Equipment™ Firmware Version 3.1 Basic Unit Control

Board Navigation Examples: . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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

LIST OF TABLES

1 ZE036-060 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 ZE036-060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZE036-060 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 8

4 ZE036-060 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 ZE036-060 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

8 ZE036-060 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 Smart Equipment™ Economizer Board Details . . . . . . . . . . 37

13 Single Enthalpy and Dual Enthalpy High Limit Curves. . . . . . 42

14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43

15 ZE Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 46

16 ZE Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 48

17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 49

19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 49

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

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

22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54

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

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

25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 56

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

27 ZE036 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61

28 ZE048 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61

29 ZE060 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 62

30 Simplicity Lite Unit Control Board Flash Codes . . . . . . . . . . 66

31 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66

32 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 70

Cable for FC Buses and SA Buses in Order of Preference . 75

LIST OF FIGURES

1 ZE036-060 Component Location . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

5 ZE036-060 Cooling Only/Electric Heat Front View Physical

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

6 ZE036-060 Cooling Only/Gas Heat Front View Physical

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

7 ZE036-060 Fixed Outdoor Air Motorized Damper Rain Hood

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

8 ZE036-060 Disconnect Location . . . . . . . . . . . . . . . . . . . . . 10

9 ZE036-060 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 11

10 ZE036-060 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

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

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

14 Typical Smart Equipment™ Control Wiring . . . . . . . . . . . . . 16

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

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

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

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

19 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 37

20 Jade Economizer LCD and Keypad Layout. . . . . . . . . . . . . 40

21 Single Enthalpy Curve And Boundaries . . . . . . . . . . . . . . . . 41

22 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

23 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 44

24 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 50

25 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

26 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 57

27 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 57

28 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 57

29 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 58

30 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 66

Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 70

Summary of Contents for ZE036

Page 1: ...ature Correction Factors 43 15 ZE Blower Performance Side Duct 46 16 ZE Blower Performance Bottom Duct 48 17 Belt Drive RPM Selection 49 18 Indoor Blower Specifications Belt Drive 49 19 Power Exhaust Specifications 49 20 Additional Static Resistance 50 21 Electric Heat Limit Setting 53 22 Electric Heat Anticipator Setpoints 54 23 Single Stage Gas Heat Limit Control Setting 55 24 2 Stage Gas Heat L...

Page 2: ...actices 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 a...

Page 3: ...tified 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 code...

Page 4: ... 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 Air Smo...

Page 5: ...ility 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 unit t...

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 ZE036 060 Unit Limitations Size Tons Unit Voltage Unit Limitations Applied Voltage Outdoor DB Temp Min Max Max F ZE036 3 0 208 230 1 60 187 252 125 208 230 3 60 ...

Page 7: ... 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 forkli...

Page 8: ...rating X Y A B C D A B C D E F 036 3 475 470 34 5 18 25 111 80 117 162 78 62 51 74 91 114 048 4 603 598 36 18 5 139 108 154 198 96 81 69 98 116 137 060 5 637 632 37 5 18 2 139 117 171 204 96 85 76 111 124 140 Table 3 ZE036 060 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 maxim...

Page 9: ...188235 YIM B 1016 Johnson Controls Unitary Products 9 Figure 5 ZE036 060 Cooling Only Electric Heat Front View Physical Dimensions Figure 6 ZE036 060 Cooling Only Gas Heat Front View Physical Dimensions ...

Page 10: ...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 72 For...

Page 11: ...Roof Curb Table 5 ZE036 060 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: ...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 t...

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: ...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 30 048 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: ...0 230 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...

Page 19: ...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 30 048 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 E20...

Page 20: ... 52 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 ZE036 060 Without Powered Conv...

Page 21: ... 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 80 048 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 9...

Page 22: ... 4 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 ...

Page 23: ... 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 35 048 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 9...

Page 24: ...100 230 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...

Page 25: ...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 35 048 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 E2...

Page 26: ... 8 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 ZE036 060 With Powered Conve...

Page 27: ... 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 90 048 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 9...

Page 28: ...4 9 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 ...

Page 29: ... 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 82 ...

Page 30: ...44 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 ...

Page 31: ...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 CFM ...

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: ...ity Lite Controls will have a field installed RRS Economizer Kit Offered This section describes how to use the Economizer s user interface for Keypad and menu navigation Settings and parameter changes Menu structure and selection User Interface The user interface consists of an LCD display and a 4 button keypad on the front of the economizer module Figure 18 RRS Economizer LCD and Keypad Layout Ke...

Page 35: ...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 Free cooling is no longer avail...

Page 36: ...essor 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 output goes to minimum position and the SAT is less than Economizer Setpoint 1 F the control starts a 12 minute timer to de energize a compressor output If at any t...

Page 37: ...onomizer 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 po...

Page 38: ...per 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 actuator Connects through circuit tra...

Page 39: ...positive input from the 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...

Page 40: ...is Modulating Damper or Variable Frequency Fan 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 co...

Page 41: ...M 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 And Configuration Before being placed into service the JADE Economizer module must be setup and configured for the installed...

Page 42: ...l exceeds its set point setting and there is no call for free cooling the actuator is proportionately modulated from the 0 to 10 Vdc signal with 0 Vdc corresponding to full closed and 10 Vdc corresponding to full open When there is no call for free cooling the damper position is limited by the IAQ Max damper position setting When the signal exceeds its set point Demand Control Ventilation Set Poin...

Page 43: ...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 44: ...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 45: ...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 46: ... 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 47: ...6 258 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 13...

Page 48: ...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 49: ...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 1461 513 1 LOW 1509 327 1477 339 Table 17 Belt Drive RPM Selection Size Tons Model HP Max BHP Motor Sheave Blower Sheave 5 Turns Open 4 Turns Open 3 Turns Open 2 Turns Open 1 Turn Open F...

Page 50: ...ometer 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 a dry coil the actual CFM through the unit can be determined from t...

Page 51: ...nthalpy Sensor Simplicity Lite or Economizer With Dry Bulb Sensor Smart Equipment When the room thermostat calls for cooling the low voltage control circuit from R to G and Y1 is completed The UCB energizes the blower motor if the fan switch on the room thermostat is set in the AUTO position and drives the economizer dampers from fully closed to their minimum position If the enthalpy Simplicity Li...

Page 52: ...vaporator low limit sensor EC1 detect a temperature below 26 F three times within two hours of operation the UCB will lock out the associated compressor and flash an error message Low Ambient Cooling Simplicity Lite Control To determine when to operate in low ambient mode the UCB has a pair of terminals connected to a temperature activated switch set at 45ºF When the low ambient switch is closed a...

Page 53: ...leting 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 Two stage heating applies only to 15 20 and 30 kW 230V heaters and 20 and 30 kW heater 460V and 575V heaters a Upon a call for first stage heat by the thermostat the heater sequencer 1S 15 20 30 kW 230 volt a...

Page 54: ...and main gas valves and performs a 30 second purging of the heat exchanger by continuing the operation of the draft motor The UCB continues the operation of the indoor blower for a configurable amount of time after the call for heat is satisfied Figure 25 Gas Valve Piping Two Stage Furnace Only If a W1 only call for heat from a two stage thermostat is present then a two stage furnace will start on...

Page 55: ... at least 15 seconds during the fan on delay for heating and the UCB no longer senses voltage at the GV W1 call for heat removed or an ICB fault exists then the UCB forces the indoor blower on for the indoor blower heating off delay The gas valve is of the redundant type If for any reason the main gas valve fails in the open position then the redundant valve ahead of the main gas valve will shut o...

Page 56: ... lower than the room temperature 3 Compressor will energize after the built in time delay five minutes Post Start Check List 1 Verify proper system pressures 2 Measure the temperature drop across the evaporator coil 3 Measure the system Amperage draw across all legs of 3 phase power wires 4 Measure the condenser fan amp draw Shut Down 1 Set the thermostat to highest temperature setting 2 Turn off ...

Page 57: ...remove pilot adjustment cover screw 2 increase or decrease the clearance for air to the desired level 3 be sure to replace cover screw after adjustment to prevent possible gas leakage Put the system into operation and observe through complete cycle to be sure all controls function properly Burner Instructions To check or change burners pilot or orifices CLOSE MAIN MANUAL SHUT OFF VALVE AND SHUT OF...

Page 58: ...f both the return air and the heated air in the ducts about six feet from the furnace where they will not be affected by radiant heat Increase the blower cfm to decrease the temperature rise decrease the blower cfm to increase the rise Refer to the In Door Blower Specification Table 18 Troubleshooting Table 26 Gas Rate Cubit Feet per Hour1 Seconds for One Rev Size of Test Dial 1 2 cu ft 1 cu ft 10...

Page 59: ...UTO position 1 If installed check the position of the economizer blades If the blades are open the economizer is providing free cooling and the compressors will not immediately operate If both stages of cooling are requested simultaneously and the economizer provides free cooling following a short delay the compressor will be energized unless it is locked out unless this option has been disabled t...

Page 60: ...Mate N Lock plug to the Y1 ECON terminal 13 For units with economizers If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug a poor connection between the UCB and economizer Mate N Lock plugs loose wiring from the Mate N Lock plug to the economizer back to the Mate ...

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 ZE048 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: ...de 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 voltage then check the wiring between the un...

Page 66: ... within five seconds any active lockouts are reset COMM SET UP If the board is to be networked with other units this button is used to set the network address The first time the button is pressed within five seconds it scans the bus then assigns itself the first available address starts at 2 It then flashes that address one time Pressing the button two times within five seconds causes the control ...

Page 67: ...duct Center Equipment Catalog Commercial Products Zoning Systems and Controls 1 Local LCD on Unit Control Board OR 2 Mobile Access Portal MAP Gateway Portable Source 1 P N S1 JC MAP1810 OP MAP Gateway Quick Start Guide P N 24 10737 16 MAP Gateway Instruction P N 24 10737 8 NOTE For more in depth sequence of operation of the Smart Equipment control please refer to 5127915 on www upgnet com under Pr...

Page 68: ... 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 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 CO2 sensor is n...

Page 69: ... 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 dem...

Page 70: ...rs 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 connecting SD 24 to SD R is in place if factory accessories for unit shutdown are not used this jum...

Page 71: ... 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 transmi...

Page 72: ... 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 calculation temperature humidity setpoint reset reheat operation DCT PRS Supply Duct Pressure input fr...

Page 73: ...tput 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 or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage co...

Page 74: ...nter 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 center...

Page 75: ...it indicates the UCB is supplying power to the communication sub board 1 When wiring unit and other devices using the SA Bus and FC Bus see Table 33 Table 32 Smart Equipment UCB Details Continued Description Function Comments Table 33 Cable for FC Buses and SA Buses in Order of Preference Bus and Cable Type Non Plenum Applications Plenum Applications Part Number O D Part Number O D FC Bus 22 AWG S...

Page 76: ...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 details...

Page 77: ...e full 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: ... 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 rotation Check for ...

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 ________________ FixedS...

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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