York ZJ037-061 Instruction Manual Download Page 1

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R-410A

ZJ SERIES W/SMART EQUIPMENT™

3 - 5 Ton
60 Hertz

5565591-YIM-B-1019

TABLE OF CONTENTS

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

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

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

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

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

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

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

Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 17

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Single Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . 31

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 31

Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 46

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 46

Electric Heating Sequence Of Operations . . . . . . . . . . . . 47

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 48

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 49

Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 49

Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Control Board Navigation Components . . . . . . . . . . . . . . . . . 54

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

LIST OF TABLES

1 ZJ037-061 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7

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

3 ZJ037-061 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8

4 ZJ037-061 Unit Physical Dimensions . . . . . . . . . . . . . . . 11

5 ZJ037-061 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11

6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 14

8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 27

12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . 28

13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 29

14 Smart Equipment™ Economizer Board Details . . . . . . . 33

15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

16 Altitude/Temperature Correction Factors . . . . . . . . . . . . 37

17 Airflow Performance - Side Duct Application . . . . . . . . . 40

18 Airflow Performance - Bottom Duct Application . . . . . . . 41

19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . 42

21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 42

22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 44

23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 45

24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 48

25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 48

26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 50

27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 52

28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . 55

30 Cable for FC Buses and SA Buses in Order of Preference . 60

31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . 60

LIST OF FIGURES

1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Component Location (ZJ037 Shown) . . . . . . . . . . . . . . . 6

5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8 ZJ037 - 049 Physical Dimensions . . . . . . . . . . . . . . . . . . 9

9 ZJ061 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 10

10 ZJ037-061 Unit Bottom Duct Openings . . . . . . . . . . . . . 12

11 ZJ037-061 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13

12 ZJ037-061 Unit Side Duct Openings . . . . . . . . . . . . . . . 13

13 ZJ037-061 Unit Left/End Duct Opening . . . . . . . . . . . . . 14

14 ZJ037-061 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 14

15 ZJ037-061 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15

16 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 15

17 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 16

18 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . 16

19 Save Side Panels For Economizer Hood Tops . . . . . . . 16

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

21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 18

22 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19

23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 28

24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 28

25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . 33

26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

27 Altitude/Temperature Correction Factors . . . . . . . . . . . . 38

28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

29 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

30 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . 53

31 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . 54

32 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Summary of Contents for ZJ037-061

Page 1: ...Altitude Temperature Correction Factors 37 17 Airflow Performance Side Duct Application 40 18 Airflow Performance Bottom Duct Application 41 19 RPM Selection 42 20 Indoor Blower Specifications 42 21...

Page 2: ...est edition Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available during brazing operations Improper installation may create a condition where the operation of...

Page 3: ...y on combustible flooring or in the U S on wood flooring or Class A Class B or Class C roof covering materials 4 For use with natural gas convertible to LP with kit This product must be installed in s...

Page 4: ...Filters Merv 13 4 Coil Guard CG STD Filter 5 2 Pleated Filter CG 6 4 Pleated Filter CG A Std Cabinet E SSD SST Drain Pan R Reverse Drain Pan A No Economizer B Economizer w Barometric RLF D Economizer...

Page 5: ...Bracket 2 Turn each bracket toward the ground and the protective plywood covering will drop to the ground 3 Remove the condenser coil external protective covering prior to operation 4 Remove the tooll...

Page 6: ...own The Smart Equipment control board used in this product will effectively operate the cooling system down to 0 F when this product is applied in a comfort cooling application for people An economize...

Page 7: ...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 dimensi...

Page 8: ...l Weight lbs Center of Gravity 4 Point Load Location lbs 6 Point Load Location lbs Shipping Operating X Y A B C D A B C D E F 037 3 ZJ 745 740 40 26 180 147 186 228 124 108 95 120 137 157 049 4 ZJ 767...

Page 9: ...ohnson Controls Ducted Systems 9 Figure 8 ZJ037 049 Physical Dimensions 25 31 59 00 15 51 29 75 59 LEFT 11 3 8 21 3 16 89 27 5 16 4 3 16 FRONT See detail A for gas inlet A See detail B for drain locat...

Page 10: ...Johnson Controls Ducted Systems Figure 9 ZJ061 Physical Dimensions LEFT A 59 00 C D E F 4 19 27 31 89 00 21 19 11 38 15 38 59 00 15 38 29 69 15 25 FRONT SEE DETAIL B FOR DRAIN LOCATION SEE DETAIL A FO...

Page 11: ...3 16 15 3 16 6 3 16 42 CABINET 3 126 2 000 3 184 4 727 7 705 14 594 Gas Pipe Inlet Gas Exhaust Vent 5 3 8 1 FPT Table 5 ZJ037 061 Unit Clearances Direction Distance in Direction Distance in Top1 1 Uni...

Page 12: ...it Bottom Duct Openings Bottom condensate drain Bottom gas supply entry FRONT RETURN AIR SUPPLY AIR RIGHT LEFT 20 1 8 19 1 8 17 1 8 6 13 16 6 13 16 32 11 16 14 1 2 16 3 8 18 1 16 25 9 16 12 5 16 27 1...

Page 13: ...Cover Power Entry 2 1 2 Control Entry 7 8 Power Entry 2 1 2 Convenience Outlet Cover Convenience Outlet Power Entry 7 8 FRONT Dot Plugs 5 5 32 31 11 16 2 31 32 18 1 4 Return Air Supply Air A B C D Tab...

Page 14: ...1 Roof Curb Table 7 Left End Duct Dimensions Unit Model Number Dimension in A B C ZJ037 30 357 13 365 22 516 ZJ049 30 357 13 365 22 516 ZJ061 30 357 13 365 22 516 4 5 16 A C B 8 or 14 50 1 2 30 20 20...

Page 15: ...the bottom of the unit For bottom duct application no duct cover changes are necessary For side duct application remove the side duct covers and install over the bottom duct openings The panels remov...

Page 16: ...tall condensate drain line from the 1 inch NPT female connection on the unit to an open drain Figure 20 Condensate Drain Compressors The scroll compressor used in this product is specifically designed...

Page 17: ...ment wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be utilized for these units Factory installed disconnects are available If i...

Page 18: ...he unit nameplate Refer to Electrical Data Table 9 to size power wiring fuses and disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the curb Fi...

Page 19: ...OL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 2 4 Second stage ot required on single stage he g units Jumper is required if there is no Smoke Detector circuit Jumper is requir...

Page 20: ...40 E06 4 5 1 12 5 24 6 30 1 35 40 E08 6 8 1 18 9 30 1 37 35 40 E15 11 3 2 31 4 45 8 52 6 50 60 E20 15 2 41 6 58 5 65 4 60 70 230 13 8 83 1 22 2 1 5 2 5 5 None 24 6 30 1 35 40 E06 6 1 14 4 24 6 31 4 35...

Page 21: ...1 12 5 24 6 30 1 35 40 E08 6 8 1 18 9 30 1 37 35 40 E15 11 3 2 31 4 45 8 52 6 50 60 E20 15 2 41 6 58 5 65 4 60 70 230 13 8 83 1 22 2 1 5 2 5 5 None 24 6 30 1 35 40 E06 6 1 14 4 24 6 31 4 35 40 E08 9 1...

Page 22: ...5 1 12 5 34 6 41 5 45 50 E08 6 8 1 18 9 42 6 49 5 45 50 E15 11 3 2 31 4 58 3 65 1 60 70 E20 15 2 41 6 71 77 9 80 80 230 13 8 83 1 22 2 1 5 2 5 5 20 None 34 6 40 1 45 50 E06 6 1 14 4 37 43 9 45 50 E08...

Page 23: ...12 5 34 6 41 5 45 50 E08 6 8 1 18 9 42 6 49 5 45 50 E15 11 3 2 31 4 58 3 65 1 60 70 E20 15 2 41 6 71 77 9 80 80 230 13 8 83 1 22 2 1 5 2 5 5 20 None 34 6 40 1 45 50 E06 6 1 14 4 37 43 9 45 50 E08 9 1...

Page 24: ...dy state efficiency 81 5 81 81 81 5 81 81 81 81 80 5 No burners 4 4 6 4 4 6 4 6 8 No stages 1 1 1 1 1 1 1 1 1 Temperature Rise Range F 20 50 F 25 65 F 50 80 F 20 50 F 25 65 F 40 70 F 25 65 F 35 65 F 4...

Page 25: ...1VM34 1VL44 1VL40 1VP56 Blower Sheave AK69 AK69 AK56 AK56 AK61 AK74 Belt A47 A47 A47 A47 A47 A51 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 RPM 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56...

Page 26: ...y 81 5 81 81 81 5 81 81 81 81 80 5 No burners 4 4 6 4 4 6 4 6 8 No stages 21 22 22 21 22 22 22 22 22 Temperature Rise Range F 20 50 F 25 65 F 50 80 F 20 50 F 25 65 F 40 70 F 25 65 F 35 65 F 45 75 F Ga...

Page 27: ...1VM34 1VL44 1VL40 1VP56 Blower Sheave AK69 AK69 AK56 AK56 AK61 AK74 Belt A47 A47 A47 A47 A47 A51 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 RPM 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56...

Page 28: ...with locality The value should be checked with the local gas utility Figure 23 Side Entry Gas Piping Figure 24 Bottom Entry Gas Piping NOTE Maximum capacity of pipe in cubic feet of gas per hour base...

Page 29: ...l numbers 1NP0454 or 1NP0455 All LP gas equipment must conform to the safety standards of the National Fire Protection Association Table 13 Gas Heat Minimum Supply Air Size Tons Model Heat Size Supply...

Page 30: ...mounted in the return air compartment The detector must be tested and maintained on a regular basis according to NFPA 72 requirements and cleaned at least once a year For specific troubleshooting and...

Page 31: ...r Minimum Position The economizer minimum position is set during occupied mode when outside air is not suitable for free cooling The position of the damper is set proportionally between the Economizer...

Page 32: ...mpressor 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...

Page 33: ...mistor MAT parameter reports input status F C 3 65 VDC reading MAT to COM with open circuit Read only use in current control revision IN1 MAT LEDs at left on upper edge of economizer board POWER POWER...

Page 34: ...power exhaust actuator and economizer actuator Connects through circuit trace to 24V IN pin HOT ECON 2 10 VDC output for the Economizer actuator Econ parameter reports output status 0 100 Used to posi...

Page 35: ...egative 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...

Page 36: ...is drawing low amperage has similar suction and discharge pressures or producing a high noise level the scroll is misphased Blower Rotation Check for proper supply air blower rotation If the blower i...

Page 37: ...or adjusting belt tension 1 Loosen six nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the sp...

Page 38: ...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 A...

Page 39: ...HP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1230 RPM is within the range of the 2 HP drives 7 Using the 2 HP motor and drive 5 turns open will achieve...

Page 40: ...0 956 0 80 1015 0 90 1072 0 99 1130 1 08 1189 1 16 1500 650 0 35 720 0 44 786 0 54 849 0 64 911 0 74 970 0 84 1028 0 93 1086 1 03 1144 1 12 1202 1 20 1600 664 0 39 734 0 49 800 0 58 863 0 68 924 0 78...

Page 41: ...2 1039 0 92 1099 1 01 1160 1 09 1223 1 16 1500 675 0 37 744 0 46 810 0 56 872 0 66 933 0 77 993 0 87 1053 0 96 1113 1 05 1174 1 14 1237 1 20 1600 690 0 42 759 0 51 825 0 61 887 0 72 948 0 82 1008 0 92...

Page 42: ...12 hrs run time is recommended Table 19 RPM Selection Size Tons Model HP Max BHP Motor Sheave Blower Sheave 6 Turns Open 5 Turns Open 4 Turns Open 3 Turns Open 2 Turns Open 1 Turn Open Fully Closed 0...

Page 43: ...motor sheave is open 5 Select the correct blower performance table for the unit from Tables 17 and 18 Tables are presented for side and down flow configuration 6 Determine the unit Measured CFM from...

Page 44: ...can result in substantial changes in static pressure and BHP BHP and AMP draw of the blower motor will increase by the cube of the blower speed Static pressure will increase by the square of the blowe...

Page 45: ...2 0 03 0 01 0 01 0 01 0 02 0 02 0 02 1200 0 04 0 00 0 04 0 01 0 01 0 01 0 02 0 02 0 02 1300 0 03 0 01 0 05 0 01 0 01 0 01 0 03 0 03 0 03 1400 0 03 0 03 0 07 0 02 0 02 0 02 0 03 0 03 0 03 1500 0 03 0 0...

Page 46: ...py controller previously determined Y1 energizes the economizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enth...

Page 47: ...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 i...

Page 48: ...erature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower Reset Remove the call for heating by lowering the thermostat setting lower than th...

Page 49: ...hree ignition attempts the furnace is locked out for one hour The furnace is monitored during this one hour period for unsafe conditions Recycle Operation When a flame is lost after the flame stabiliz...

Page 50: ...re switch closes or W1 is lost Roll out Switch ROS The roll out switch is wired in series with the pressure switch As such the ICB cannot distinguish the roll out switch operation from that of the pre...

Page 51: ...time should the standby gas pressure exceed 10 5 in or the operating pressure drop below 4 5 in for natural gas units If gas pressure is outside these limits contact the local gas utility or propane s...

Page 52: ...This gas furnace has two heat stages Therefore the gas valve has two adjustment screws located under a plastic protective cover The second stage 100 input adjustment screw is adjacent to the HI marki...

Page 53: ...ove the screws holding each end of the manifold to the manifold supports 3 Disconnect wiring to the gas valves and spark igniter s Remove the manifold gas valve assembly Orifices can now be inspected...

Page 54: ...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...

Page 55: ...left edge of UCB W1 1st stage heating request 24 VAC input switched from R Not effective for cooling only units W2 2nd stage heating request 24 VAC input switched from R Not effective for cooling onl...

Page 56: ...ool cutouts low ambient cooling determination dry bulb free cooling changeover outside air enthalpy calculation economizer loading operation heat pump demand defrost calculation CC1 1 refrigerant circ...

Page 57: ...effective for cooling only units Output if demand is present and permissions allow one stage or two stages of heat section operation H2 24 VAC hot output for heat section stage 2 Not effective for coo...

Page 58: ...Not effective for one stage compressor UCBs Connects through circuit trace to the left HSP2 pin LPS2 left pin 24 VAC hot return from refrigerant circuit 2 Low Pressure Switch Not effective for one st...

Page 59: ...ected BUS BACnet MSTP communication Positive of the VDC typically a fluctuating 1 5 to 3 5 volts reading to COM at least 0 25 volts higher than FC bus BACnet MSTP communication circuit FC FC Field Con...

Page 60: ...air Cable2 2 We recommend 26 AWG solid 6 wire 3 twisted pairs cable as the best fit for fabricating modular cables with the modular jack housing assembly Be sure the cable you use fits the modular jac...

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