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York ZK Series Installation Manual Download Page 40

5566228-BIM-A-0818

40

Johnson Controls Ducted Systems

Airflow Performance

Table 17: ZK-A3 thru -A5 Side Duct Application

ZK-A3 (3.0 Ton) Side Duct

ZK-A4 (4.0 Ton) Side Duct

ZK-A5 (5.0 Ton) Side Duct

Air 

Flow

(CFM)

Available External Static Pressure - IWG

1

1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW =  BHP x 0.932.
4. Field Supplied Drive.

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

FS

4

Standard 1.5 HP & Drive

Hi Static 1.5 HP & Drive

900

480

0.4

582

0.4

673

0.5

756

0.5

830

0.6

898

0.7

960

0.8

1018

0.9

1072

1.0

1124

1.1

1000

489

0.4

591

0.4

682

0.5

764

0.6

839

0.6

907

0.7

969

0.8

1026

0.9

1080

1.0

1132

1.1

1100

500

0.4

602

0.4

693

0.5

776

0.6

850

0.6

918

0.7

980

0.8

1038

0.9

1092

1.0

1144

1.1

1200

513

0.4

614

0.5

706

0.5

788

0.6

863

0.7

931

0.8

993

0.8

1050

0.9

1104

1.0

1156

1.1

1300

525

0.4

627

0.5

719

0.6

801

0.6

876

0.7

943

0.8

1005

0.9

1063

1.0

1117

1.1

1169

1.2

1400

537

0.5

639

0.5

731

0.6

813

0.7

888

0.7

955

0.8

1017

0.9

1075

1.0

1129

1.1

1181

1.2

1500

549

0.5

650

0.6

742

0.6

824

0.7

899

0.8

966

0.9

1028

0.9

1086

1.0

1140

1.1

1192

1.2

Air 

Flow

(CFM

Available External Static Pressure - IWG

1

1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW =  BHP x 0.932.
4. Field Supplied Drive.

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

1.5 HP & Field 
Supplied Drive

Standard 1.5 HP & Drive

Hi Static 1.5 HP & Drive

1200

513

0.4

614

0.5

706

0.5

788

0.6

863

0.7

931

0.8

993

0.8

1050

0.9

1104

1.0

1156

1.1

1300

525

0.4

627

0.5

719

0.6

801

0.6

876

0.7

943

0.8

1005

0.9

1063

1.0

1117

1.1

1169

1.2

1400

537

0.5

639

0.5

731

0.6

813

0.7

888

0.7

955

0.8

1017

0.9

1075

1.0

1129

1.1

1181

1.2

1500

549

0.5

650

0.6

742

0.6

824

0.7

899

0.8

966

0.9

1028

0.9

1086

1.0

1140

1.1

1192

1.2

1600

558

0.6

660

0.6

752

0.7

834

0.8

909

0.8

976

0.9

1038

1.0

1096

1.1

1150

1.2

1202

1.3

1700

566

0.6

668

0.7

760

0.7

842

0.8

917

0.9

984

1.0

1046

1.1

1104

1.1

1158

1.2

1210

1.4

1800

573

0.7

675

0.7

766

0.8

849

0.9

923

1.0

991

1.0

1053

1.1

1110

1.2

1164

1.3

1216

1.4

1900

577

0.8

679

0.8

771

0.9

853

1.0

928

1.0

995

1.1

1057

1.2

1115

1.3

1169

1.4

1221

1.5

2000

580

0.8

682

0.9

773

1.0

856

1.0

930

1.1

998

1.2

1060

1.3

1117

1.4

1172

1.5

1224

1.6

FS

4

Air 

Flow

(CFM)

Available External Static Pressure - IWG

1

1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW =  BHP x 0.932.

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Standard 1.5 HP & Drive

Hi Static 2 HP & Drive

1500

616

0.5

685

0.6

766

0.7

833

0.8

905

0.9

975

1.0

1035

1.0

1101

1.1

1163

1.2

1229

1.3

1600

638

0.6

707

0.7

781

0.7

848

0.8

920

0.9

990

1.0

1050

1.1

1104

1.1

1166

1.2

1232

1.3

1700

655

0.6

724

0.7

796

0.8

863

0.9

935

1.0

1005

1.1

1064

1.1

1109

1.2

1172

1.3

1238

1.4

1800

670

0.7

739

0.8

810

0.8

877

0.9

949

1.0

1018

1.1

1078

1.2

1117

1.2

1179

1.3

1245

1.5

1900

686

0.7

755

0.8

823

0.9

890

1.0

962

1.1

1032

1.2

1091

1.2

1125

1.3

1187

1.4

1253

1.5

2000

702

0.8

772

0.9

836

1.0

903

1.1

975

1.2

1045

1.3

1078

1.3

1135

1.4

1197

1.5

1263

1.6

2100

722

0.9

791

1.0

849

1.0

916

1.1

988

1.2

1058

1.3

1089

1.4

1147

1.5

1209

1.6

1275

1.7

2200

745

0.9

814

1.0

861

1.1

928

1.2

1000

1.3

1050

1.4

1102

1.5

1159

1.6

1221

1.7

1287

1.8

2300

772

1.0

841

1.1

874

1.2

941

1.3

1013

1.4

1064

1.5

1115

1.6

1173

1.7

1235

1.8

-

-

2400

804

1.1

832

1.2

886

1.3

953

1.4

1033

1.4

1078

1.6

1130

1.7

1188

1.8

-

-

-

-

2500

841

1.2

844

1.3

898

1.4

965

1.5

1049

1.5

1094

1.7

-

-

-

-

2 HP & Field Supplied Drive

Summary of Contents for ZK Series

Page 1: ...thru A5 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 El...

Page 2: ...test 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 o...

Page 3: ...d directly 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 insta...

Page 4: ...erv 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 w Power E...

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: ...operate the cooling system down to 0 F when this product is applied in a comfort cooling application for people An economizer is typically included in this type of application When applying this prod...

Page 7: ...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 acr...

Page 8: ...s 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 A3 3 ZK 851 846 47 25 24 00 161 183 266 235 105 114 124 181 167 154 A4 4 ZK 870 865 4...

Page 9: ...Johnson Controls Ducted Systems 9 Figure 8 ZK A3 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 locatio...

Page 10: ...Controls Ducted Systems Figure 9 ZK A4 thru A5 Physical Dimensions 24 47 TYP 2 PL 15 38 15 38 59 00 15 25 29 69 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...

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 ZK A3 thru A5 Unit Clearances Direction Distance in Direction Distance in Top1 1...

Page 12: ...Unit 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...

Page 13: ...ith 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...

Page 14: ...ru A5 Roof Curb 4 5 16 A C B Table 7 Left End Duct Dimensions Unit Model Number Dimension in A B C ZK A3 30 357 13 365 22 516 ZK A4 30 357 13 365 22 516 ZK A5 30 357 13 365 22 516 8 or 14 50 1 2 30 20...

Page 15: ...r 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 removed from the side duct conn...

Page 16: ...ing must conform to local codes Use a sealing compound on male pipe threads Install condensate drain line from the 1 inch NPT female connection on the unit to an open drain Figure 20 Condensate Drain...

Page 17: ...red If any of the wire supplied with the unit must be replaced replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be uti...

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: ...F THERMOSTATS 1 4 3 1 4 Second stage ot required on single stage he g units Jumper is required for any co of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied on X is an inp...

Page 20: ...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 26 7 32 2 35 45 E06 6 1 14 4 26 7 32 2 35 45 E08 9 1 21 7 33 6 40 5 40 45 E15 15 2 36 1 51 6 58 5 60 60 E20 20 2 48 1...

Page 21: ...1 12 5 26 7 32 2 35 45 E08 6 8 1 18 9 30 1 37 40 45 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 26 7 32 2 35 45 E06 6 1 14 4 26 7 32 2 35 45 E08 9...

Page 22: ...5 1 12 5 36 7 42 2 50 50 E08 6 8 1 18 9 42 6 49 5 50 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 36 7 42 2 50 50 E06 6 1 14 4 37 43 9 50 50 E08...

Page 23: ...5 1 12 5 36 7 42 2 50 50 E08 6 8 1 18 9 42 6 49 5 50 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 36 7 42 2 50 50 E06 6 1 14 4 37 43 9 50 50 E08...

Page 24: ...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 50 80 F 25 65 F 35 65 F 45 75 F Gas Limit Setting F 235 200 255 235 200 255 200 245 240 Gas piping conne...

Page 25: ...ntrifugal Centrifugal Centrifugal Motor Sheave 1VP34 1VL44 1VP34 1VL44 1VP34 1VL44 Blower Sheave AK61 AK59 AK61 AK59 AK61 AK59 Belt A47 A47 A47 A47 A47 A47 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2...

Page 26: ...2 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 50 80 F 25 65 F 35 65 F 45 75 F Gas Limit Setting F 235 200 255 235 200 255 200 245 240 Gas piping connection in...

Page 27: ...ntrifugal Centrifugal Centrifugal Motor Sheave 1VP34 1VL44 1VP34 1VL44 1VP34 1VL44 Blower Sheave AK61 AK59 AK61 AK59 AK61 AK59 Belt A47 A47 A47 A47 A47 A47 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2...

Page 28: ...ith the local gas utility Figure 23 Side Entry Gas Piping NOTE Routing of gas piping must not interfere with the flue or heat compartment access Figure 24 Bottom Entry Gas Piping NOTE Maximum capacity...

Page 29: ...del 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 Supp...

Page 30: ...t least once a year For specific troubleshooting and maintenance procedures please refer to the smoke detector s installation instructions which accompanies the unit Motorized Outdoor Damper The Motor...

Page 31: ...y fan system 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 Bul...

Page 32: ...e 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...

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: ...ield supplied disconnect to obtain proper rotation Blower Rotation Check for proper supply air blower rotation If the blower is rotating backwards the line voltage at the unit point of power connectio...

Page 37: ...e the air at high altitude is less dense less static pressure will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Tabl...

Page 38: ...iven is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 0 6 832 0 72 Enter the blower table at 1 400 sCFM and...

Page 39: ...r and drive 5 turns open will achieve 1230 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 RPM BHP...

Page 40: ...627 0 5 719 0 6 801 0 6 876 0 7 943 0 8 1005 0 9 1063 1 0 1117 1 1 1169 1 2 1400 537 0 5 639 0 5 731 0 6 813 0 7 888 0 7 955 0 8 1017 0 9 1075 1 0 1129 1 1 1181 1 2 1500 549 0 5 650 0 6 742 0 6 824 0...

Page 41: ...7 0 8 942 0 8 994 0 9 1046 1 0 1100 1 2 1157 1 3 1400 617 0 5 705 0 6 781 0 6 847 0 7 907 0 8 962 0 9 1014 1 0 1066 1 1 1119 1 2 1177 1 3 1500 637 0 6 724 0 6 800 0 7 867 0 8 927 0 8 981 0 9 1034 1 0...

Page 42: ...on Size Tons Model Airflow Option 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 A3 3 0 ZK Std 1 5 1 5 1VP34 AK61 N A 5...

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: ...llation errors leaks or undesirable systems effects that can result in loss of airflow Even small changes in blower speed can result in substantial changes in static pressure and BHP BHP and AMP draw...

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: ...onomizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enthalpy is above the setpoint Y1 energizes the compressor...

Page 47: ...calling for cooling the UCB will operate in the low ambient mode Low ambient mode operates the compressors in this manner 10 minutes on 5 minutes off The indoor blower is operated throughout the cycl...

Page 48: ...the unit continues to operate with refrigerant flow in the reheat coil and condenser coil 1 See Figure 29 Indoor blower operation is initiated upon a call for first stage cooling second stage cooling...

Page 49: ...The control circuit includes the following safety controls Limit Switch LS This control is located inside the heater compartment and is set to open at the temperature indicated in the Electric Heat L...

Page 50: ...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 stabilization period a...

Page 51: ...r 2 seconds the GV will be de energized the ignition cycle is aborted and the ICB flashes the appropriate code See Table 31 Ignition Control Flash Codes The draft motor is energized until the pressure...

Page 52: ...k for correct manifold gas pressures See CHECKING GAS INPUT 3 Check the supply gas pressure It must be within the limits shown on the rating nameplate Supply pressure should be checked with all gas ap...

Page 53: ...a 1 cubic foot test dial 5 Using the number of seconds it takes for one revolution of the dial calculate the cubic feet of gas consumed per hour See example below 6 If necessary adjust the low pressur...

Page 54: ...unit on first stage 9 Once pressure has been checked replace the plastic cap covering the HI and LO pressure adjustment screws NOTE When using natural gas the manifold pressure for second stage 100 i...

Page 55: ...ource 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...

Page 56: ...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 Connec...

Page 57: ...t indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout networking error and firmware error indicator 1 2 second on off flashing indicates one or more alarm is currently active 1 1...

Page 58: ...C 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 re...

Page 59: ...ut 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 permis...

Page 60: ...er 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...

Page 61: ...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 30 Table 29 Smart Equipment UCB Details Continued Descri...

Page 62: ...incline manometer digital manometer or Magnehelic gauge teed into the pressure switch sensing line verify that the negative pressure exceeds the setting listed on the induced draft pressure switch lab...

Page 63: ...16 6 7 95 171 71 383 102 14 7 3 400 Cfm Ton 75 63 75 138 62 288 82 21 6 3 85 141 62 321 90 20 6 7 95 144 61 372 98 18 7 2 Table 33 ZK A4 Charging Table Air Flow Indoor Db Wb Outdoor DB Suction Pressur...

Page 64: ...70 114 26 8 4 300 Cfm Ton 80 72 75 140 59 376 97 28 7 2 85 145 61 425 106 26 7 9 95 150 63 475 115 24 8 5 300 Cfm Ton 75 62 75 135 57 368 95 25 7 2 85 135 57 415 104 25 7 8 95 136 57 461 112 25 8 4 40...

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