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5803640-BIM-B-0620

28

Johnson Controls Ducted Systems

For satisfactory operation, LP gas pressure must be 10.5 inch 
W.C. at the unit under full load. Maintaining proper gas 
pressure depends on three main factors:
1.

The vaporization rate which depends on the temperature of 
the liquid and the “wetted surface” area of the container(s).

2.

The proper pressure regulation. (Two-stage regulation is 
recommended).

3.

The pressure drop in the lines between regulators and 
between the second stage regulator and the appliance. 
Pipe size required will depend on the length of the pipe run 
and the total load of all appliances.

Complete information regarding tank sizing for vaporization, 
recommended regulator settings, and pipe sizing is available 
from most regulator manufacturers and LP gas suppliers.

Check all connections for leaks when piping is completed using 
a soap solution. 

NEVER USE A FLAME.

Vent And Combustion Air

Venting slots in the heating compartment access panel remove 
the need for a combustion air hood. The gas heat flue exhaust 
is routed through factory installed exhaust piping with screen. If 
necessary, a flue exhaust extension may be installed at the 
point of installation.

Options/Accessories

Electric Heat

Electric heaters are available as factory-installed options or 
field-installed accessories. Refer to electric heat instructions for 
installation. These heaters mount in the heat compartment with 
the heating elements extending into the supply air chamber. All 

electric heaters are fused and intended for use with single point 
power supply.

Smoke Detectors

The factory-installed smoke detector will shut down operation of 
the unit by interrupting power to the UCB when smoke is 
detected within its mounting compartment. The smoke detector 
option is available for both supply and/or return air configura-
tions. Be aware that the supply air configuration has the sensor 
component mounted in the blower section, with its control mod-
ule 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 maintenance 
procedures, please refer to the smoke detector's installation 
instructions which accompanies the unit.

Motorized Outdoor Damper

The Motorized Outdoor Damper can be a factory installed 
option or a field installed accessory. If factory installed, refer to 
the instructions included with the outdoor air hood to complete 

LP gas is an excellent solvent and will quickly dissolve 
white lead and most standard commercial compounds. A 
special pipe dope must be used when assembling 
wrought iron or steel pipe for LP. Shellac base 
compounds such as Gaskolac or Stalastic, and 
compounds such as Rectorseal #5, Clyde’s, or John 
Crane may be used.

FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could result 
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a 
commercially available soap solution made specifically 
for the detection of leaks to check all connections. A fire 
or explosion may result causing property damage, 
personal injury or loss of life.

The use of duct smoke detectors have specific limitations 
as established by the National Fire Protection 
Association. Duct smoke detectors are; NOT a substitute 
for an open area smoke detector, NOT a substitute for 
early warning detection, and NOT a replacement for a 
building's regular fire detection system. Refer to NFPA 
Code 72 and Standard 90A for additional information.

Factory-installed smoke detectors may be subjected to 
extreme temperatures during "off" times due to outside air 
infiltration. These smoke detectors have an operational 
limit of -4°F to 158°F. Smoke detectors installed in areas 
that could be outside this range will have to be relocated to 
prevent false alarms.

To assure adequate airflow reaches the smoke detector's 
sensor, make sure that the holes of the sampling tube 
face into the air stream, and that the far-end of the 
sampling tube is sealed with the plastic end cap.
In addition, the unit's supply airflow must be adjusted to 
provide a pressure differential across the smoke 
detector's sampling and exhaust ports of at least 0.01 
inches of water and no more than 1.11 inches of water, as 
measured by a manometer.

Summary of Contents for ZW Series

Page 1: ...ils 31 15 Supply Air Limitations 34 16 Altitude Temperature Correction Factors 35 17 Airflow Performance Side Duct Application 38 18 Airflow Performance Bottom Duct Application 39 19 RPM Selection 40...

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: ...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 EXH H Motorized Damper Outdo...

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: ...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 product for process cool...

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: ...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 A3 3 ZW 745 740 40 26 180 147 186 228 124 108 95 120 137 157 A4 4 ZW 767 76...

Page 9: ...nson Controls Ducted Systems 9 Figure 8 ZW A3 thru A4 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 loc...

Page 10: ...Johnson Controls Ducted Systems Figure 9 ZW A5 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 ZW 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 ZW A3 30 357 13 365 22 516 ZW A4 30 357 13 365 22 516 ZW A5 30 357 13 365 22 516 8 or 14 50 1 2 30 20...

Page 15: ...er 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 rem...

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: ...cement 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...

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: ...35 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...

Page 21: ...06 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 40...

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: ...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 9...

Page 24: ...tate 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 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 6...

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: ...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 27: ...h accessory kit model 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 Mo...

Page 28: ...ing to NFPA 72 requirements and cleaned at least once a year For specific troubleshooting and maintenance procedures please refer to the smoke detector s installation instructions which accompanies th...

Page 29: ...for free cooling The position of the damper is set proportionally between the Economizer Minimum Position and the Economizer Minimum Position Low Speed Fan set points in relationship to the VFD output...

Page 30: ...sor 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 s...

Page 31: ...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 32: ...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 33: ...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 34: ...s 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 is...

Page 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...10 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 Close...

Page 41: ...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 42: ...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 43: ...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 44: ...ntroller 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 enthalpy...

Page 45: ...or coil Low ambient mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor operation The off cycle will begin immediately following the elapse of...

Page 46: ...h operates when a high temperature 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 therm...

Page 47: ...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 48: ...e 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 pres...

Page 49: ...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 50: ...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 51: ...inspection and or replacement NOTE Reverse the above procedure to replace the assemblies Make sure that burners are level and seat at the rear of the gas orifice Figure 29 Typical Flame Figure 30 Typ...

Page 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 57: ...ication 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 top edge of the communication board...

Page 58: ...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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