zca series warning warning caution

Service Literature
ZCA SERIES
3, 4 and 5 ton
10.6 to 17.6 kW
Corp. 1308-L2
Revised 3-2016
ZCA036, 048, 060
The ZCA packaged electric cooling units are available in
standard cooling efficiency (036S, 048S, 060S). Cool­
ing capacities are 3, 4 and 5 tons (10.6 to 17.6kW).
Optional electric heat is field-installed and is available in
5kW through 22.5kW. Electric heat operates in single
stage only.
Information contained in this manual is intended for use
by qualified service technicians only. All specifications
are subject to change. Procedures outlined in this manu­
al are presented as a recommendation only and do not
supersede or replace local or state codes.
If the unit must be lifted for service, rig unit by attaching
four cables to the holes located in the unit base rail (two
holes at each corner). Refer to the installation instruc­
tions for the proper rigging technique. Stacking brackets
can be removed or left on the unit permanently. If brack­
ets are removed, any screws removed during installation
must be replaced.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic
components. Take precautions during unit instal­
lation and service to protect the unit's electronic
controls. Precautions will help to avoid control
exposure to electrostatic discharge by putting
the furnace, the control and the technician at the
same electrostatic potential. Neutralize electro­
static charge by touching hand and all tools on an
unpainted unit surface, such as the blower deck,
before performing any service procedure.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person­
al injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent).
Table of Contents
Options . . . . . . . . . . . . . . . . . . . . . . . Page 2
WARNING
Specifications . . . . . . . . . . . . . . . . . . Page 4
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon­
nect switch(es). Unit may have multiple
power supplies.
Blower Data . . . . . . . . . . . . . . . . . . . Page 5
Electrical Data . . . . . . . . . . . . . . . . . Page 9
I Unit Components . . . . . . . . . . . . . Page 14
II Placement and Installation . . . . . Page 20
III Start Up Operation . . . . . . . . . . . Page 20
CAUTION
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal in­
jury. Take care while handling this equipment and
wear gloves and protective clothing.
IV Charging . . . . . . . . . . . . . . . . . . . Page 21
V System Service Checks . . . . . . . Page 24
VI Maintenance . . . . . . . . . . . . . . . . Page 24
VII Accessories . . . . . . . . . . . . . . . . Page 26
VIII Diagrams . . . . . . . . . . . . . . . . . . Page 32
Page 1
© 2016
OPTIONS / ACCESSORIES
Item
COOLING SYSTEM
Condensate Drain Trap
Compressor Crankcase Heater
Drain Pan Overflow Switch
Low Ambient Kit
BLOWER - SUPPLY AIR
Motors
Drive Kits
See Blower Data Tables for selection
CABINET
Coil/Hail Guards
Corrosion Protection
ELECTRICAL
Voltage
60 hz
Bottom Power Entry Kit
ELECTRIC HEAT
5 kW
7.5 kW
10 kW
15 kW
22.5 kW
Catalog
No.
036
048
060
PVC - C1TRAP20AD2
Copper - C1TRAP10AD2
208/230V-1 or 3ph - Z1CCHT10A-1P
208/230V-1 or 3 ph - Z1CCHT11A-1P
460V - 3 ph - Z1CCHT10A-1G
460V - 3 ph - Z1CCHT11A-1G
575V - 3 ph - Z1CCHT10A-1J
575V - 3 ph - Z1CCHT11A-1J
Z1SNSR90A1
Z1SNSR33A-1
76W26
76W27
99W61
99W64
99W62
99W65
99W63
99W66
99W59
99W67
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Belt Drive - 1 hp Standard Efficiency
Belt Drive - 1.5 hp Standard Efficiency
Kit #Z01 - 678-1035 rpm
Kit #Z02 - 803-1226 rpm
Kit #Z03 - 906-1383 rpm
Kit #Z04 - 964-1471 rpm
2
Kit #Z05 -1098-1490 rpm
2
Kit #Z06 - 1262-1634 rpm
Factory
Factory
Factory
Factory
Factory
Factory
Factory
Factory
O
O
O
O
O
O
O
Z1GARD10A-1
97W53
Factory
X
O
X
O
X
O
208/230V - 1 phase
208/230V - 3 phase
460V - 3 phase
575V - 3 phase
Z1PEKT01A-1
Factory
Factory
Factory
Factory
98W08
O
O
O
O
X
O
O
O
O
X
O
O
O
O
X
208/230V-1ph - Z1EH0050AN1P
208/230V-3ph - Z1EH0050AN1Y
460V-3ph - Z1EH0050AN1G
575V-3ph - Z1EH0050AN1J
208/230V-1ph - Z1EH0075AN1P
208/230V-3ph - Z1EH0075AN1Y
460V-3ph - Z1EH0075AN1G
575V-3ph - Z1EH0075AN1J
208/230V-1ph - Z1EH0100AN1P
208/230V-3ph - Z1EH0100AN1Y
460V-3ph - Z1EH0100AN1G
575V-3ph - Z1EH0100AN1J
208/230V-1ph - Z1EH0150AN1P
208/230V-3ph - Z1EH0150AN1Y
460V-3ph - Z1EH0150AN1G
575V-3ph - Z1EH0150AN1J
208/230V-1ph - Z1EH0225AN1P
208/230V-3ph - Z1EH0225AN1Y
460V-3ph - Z1EH0225AN1G
575V-3ph - Z1EH0225AN1J
98W96
99W01
99W06
99W11
98W97
99W02
99W07
99W12
98W98
99W03
99W08
99W13
98W99
99W04
99W09
99W14
99W00
99W05
99W10
99W15
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1
ELECTRIC HEAT ACCESSORIES
Unit Fuse Block - See Electrical/Electric Heat Tables for Selection
1 hp blower motor is not available for 208/230V-1ph applications.
2
1.5 hp motor is required with Z05 and Z06 drive kits.
1
NOTE - The catalog and model numbers that appear here are for ordering field installed accessories only.
OX - Field Installed or Configure to Order (Factory Installed)
O - Configure to Order (Factory Installed)
X - Field Installed.
Page 2
X
X
X
X
O
O
O
O
O
OPTIONS / ACCESSORIES
Item
Catalog
No.
036
048
060
ECONOMIZER
Economizer - With Barometric Relief Dampers and Exhaust Hood (Downflow)
Z1ECON30A-1
98W09
OX
OX
OX
Economizer - With Barometric Relief Dampers and Exhaust Hood (Horizontal)
Z1ECON16A-1
98W68
X
X
X
C1SNSR64FF1
53W64
X
X
X
Motorized
Z1DAMP21A-1
95W74
X
X
X
Manual
Z1DAMP11A-1
95W73
X
X
X
208/230V-1 or 3ph - Z1PWRE10A-1P
21E01
X
X
X
460V-3ph - Z1PWRE10A-1G
23E01
X
X
X
208/230V-1 or 3ph - Z1PWRE15A-1P
24E01
X
X
X
460V-3ph - Z1PWRE15A-1G
28E01
X
X
X
575V-3ph - Z1TRFM20A-1J
59E02
X
X
X
Economizer Controls
Single Enthalpy Control
OUTDOOR AIR
Outdoor Air Dampers - Includes Outdoor Air Hood
POWER EXHAUST FAN
Standard Static (Downflow)
Standard Static (Horizontal)
575V Transformer Kit
NOTE - Order 575V Transformer Kit with 208/230V Power Exhaust Fan for 575V applications.
INDOOR AIR QUALITY
Indoor Air Quality (Co2) Sensors
Sensor - Wall-mount, off-white plastic cover with LCD display
C0SNSR50AE1L
77N39
X
X
X
Sensor - Wall-mount, black plastic case, no display, rated for plenum
mounting
C0SNSR53AE1L
87N54
X
X
X
CO2 Sensor Duct Mounting Kit - for downflow applications
C0MISC19AE1
85L43
X
X
X
Aspiration Box - for duct mounting non-plenum rated CO2 sensor (77N39)
C0MISC16AE1
90N43
X
X
X
8 in. height
Z1CURB40A-1
95W18
X
X
X
14 in. height
Z1CURB41A-1
95W19
X
X
X
18 in. height
Z1CURB42A-1
95W20
X
X
X
24 in. height
Z1CURB43A-1
95W21
X
X
X
Z1CURB10A-1
92W50
X
X
X
RTD9-65-R
27G87
X
X
X
FD9-65-R
27G86
X
X
X
ROOF CURBS - DOWNFLOW
Clip Curb
Standard Curb
14 in. height
CEILING DIFFUSERS
Step-Down - Order one
Flush - Order one
NOTE - Ceiling Diffuser Transitions are not furnished and must be field fabricated.
NOTE - The catalog and model numbers that appear here are for ordering field installed accessories only.
OX - Field Installed or Configure to Order (Factory Installed)
O - Configure to Order (Factory Installed)
X - Field Installed.
Page 3
SPECIFICATIONS
General Data
Nominal Tonnage
Model No.
3 Ton
4 Ton
5 Ton
ZCA036S4B
ZCA048S4B
ZCA060S4B
Efficiency Type
Cooling
Performance
Standard
Standard
Standard
Gross Cooling Capacity - Btuh
36,100
47,000
58,900
Net Cooling Capacity - Btuh
34,600
45,000
57,000
1200
1550
1650
77
80
83
1
AHRI Rated Air Flow - cfm
2
Sound Rating Number (SRN) (dBA)
Total Unit Power - kW
1
3.0
4.3
SEER (Btuh/Watt)
13.00
13.00
13.00
EER (Btuh/Watt)
11.50
10.60
10.70
1
Refrigerant
Type
Charge Furnished
Electric Heat Available - See page 2
Outdoor Coil
Net face area - sq. ft.
Number of rows
Outdoor
Coil Fan
Scroll
Scroll
Scroll
12.8
12.8
15.2
1
1
1
23
23
23
(1) 1/4 (PSC)
(1) 1/3 (PSC)
Motor rpm
825
825
1075
Total motor watts
200
310
360
(1) 22
(1) 22
(1) 22
4
4
3
Total air volume - cfm
2700
3300
3800
Net face area - sq. ft.
8.4
8.4
8.4
Tube diameter - in.
3/8
3/8
3/8
Number of rows
2
2
3
Fins per inch
14
14
14
Expansion device type
Nominal Motor HP
(1) 1 NPT
(1) 1 NPT
(1) 1 NPT
Fixed Orifice
Fixed Orifice
Fixed Orifice
4
1 hp, 1.5 hp
4
1 hp, 1.5 hp
4
1 hp, 1.5 hp
Maximum Usable Motor HP
1.15 hp, 1.7 hp
1.15 hp, 1.7 hp
1.15 hp, 1.7 hp
Available Drive Kits
Kit #Z01
678-1035 rpm
Kit #Z02
803-1226 rpm
Kit #Z03
906-1383 rpm
Kit #Z04
964-1471 rpm
5
Kit #Z05
1098-1490 rpm
5
Kit #Z06
1262-1634 rpm
10 x 10
10 x 10
Wheel nominal diameter x width - in.
Filters
5, 7.5, 10, 15, 22.5 kW
(1) 1/6 (PSC)
Drain Connection (no.and size) - in.
Indoor
Blower & Drive
Selection
R-410A
5 lbs. 6 oz.
Motor HP
Number of blades
3
R-410A
4 lbs. 6 oz.
Fins / inch
Diameter - in.
Indoor Coil
R-410A
4 lbs. 1 oz.
5, 7.5, 10, 15 kW
Compressor Type (one per unit)
5.3
10 x 10
Type
Disposable
Number and size - in.
Electrical Characteristics - 60 Hz
(4) 14 x 20 x 2
208/230V
1 phase
208/230V,
1 phase
208/230V,
1 phase
208/230V,
460V & 575V
3 phase
208/230V
460V & 575V
3 phase
208/230V
460V & 575V
3 phase
NOTE - Net capacity includes evaporator blower motor heat deduction. Gross capacity does not include evaporator blower motor heat deduction.
1
AHRI Certified to AHRI Standard 210/240: 95°F outdoor air temperature and 80°F db/67°F wb entering evaporator air; minimum external duct static pressure.
2
Sound Rating Number (SRN) rated in accordance with test conditions included in ANSI/AHRI Standard 270-2008.
3
Using total air volume and system static pressure requirements determine from blower performance tables rpm and motor hp required. Maximum usable hp of motors
furnished are shown. In Canada, nominal motor hp is also maximum usable motor hp output. If motors of comparable hp are used, be sure to keep within the service
factor limitations outlined on the motor nameplate.
4
1 hp blower motor is not available for 208/230V-1ph applications.
5
1.5 hp motor is required with Z05 and Z06 drive kits.
Page 4
BLOWER DATA - BELT DRIVE - ZCA036
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
See page 8 for blower motors and drives and wet coil and options/accessory air resistance data.
DOWNFLOW
External Static - in. w.g.
Air
Volume
cfm
RPM
900
555
0.10
BHP
0.20
RPM
BHP
0.30
RPM
BHP
0.40
RPM
0.50
BHP
RPM
Field Furnished
0.16
621
0.60
BHP
RPM
0.70
0.80
BHP
RPM
BHP
RPM
BHP
0.24
956
0.26
1010
0.29
Kit Z01
0.17
691
0.19
763
0.20
832
0.22
897
1000
577
0.18
644
0.19
715
0.21
786
0.23
855
0.24
919
0.27
976
0.29
1028
0.32
1100
601
0.20
670
0.22
741
0.23
812
0.25
879
0.28
941
0.30
996
0.33
1047
0.37
1200
629
0.22
698
0.24
770
0.26
840
0.28
905
0.31
965
0.34
1018
0.38
1066
0.41
1300
659
0.25
729
0.27
800
0.30
869
0.32
932
0.35
989
0.39
1040
0.43
1087
0.47
1400
692
0.28
763
0.31
833
0.34
899
0.37
960
0.40
1014
0.44
1063
0.48
1108
0.52
1500
728
0.32
798
0.35
866
0.38
930
0.41
987
0.45
1039
0.50
1086
0.54
1130
0.58
External Static - in. w.g.
Air
Volume
cfm
RPM
900
1060
0.90
BHP
1.00
RPM
BHP
1.10
RPM
BHP
1.20
RPM
1.30
BHP
RPM
1.40
1.50
1.60
BHP
RPM
BHP
RPM
BHP
RPM
BHP
0.44
1279
0.47
1319
0.51
1359
0.55
Kit Z04
0.31
1108
0.34
1154
0.37
1197
0.40
1239
1000
1077
0.35
1123
0.38
1168
0.42
1211
0.45
1252
0.49
1291
0.52
1330
0.56
1370
0.60
1100
1094
0.40
1139
0.43
1183
0.46
1225
0.50
1266
0.54
1305
0.58
1343
0.62
1382
0.66
1200
1112
0.45
1156
0.48
1199
0.52
1241
0.55
1281
0.59
1319
0.64
1357
0.68
1394
0.72
1300
1131
0.50
1174
0.54
1216
0.57
1257
0.61
1296
0.66
1334
0.70
1371
0.74
1408
0.78
1400
1151
0.56
1193
0.60
1234
0.64
1274
0.68
1313
0.72
1351
0.77
1387
0.81
1423
0.86
1500
1172
0.62
1213
0.66
1253
0.71
1293
0.75
1331
0.79
1368
0.84
1404
0.89
1440
0.93
HORIZONTAL
Air
Volume
cfm
External Static - in. w.g.
0.10
RPM
BHP
0.20
RPM
BHP
0.30
RPM
BHP
0.40
RPM
0.50
BHP
RPM
Field Furnished
BHP
0.60
RPM
BHP
0.70
RPM
BHP
Kit Z01
0.80
RPM
BHP
Kit Z04
900
572
0.14
641
0.16
712
0.19
785
0.22
860
0.24
931
0.27
991
0.29
1039
0.32
1000
602
0.16
671
0.19
742
0.22
815
0.24
887
0.27
954
0.30
1010
0.33
1055
0.36
1100
636
0.19
706
0.22
776
0.25
847
0.28
916
0.31
977
0.34
1028
0.37
1070
0.41
1200
674
0.23
744
0.26
813
0.29
881
0.32
944
0.35
999
0.38
1045
0.42
1087
0.45
1300
716
0.26
784
0.29
851
0.33
914
0.36
971
0.40
1020
0.43
1064
0.47
1106
0.50
1400
759
0.30
824
0.34
888
0.37
946
0.41
998
0.45
1043
0.49
1086
0.52
1129
0.55
1500
803
0.35
865
0.39
925
0.43
979
0.47
1027
0.52
1070
0.55
1113
0.58
1156
0.61
Air
Volume
cfm
External Static - in. w.g.
0.90
RPM
BHP
1.00
RPM
BHP
1.10
RPM
BHP
1.20
RPM
1.30
BHP
RPM
BHP
1.40
RPM
BHP
1.50
RPM
BHP
1.60
RPM
BHP
Kit Z04
900
1085
0.35
1135
0.38
1183
0.40
1227
0.42
1268
0.45
1305
0.49
1342
0.53
1379
0.57
1000
1099
0.39
1148
0.42
1195
0.44
1239
0.47
1279
0.50
1316
0.54
1352
0.58
1389
0.62
1100
1114
0.44
1163
0.46
1210
0.49
1253
0.52
1292
0.55
1329
0.59
1364
0.64
1401
0.68
1200
1131
0.48
1180
0.51
1226
0.54
1269
0.57
1308
0.61
1343
0.66
1378
0.70
1414
0.75
1300
1151
0.53
1199
0.56
1245
0.59
1287
0.63
1324
0.68
1359
0.72
1394
0.77
1429
0.82
1400
1175
0.58
1222
0.62
1266
0.66
1306
0.70
1342
0.75
1376
0.80
1410
0.85
1446
0.89
1500
1201
0.65
1246
0.68
1289
0.73
1327
0.78
1362
0.83
1395
0.88
1429
0.93
1464
0.98
Page 5
BLOWER DATA - BELT DRIVE - ZCA048
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
See page 8 for blower motors and drives and wet coil and options/accessory air resistance data.
DOWNFLOW
Air
Volume
cfm
1200
1300
1400
1500
1600
1700
1800
1900
2000
Air
Volume
cfm
0.10
RPM BHP
629
659
692
728
766
806
845
884
923
0.90
RPM BHP
1200
1112
1300
1131
1400
1151
1500
1172
1600
1193
1700
1216
1800
1239
1900
1264
2000
1290
HORIZONTAL
Air
Volume
cfm
1200
1300
1400
1500
1600
1700
1800
1900
2000
Air
Volume
cfm
1200
1300
1400
1500
1600
1700
1800
1900
2000
0.22
0.25
0.28
0.32
0.37
0.42
0.47
0.53
0.59
0.45
0.50
0.56
0.62
0.69
0.76
0.84
0.92
1.01
0.20
0.30
RPM BHP RPM BHP
Field Furnished
698
0.24
770
0.26
729
0.27
800
0.30
763
0.31
833
0.34
798
0.35
866
0.38
835
0.40
900
0.43
871
0.45
934
0.48
908
0.50
967
0.54
944
0.56 1000 0.60
979
0.63 1032 0.67
1.00
RPM BHP
Kit Z02
1156 0.48
1174 0.54
1193 0.60
1213 0.66
1234 0.73
1255 0.81
1279 0.89
1303 0.98
1328 1.07
External Static - in. w.g.
0.40
0.50
RPM BHP RPM BHP
1.10
RPM BHP
840
0.28
905
0.31
869
0.32
932
0.35
899
0.37
960
0.40
930
0.41
987
0.45
960
0.47 1015 0.51
991
0.52 1043 0.56
1021 0.58 1071 0.63
1051 0.64 1099 0.69
1082 0.72 1128 0.77
External Static - in. w.g.
1.20
1.30
RPM BHP RPM BHP
1199
1216
1234
1253
1273
1295
1317
1341
1366
1241
1257
1274
1293
1313
1333
1355
1378
1402
0.52
0.57
0.64
0.71
0.78
0.86
0.94
1.03
1.13
0.10
0.20
RPM BHP RPM BHP
Field Furnished
674
0.23
744
0.26
716
0.26
784
0.29
0.34
759
0.30
824
803
0.35
865
0.39
847
0.40
905
0.45
890
0.47
944
0.52
930
0.54
982
0.60
970
0.62 1020 0.68
1009 0.71 1058 0.76
0.30
RPM BHP
0.90
1.00
RPM BHP RPM BHP
Kit Z02
1131 0.48 1180 0.51
1151 0.53 1199 0.56
1175 0.58 1222 0.62
1201 0.65 1246 0.68
1229 0.72 1273 0.76
1258 0.80 1300 0.85
1289 0.89 1328 0.94
1319 0.99 1357 1.05
1350 1.10 1387 1.16
1.10
RPM BHP
813
851
888
925
961
997
1033
1069
1106
1226
1245
1266
1289
1313
1338
1365
1392
1421
0.29
0.33
0.37
0.43
0.50
0.57
0.65
0.73
0.81
0.54
0.59
0.66
0.73
0.81
0.90
1.00
1.11
1.23
0.55
0.61
0.68
0.75
0.82
0.90
0.99
1.08
1.19
1281
1296
1313
1331
1350
1370
1391
1413
1436
0.59
0.66
0.72
0.79
0.87
0.95
1.04
1.14
1.24
0.60
RPM BHP
Kit Z02
965
0.34
989
0.39
1014 0.44
1039 0.50
1065 0.55
1091 0.61
1117 0.68
1143 0.75
1171 0.83
1.40
RPM BHP
Kit Z05
1319 0.64
1334 0.70
1351 0.77
1368 0.84
1387 0.92
1406 1.00
1426 1.09
1448 1.19
1470 1.29
External Static - in. w.g.
0.40
0.50
0.60
RPM BHP RPM BHP RPM BHP
Kit Z02
881
0.32
944
0.35
999
0.38
914
0.36
971
0.40 1020 0.43
946
0.41
998
0.45 1043 0.49
979
0.47 1027 0.52 1070 0.55
1013 0.54 1058 0.58 1100 0.62
1047 0.62 1091 0.66 1132 0.69
1081 0.70 1124 0.74 1165 0.77
1116 0.78 1158 0.81 1199 0.85
1151 0.86 1193
0.9
1233 0.94
External Static - in. w.g.
1.20
1.30
1.40
RPM BHP RPM BHP RPM BHP
Kit Z05
1269 0.57 1308 0.61 1343 0.66
1287 0.63 1324 0.68 1359 0.72
1306 0.70 1342 0.75 1376 0.80
1327 0.78 1362 0.83 1395 0.88
1350 0.86 1384 0.92 1416 0.97
1374 0.96 1407 1.02 1440 1.07
1399 1.06 1432 1.13 1465 1.18
1426 1.18 1459 1.24 1491 1.30
1454 1.30 1486 1.36 1518 1.42
Page 6
0.70
RPM BHP
0.80
RPM BHP
1018
1040
1063
1086
1110
1134
1159
1185
1211
1066
1087
1108
1130
1152
1176
1200
1225
1251
0.38
0.43
0.48
0.54
0.60
0.66
0.73
0.80
0.89
0.41
0.47
0.52
0.58
0.65
0.71
0.78
0.86
0.95
1.50
RPM BHP
1.60
RPM BHP
1357
1371
1387
1404
1422
1441
1461
1481
1503
1394
1408
1423
1440
1457
1475
1494
1514
1535
0.68
0.74
0.81
0.89
0.97
1.05
1.14
1.24
1.35
0.72
0.78
0.86
0.93
1.01
1.10
1.19
1.29
1.40
0.70
RPM BHP
0.80
RPM BHP
1045
1064
1086
1113
1142
1173
1206
1239
1273
1087
1106
1129
1156
1185
1216
1248
1280
1312
0.42
0.47
0.52
0.58
0.65
0.72
0.80
0.89
0.98
0.45
0.50
0.55
0.61
0.68
0.76
0.84
0.93
1.04
1.50
RPM BHP
1.60
RPM BHP
1378
1394
1410
1429
1450
1473
1498
1524
1551
1414
1429
1446
1464
1485
1508
1532
1558
1584
0.70
0.77
0.85
0.93
1.02
1.12
1.23
1.35
1.47
0.75
0.82
0.89
0.98
1.07
1.17
1.28
1.39
1.51
BLOWER DATA - BELT DRIVE - ZCA060
BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE.
FOR ALL UNITS ADD:
1 - Any factory installed options air resistance (heat section, economizer, wet coil, etc.).
2 - Any field installed accessories air resistance (duct resistance, diffuser, etc.).
See page 8 for blower motors and drives and wet coil and options/accessory air resistance data.
DOWNFLOW
Air
Volume
cfm
1600
1700
1800
1900
2000
2100
2200
2300
2400
Air
Volume
cfm
0.10
0.20
RPM BHP RPM BHP
Field Furnished
787
0.38
854
0.41
827
0.43
892
0.46
868
0.48
929
0.52
907
0.54
966
0.58
946
0.60 1001 0.65
984
0.68 1037 0.72
1021 0.75 1072 0.81
1059 0.84 1108 0.90
1097 0.95 1144 1.01
0.90
RPM BHP
Air
Volume
cfm
1600
1700
1800
1900
2000
2100
2200
2300
2400
Air
Volume
cfm
1600
1700
1800
1900
2000
2100
2200
2300
2400
918
952
986
1019
1053
1086
1120
1154
1188
0.44
0.49
0.55
0.62
0.69
0.77
0.86
0.96
1.08
0.75
0.82
0.91
1.00
1.10
1.21
1.32
1.45
1.59
1.10
RPM BHP
Kit Z03
1284 0.79
1307 0.87
1331 0.96
1355 1.05
1380 1.15
1407 1.26
1434 1.38
1462 1.51
1490 1.65
0.10
RPM BHP
Field Furn.
864
0.42
907
0.48
948
0.56
987
0.64
1028 0.73
1071 0.81
1116 0.91
1161 1.02
1207 1.14
0.20
RPM BHP
0.30
RPM BHP
921
961
999
1037
1076
1117
1160
1204
1248
976
1013
1049
1086
1123
1163
1204
1245
1288
0.90
RPM BHP
1.00
1.10
RPM BHP RPM BHP
Kit Z03
1284 0.77 1324 0.82
1312 0.86 1350 0.92
1341 0.96 1377 1.02
1371 1.07 1406 1.13
1401 1.19 1435 1.25
1433 1.31 1466 1.38
1465 1.45 1497 1.52
1498 1.59 1529 1.66
1532 1.74 1563 1.80
1600
1205
1700
1228
1800
1253
1900
1279
2000
1305
2100
1333
2200
1361
2300
1391
2400
1421
HORIZONTAL
1242
1272
1302
1334
1365
1398
1431
1466
1500
0.70
0.78
0.85
0.94
1.04
1.14
1.26
1.39
1.52
0.73
0.81
0.90
1.01
1.12
1.25
1.38
1.52
1.67
1.00
RPM BHP
0.30
RPM BHP
1245
1268
1292
1317
1343
1370
1398
1427
1456
0.46
0.53
0.61
0.69
0.78
0.86
0.96
1.07
1.20
0.51
0.58
0.66
0.74
0.83
0.91
1.01
1.13
1.26
External Static - in. w.g.
0.40
0.50
0.60
RPM BHP RPM BHP RPM BHP
Kit Z03
976
0.48 1030 0.52 1078 0.56
1007 0.53 1058 0.58 1105 0.63
1038 0.59 1087 0.64 1132 0.69
1069 0.66 1116 0.71 1160 0.77
1101 0.74 1146 0.79 1188 0.85
1132 0.83 1176 0.89 1217 0.95
1165 0.92 1207 0.99 1247 1.05
1197 1.03 1239 1.10 1278 1.17
1231 1.15 1271 1.22 1310 1.30
External Static - in. w.g.
1.20
1.30
1.40
RPM BHP RPM BHP RPM BHP
1323
1345
1368
1392
1416
1442
1468
1495
1523
0.84
0.92
1.01
1.10
1.21
1.32
1.44
1.57
1.71
1361
1382
1404
1427
1450
1475
1501
1527
1555
0.88
0.97
1.06
1.16
1.26
1.38
1.50
1.63
1.76
External Static - in. w.g.
0.40
0.50
RPM BHP RPM BHP
Kit Z03
1027 0.56 1072 0.60
1061 0.63 1105 0.67
1096 0.71 1139 0.75
1132 0.79 1174 0.83
1168 0.87 1210 0.91
1206 0.96 1247 1.01
1245 1.07 1285 1.12
1285 1.19 1323 1.25
1326 1.32 1362 1.39
External Static - in. w.g.
1.20
1.30
RPM BHP RPM BHP
1360
1385
1411
1439
1468
1497
1528
1560
1593
0.88
0.98
1.08
1.20
1.32
1.45
1.58
1.72
1.86
Page 7
1394
1418
1444
1471
1500
1529
1560
1591
1624
0.93
1.04
1.15
1.26
1.38
1.51
1.64
1.77
1.91
0.70
RPM BHP
0.80
RPM BHP
1123
1148
1174
1200
1228
1256
1286
1316
1348
1164
1189
1214
1240
1267
1295
1324
1354
1385
0.61
0.68
0.75
0.82
0.91
1.01
1.12
1.24
1.38
0.66
0.73
0.80
0.88
0.98
1.08
1.19
1.32
1.45
0.93
1.02
1.11
1.21
1.32
1.43
1.55
1.68
1.82
1.50
RPM BHP
Kit Z06
1432 0.98
1452 1.07
1473 1.16
1494 1.26
1516 1.37
1540 1.48
1564 1.61
1590 1.73
1617 1.87
1467
1486
1506
1527
1549
1572
1596
1622
1649
0.60
RPM BHP
0.70
RPM BHP
0.80
RPM BHP
1113
1146
1180
1214
1250
1286
1323
1360
1398
1155
1187
1221
1255
1289
1324
1360
1396
1433
1198
1230
1262
1295
1328
1362
1396
1432
1468
1397
1417
1439
1461
1484
1508
1533
1559
1586
0.63
0.70
0.78
0.86
0.96
1.06
1.18
1.32
1.46
0.66
0.73
0.82
0.90
1.00
1.12
1.25
1.38
1.53
1.40
1.50
RPM BHP RPM BHP
Kit Z06
1426 0.99 1460 1.04
1451 1.09 1485 1.14
1477 1.20 1510 1.25
1504 1.32 1537 1.37
1532 1.44 1565 1.49
1561 1.56 1594 1.61
1591 1.69 1623 1.73
1623 1.82 1654 1.86
1655 1.96 1686 2.00
1.60
RPM BHP
1.03
1.11
1.21
1.31
1.42
1.53
1.66
1.78
1.92
0.69
0.77
0.86
0.95
1.06
1.18
1.31
1.45
1.60
1.60
RPM BHP
1495
1519
1544
1571
1598
1626
1656
1686
1718
1.08
1.19
1.30
1.41
1.53
1.65
1.77
1.90
2.04
BLOWER DATA
DRIVE KIT SPECIFICATIONS
Model No.
Blower Motor Choice (HP)
Maximum
Nominal
Nominal
Maximum
036
1
1.15
1.5
1.7
048
1
1.15
1.5
1.7
060
1
1.15
1.5
1.7
Drive Kit No.
RPM Range
Z01
Z04
Z02
1
Z05
Z03
1
Z06
678 - 1035
964 - 1471
803 - 1226
1098 - 1490
906 - 1383
1262 - 1634
NOTE - Using total air volume and system static pressure requirements determine from blower performance tables rpm and motor hp required. Maximum usable hp of
motors furnished are shown. In Canada, nominal motor hp is also maximum usable motor hp. If motors of comparable hp are used, be sure to keep within the service
factor limitations outlined on the motor nameplate.
1
1.5 hp motor is required with Z05 and Z06 drive kits.
POWER EXHAUST FAN PERFORMANCE
Air Volume Exhausted
cfm
1865
1785
1710
1630
1545
1450
1350
1240
Return Air System Static Pressure - in. w.g.
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
OPTIONS / ACCESSORIES AIR RESISTANCE - in. w.g.
Wet Indoor Coil
Air Volume
cfm
036-048
060
900
0.01
--1000
0.01
--1100
0.02
--1200
0.02
--1300
0.02
--1400
0.03
--1500
0.03
--1600
0.03
0.04
1700
0.04
0.05
1800
0.04
0.05
1900
0.04
0.06
2000
0.05
0.06
2100
--0.07
2200
--0.08
2300
--0.08
2400
--0.09
CEILING DIFFUSERS AIR RESISTANCE (in. w.g.)
RTD9-65 Step-Down Diffuser
Air Volume
2 Ends
1 Side &
All Ends &
cfm
Open
2 Ends Open
Sides Open
800
0.15
0.13
0.11
1000
0.19
0.16
0.14
1200
0.25
0.20
0.17
1400
0.33
0.26
0.20
1600
0.43
0.32
0.20
1800
0.56
0.40
0.30
2000
0.73
0.50
0.36
2200
0.95
0.63
0.44
Electric Heat
0.02
0.04
0.05
0.06
0.08
0.09
0.10
0.12
0.13
0.15
0.16
0.17
0.19
0.20
0.21
0.23
FD9-65
Flush
Diffuser
0.11
0.14
0.17
0.20
0.24
0.30
0.36
0.44
Page 8
Economizer
Downflow
Horizontal
0.04
0.05
0.04
0.05
0.04
0.06
0.05
0.06
0.05
0.07
0.06
0.07
0.07
0.08
0.08
0.09
0.08
0.10
0.09
0.11
0.10
0.12
0.12
0.13
0.13
0.14
0.14
0.15
0.15
0.17
0.17
0.18
CEILING DIFFUSER AIR THROW DATA
1
Effective Throw - ft.
Air Volume - cfm
Model No.
RTD9-65
FD9-65
800
10 - 17
14 - 18
1000
10 - 17
15 - 20
1200
11 - 18
16 - 22
1400
12 - 19
17 - 24
1600
12 - 20
18 - 25
1800
13 - 21
20 - 28
2000
14 - 23
21 - 29
2200
16 - 25
22 - 30
1 Effective throw based on terminal velocities of 75 ft. per minute.
ELECTRICAL DATA
ZCA036S4
208/230V - 1 Ph
208/230V - 3 Ph
460V - 3 Ph
575V - 3 Ph
15.3
8.7
4
3.6
Locked Rotor Amps
70
70
31
27
Outdoor Fan
Motor
Full Load Amps
1
1
0.6
0.45
Power Exhaust
(1) 0.5 HP
Full Load Amps
1.5
1.5
0.6
0.6
Horsepower
1.5
1
1.5
1
1.5
1
1.5
Full Load Amps
11
4.6
6.6
2.1
3
1.7
2.4
Unit Only
45
25
25
15
15
15
15
With (1) 0.5 HP
Power Exhaust
45
25
25
15
15
15
15
Unit Only
32
17
19
8
9
7
8
With (1) 0.5 HP
Power Exhaust
33
18
20
9
10
8
8
1
Voltage - 60hz
Compressor
Rated Load Amps
Indoor Blower
Motor
2
3
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
3
2
3
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
208V
240V
208V
240V
208V
240V
480V
480V
600V
600V
5 kW
45
45
25
25
25
25
15
15
15
15
7.5 kW
50
60
30
30
30
35
15
20
15
15
10 kW
60
70
35
40
35
40
20
20
15
20
15 kW
90
100
45
60
50
60
30
30
25
25
5 kW
37
40
19
21
22
24
11
12
9
10
7.5 kW
48
53
26
29
28
31
14
16
12
13
10 kW
59
66
32
36
35
39
18
19
15
16
15 kW
82
92
45
51
48
54
26
27
21
22
Unit+
5 kW
Electric Heat
7.5 kW
and
(1) 0.5 HP 10 kW
Power Exhaust
15 kW
45
45
25
25
25
30
15
15
15
15
50
60
30
35
30
35
15
20
15
15
70
70
35
40
40
45
20
20
15
20
90
100
50
60
50
60
30
30
25
25
39
42
21
23
24
26
11
13
9
10
50
55
28
31
30
33
15
16
12
13
61
68
34
38
37
41
19
20
15
16
84
94
47
53
50
56
26
28
21
22
Unit+
Electric Heat
Unit+
Electric Heat
Unit+
5 kW
Electric Heat
7.5 kW
and
(1) 0.5 HP 10 kW
Power Exhaust
15 kW
ELECTRIC HEAT ACCESSORIES
Unit Fuse Block
Unit Only
10A26
10A27
10A27
10A29
10A29
10A29
10A29
Unit + Power Exhaust
10A26
10A27
10A27
10A29
10A29
10A29
10A29
NOTE - All units have a minimum Short Circuit Current Rating (SCCR) of 5000 amps.
1
Extremes of operating range are plus and minus 10% of line voltage.
2
HACR type breaker or fuse.
3
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
Page 9
ELECTRICAL DATA
4 TON
ZCA048S4
208/230V - 1 Ph
208/230V - 3 Ph
460V - 3 Ph
575V - 3 Ph
Rated Load Amps
20
11
5.5
4.7
Locked Rotor Amps
99
86
37
34
Outdoor Fan
Motor
Full Load Amps
1.7
1.7
0.9
0.7
Power Exhaust
(1) 0.5 HP
Full Load Amps
1.5
1.5
0.6
0.6
Horsepower
1.5
1
1.5
1
1.5
1
1.5
Full Load Amps
11
4.6
6.6
2.1
3
1.7
2.4
Unit Only
50
30
30
15
15
15
15
With (1) 0.5 HP
Power Exhaust
50
30
30
15
15
15
15
Unit Only
38
21
23
10
11
9
9
With (1) 0.5 HP
Power Exhaust
40
22
24
11
12
9
10
1
Voltage - 60hz
Compressor
Indoor Blower
Motor
2
3
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
3
2
3
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
208V
240V
208V
240V
208V
240V
480V
480V
600V
600V
5 kW
50
50
30
30
30
30
15
15
15
15
7.5 kW
50
60
30
30
30
35
15
20
15
15
10 kW
60
70
35
40
35
40
20
20
15
20
15 kW
90
100
45
60
50
60
30
30
25
25
22.5 kW
125
150
70
80
70
80
40
40
30
35
5 kW
38
40
21
21
23
24
11
12
9
10
7.5 kW
48
53
26
29
28
31
14
16
12
13
10 kW
59
66
32
36
35
39
18
19
15
16
15 kW
82
92
45
51
48
54
26
27
21
22
22.5 kW
116
131
65
74
67
76
37
38
30
31
Unit+
5 kW
Electric Heat
7.5 kW
and
(1) 0.5 HP 10 kW
Power Exhaust
15 kW
50
50
30
30
30
30
15
15
15
15
50
60
30
35
30
35
15
20
15
15
70
70
35
40
40
45
20
20
15
20
90
100
50
60
50
60
30
30
25
25
22.5 kW
125
150
70
80
70
80
40
40
30
35
Unit+
5 kW
Electric Heat
7.5 kW
and
(1) 0.5 HP 10 kW
Power Exhaust
15 kW
40
42
22
23
24
26
11
13
9
10
50
55
28
31
30
33
15
16
12
13
61
68
34
38
37
41
19
20
15
16
84
94
47
53
50
56
26
28
21
22
22.5 kW
118
133
67
76
69
78
38
39
30
31
Unit+
Electric Heat
Unit+
Electric Heat
ELECTRIC HEAT ACCESSORIES
Unit Fuse Block
Unit Only
10A26
10A27
10A27
10A29
10A29
10A29
10A29
Unit + Power Exhaust
10A26
10A27
10A27
10A29
10A29
10A29
10A29
NOTE - All units have a minimum Short Circuit Current Rating (SCCR) of 5000 amps.
1
Extremes of operating range are plus and minus 10% of line voltage.
2
HACR type breaker or fuse.
3
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
Page 10
ELECTRICAL DATA
5 TON
ZCA060S4
208/230V - 1 Ph
208/230V - 3 Ph
460V - 3 Ph
575V - 3 Ph
Rated Load Amps
22.1
13.5
8
5
Locked Rotor Amps
125
109
59
40
Outdoor Fan
Motor
Full Load Amps
1.7
1.7
1
0.9
Power Exhaust
(1) 0.5 HP
Full Load Amps
1.5
1.5
0.6
0.6
Horsepower
1.5
1
1.5
1
1.5
1
1.5
Full Load Amps
11
4.6
6.6
2.1
3
1.7
2.4
Unit Only
60
35
35
20
20
15
15
With (1) 0.5 HP
Power Exhaust
60
35
40
20
20
15
15
Unit Only
41
24
26
14
14
9
10
With (1) 0.5 HP
Power Exhaust
42
25
27
14
15
10
11
1
Voltage - 60hz
Compressor
Indoor Blower
Motor
2
3
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
ELECTRIC HEAT DATA
Electric Heat Voltage
2
3
2
3
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
aximum
M
Overcurrent
Protection
Minimum
Circuit
Ampacity
Unit+
Electric Heat
Unit+
Electric Heat
Unit+
Electric Heat
and
(1) 0.5 HP
Power Exhaust
Unit+
Electric Heat
and
(1) 0.5 HP
Power Exhaust
208V
240V
208V
240V
208V
240V
480V
480V
600V
600V
5 kW
60
60
35
35
35
35
20
20
15
15
7.5 kW
60
60
35
35
35
35
20
20
15
15
10 kW
60
70
35
40
35
40
20
20
15
20
15 kW
90
100
45
60
50
60
30
30
25
25
22.5 kW
125
150
70
80
70
80
40
40
30
35
5 kW
41
41
24
24
26
26
14
14
9
10
7.5 kW
48
53
26
29
28
31
14
16
12
13
10 kW
59
66
32
36
35
39
18
19
15
16
15 kW
82
92
45
51
48
54
26
27
21
22
22.5 kW
116
131
65
74
67
76
37
38
30
31
5 kW
60
60
35
35
40
40
20
20
15
15
7.5 kW
60
60
35
35
40
40
20
20
15
15
10 kW
70
70
35
40
40
45
20
20
15
20
15 kW
90
100
50
60
50
60
30
30
25
25
22.5 kW
125
150
70
80
70
80
40
40
30
35
5 kW
42
42
25
25
27
27
14
15
10
11
7.5 kW
50
55
28
31
30
33
15
16
12
13
10 kW
61
68
34
38
37
41
19
20
15
16
15 kW
84
94
47
53
50
56
26
28
21
22
22.5 kW
118
133
67
76
69
78
38
39
30
31
ELECTRIC HEAT ACCESSORIES
Unit Fuse Block
Unit Only
10A26
10A28
10A28
10A29
10A29
10A29
10A29
Unit + Power Exhaust
10A26
10A28
10A28
10A29
10A29
10A29
10A29
NOTE - All units have a minimum Short Circuit Current Rating (SCCR) of 5000 amps.
1
Extremes of operating range are plus and minus 10% of line voltage.
2
HACR type breaker or fuse.
3
Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.
Page 11
ELECTRIC HEAT CAPACITIES
5 kW
7.5 kW
10 kW
15 kW
22.5 kW
Input
Btuh No of kW
Btuh No of kW
Btuh No of kW
Btuh No of kW
Btuh
Voltage No of kW
Stages input Output Stages input Output Stages input Output Stages input Output Stages input Output
208
1
3.8
12,800
1
5.6
19,200
1
7.5
25,600
1
11.2
38,400
1
16.9
57,700
220
1
4.2
14,300
1
6.3
21,500
1
8.4
28,700
1
12.6
43,000
1
18.9
64,500
230
1
4.6
15,700
1
6.9
23,500
1
9.2
31,400
1
13.8
47,000
1
20.7
70,700
240
1
5.0
17,100
1
7.5
25,600
1
10.0
34,200
1
15.0
51,200
1
22.5
76,800
440
1
4.2
14,300
1
6.3
21,500
1
8.4
28,700
1
12.6
43,000
1
18.9
64,500
460
1
4.6
15,700
1
6.9
23,500
1
9.2
31,400
1
13.8
47,000
1
20.7
70,700
480
1
5.0
17,100
1
7.5
25,600
1
10.0
34,200
1
15.0
51,200
1
22.5
76,800
550
1
4.2
14,300
1
6.3
21,500
1
8.4
28,700
1
12.6
43,000
1
18.9
64,500
575
1
4.6
15,700
1
6.9
23,500
1
9.2
31,400
1
13.8
47,000
1
20.7
70,700
600
1
5.0
17,100
1
7.5
25,600
1
10.0
34,200
1
15.0
51,200
1
22.5
76,800
Page 12
ZCA PARTS ARRANGEMENT
EVAPORATOR
COIL
CONTROL
PANEL
BLOWER
MOTOR
CONDENSER
FAN
COMPRESSOR
BLOWER
HOUSING
ELECTRIC HEAT
(OPTIONAL)
TB2 UNIT
TERMINAL STRIP (IN
UNIT FUSE ASSEMBLY)
CONDENSER
COIL
F4
UNIT FUSE
SIDE POWER
ENTRY
BOTTOM POWER
ENTRY
FIGURE 1
ZCA CONTROL BOX
OUTDOOR
FAN RELAY
K10
POWER EXHAUST
TRANSFORMER
T10
CAPACITOR
C1 or C12
CONTACTOR
K1
FIGURE 2
Page 13
TRANSFORMER
T1
BLOWER
CONTACTOR
K3
I-UNIT COMPONENTS
5-Blower Contactor K3
The ZCA unit components are shown in figure 1. All units
come standard with removable unit panels. All L1, L2,
and L3 wiring is color coded; L1 is red, L2 is yellow, and
L3 is blue.
On three phase units, K3 is a two pole double‐break contactor
with a 24VAC coil and on single phase units is a single pole
double break contactor with a 24 volt coil. K3 energizes the in­
door blower motor B3 in response to blower demand.
A-Control Box Components
6-Outdoor Fan Relay K10 (G, J voltage)
ZCA control box components are shown in figure 2. The
control box is in the outdoor section to the left of the blower
and heat section.
Outdoor fan relay K10 is an optional, field-installed DPDT
relay with a 24VAC coil. K10 relay coil is in series with S11
low ambient pressure switch and cycles B4 outdoor fan via
K10-1 n.o. contacts.
1-Control Transformer T1
All use a single line voltage to 24VAC transformer
mounted in the control box. Transformer supplies power
to control circuits in the unit. The transformer is rated at
70VA and is protected by a 3 amp (auto) fuse F1. The
208/230 (Y) voltage transformers use two primary volt­
age taps as shown in
208/230V TRANSFORMER
figure 3, while 460 (G)
PINK
GRAY
SECONDARY
and 575 (J) voltage
transformers use a
single primary voltage
208 VOLTS
tap.
230 VOLTS
PRIMARY
YELLOW
PINK
FIGURE 3
2-Fan Capacitor C1 (three phase)
Fan capacitors C1 is used to assist in the start up of con­
denser fan B4. Ratings will be on side of capacitor or out­
door fan motor nameplate.
3-Dual Capacitor C12 (single phase)
7-Exhaust Fan Transformer T10 (J voltage)
Transformer T10 is a field-installed 600/230V transformer
which provides power to the 208/230V power exhaust fan in
575V applications.
8-Compressor B1
IMPORTANT
The Clean Air Act of 1990 bans the intentional vent­
ing of refrigerant (CFC's and HCFC's) as of July 1,
1992. Approved methods of recovery, recycling or re­
claiming must be followed. Fines and/or incarcera­
tion may be levied for non-compliance.
All units use one scroll compressor. See “SPECIFI­
CATIONS” and “ELECTRICAL DATA” (table of contents) or
compressor nameplate for compressor specifications.
A single dual capacitor is used for both the outdoor fan and
compressor (see unit diagram). The fan side and the com­
pressor side have different MFD ratings. See side of capac­
itor for ratings.
4-Compressor Contactor K1
In all ZCA units, K1 energizes compressors B1 in re­
sponse to thermostat demand. Three phase units use two
pole double break contactors with a 24 volt coil. Single
phase units use single pole double break contactors with a
24 volt coil.
Page 14
WARNING
Electrical shock hazard. Compressor must be
grounded. Do not operate without protective cover
over terminals. Disconnect power before removing
protective cover. Discharge capacitors before servic­
ing unit. Failure to follow these precautions could
cause electrical shock resulting in injury or death.
ZCA PLUMBING
FIXED ORIFICE
REFRIGERANT
METERING
DEVICE (RFC)
DRIER
EVAPORATOR
COIL
S4 HIGH
PRESSURE LIMIT
DISCHARGE
PRESSURE TAP
LIQUID
PRESSURE TAP
SUCTION
PRESSURE TAP
COMPRESSOR
CONDENSER COIL
FIGURE 4
The compressor is energized by a compressor contactor.
NOTE-Refer to the wiring diagram section for specific unit
operation.
If Interlink compressor replacement is necessary, call
1-800-4-453-6669.
IMPORTANT
Some scroll compressors have an internal vacuum
protector that will unload scrolls when suction
pressure goes below 20 psig. A hissing sound will
be heard when the compressor is running un­
loaded. Protector will reset when low pressure in
system rises above 40 psig. DO NOT REPLACE
COMPRESSOR.
Page 15
9-High Pressure Switch S4
B-Blower Compartment
The high pressure switch is an automatic reset SPST N.C.
switch which opens on a pressure rise.
All units are equipped with belt drive blowers. See unit
nameplate for blower type.
S4 is located in the compressor discharge line and wired in se­
ries with the compressor contactor coil.
1-Blower Wheels
When discharge pressure rises to 640 ± 10 psig (4412 ±
69 kPa) (indicating a problem in the system) the switch
opens and the compressor is de-energized (the econo­
mizer can continue to operate).
When discharge pressure drops to 475 ± 20 (3275 ± 138
kPa) psig, the switch closes and the compressor is ener­
gized. The CMC1 board monitors the pressure switch when
the compressor demand Y1 is active, allowing five strike
lockout. The compressor is shut down indefinitely in this
condition. A pressure switch may open and close again four
times during a current demand cycle without causing a
lockout condition by resetting the count at the end of the de­
mand cycle (CMC1 Y1 input OFF). The five-strike lockout
can only be reset by one of the following actions:
-Power cycle the controller
-Apply the TEST mode
10-Low Ambient Switches S11 (field-installed
option)
ZCA belt drive units use 10” x 10” (254 mm x 254 mm) blow­
er wheels.
2-Indoor Blower Motor B3
Belt drive units use single or three phase motors (same as
supply voltage). CFM adjustments are made by adjusting
the motor pulley (sheave). Motors are equipped with sealed
ball bearings. All motor specifications are listed in the Spec­
ifications (see table of contents) section in the front of this
manual. Units may be equipped with motors manufactured
by various manufacturers, therefore electrical FLA and
LRA specifications will vary. See unit rating plate for infor­
mation specific to your unit.
IMPORTANT
Three phase scroll compressors must be phased se­
quentially for correct compressor and blower rota­
tion. Follow “COOLING START-UP” section of instal­
lation instructions to ensure proper compressor and
blower operation.
A-Blower Operation
The low ambient switch is an auto‐reset SPST N.O. pres­
sure switch which allows for mechanical cooling opera­
tion at low outdoor temperatures. The switch is located
in the liquid line in the compressor section.
On P and Y volt units, S11 is wired in series with the com­
mon (black) lead to K10 outdoor fan motor.
On G and J volt units, S11 is wired in series with outdoor fan
relay K10 coil and when opened breaks 24 volts to the coil,
de-energizing outdoor fan B4.
When liquid pressure rises to 450 ± 10 psig (3102 ± 69
kPa), the switch closes and the condenser fan is ener­
gized. When discharge pressure in drops to 240 ± 10 psig
(1655 ± 69 kPa), the switch opens and the condenser fan is
de-energized. This intermittent fan operation results in
higher evaporating temperature allowing the system to op­
erate without icing the evaporator coil and losing capacity.
11-Compressor Low Discharge Temperat­
ure Limit S3 (field-supplied option)
S3 is a thermostat which opens on temperature drop. It is
wired in line with the 24VAC compressor contactor.
12-Compressor High Temperature Limit S5
The compressor thermal protector is located on top of the
compressor. S5 is wired in series with S4 high pressure
limit. The protector opens at 248°F + 9°F (120°C + 5°C)
and closes at 169°F + 18°F (76°C + 10°C).
Initiate blower demand at thermostat according to instruc­
tions provided with thermostat. Unit will cycle on thermostat
demand. The following steps apply to applications using a
typical electro-mechanical thermostat.
1- Blower operation is manually set at the thermostat sub­
base fan switch. With fan switch in ON position, blow­
ers will operate continuously.
2- With fan switch in AUTO position, the blowers will cycle
with demand. Blowers and entire unit will be off when
system switch is in OFF position.
B-Determining Unit CFM
1- The following measurements must be made with air fil­
ters in place and no cooling demand.
2- With all access panels in place, measure static pres­
sure external to unit (from supply to return). Blower per­
formance data is based on static pressure readings
taken in locations shown in figure 5.
Note - Static pressure readings can vary if not taken where
shown.
3- Referring to the blower tables starting on Page 5, use
static pressure and RPM readings to determine unit
CFM. Use air resistance table when installing units with
any of the options or accessories listed.
4- The blower RPM can be adjusted at the motor pulley.
Loosen Allen screw and turn adjustable pulley clock­
wise to increase CFM. Turn counterclockwise to de­
crease CFM. See figure 6. Do not exceed minimum
and maximum number of pulley turns as shown in
table 1.
Page 16
LOCATION OF STATIC PRESSURE READINGS
(END OF UNIT SHOWN)
INSTALLATIONS WITH CEILING DIFFUSERS
ROOFTOP UNIT
INSTALLATIONS WITH DUCTWORK
ROOFTOP UNIT
RETURN AIR
READING LOCATION
SUPPLY
SUPPLY
RETURN AIR
READING
LOCATION
FIRST BRANCH
OFF OF MAIN RUN
MAIN
DUCT RUN
SUPPLY AIR
READING
LOCATION
SUPPLY AIR
READING
LOCATION
DIFFUSER
FIGURE 5
BLOWER ASSEMBLY
TO INCREASE BELT TENSION
1-Loosen four bolts securing motor base to mounting frame.
2-Slide the motor downward to tighten the belt.
3-Tighten four bolts on motor base.
LOOSEN FOUR BOLTS
AND SLIDE BLOWER
MOTOR DOWNWARD
TO TIGHTEN BELT
SIDE VIEW
MOTOR
ALLEN
SCREW
PULLEY
TO INCREASE CFM
TO DECREASE CFM
LOOSEN ALLEN SCREW &
TURN PULLEY CLOCKWISE
TURN PULLEY
COUNTERCLOCKWISE
FIGURE 6
1- Loosen four bolts securing motor base to mounting
TABLE 1
MINIMUM AND MAXIMUM PULLEY ADJUSTMENT
frame. See figure 6.
Belt
Min. Turns Open
Maxi. Turns Open
A Section
No minimum
5
C-Blower Belt Adjustment
Maximum life and wear can be obtained from belts only if
proper pulley alignment and belt tension are main­
tained. Tension new belts after a 24-48 hour period of op­
eration. This will allow belt to stretch and seat grooves.
Make sure blower and motor pulley are aligned as shown in
figure 7.
2- To increase belt tension Slide blower motor downward to tighten the belt. This
increases the distance between the blower motor and
the blower housing.
3- To loosen belt tension Slide blower motor upward to loosen the belt. This de­
creases the distance between the blower motor and
the blower housing.
4- Tighten four bolts securing motor base to the mounting
frame.
Page 17
3- Measure belt deflection force. For a used belt, the
deflection force should be 5 lbs. (35kPa). A new belt
deflection force should be 7 lbs. (48kPa).
PULLEY ALIGNMENT
ALIGNED
MOTOR
PULLEY
A force below these values indicates an underten­
sioned belt. A force above these values indicates an
overtensioned belt.
BLOWER
PULLEY
BELT
NOT ALIGNED
MEASURE BELT TENSION
FIGURE 7
D-Check Belt Tension
Overtensioning belts shortens belt and bearing life. Check
belt tension as follows:
FORCE
1- Measure span length X. See figure 8.
DEFLECTION 1/64” PER INCH OF SPAN
OR 1.5mm PER 100mm OF SPAN
2- Apply perpendicular force to center of span (X) with
enough pressure to deflect belt 1/64” for every inch of
span length or 1.5mm per 100mm of span length.
Example: Deflection distance of a 40” span would be
40/64” or 5/8”.
Example: Deflection distance of a 400mm span would
be 6mm.
FIGURE 8
F-Field-Furnished Blower Drives
See blower data tables for field-furnished blower drives to
determine BHP and RPM required. See table 2 for drive
component manufacturers numbers.
TABLE 2
DRIVE COMPONENT MANUFACTURER'S NUMBERS
DRIVE COMPONENT PART NUMBERS
Drive No.
Motor Pulley
Blower Pulley
Belts
Browning
OEM
Browning
OEM
Browning
OEM
Z01
1VP34 X 7/8
31K6901
AK54 X 5/8
100244­30
A40
100245­17
Z02
1VP34 X 7/8
31K6901
AK46 X 5/8
100244­31
A39
100245­16
Z03
1VP34 X 7/8
31K6901
AK41 X 5/8
100244­28
A39
100245­16
Z04
1VP34 X 7/8
31K6901
AK39 X 5/8
100244­32
A38
100245­15
Z05
1VP44 X 7/8
P­8­1488
AK49 X 5/8
100244­26
A41
100245­18
Z06
1VP50 X 7/8
53J1501
AK51 X 5/8
100244­29
A42
100245­19
Page 18
C-ELECTRIC HEAT COMPONENTS
4-Terminal Strip TB3
Electric heat match-ups are found in the ELECTRICAL
DATA tables. See table of contents.
All electric heat sections consist of electric heating ele­
ments exposed directly to the air stream. See figure 9. See
figure 10 for vestibule parts arrangement.
P and Y voltage units are equipped with terminal strip TB3.
Electric heat line voltage connections are made to TB3,
which distributes power to the electric heat components
and is located on the vestibule. See figure 10.
5-High Temperature Limit S20, S157, S158
(Secondary)
1-Contactors K15, K16
All contactors are double break and either single, double
or three pole (see diagram) and equipped with a 24VAC
coil. The coils in the K15 and K16 contactors are energized
by the indoor thermostat. In all units K15 energizes the
heating elements, while in the 10 and 22.5 kW P volt units,
K15 and K16 energize the heating elements simulta­
neously.
2-High Temperature Limits S15 (Primary)
Switches are SPST N.C. manual‐reset thermostats. All
are wired in series with the heating elements. See wiring
diagrams. When either limit opens K15 and K16 are de‐
energized. When the contactors are de‐energized, all
stages of heat are de‐energized. The thermostat is fact­
ory-set to open at 180_F + 6_F (82_C + 3.3_C) on a tem­
perature rise and can be manually reset when tempera­
ture falls below 160_F (71.0_C). See figure 10 for location.
On 22.5kW (P, G and J volt) units, S15 opens at 190_F +
6_F (88_C + 3.3_C).
S15 is a SPST N.C. auto‐reset thermostat high tempera­
ture limit for the electric heat section. When S15 opens, in­
dicating a problem in the system, contactor K15 is de‐en­
ergized (including K16 in 10 and 22.5 kW P volt units).
When K15 is de‐energized, all stages of heat are de‐ener­
gized. See table 3 for S15 set points. Set points are factory
set and not adjustable.
ELECTRIC HEAT ELEMENTS
3-Terminal Strip TB2
Terminal strip TB2 is used for single point power installa­
tions only. TB2 distributes power to TB3. Units with multipoint power connections will not use TB2.
FIGURE 9
ELECTRIC HEAT VESTIBULE PARTS ARRANGEMENT
S15
PRIMARY
LIMIT
S20
ELECTRIC HEAT
SECONDARY LIMIT
S158
ELECTRIC HEAT
SECONDARY LIMIT
S157
ELECTRIC HEAT
SECONDARY LIMIT
F42
ELECTRIC
HEAT FUSE
K9
HEAT RELAY
K15
ELECTRIC
HEAT
CONTACTOR
K16
ELECTRIC
HEAT
CONTACTOR
FIGURE 10
Page 19
F3
ELECTRIC
HEAT FUSE
TB3
ELECTRIC
HEAT
TERMINAL
STRIP
TABLE 4
TABLE 3
S15 PRIMARY HIGH TEMPERATURE LIMIT SETPOINTS
Unit kW
Voltage
S15 Opens ° F
S15 Closes ° F
160
120
5.0, 7.5, 10.0, 15.0
P
7.5, 15.0
G
5.0, 7.5, 10.0
J
22.5
P
7.5, 10.0, 15.0, 22.5
Y
5.0, 10.0
G
15.0, 22.5
J
5.0
Y
140
95
22.5
G
180
140
170
130
5.0
Voltage
P
Fuse
F3
30A - 250V
Qty
2
7.5
P
40A - 250V
2
10*
P
35A - 250V
2
15
P
40A - 250V
4
22.5
P
40A - 250V
6
5.0
Y
20A - 250V
3
7.5
Y
25A - 250V
3
10
Y
35A - 250V
3
15
Y
50A - 250V
3
kW
22.5
Y
40A - 250V
6
6-Heating Elements HE1 through HE3
5.0
G
15A - 600V
3
Heating elements are composed of helix wound bare nich­
rome wire exposed directly to the air stream. Three ele­
ments are connected in a three‐phase arrangement. The
elements in 208/230V units are connected in a “Delta” ar­
rangement. Elements in 460 and 575V units are con­
nected in “Wye” arrangement. Each stage is energized in­
dependently by the corresponding contactors located on
the electric heat vestibule panel. Once energized, heat
transfer is instantaneous. High temperature protection is
provided by primary and redundant high temperature lim­
its and overcurrent protection is provided by fuses.
7.5
G
15A - 600V
3
10
G
20A - 600V
3
15
G
25A - 600V
3
22.5
G
35A - 600V
3
5.0
J
15A - 600V
3
7.5
J
15A - 600V
3
10
J
15A - 600V
3
15
J
20A - 600V
3
22.5
J
30A - 600V
3
7-Fuse F3 and F42
*This heater is equipped with two F42, 20A, 250V fuses.
Fuse F3 and F42 are housed in a fuse block. Each fuse is
connected in series with each leg of electric heat. Figure
10 and table 4 show the fuses used with each electric
heat section.
III-START UP - OPERATION
8-Unit Fuse Block & Fuse F4
Line voltage fuses F4 provide short circuit and ground fault
protection to all cooling components in ZCA units with elec­
tric heat. Single phase units are equipped with two fuses
and three phase units are equipped with three fuses. The
fuses are rated in accordance with the amperage of the
cooling components. The F4 fuse block is located inside a
sheet metal enclosure.
9-Electric Heat Relay K9
K9 is a SPDT pilot relay intended to energize blower con­
tactor K3 and electrically isolate the unit's 24V circuit from
the electric heat 24V circuit. K9 is energized by the indoor
thermostat. K9-1 closes, energizing blower contactor K3.
II-PLACEMENT AND INSTALLATION
Make sure the unit is installed in accordance with the instal­
lation instructions and all applicable codes. See accesso­
ries section for conditions requiring use of the optional roof
mounting frame (Z1CURB).
A-Preliminary and Seasonal Checks
1- Make sure the unit is installed in accordance with the
installation instructions and applicable codes.
2- Inspect all electrical wiring, both field and factory
installed for loose connections. Tighten as required.
Refer to unit diagram located on inside of control panel.
3- Check to ensure that refrigerant lines are in good
condition and do not rub against the cabinet or other
refrigerant lines.
4- Check voltage at the disconnect switch. Voltage must
be within the range listed on the nameplate. If not, con­
sult the power company and have the voltage cor­
rected before starting the unit.
5- Recheck voltage and amp draw with unit running. If
voltage is not within range listed on unit nameplate,
stop unit and consult power company. Refer to unit
nameplate for maximum rated load amps.
6- Inspect and adjust blower belt (see section on Blower
Compartment - Blower Belt Adjustment).
Page 20
B-Cooling Start-Up
IV-CHARGING
A-Operation
WARNING-Do not exceed nameplate charge under any
condition.
1- Initiate first and second stage cooling demands ac­
cording to instructions provided with thermostat.
2- No Economizer Installed in Unit A first-stage cooling demand (Y1) will energize com­
pressor 1 and the condenser fan. An increased cool­
ing demand (Y2) will not change operation.
Units Equipped With Economizer When outdoor air is acceptable, a first-stage cooling
demand (Y1) will energize the economizer. An in­
creased cooling demand (Y2) will energize com­
pressor 1 and the condenser fan. When outdoor air
is not acceptable unit will operate as though no
economizer is installed.
3- Units contain one refrigerant circuit or stage.
4- Unit is charged with R-410A refrigerant. See unit rating
plate for correct amount of charge.
5- Refer to Refrigerant Charge and Check section for prop­
er method to check refrigerant charge.
B-Three Phase Scroll Compressor Voltage Phasing
Three phase scroll compressors must be phased sequen­
tially to ensure correct compressor and blower rotation and
operation. Compressor and blower are wired in phase at
the factory. Power wires are color-coded as follows: line
1-red, line 2-yellow, line 3-blue.
This unit is factory charged and should require no further
adjustment. If the system requires additional refrigerant, re­
claim the charge, evacuate the system, and add required
nameplate charge.
NOTE - System charging is not recommended below 60°F
(15°C). In temperatures below 60°F (15°C), the charge
must be weighed into the system.
If weighing facilities are not available, or to check the
charge, use the following procedure:
IMPORTANT - Charge unit in standard cooling mode
high stage only.
1- Make sure outdoor coil is clean. Attach gauge manifolds
and operate unit at full CFM in cooling mode with econo­
mizer disabled until system stabilizes (approximately five
minutes). Make sure all outdoor air dampers are closed.
2- Compare the normal operating pressures (see tables
5 - 7) to the pressures obtained from the gauges.
Check unit components if there are significant differ­
ences.
3- Measure the outdoor ambient temperature and the suc­
tion pressure. Refer to the appropriate circuit charging
curve to determine a target liquid temperature.
Note - Pressures are listed for sea level applications.
4- Use the same thermometer to accurately measure the
liquid temperature (in the outdoor section).
S If measured liquid temperature is higher than the
target liquid temperature, add refrigerant to the
system.
1- Observe suction and discharge pressures and blower
rotation on unit start-up.
S If measured liquid temperature is lower than the
target liquid temperature, recover some refrigerant
from the system.
2- Suction pressure must drop, discharge pressure must
rise and blower rotation must match rotation marking.
If pressure differential is not observed or blower rotation is
not correct:
3- Disconnect all remote electrical power supplies.
4- Reverse any two field-installed wires connected to the
line side of K1 contactor. Do not reverse wires at blower
contactor.
5- Make sure the connections are tight.
Discharge and suction pressures should operate at their
normal start‐up ranges.
C-Safety or Emergency Shutdown
Turn off power to unit.
5- Add or remove charge in increments. Allow the system
to stabilize each time refrigerant is added or removed.
6- Continue the process until measured liquid tempera­
ture agrees with the target liquid temperature. Do not
go below the target liquid temperature when adjusting
charge. Note that suction pressure can change as
charge is adjusted.
7- Example ZC 036: At 95°F outdoor ambient and a
measured suction pressure of 130psig, the target liq­
uid temperature is 102°F. For a measured liquid tem­
perature of 106°F, add charge in increments until
measured liquid temperature agrees with the target
liquid temperature.
Page 21
TABLE 5
ZC 036 NORMAL OPERATING PRESSURES - ALL-ALUMINUM COIL
Outdoor Coil Entering Air Temperature
65 °F
75 °F
85 °F
95 °F
105 °F
115 °F
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
112
118
132
147
242
244
254
269
115
121
137
152
281
283
293
308
117
125
140
157
327
326
338
351
121
128
145
161
375
375
387
400
119
132
149
166
421
429
442
454
125
134
147
170
490
488
499
516
TABLE 6
ZC 048 NORMAL OPERATING PRESSURES - ALL-ALUMINUM COIL
Outdoor Coil Entering Air Temperature
65 °F
75 °F
85 °F
95 °F
105 °F
115 °F
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
108
114
128
149
254
259
273
310
111
118
133
150
295
299
314
342
115
122
137
155
338
344
358
388
118
125
141
158
386
392
408
436
121
129
145
163
437
445
462
474
122
130
148
167
491
502
524
556
TABLE 7
ZC 060 NORMAL OPERATING PRESSURES - ALL-ALUMINUM COIL
Outdoor Coil Entering Air Temperature
65 °F
75 °F
85 °F
95 °F
105 °F
115 °F
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
Suct
(psig)
Disc
(psig)
107
115
137
147
257
277
297
312
110
117
135
151
299
304
320
352
114
120
138
156
343
350
366
397
117
124
141
160
388
396
419
449
120
128
144
165
440
446
473
505
122
131
149
169
498
501
530
576
ZC 036 CHARGING CURVE - ALL-ALUMINUM COIL
Outdoor Temperature (°F)
130
115°
120
105°
110
100
95°
90
85°
80
75°
70
65°
60
100
110
120
130
140
Suction Pressure (psig)
Page 22
150
160
170
ZC 048 CHARGING CURVE - ALL-ALUMINUM COIL
Outdoor Temperature (°F)
130
115°
120
110
105°
100
95°
90
85°
80
75°
70
65°
60
100
110
120
130
140
150
160
170
Suction Pressure (psig)
ZC 060 CHARGING CURVE - ALL-ALUMINUM COIL
Outdoor Temperature (°F)
130
115°
120
110
105°
100
95°
90
85°
80
75°
70
65°
60
100
110
120
130
140
Suction Pressure (psig)
Page 23
150
160
170
V- SYSTEM SERVICE CHECKS
A-Cooling System Service Checks
B-Lubrication
ZCA units are factory charged and require no further adjust­
ment; however, charge should be checked periodically. See
section IV- CHARGING.
All motors are lubricated at the factory. No further lubrica­
tion is required.
NOTE-When unit is properly charged discharge and
suction pressures should approximate those in tables
5 through 7.
VI-MAINTENANCE
BACK OF UNIT
LIFT UP AND PULL
OUT (TOOLLESS)
FILTER ACCESS PANEL
The unit should be inspected once a year by a qualified ser­
vice technician.
! WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at
disconnect switch(es). Unit may have
multiple power supplies.
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan­
gerous operation. Verify proper operation after ser­
vicing.
FIGURE 11
REMOVE FILTERS
SLIDE FILTER STOP UP
TO REMOVE FILTERS
WARNING
The State of California has determined that this prod­
uct may contain or produce a chemical or chemicals,
in very low doses, which may cause serious illness
or death. It may also cause cancer, birth defects, or
reproductive harm.
A-Filters
Units are equipped with temporary filters which must be
replaced prior to building occupation. All units use 14 X 20
X 2” (352 X 508 X 51mm) filters. Refer to local codes or ap­
propriate jurisdiction for approved filters. Filters should
be checked monthly and replaced when necessary with fil­
ters of like kind and size. Take note of air flow direction
marking on filter frame when reinstalling filters.
NOTE-Filters must be U.L.C. certified or equivalent for use
in Canada.
To change filters, open filter access panel on back side of
unit. See figure 11. Lift filter stop to remove filters. See fig­
ure 12.
WARNING
Units are shipped from the factory with temporary fil­
ters. Replace filters before building is occupied.
Damage to unit could result if filters are not replaced
with approved filters. Refer to appropriate codes.
Page 24
FIGURE 12
C-Evaporator Coil
Inspect and clean coil at beginning of each cooling season.
Clean using mild detergent or commercial coil cleanser.
Flush coil and condensate drain with water taking care not to
get insulation, filters and return air ducts wet.
Clean the all-aluminum coil by spraying the coil steadily and
uniformly from top to bottom. Do not exceed 900 psi or a 45
degree angle; nozzle must be at least 12 inches from the
coil face. Take care not to fracture the braze between the
fins and refrigerant tubes. Reduce pressure and work cau­
tiously to prevent damage.
D-Condenser Coil
Clean condenser coil annually with water and inspect
monthly during the cooling season.
E-Supply Blower Wheel
Note - Do not use commercial coil cleaner on the all alumin­
um coil. Using anything other than water could result in cor­
rosion and/or leaks.
Annually inspect supply air blower wheel for accumulated
dirt or dust. Turn off power before attempting to remove ac­
cess panel or to clean blower wheel.
Page 25
VII-ACCESSORIES
TYPICAL FLASHING DETAIL
The accessories section describes the application of most of
the optional accessories which can be factory or field installed
to the ZCA units.
GASKET
(Supplied with Curb)
PACKAGED
UNIT
A-Z1CURB
When installing the ZCA units on a combustible surface for
downflow discharge applications, a Z1CURB 8-inch,
14‐inch, 18-inch, or 24‐inch height roof mounting frame is
used. The roof mounting frames are recommended in all
other applications but not required. If the ZCA units are not
mounted on a flat (roof) surface, they MUST be supported
under all edges and under the middle of the unit to prevent
sagging. The units MUST be mounted level within 1/16”
per linear foot or 5mm per meter in any direction.
The assembled mounting frame is shown in figure 13. Re­
fer to the roof mounting frame installation instructions for
details of proper assembly and mounting. The roof mount­
ing frame MUST be squared to the roof and level before
mounting. Plenum system and block-off panels MUST be
installed before the unit is set on the mounting frame. Typi­
cal roof curbing and flashing is shown in figure 14. Refer to
the roof mounting frame installation instructions for proper
plenum construction and attachment.
B-Transitions
Supply/return transitions are field-provided.
C-Supply and Return Diffusers (all units)
Optional flush mount diffuser/return FD9-65 and ex­
tended mount diffuser/return RTD9-65 are available for
use with all ZCA units. Refer to manufacturer's instruc­
tions included with transition for detailed installation
procedures.
ASSEMBLED ROOF MOUNTING FRAME
BASE
BOTTOM
COUNTER FLASHING
(Field Supplied)
NAILER STRIP
(Furnished)
CANT STRIP
(Field Supplied)
ROOF CURB
(Extends around entire
perimeter of unit)
ROOFING
MATERIAL
RIGID INSULATION
(Field Supplied)
FIGURE 14
D-Economizer
(Field or Factory Installed)
Downflow economizers are a factory-installed option.
Downflow and horizontal air flow economizers are a fact­
ory- or field-installed option. Economizers are equipped
with an A6 enthalpy control, an R1 mixed air sensor and an
S175 outdoor sensible sensor. The modulating economizer
opens fully to use outdoor air for free cooling when temper­
ature is suitable and opens to minimum position during the
occupied time period.
When A6 determines outdoor air is suitable (via input from
S175 outdoor air sensor), dampers will modulate open (via
B7 damper motor) to maintain 55°F (13°C) supply air (de­
termined by input from R1 mixed/supply air sensor).
The A6 enthalpy control and B7 damper motor are shown in
figure 15 for downflow air discharge and figure 16 for
horizontal air discharge. The R1 mixed air sensor is shown
in figure 17. An A7 outdoor enthalpy sensor is optional and
replaces the S175 sensible sensor. See figure 18.
ECONOMIZER - DOWNFLOW
B7
DAMPER
MOTOR
A6
ENTHALPY
CONTROL
FIGURE 13
FIGURE 15
Page 26
ECONOMIZER - HORIZONTAL
(FIELD-INSTALLED OPTION)
B7
DAMPER
MOTOR
A6
ENTHALPY
CONTROL
FIGURE 16
R1 MIXED AIR SENSOR
BLOWER MOTOR
S175 OUTDOOR SENSIBLE SENSOR
BLOWER HOUSING
DOWNFLOW
HEAT
SECTION
S175
R1 MIXED AIR OR
SUPPLY AIR SENSOR
HORIZONTAL
FIGURE 17
An optional IAQ sensor (A63) may be used to lower operat­
ing costs by controlling outdoor air based on CO2 level or
room occupancy (also called demand control ventilation or
DCV). Damper minimum position can be set lower than
traditional minimum air requirements; dampers open to
traditional ventilation requirements when CO2 level reach­
es DCV (IAQ) setpoint.
Refer to instructions provided with sensors for installation.
FIGURE 18
A6 Enthalpy Control LEDs
A steady green Free Cool LED indicates that outdoor air is
suitable for free cooling.
When an optional IAQ sensor is installed, a steady green
DCV LED indicates that the IAQ reading is higher than set­
point requiring more fresh air. See figure 19.
Page 27
Damper Minimum Position
A6 ENTHALPY CONTROLLER
2V
EXH
Set
10V
DAMPER MINI­
MUM POSITION
EXH
Open
2V
Min
Pos
2- Rotate MIN POS SET potentiometer to approximate
desired fresh air percentage.
IAQ MAXIMUM
POSITION
Note - Damper minimum position can be set lower than
traditional minimum air requirements when an IAQ sensor
is specified. Dampers will open to DCV MAX setting (if CO2
is above setpoint) to meet traditional ventilation require­
ments.
(set higher than
minimum position)
DCV
Max
10V
IAQ READING IS
ABOVE SETPOINT
DCV
2V
1- Set thermostat to occupied mode if the feature is avail­
able. Make sure unit 24V control leads R and OC are
connected if using a thermostat which does not have
the feature.
3- Measure outdoor air temperature. Mark the point on
the bottom line of chart 1 and label the point “A” (40_F,
4_C shown).
DCV
Set
10V
IAQ SETPOINT
Free
Cool
B
C
A
D
4- Measure return air temperature. Mark that point on the
top line of chart 1 and label the point “B” (74_F, 23_C
shown).
OUTDOOR AIR
SUITABLE LED
5- Measure mixed air (outdoor and return air) tempera­
ture. Mark that point on the top line of chart 1 and label
point “C” (70_F, 21_C shown).
FREE COOLING SETPOINT;
A=Completely counterclockwise
D=Completely clockwise
6- Draw a straight line between points A and B.
FIGURE 19
7- Draw a vertical line through point C.
8- Draw a horizontal line where the two lines meet. Read
the percent of fresh air intake on the side.
Free Cooling Setpoint
Outdoor air is considered suitable when temperature and
humidity are less than the free cooling setpoints shown in
table 8. Setting A is recommended. See figure 19. At setting
A, free cooling will be energized when outdoor air is approx­
imately 73°F (23°C) and 50% relative humidity. If indoor air
is too warm or humid, lower the setpoint to B. At setting B,
free cooling will be energized at 70°F (21°C) and 50% rela­
tive humidity.
When an optional A62 differential sensor is installed, turn
A6 enthalpy control free cooling setpoint potentiometer
completely clockwise to position “D”.
TABLE 8
ENTHALPY CONTROL SETPOINTS
Control Setting
Free Cooling Setpoint At 50% RH
A
73° F (23° C)
B
70° F (21° C)
C
67° F (19° C)
D
63° F (17° C)
9- If fresh air percentage is less than desired, adjust MIN
POS SET potentiometer higher. If fresh air percentage
is more than desired, adjust MIN POS SET potentiom­
eter lower. Repeat steps 3 through 8 until calculation
reads desired fresh air percentage.
DCV Set and Max Settings
Adjust settings when an optional IAQ sensor is installed.
The DCV SET potentiometer is factory-set at approxi­
mately 50% of the potentiometer range. Using a standard
1-2000ppm CO2 sensor, dampers will start to open when
the IAQ sensor reads approximately 1000ppm. Adjust
the DCV SET potentiometer to the approximate setting
specified by the controls contractor. Refer to figure 19.
The DCV MAX potentiometer is factory-set at approxi­
mately 50% of the potentiometer range or 6VDC. Damp­
ers will open approximately half way when CO2 rises
above setpoint. Adjust the DCV MAX potentiometer to
the approximate setting specified by the controls con­
tractor. Refer to figure 19.
Note - DCV Max must be set higher than economizer mini­
mum position setting for proper demand control ventilation.
Page 28
CHART 1
CALCULATE MINIMUM FRESH AIR PERCENTAGE
MIXED AND RETURN AIR TEMPERATURE
_F
_C
0
-20
-29
-10
-23
0
-18
10
-12
20
-7
30
-1
40
4
50
10
60
16
70
21
C
80
27
90
32
100 _F
38 _C
B
0
10
10
20
20
30
30
40
40
50
50
60
60
70
70
80
80
90
90
A
100
_F -20
_C -29
-10
-23
0
-18
10
-12
20
-7
30
-1
40
4
100
50
10
60
16
70
21
80
27
90
32
100 _F
38 _C
OUTDOOR AIR TEMPERATURE
Economizer Operation
Outdoor Air Suitable:
The occupied time period is determined by the thermostat
or energy management system.
See table 9 for economizer operation with a standard twostage thermostat.
Outdoor Air Not Suitable:
During the occupied period, dampers will open to DCV
MAX when IAQ reading is above setpoint (regardless of
thermostat demand or outdoor air suitability). DCV MAX will
NOT override damper full-open position. When an R1
mixed air sensor for modulating dampers is installed, DCV
MAX may override damper free cooling position when oc­
cupancy is high and outdoor air temperatures are low. If R1
senses discharge air temperature below 45_F (7_C),
dampers will move to minimum position until discharge air
temperature rises to 48_F (9_C).
During the unoccupied time period dampers are closed.
During the occupied time period a cooling demand will open
dampers to minimum position and mechanical cooling
functions normally.
During the occupied time period dampers will open to DCV
MAX when IAQ reading is above setpoint (regardless of
thermostat demand or outdoor air suitability).
TABLE 9
ECONOMIZER OPERATION
OUTDOOR AIR IS SUITABLE FOR FREE COOLING -- FREE COOL LED “ON”
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
THERMOSTAT DEMAND
DAMPER POSITION
MECHANICAL COOLING
UNOCCUPIED
OCCUPIED
OFF
CLOSED
CLOSED
NO
G
CLOSED
MINIMUM
NO
Y1
OPEN*
OPEN*
NO
Y2
OPEN*
OPEN*
STAGE 1
*Dampers will modulate to maintain 55_F (13_C) supply air when an R1 mixed air sensor is installed.
Page 29
Set damper minimum position in the same manner as
economizer minimum position. Adjust motorized damper
position as shown in figure 21. Manual damper fresh air
intake percentage can be determined in the same manner.
E-Outdoor Air Dampers
OUTDOOR AIR DAMPER
MOTORIZED
DAMPER
MANUAL
DAMPER
F-Power Exhaust Relay K65
(power exhaust units)
Power exhaust relay K65 is a DPDT relay with a 24VAC
coil. K65 is used in all ZCA units equipped with the op­
tional power exhaust dampers. K65 is energized by the
economizer enthalpy control A6, after the economizer
dampers reach 50% open (adjustable) When K65
closes, exhaust fan B10 is energized.
INTERLINK DAMPER MOTOR
Damper stops are factory-set at 100% outdoor air and
are adjustable in five degree increments. To adjust fresh
air percentage, remove retainer clip and adjust damper
stop to desired air percentage. Replace retainer clip.
FIGURE 20
Z1DAMP21 is a motorized outdoor air damper and
Z1DAMP11 is a manual outdoor air damper. See figure 20.
Both sets include the outdoor air hood. The dampers
provide motorized or manual operation to allow up to 35
percent outside air into the system at all times. Washable
filter supplied with the outdoor air dampers can be cleaned
with water and a mild detergent. It should be sprayed with
Filter Handicoater when dry prior to reinstallation. Filter
Handicoater is R.P. Products coating no. 418 and is avail­
able as Part No. P-8-5069.
Optional manual and motorized outdoor air dampers pro­
vide fresh outdoor air. The motorized damper assembly
opens to minimum position during the occupied time peri­
od and remains closed during the unoccupied period.
Manual damper assembly is set at installation and re­
mains in that position.
Page 30
100%
OPEN
100%
CLOSED
RETAINER
CLIP
DAMPER
STOP
FIGURE 21
G-Power Exhaust Fans (Field-Installed)
Z1PWRE10 is available for downflow units and
Z1PWRE15 is available for horizontal air flow units. Fans
provide exhaust air pressure relief and also run when re­
turn air dampers are closed and supply air blowers are op­
erating. See figure 22, 23 and installation instructions for
more detail.
H-Control Systems
POWER EXHAUST FAN - DOWNFLOW APPLICATIONS
1- Electro‐mechanical thermostat (13F06)
The electro‐mechanical thermostat is a two stage heat /
two stage cool thermostat with dual temperature levers.
A non‐switching or manual system switch subbase
may be used.
Different types of control systems may be used with the
ZCA series units. All thermostat wiring is connected to low
voltage pigtails located in the control box. Each thermostat
has additional control options available. See thermostat
installation instructions for more detail.
2- Electronic thermostat (see price book)
Any two stage heat / two stage cool electronic ther­
mostat may be used.
I-Indoor Air Quality (CO2) Sensor A63
The indoor air quality sensor monitors CO2 levels and re­
ports the levels to the economizer enthalpy control A6. Con­
troller A6 adjusts the economizer dampers according to the
CO2 levels. The sensor is mounted next to the indoor ther­
mostat or in the return air duct. Refer to the indoor air quality
sensor installation instructions for proper adjustment.
POWER EXHAUST FAN
FIGURE 22
POWER EXHAUST FAN - HORIZONTAL APPLICATIONS
FIELD-PROVIDED
AND INSTALLED
DUCTWORK
16 1/2”
25” MIN.
20”
16 1/2”
2 1/2”
POWER EXHAUST FAN
FIGURE 23
Page 31
VIII-Wiring Diagrams and Sequence of Operation
Page 32
ZCA036, 048, 060 UNIT DIAGRAM
12
2
14 11
15
7
8
12
2
13
16
10
16
13
1
9
16
13
3
Page 33
ZCA036, 048, 060 UNIT DIAGRAM
4
5
6
Page 34
ZCA036, 048, 060 P, Y, G, J & M Voltage Sequence of Operation
Power:
1- Line voltage from unit disconnect energizes transformer T1. T1 provides 24VAC power to the
unit cooling, heating and blower controls.
Blower Operation:
2- Indoor thermostat terminal G energizes blower contactor K3 with 24VAC.
3- N.O. K3 closes, energizing blower B3.
Economizer Operation:
4- The A6 economizer control module receives a Y1 thermostat demand. If outdoor air is suitable, eco­
nomizer modulates open (see table 9 in VII-ACCESSORIES section).
Power Exhaust Fan Operation:
5- The A6 economizer control module receives a Y1 thermostat demand and energizes exhaust fan
relay K65 with 24VAC at 50% outside air damper open (adjustable).
6- N.O. K65-1 closes, energizing exhaust fan motor B10.
Cooling Demand
7- First stage cooling demand Y1 and G is energized by the thermostat. G energizes blower.
8- 24VAC is routed through low voltage Y1 lead to optional N.C. compressor low discharge temperature
limit S3, N.C. high pressure switch S4 and N.C. compressor high temperature limit S5. Compressor
contactor K1 is energized.
9- N.O. K1-1 close energizing compressor B1 and outdoor fan B4.
Heating Demand:
10- Terminal Strip TB2 is energized when the unit disconnect closes. TB2 supplies line voltage to
TB3 or F3. Elements are protected by fuses F3 and F42.
11- Heating demand initiates at W1 in thermostat.
12- 24VAC is routed from the indoor thermostat through N.C. primary limit S15. Electric heat con­
tactors K15, K16 (on P volt 10 and 22.5kW heaters) and heat relay K9 are energized. K9 energi­
zes blower contactor K3 and economizer.
13- N.O. contacts K15-1, K15-2, K16-1 and K16-2 close energizing HE1, HE2 and HE3.
End of Heating Demand:
14- Heating demand is satisfied. Terminal W1 in the thermostat is de-energized.
15- Electric heat contactors K15 and K16 are de-energized.
16- N.O. contacts K15-1, K15-2, K16-1 and K16-2 open de-energizing HE1, HE2 and HE3.
Page 35
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