advertisement
R-410A
ZF SERIES
6-1/2 - 12-1/2 Ton
60 Hertz
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . . 36
Standard Economizer And Power Exhaust Set Point
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electric Heating Sequence Of Operations . . . . . . . . . . . . . . . . 53
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54
Ignition Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 55
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . . . . . 61
Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LIST OF TABLES
1 ZF078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZF078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 9
4 ZF078-150 Unit Physical Dimensions . . . . . . . . . . . . . . . . . . 11
5 ZF078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 ZF078-150 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 30
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 31
12 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 32
13 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 40
15 Airflow Performance - Side Duct Application . . . . . . . . . . . . . 42
16 Airflow Performance - Bottom Duct Application . . . . . . . . . . 44
17 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 46
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 46
20 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . . 48
21 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
22 Electric Heat Limit Setting 50” Cabinet . . . . . . . . . . . . . . . . . 53
23 Electric Heat Limit Setting 42” Cabinet . . . . . . . . . . . . . . . . . 54
24 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54
25 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 56
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
29 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 60
30 Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 62
32 VAV Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . 62
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Predator
®
Component Location (ZF120 Shown) . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZF078-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZF150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZF078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . . . 12
11 ZF078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . . 13
12 ZF078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 13
13 ZF150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . 14
14 ZF078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . . . . 14
15 ZF078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZF078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . 16
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect - Cooling Unit With/Without Electric
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . 18
22 Field Wiring Disconnect - Cooling Unit With Gas Heat Without
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
23 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . . 19
24 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . . . . 19
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
28 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
29 Honeywell Economizer Control W7212 . . . . . . . . . . . . . . . . 38
30 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
31 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 40
32 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
33 Occupied Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
34 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
35 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
36 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
37 Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . 63
38 Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
39 Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
518674-YIM-E-1210
518674-YIM-E-1210
General
York
®
Predator
®
units are single package air conditioners with optional gas heating designed for outdoor installation on a rooftop or slab and for non-residential use. These units can be equipped with factory or field installed electric heaters for heating applications.
These units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested. The units require electric power, gas supply (where applicable), and duct connections.
The electric heaters have nickel-chrome elements and utilize single-point power connection.
Safety Considerations
This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.
This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention the signal words
DANGER, WARNING or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate injury. It is also used to alert against unsafe practices and hazards involving only property damage.
Improper installation may create a condition where the operation of the product could cause personal injury or property damage. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for assistance or for additional information, consult a qualified contractor, installer or service agency.
This product must be installed in strict compliance with the installation instructions and any applicable local, state and national codes including, but not limited to building, electrical, and mechanical codes.
Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual.
For assistance or additional information consult a qualified installer, service agency or the gas supplier.
This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. Gage sets, hoses, refrigerant containers and recovery systems must be designed to handle R-410A. If you are unsure, consult the equipment manufacturer. Failure to use R-410A compatible servicing equipment may result in property damage or injury.
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS: a. Do not try to light any appliance.
b. Do not touch any electrical switch; do not use any phone in your building.
c. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
d. If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Due to system pressure, moving parts, and electrical components, installation and servicing of air conditioning equipment can be hazardous. Only qualified, trained service personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags accompanying the equipment whenever working on air conditioning equipment. Be sure to follow all other applicable safety precautions and codes including ANSI Z223.1 or CSA-
B149.1- latest edition.
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518674-YIM-E-1210
Wear safety glasses and work gloves. Use quenching cloth and have a fire extinguisher available during brazing operations.
Inspection
As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier’s freight bill. A separate request for inspection by the carrier’s agent should be made in writing.
This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state and national codes including, but not limited to, building, electrical, and mechanical codes.
The furnace and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas valve damage resulting in a hazardous condition. If it is subjected to a pressure greater than 1/2 PSIG, the gas valve must be replaced.
The furnace must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG
Reference
Additional information is available in the following reference forms:
• Technical Guide - ZF078-150, 528194
• General Installation - ZF078-150, 518674
• Pre-start & Post-start Check List
• Economizer Accessory -
Downflow Factory Installed
Downflow Field Installed
Horizontal Field Installed
• Motorized Outdoor Air Damper
• Manual Outdoor Air Damper (0-100%)
• Manual Outdoor Air Damper (0-35%)
• Gas Heat Propane Conversion Kit
• Gas Heat High Altitude Kit (Natural Gas)
• Gas Heat High Altitude Kit (Propane)
• –60
F Gas Heat Kit
• Electric Heater Accessory 50” cabinet
• Electric Heater Accessory 42” cabinet
Renewal Parts
Contact your local York
® parts distribution center for authorized replacement parts.
Approvals
Design certified by CSA as follows:
1.
For use as a cooling only unit, cooling unit with supplemental electric heat or a forced air furnace.
2.
For outdoor installation only.
3.
For installation on combustible material and may be installed 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 installed in strict compliance with the enclosed installation instructions and any applicable local, state, and national codes including, but not limited to, building, electrical, and mechanical codes.
Improper installation may create a condition where the operation of the product could cause personal injury or property damage.
This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system.
Johnson Controls Unitary Products 3
518674-YIM-E-1210
Nomenclature
6.5-12.5 Ton York
®
Model Number Nomenclature
Z F 090 N10 A 2 A AA 5 0 1 2 4 A
Product Category
Z = A/C, Single Pkg., R-410A
Product Identifier
F = 11.2 + EER A/C
Nominal Cooling Capacity
078 = 6.5 Ton
090 = 7.5 Ton
102 = 8.5 Ton
120 = 10.0 Ton
150 = 12.5 Ton
Heat Type and Nominal Heat Capacity
C00 = Cooling Only. No heat installed
Gas Heat Options
N10 = 100 MBH Output Aluminized Steel
N15 = 150 MBH Output Aluminized Steel
N20 = 200 MBH Output Aluminized Steel
S10 = 100 MBH Output Stainless Steel
S15 = 150 MBH Output Stainless Steel
S20 = 200 MBH Output Stainless Steel
Electric Heat Options
E09 = 9 KW
E18 = 18 KW
E24 = 24 KW
E36 = 36 KW
E54 = 54 KW
Product Style
A = Style A
B = Style B
C = Style C
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
SS Drain Pan
CPC Controller, DFS, APS
Johnson Controller UNT 1126 (N2 protocol), DFS, APS
Honeywell Controller, DFS, APS
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/Simplicity®LINC
York Commercial Comfort System (YCCS) Rtu Controller
Hot Gas Bypass (Standard on VAV, Optional on CV)
Variable Air Volume, VFD (not available with factory installed BAS options)
Variable Air Volume, VFD with Simplicity®LINC (not available with factory installed BAS options)
Variable Air Volume, VFD and Manual Bypass
(not available with factory installed BAS options)
Variable Air Volume, VFD and Manual Bypass with Simplicity®LINC
(not available with factory installed BAS options)
Variable Air Volume, VFD (BAS ready)
Variable Air Volume, VFD and Manual Bypass (BAS ready)
Variable Air Volume, VFD Ready (for customer-provided, field-installed drive)
Variable Air Volume, VFD Ready with Simplicity®LINC
(for customer-provided, field-installed drive)
2" Pleated filters
4" Pleated filters
BAS Ready Economizer (2-10 V.D.C. Actuator without a Controller)
Shipping Bag
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
Product Generation
5 = Fifth Generation
Airflow
A = Std. Motor
B = Std. Motor/Econo./Barometric Relief (Downflow
Only)
C = Std. Motor/Econo./Power Exhaust (Downflow Only)
D = Std. Motor/Motorized Damper (Downflow Only)
E = Std. Motor/Horizontal Economizer (No Baro.)
F = Std. Motor/Slab Econo./Power Exhaust
(Downflow Only)
G = Std. Motor/Slab Econo./Barometric Relief
(Downflow Only)
N = Hi Static
P = Hi Static/Econo./Barometric Relief
(Downflow Only)
Q = Hi Static/Econo./Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper (Downflow Only)
S = Hi Static/Horizontal Economizer (No Baro.)
T = Hi Static/Slab Econo./Power Exhaust
(Downflow Only)
U = Hi Static/Slab Econo./Barometric Relief
(Downflow only)
AA = None
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
Additional Options
RC = Coil Guard, Shipping Bag & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be located in digits 15-18.
Voltage
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
Installation Options
A = No Options Installed
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
Options
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
4 Johnson Controls Unitary Products
518674-YIM-E-1210
Installation
Installation Safety Information
Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference.
1.
Refer to the unit rating plate for the approved type of gas for this product.
2.
Install this unit only in a location and position as specified
on Page 7 of these instructions.
3.
Never test for gas leaks with an open flame. Use commercially available soap solution made specifically for the detection of leaks when checking all connections, as
specified on Pages 5, 32, 33 and 57 of these instructions.
4.
Always install furnace to operate within the furnace's intended temperature-rise range with the duct system and within the allowable external static pressure range, as specified on the unit name/rating plate, specified on
Page 59 of these instructions.
5.
This equipment is not to be used for temporary heating of buildings or structures under construction.
3.
Remove the condenser coil external protective covering prior to operation.
4.
Remove the toolless doorknobs and instruction packet prior to installation.
Condenser
Coil External
Protective
Covering
Barometric
Relief Hood in Shipping
Location
(if Included)
Figure 2: Condenser Covering
Toolless
Doorknobs
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.
Preceding Installation
1.
Remove the two screws holding the brackets in the front, rear and compressor side fork-lift slots.
Installation
Instruction
Packet
Figure 3: Compressor Section
5.
If a factory option convenience outlet is installed, the weatherproof outlet cover must be field installed. The cover shall be located behind the filter access panel. To install the cover, remove the shipping label covering the convenience outlet, follow the instructions on the back of the weatherproof cover box, and attach the cover to the unit using the (4) screws provided.
Bracket
Screws
Turn down
Figure 1: Unit Shipping Bracket
2.
Turn each bracket toward the ground and the protective plywood covering will drop to the ground.
208/230-3-60 and 380/415-3-50 units with factory installed Powered Convenience Outlet Option are wired for 230v and 415v power supply respectively. Change
Tap on transformer for 208-3-60 or 380-3-50 operation.
See unit wiring diagram.
Johnson Controls Unitary Products 5
518674-YIM-E-1210
Limitations
These units must be installed in accordance with the following:
In U.S.A.:
1.
National Electrical Code, ANSI/NFPA No. 70 - Latest
Edition
2.
National Fuel Gas Code, ANSI Z223.1 - Latest Edition
3.
Gas-Fired Central Furnace Standard, ANSI Z21.47a. -
Latest Edition
4.
Local building codes, and
5.
Local gas utility requirements
In Canada:
1.
Canadian Electrical Code, CSA C22.1
2.
Installation Codes, CSA - B149.1.
3.
Local plumbing and waste water codes, and
4.
Other applicable local codes.
Refer to unit application data found in this document.
After installation, gas fired units must be adjusted to obtain a temperature rise within the range specified on the unit rating plate.
If components are to be added to a unit to meet local codes, they are to be installed at the dealer’s and/or customer’s expense.
Size of unit for proposed installation should be based on heat loss/heat gain calculation made according to the methods of Air
Conditioning Contractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings or structures under construction.
The Simplicity® control board used in this product will effectively operate the cooling system down to 0°F when this product is applied in a comfort cooling application for people. An economizer is typically included in this type of application. When applying this product for process cooling applications (computer rooms, switchgear, etc.), please reference applications bulletin
AE-011-07 or call the applications department for
Unitary Products @ 1-877-UPG-SERV for guidance.
Additional accessories may be needed for stable operation at temperatures below 30° F.
Simplicity® control board w/screw connector for T-stat wiring and network connections
Disconnect location
(optional disconnect switch)
Filter access
(2” or 4” Filter Options)
Terminal block for hi-voltage connection
Filter drier
(solid core)
Micro-Channel Aluminum Tube
Aluminum Fin Condenser
Second model nameplate inside hinged access panel
Dual stage cooling for maximum comfort
Compressor #2 access (high- efficiency compressor w/crankcase heater)
Base rails w/forklift slots (three sides) and lifting holes
Roof curbs in eight- and fourteen-inch heights. Roof curbs for transitioning from
York Sunline™ footprint to the ZF Series footprints are also available (field installed accessory)
Toolless door latch
Side entry power and control wiring knockouts
Figure 4: Predator
®
Component Location (ZF120 Shown)
Slide-out motor and blower assembly for easy adjustment and service
Belt-drive blower motor
VFD Location (optional)
Power ventor motor
20-gauge aluminized steel tubular heat exchanger for long life (stainless steel option) warm, comfortable
Slide-out drain pan temperature
with 3/4” NPT, female connection
Intelligent control
Compressor #1 access
(high-efficiency compressor board for safe and efficient operation w/crankcase heater)
Two-stage gas heating to maintain
6 Johnson Controls Unitary Products
518674-YIM-E-1210
Table 1: ZF078-150 Unit Limitations
Size
(Tons)
Model Unit Voltage
078
(6.5)
090
(7.5)
102
(8.5)
120
(10)
150
(12.5)
ZF
ZF
ZF
ZF
ZF
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
208/230-3-60
460-3-60
575-3-60
Location
Use the following guidelines to select a suitable location for these units:
1.
Unit is designed for outdoor installation only.
2.
Condenser coils must have an unlimited supply of air.
Where a choice of location is possible, position the unit on either north or east side of building.
3.
Suitable for mounting on roof curb.
4.
For ground level installation, use a level concrete slab with a minimum thickness of 4 inches. The length and width should be at least 6 inches greater than the unit base rails.
Do not tie slab to the building foundation.
5.
Roof structures must be able to support the weight of the unit and its options/accessories. Unit must be installed on a solid, level roof curb or appropriate angle iron frame.
6.
Maintain level tolerance to 1/2” across the entire width and length of unit.
Excessive exposure of this furnace to contaminated combustion air may result in equipment damage or personal injury. Typical contaminates include: permanent wave solution, chlorinated waxes and cleaners, chlorine based swimming pool chemicals, water softening chemicals, carbon tetrachloride,
Halogen type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, antistatic fabric softeners for clothes dryers, masonry acid washing materials.
187
432
540
187
432
540
540
187
432
540
Min
187
432
540
187
432
Unit Limitations
Applied Voltage
Max
252
504
630
252
504
252
504
630
252
630
252
504
630
504
630
Outdoor DB Temp
Max (°F)
125
125
125
125
125
125
125
125
125
125
125
125
125
125
125
Clearances
All units require particular clearances for proper operation and service. Installer must make provisions for adequate combustion and ventilation air in accordance with section 5.3 of
Air for Combustion and Ventilation of the National Fuel Gas
Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2,
7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) -
Latest Edition, and/or applicable provisions of the local building
codes. Refer to Table 5 for clearances required for combustible
construction, servicing, and proper unit operation.
Do not permit overhanging structures or shrubs to obstruct condenser air discharge outlet, combustion air inlet or vent outlets.
Rigging And Handling
Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreader bars, whose length exceeds the largest dimension across the unit, MUST be used across the top of the unit.
If a unit is to be installed on a roof curb other than a
York
®
roof curb, gasketing must be applied to all surfaces that come in contact with the unit underside.
Johnson Controls Unitary Products 7
518674-YIM-E-1210
Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly.
Units may be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose.
LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES.
All panels must be secured in place when the unit is lifted.
The condenser coils should be protected from rigging cable damage with plywood or other suitable material.
LEFT
C
A
B
F
Figure 6: Unit 6 Point Load Weight
E
FRONT
D
X
LEFT
Figure 7: Center of Gravity
Y
FRONT
FRONT
LEFT
B
A
D
Figure 5: Unit 4 Point Load Weight
C
Table 2: Weights and Dimensions
Size
(Tons)
078
(6.5)
090
(7.5)
102
(8.5)
120
(10)
150
(12.5)
Model
ZF
ZF
ZF
ZF
ZF
Weight (lbs.)
Shipping Operating
Center of Gravity 4 Point Load Location (lbs.)
X Y A B C D
865
885
1025
1065
1258
860
860
1020
1060
1253
38
38
38
38
47
24
24
24
24
25
200
205
238
247
251
149
153
177
184
280
218
223
258
268
381
292
299
347
360
341
A
140
144
167
173
164
6 Point Load Location (lbs.)
B C D E
114 95 138 167
117
136
141
176
97
113
117
190
142
164
171
259
171
198
206
240
F
205
210
243
253
223
8 Johnson Controls Unitary Products
518674-YIM-E-1210
Table 3: ZF078-150 Unit Accessory Weights
Unit Accessory
Economizer
Power Exhaust
Electric Heat
1
Gas Heat
2
Variable Frequency Drive
3
Weight (lbs.)
Shipping
90
Operating
85
40
49
110
30
35
49
110
30
1. Weight given is for the maximum heater size available
(54KW).
2. Weight given is for the maximum number of tube heat exchangers available (8 tube).
3. Weight includes mounting hardware, controls and manual bypass option.
LEFT
59
Figure 8: ZF078-120
29.69
15.25
15.38
59.00
15.38
B
Ø 24.47 TYP. 2 PL.
See detail A for gas inlet
A
C
D
E
F
4 3/16
27 5/16
See detail B for drain location
FRONT
89
21 3/16
11 3/8
Johnson Controls Unitary Products 9
518674-YIM-E-1210
Figure 9: ZF150
LEFT
59
29.95
45.64
30.11
14.92
14.92
58.09
B
Ø 24.47 TYP. 4 PL.
See detail A for gas inlet
14.92
A
C
D
E
F
4 3/16
27 5/16
See detail B for drain location
FRONT
89
21 3/16
11 3/8
10 Johnson Controls Unitary Products
518674-YIM-E-1210
Table 4: ZF078-150 Unit Physical Dimensions
Detail A
Unit Model Number
ZF078
ZF090
ZF102
ZF120
ZF150
A
42
42
50 3/4
50 3/4
50 3/4
3.184
Gas Pipe Inlet
B
89
89
89
89
119 1/2
Ø 2.000
Gas Exhaust Vent
Dimension (in.)
C
22 1/8
22 1/8
D
18 3/16
18 3/16
30 3/16
30 3/16
30 3/16
24 3/16
24 3/16
24 3/16
Gas Pipe Inlet
3.184
E
15 3/16
15 3/16
17 3/16
17 3/16
17 3/16
Ø 2.000
Gas Exhaust Vent
F
6 3/16
6 3/16
6 3/16
6 3/16
6 3/16
Ø 3.126
Ø 3.126
14.594
7.705
17.541
7.715
4.727
42” CABINET
4.737
50 3/4” CABINET
Detail B
5-3/8
3/4” FPT
Table 5: ZF078-150 Unit Clearances
Direction
Top
1
Front
Rear
Distance (in.)
72
36
36
Direction
Right
Left
Bottom
2
Distance (in.)
12
36
0
1. Units must be installed outdoors. Over hanging structure or shrubs should not obscure condenser air discharge outlet.
2. Units may be installed on combustable floors made from wood or class A, B or C roof covering materials.
Johnson Controls Unitary Products 11
518674-YIM-E-1210
LEFT
Bottom power, control and convenience outlet wiring entry
6 13/16
6 13/16
89
32 11/16
RETURN
AIR
18
27 1/2
SUPPLY
AIR
24
21
20 1/8 19 1/8
17 1/8
14 1/2
16 3/8
18 1/16
Bottom condensate drain
Bottom gas supply entry
FRONT
TOP VIEW
25 9/16
RIGHT
12 5/16
3X Ø 0.875
Ø 2.469
Figure 10: ZF078-150 Unit Bottom Duct Openings
12 Johnson Controls Unitary Products
Disconnect Swith Cover
Power Entry Ø 2-1/2
Control Entry Ø 7/8
Power Entry Ø 2-1/2
Convenience Outlet Cover
Convenience Outlet
Power Entry Ø 7/8
Figure 11: ZF078-150 Unit Electrical Entry
FRONT
Dot Plugs 18-1/4
Supply
Air
Return
Air
D
5-5/32
Figure 12: ZF078-120 Unit Side Duct Openings
C
2-31/32
31-11/16
A
B
518674-YIM-E-1210
Johnson Controls Unitary Products 13
518674-YIM-E-1210
Dot Plugs 18-1/4
A
D
5-5/32
C
Figure 13: ZF150 Unit Side Duct Openings
Table 6: Side Duct Dimensions
Unit Model Number
ZF078
ZF090
ZF102
ZF120
ZF150
A
27 3/4
27 3/4
28 1/4
28 1/4
28 1/4
Dimension (in.)
B
12 1/16
C
27 1/2
12 1/16
18 1/16
18 1/16
18 1/16
27 1/2
28 1/4
28 1/4
28 1/4
30-3/8
31-5/8
D
16
16
18 1/4
18 1/4
18 1/4
B
2-7/8
4-5/16
Figure 14: ZF078-150 Unit Left Duct Opening
14 Johnson Controls Unitary Products
518674-YIM-E-1210
2 TYP.
50-1/2
30
20
6
80-5/8
20
RETURN
SUPPLY
RIGHT
INSULATED DECK UNDER
CONDENSER SECTION
8 or 14
INSULATED DECK UNDER
COMPRESSOR SECTION
FRONT
Figure 15: ZF078-150 Roof Curb
50-1/2
30-1/2
RETURN
2 TYP
23 4
SUPPLY
26 80-5/8
10
76-5/8
94
FRONT
59-1/4
64-1/4
RIGHT
Figure 16: ZF078-150 Transition Roof Curb
Ductwork
Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of
America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA.
A closed return duct system should be used. This will not preclude use of economizers or outdoor fresh air intake. The supply and return air duct connections at the unit should be made with flexible joints to minimize noise.
The supply and return air duct systems should be designed for the CFM and static pressure requirements of the job. They should NOT be sized to match the dimensions of the duct connections on the unit.
Refer to Figure 10 for bottom air duct openings. Refer to
Figures 12, 13 and Table 6 for side air duct openings.
Johnson Controls Unitary Products 15
518674-YIM-E-1210
Duct Covers
Units are shipped with the side duct openings covered and a covering over 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 removed from the side duct connections are designed to be reused by securing each panel to its respective downflow opening. But keep in mind that the supply panel is installed with the painted surface UP, facing the heat exchanger, while the return panel is installed with the painted surface DOWN, facing the downflow duct opening. The supply panel is secured with the bracket (already in place from the factory) and two screws. It’s a snug fit for the panel when sliding it between the heat exchanger and unit bottom, but there is room. The return panel is secured with four screws.
When fastening ductwork to side duct flanges on unit, insert screws through duct flanges only. DO NOT insert screws through casing. Outdoor ductwork must be insulated and water-proofed.
Figure 19: Discharge Panel In Place
Condensate Drain
The side condensate drain is reversible and maybe re-oriented to the rear of the cabinet to facilitate condensate piping. A condensate drain connection is available through the base pan
for piping inside the roof curb. Trap the connection per Figure 20.
The trap and drain lines should be protected from freezing.
Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install condensate drain line from the 3/4 inch NPT female connection on the unit to an open drain.
OPTIONAL COIL
GUARD
3" Minimum
Figure 17: Side Panels With Hole Plugs
NOTE: Orientation. Panel is “insulation” side up.
Figure 20: Condensate Drain
Compressors
The scroll compressor used in this product is specifically designed to operate with R-410A Refrigerant and cannot be interchanged.
Figure 18: Return Downflow Plenum With Panel
16
This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system.
The compressor also uses a polyolester (POE oil), Mobil 3MA
POE. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.
Johnson Controls Unitary Products
518674-YIM-E-1210
Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are
indicated on the unit Rating Plate and Table 1.
Do not leave the system open to the atmosphere. Unit damage could occur due to moisture being absorbed by the POE oil in the system. This type of oil is highly susceptible to moisture absorption
POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials.
Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take precautions to protect roofing.
Procedures which risk oil leakage include, but are not limited to, compressor replacement, repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure switch, metering device or coil.
Units are shipped with compressor mountings which are factory-adjusted and ready for operation.
208/230-3-60 and 380/415-3-50 units control transformers are factory wired for 230v and 415v power supply respectively. Change tap on transformer for 208-
3-60 or 380-3-50 operation. See unit wiring diagram.
The internal wiring harnesses furnished with this unit are an integral part of the design certified unit. Field alteration to comply with electrical codes should not be required. 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 utilized for these units. Factory installed disconnects are available. If installing a disconnect (field supplied or York International
®
supplied accessory), refer to
Figure 4 for the recommended mounting location.
Do not loosen compressor mounting bolts.
Filters
Two-inch filters are supplied with each unit. One-inch filters may be used with no modification to the filter racks. Filters must always be installed ahead of evaporator coil and must be kept clean or replaced with same size and type. Dirty filters reduce the capacity of the unit and result in frosted coils or safety shutdown. Refer to physical data tables, for the number and size of filters needed for the unit. The unit should not be operated without filters properly installed.
Avoid damage to internal components if drilling holes for disconnect mounting.
NOTE: Since not all local codes allow the mounting of a disconnect on the unit, please confirm compliance with local code before mounting a disconnect on the unit.
Electrical line must be sized properly to carry the load. USE
COPPER CONDUCTORS ONLY. Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused.
Refer to Figures 21, 22, 23 and 24 for typical field wiring and to
the appropriate unit wiring diagram mounted inside control doors for control circuit and power wiring information.
Make sure that panel latches are properly positioned on the unit to maintain an airtight seal.
Power And Control Wiring
Field wiring to the unit, fuses, and disconnects must conform to provisions of National Electrical Code (NEC), ANSI/NFPA No.
70 – Latest Edition (in U.S.A.), current Canadian Electrical
Code C221, and/or local ordinances. The unit must be electrically grounded in accordance with NEC and CEC as specified above and/or local codes.
When connecting electrical power and control wiring to the unit, water-proof connectors must be used so that water or moisture cannot be drawn into the unit during normal operation. The above water-proofing conditions will also apply when installing a field supplied disconnect switch.
Power Wiring Detail
Units are factory wired for the voltage shown on the unit
nameplate. Refer to Electrical Data Table 8 to size power
wiring, fuses, and disconnect switch.
Johnson Controls Unitary Products 17
518674-YIM-E-1210
TERMINAL BLOCK TB1
Power wiring is brought into the unit through the side of the unit or the basepan inside the curb.
GROUND
LUG
FACTORY OR FIELD
SUPPLIED DISCONNECT
THREE
PHASE
POWER
SUPPLY
Figure 21: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat and All Units With VFD Option
CONTACTOR 1M
T1 T2 T3
L1
L2 L3
GROUND
LUG
FACTORY OR FIELD
SUPPLIED DISCONNECT
THREE
PHASE
POWER
SUPPLY
Figure 22: Field Wiring Disconnect - Cooling Unit With Gas Heat Without VFD Option
18 Johnson Controls Unitary Products
518674-YIM-E-1210
Thermostat Wiring (Not applicable to units with VFD)
The thermostat should be located on an inside wall approximately 56 inch above the floor where it will not be subject to drafts, sun exposure or heat from electrical fixtures or appliances. Follow the manufacturer's instructions enclosed with thermostat for general installation procedure. Seven (7) color-coded, insulated wires should be used to connect the
thermostat to the unit. Refer to Table 7 for control wire sizing
and maximum length.
Table 7: Control Wire Sizes
Wire Size
18 AWG
Maximum Length
150 Feet
1. From the unit to the thermostat and back to the unit.
1
THERMOSTAT 1
TERMINALS
RC
G
C
X1
X3
RH
Y1
Y2
W1
W2
X4
A1
2
UNIT TERMINALS
STRIP TB1
R
G
C
X
OCC
Y1
Y2
W1
W2
24 Volt
Transformer
A2
T
T
TO REMOTE SENSOR
2ET04701324 IF USED
1 Electronic programmable Thermostat 2ET0770010024 (includes subbase).
2 Terminals A1 and A2 provide a relay output to close the outdoor economizer dampers when the thermostat switches to the set-back position.
Figure 23: Typical Electronic Thermostat Field Wiring
208/230-3-60 and 380/415-3-50 units control transformers are factory wired for 230v and 415v power supply respectively. Change tap on transformer for 208-
3-60 or 380-3-50 operation. See unit wiring diagram.
T-STAT
W1
W2
Y1
G
Y2
C
RH
RC
Y2
X
R
SD
C
W1
W2
Y1
G
OCC
UNIT CONTROL
BOARD
Figure 24: Typical Field Wiring 24 Volt Thermostat
Johnson Controls Unitary Products 19
518674-YIM-E-1210
Table 8: Electrical Data
ZF078-150 Standard Motor - Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
078
(6.5)
090
(7.5)
102
(8.5)
208 9.3
230 9.3
460 4.9
575 3.8
68 14.5
68 14.5
34
28
7.7
6
208 11.9
88 18.5
230 11.9
88 18.5
460 5.2
575 4.8
44
36
208 12.2
88
230 12.2
88
460 5.8
575 4.4
44
36
8.1
7.5
19
19
9
5.5
OD Fan
Motors
(each)
FLA
1.5
1.5
0.8
0.6
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
6.0
6.0
3.0
2.4
6.0
6.0
3.0
2.4
6.8
6.8
3.4
2.7
Pwr
Exh
Motor
FLA
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
FLA
0
0
0
0
0
0
0
0
0
0
0
0
Model
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E24
E36
None
E09
E18
E24
E36
None
E09
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
None
E09
E18
E24
E36
None
E09
E18
Electric Heat Option kW
-
9
18
24
34
9
18
24
34
18
24
34
-
34
-
6.8
13.5
18
25.5
-
9
18
24
34
-
9
18
24
18
25.5
-
9
18
24
34
-
9
9
18
24
34
-
6.8
13.5
24
34
-
9
18
24
34
-
-
6.8
13.5
18
25.5
-
9
18
Stages Amps
2
2
-
1
2
2
2
1
2
2
-
2
2
-
1
2
2
1
2
2
-
2
2
-
1
2
2
2
-
1
2
2
-
1
2
2
2
-
1
2
2
2
1
2
2
2
1
2
-
2
2
-
1
2
2
-
2
2
-
1
-
8.7
17.3
23.1
32.7
43.3
57.7
81.8
-
10.8
21.7
28.9
40.9
32.7
-
18.9
37.5
50.0
70.8
-
21.7
21.7
28.9
40.9
-
8.7
17.3
23.1
50.0
70.8
-
21.7
43.3
57.7
81.8
-
10.8
8.7
17.3
23.1
32.7
-
18.9
37.5
57.7
81.8
-
10.8
21.7
28.9
40.9
-
-
18.9
37.5
50.0
70.8
-
21.7
43.3
MCA
1
(Amps)
MCA
w/Pwr
Exh
(Amps)
69.5
87.5
117.6
21.9
21.9
34.1
43.1
58.1
17
17
27.3
34.5
46.5
46.1
46.8
46.8
62.2
77.8
103.9
46.8
46.8
33.6
42.6
57.6
17.6
17.6
26.9
34.1
76.8
102.9
45.3
45.3
68.5
86.5
116.6
20.1
20.1
16.1
26.9
34.1
46.1
45.3
45.3
61.2
86.5
116.6
17.8
20
33.6
42.6
57.6
14
35.4
38
61.2
76.8
102.9
35.4
41.4
68.5
20
20
25
35
25
35
45
60
45
80
100
50
50
70
90
125
25
45
50
50
60
20
20
25
35
80
110
20
20
35
40
60
50
50
60
70
100
50
50
70
15
25
35
45
20
35
40
60
15
Max Fuse
2
/
Breaker
3
Size
/
Size w/
(Amps)
Pwr Exh
(Amps)
35
35
40
40
60
70
70
80
100
35
35
70
80
110
20
110
40
45
70
90
125
20
50
50
70
80
110
50
50
70
20
30
35
50
20
35
45
60
15
20
20
30
35
25
35
45
60
50
80
110
50
50
70
90
125
25
50
50
50
70
20
20
30
35
90
125
25
25
35
45
60
62.6
80.7
110.7
19.7
19.7
31.3
40.3
55.4
15.2
15.2
25
32.2
44.3
43.9
41.3
41.3
55.3
71
97
41.3
41.3
30.8
39.8
54.9
15.8
15.8
24.7
31.9
70
96
39.8
39.8
61.6
79.7
109.7
17.9
17.9
13.8
24.7
31.9
43.9
39.8
39.8
54.3
79.7
109.7
15.6
17.3
30.8
39.8
54.9
12.2
29.9
31.1
54.3
70
96
29.9
34.6
61.6
20 Johnson Controls Unitary Products
518674-YIM-E-1210
ZF078-150 Standard Motor - Without Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
120
(10)
150
(12.5)
208 13.9
110 21.7
230 13.9
110 21.7
460 7.4
575 5.6
55 11.5
43
208 23.1
160
230 23.1
160
460 12.2
87
575 8.7
8.7
36
36
19
62 13.5
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
Pwr
Conv
Outlet
FLA
6.8
6.8
3.4
2.7
9.6
9.6
4.8
3.9
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
0
0
0
0
0
0
0
0
Model
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
Electric Heat Option kW
18
25.5
40.6
-
18
24
34
54
-
18
24
34
54
-
13.5
54
-
18
24
54
-
18
24
34
34
54
-
18
24
34
-
18
24
34
54
-
13.5
18
25.5
40.6
Stages Amps
2
2
2
2
-
2
2
2
-
2
2
2
2
-
2
2
2
2
-
2
2
2
2
2
-
2
2
2
-
2
2
2
-
2
2
2
2
2
-
2
50.0
70.8
112.7
-
43.3
57.7
81.8
65.0
-
17.3
23.1
32.7
52.0
-
37.5
129.9
-
21.7
28.9
40.9
65.0
-
17.3
23.1
32.7
52.0
-
37.5
50.0
70.8
112.7
-
43.3
57.7
81.8
129.9
-
21.7
28.9
40.9
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
75.6
100.5
152.9
75.6
75.6
84.2
114.2
69.2
17.9
25
32.2
44.3
55.3
75.6
75.6
141.9
38.7
38.7
42.1
57.1
71.0
28.7
28.7
33.7
45.8
56.8
45.1
55.3
71
97
149.4
45.1
62.6
80.7
110.7
138.4
23.3
31.3
40.3
55.4
MCA
1
(Amps)
MCA
1 w/Pwr
Exh
(Amps)
81.3
107.4
159.7
81.1
81.1
91.0
121.1
72
19.7
27.3
34.5
46.5
57.6
81.1
81.1
148.8
40.9
40.9
44.8
59.9
73.7
30.5
30.5
36.0
48.0
59.1
50.6
62.2
77.8
103.9
156.2
50.6
69.5
87.5
117.6
145.3
25.5
34.1
43.1
58.1
90
110
175
90
90
90
125
80
20
25
35
45
60
90
90
80
35
35
35
175
50
50
50
60
50
70
30
35
45
60
50
70
90
125
150
Max Fuse
2
/
Breaker
3
Size
Max Fuse
2
/
Breaker
3
Size w/
(Amps)
Pwr Exh
(Amps)
50
60
60
70
80
100
150
80
110
175
60
70
90
125
175
30
35
45
60
80
35
35
40
175
50
50
50
60
50
70
100
110
175
100
100
100
125
80
25
30
35
50
60
100
100
Johnson Controls Unitary Products 21
518674-YIM-E-1210
ZF078-150 Hi Static Motor - Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
078
(6.5)
090
(7.5)
102
(8.5)
208 9.3
230 9.3
460 4.9
575 3.8
68 14.5
68 14.5
34
28
7.7
6
208 11.9
88 18.5
230 11.9
88 18.5
460 5.2
575 4.8
44
36
208 12.2
88
230 12.2
88
460 5.8
575 4.4
44
36
8.1
7.5
19
19
9
5.5
1.5
1.5
0.8
0.6
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
6.8
6.8
3.4
2.7
9.6
9.6
4.8
3.9
9.6
9.6
4.8
3.9
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
Electric Heat Option
FLA Model kW Stages Amps
0
0
0
0
0
0
0
0
0
0
0
0
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
E24
E36
None
E09
E18
E24
E36
None
E09
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
24
34
-
9
18
24
34
34
-
9
18
-
9
18
24
18
24
34
-
6.8
13.5
18
25.5
-
9
18
24
34
-
9
13.5
18
25.5
-
9
18
24
34
24
34
-
6.8
24
34
-
9
18
9
18
24
34
-
9
18
-
6.8
13.5
18
25.5
-
2
2
2
-
1
2
2
1
2
2
-
2
2
-
1
2
2
1
2
2
-
2
2
2
-
1
2
2
-
1
2
2
-
1
2
2
2
2
-
1
2
2
-
1
2
2
2
-
1
2
2
2
1
2
-
2
2
1
2
-
28.9
40.9
-
8.7
17.3
23.1
32.7
-
21.7
43.3
57.7
81.8
-
10.8
21.7
17.3
23.1
32.7
-
18.9
37.5
50.0
70.8
-
10.8
21.7
28.9
40.9
-
8.7
37.5
50.0
70.8
-
21.7
43.3
57.7
81.8
28.9
40.9
-
8.7
17.3
23.1
32.7
-
18.9
21.7
43.3
57.7
81.8
-
10.8
21.7
-
18.9
37.5
50.0
70.8
-
MCA
1
(Amps)
42.1
57.1
16.4
16.4
26.5
33.7
45.8
44.1
44.1
66.1
84.2
114.2
21.1
21.1
33.1
26.5
33.7
45.8
44.1
44.1
58.8
74.5
100.5
19.7
19.7
33.1
42.1
57.1
17.3
17.3
58.8
74.5
100.5
43.4
43.4
66.1
84.2
114.2
40.3
55.4
12.5
14.2
25
32.2
44.3
43.4
43.4
35.6
62.6
80.7
110.7
16
17.8
31.3
30.7
32.1
55.3
71
97
30.7
MCA
w/Pwr
Exh
(Amps)
44.8
59.9
18.2
18.2
28.8
36
48
49.6
49.6
73
91
121.1
23.3
23.3
35.8
28.8
36
48
49.6
49.6
65.7
81.3
107.4
21.9
22.3
35.8
44.8
59.9
19.1
19.1
65.7
81.3
107.4
48.9
48.9
73
91
121.1
43.1
58.1
14.3
16.5
27.3
34.5
46.5
48.9
48.9
36.2
39
62.2
77.8
103.9
36.2
42.4
69.5
87.5
117.6
18.2
20.5
34.1
Max Fuse
Breaker
3
2
/
Size
(Amps)
45
60
20
20
30
40
50
60
60
80
100
125
25
25
40
60
70
90
110
30
40
50
60
25
25
40
45
60
20
20
70
90
110
60
60
80
100
125
35
50
60
60
45
60
15
20
30
/
Size w/ Pwr
Exh
(Amps)
45
45
70
80
110
45
45
70
90
125
20
25
35
45
60
20
20
30
35
50
125
25
25
35
50
50
70
90
50
60
80
110
30
35
50
50
20
20
35
45
60
20
20
60
80
110
50
50
70
90
125
35
45
50
50
45
60
15
15
25
40
70
90
125
20
20
35
40
40
60
80
100
40
22 Johnson Controls Unitary Products
518674-YIM-E-1210
ZF078-150 Hi Static Motor - Without Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
120
(10)
150
(12.5)
208 13.9
110 21.7
230 13.9
110 21.7
460 7.4
575 5.6
55 11.5
43
208 23.1
160
230 23.1
160
460 12.2
87
575 8.7
8.7
36
36
19
62 13.5
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
9.6
9.6
4.8
3.9
15.2
15.2
7.6
6.1
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
Electric Heat Option
FLA Model kW Stages Amps
0
0
0
0
0
0
0
0
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
18
25.5
40.6
-
18
24
34
54
-
18
24
34
54
-
13.5
54
-
18
24
54
-
18
24
34
34
54
-
18
24
34
-
18
24
34
54
-
13.5
18
25.5
40.6
2
2
2
2
-
2
2
2
-
2
2
2
2
-
2
2
2
2
-
2
2
2
2
2
-
2
2
2
-
2
2
2
-
2
2
2
2
2
-
2
50.0
70.8
112.7
-
43.3
57.7
81.8
65.0
-
17.3
23.1
32.7
52.0
-
37.5
129.9
-
21.7
28.9
40.9
65.0
-
17.3
23.1
32.7
52.0
-
37.5
50.0
70.8
112.7
-
43.3
57.7
81.8
129.9
-
21.7
28.9
40.9
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
MCA
1
(Amps)
81.5
107.5
159.9
81.2
81.2
91.2
121.2
71
19.1
26.5
33.7
45.8
56.8
81.2
81.2
148.9
41.5
41.5
45.6
60.6
74.5
30.9
30.9
36.5
48.5
59.6
47.9
58.8
74.5
100.5
152.9
47.9
66.1
84.2
114.2
141.9
24.7
33.1
42.1
57.1
MCA
1 w/Pwr
Exh
(Amps)
88.3
114.4
166.7
86.7
86.7
98.0
128.1
73.7
20.9
28.8
36
48
59.1
86.7
86.7
155.8
43.7
43.7
48.3
63.4
77.2
32.7
32.7
38.7
50.8
61.8
53.4
65.7
81.3
107.4
159.7
53.4
73
91
121.1
148.8
26.9
35.8
44.8
59.9
Max Fuse
Breaker
3
2
/
Size
(Amps)
100
125
175
100
100
100
150
80
25
30
40
50
70
100
100
90
40
40
40
175
50
50
50
70
60
70
Max Fuse
2
/
Breaker
3
Size w/ Pwr
Exh
(Amps)
60
70
90
110
175
30
40
45
60
60
80
100
125
175
100
110
175
100
100
100
125
80
20
30
35
50
70
100
100
90
35
35
40
175
50
50
50
70
50
70
30
35
45
60
60
70
90
125
175
60
60
80
110
175
Johnson Controls Unitary Products 23
518674-YIM-E-1210
ZF078-150 Standard Motor - With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
078
(6.5)
090
(7.5)
102
(8.5)
208 9.3
230 9.3
460 4.9
575 3.8
68 14.5
68 14.5
34
28
7.7
6
208 11.9
88 18.5
230 11.9
88 18.5
460 5.2
575 4.8
44
36
208 12.2
88
230 12.2
88
460 5.8
575 4.4
44
36
8.1
7.5
19
19
9
5.5
1.5
1.5
0.8
0.6
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
6.0
6.0
3.0
2.4
6.0
6.0
3.0
2.4
6.8
6.8
3.4
2.7
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
Electric Heat Option
FLA Model kW Stages Amps
10
10
5
4
10
10
5
4
10
10
5
4
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
E24
E36
None
E09
E18
E24
E36
None
E09
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
24
34
-
9
18
24
34
34
-
9
18
-
9
18
24
18
24
34
-
6.8
13.5
18
25.5
-
9
18
24
34
-
9
13.5
18
25.5
-
9
18
24
34
24
34
-
6.8
24
34
-
9
18
9
18
24
34
-
9
18
-
6.8
13.5
18
25.5
-
2
2
2
-
1
2
2
1
2
2
-
2
2
-
1
2
2
1
2
2
-
2
2
2
-
1
2
2
-
1
2
2
-
1
2
2
2
2
-
1
2
2
-
1
2
2
2
-
1
2
2
2
1
2
-
2
2
1
2
-
28.9
40.9
-
8.7
17.3
23.1
32.7
-
21.7
43.3
57.7
81.8
-
10.8
21.7
17.3
23.1
32.7
-
18.9
37.5
50.0
70.8
-
10.8
21.7
28.9
40.9
-
8.7
37.5
50.0
70.8
-
21.7
43.3
57.7
81.8
28.9
40.9
-
8.7
17.3
23.1
32.7
-
18.9
21.7
43.3
57.7
81.8
-
10.8
21.7
-
18.9
37.5
50.0
70.8
-
MCA
1
(Amps)
46.6
61.6
19.2
19.2
30
37.2
49.3
51.3
51.3
75.1
93.2
123.2
24.7
24.7
37.6
29.7
36.9
48.9
51.3
51.3
67.8
83.5
109.5
22.9
23.5
37.1
46.1
61.1
19.8
19.8
66.8
82.5
108.5
49.8
49.8
74.1
92.2
122.2
46.1
61.1
16.2
18.8
29.7
36.9
48.9
49.8
49.8
40.1
43.6
66.8
82.5
108.5
40.1
47.1
74.1
92.2
122.2
20.7
23.5
37.1
MCA
w/Pwr
Exh
(Amps)
49.3
64.4
21
21.5
32.3
39.5
51.5
56.8
56.8
82
100
130.1
26.9
26.9
40.3
31.9
39.1
51.1
56.8
56.8
74.7
90.3
116.4
25.1
26.3
39.8
48.8
63.9
21.6
21.6
73.7
89.3
115.4
55.3
55.3
81
99
129.1
48.8
63.9
18
21.1
31.9
39.1
51.1
55.3
55.3
45.6
50.5
73.7
89.3
115.4
45.6
53.9
81
99
129.1
22.9
26.3
39.8
Max Fuse
2
/
Breaker
3
Size
(Amps)
50
70
25
25
35
40
60
60
60
90
100
150
30
30
45
60
80
100
125
35
40
60
60
30
30
40
50
70
25
25
80
90
125
60
60
90
100
150
40
60
60
60
50
70
20
25
35
/
Size w/ Pwr
Exh
(Amps)
50
60
80
90
125
50
60
90
100
150
25
30
40
50
70
20
20
30
40
50
60
60
80
100
125
30
30
40
60
70
90
110
30
40
50
60
25
25
40
50
70
20
20
70
90
110
60
60
80
100
125
40
50
60
60
50
70
20
20
30
50
80
100
125
25
25
40
50
50
70
90
110
50
24 Johnson Controls Unitary Products
518674-YIM-E-1210
ZF078-150 Standard Motor - With Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
120
(10)
150
(12.5)
208 13.9
110 21.7
230 13.9
110 21.7
460 7.4
575 5.6
55 11.5
43
208 23.1
160
230 23.1
160
460 12.2
87
575 8.7
8.7
36
36
19
62 13.5
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
6.8
6.8
3.4
2.7
9.6
9.6
4.8
3.9
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
Electric Heat Option
FLA Model kW Stages Amps
10
10
5
4
10
10
5
4
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
18
25.5
40.6
-
18
24
34
54
-
18
24
34
54
-
13.5
54
-
18
24
54
-
18
24
34
34
54
-
18
24
34
-
18
24
34
54
-
13.5
18
25.5
40.6
2
2
2
2
-
2
2
2
-
2
2
2
2
-
2
2
2
2
-
2
2
2
2
2
-
2
2
2
-
2
2
2
-
2
2
2
2
2
-
2
50.0
70.8
112.7
-
43.3
57.7
81.8
65.0
-
17.3
23.1
32.7
52.0
-
37.5
129.9
-
21.7
28.9
40.9
65.0
-
17.3
23.1
32.7
52.0
-
37.5
50.0
70.8
112.7
-
43.3
57.7
81.8
129.9
-
21.7
28.9
40.9
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
MCA
1
(Amps)
87.0
113.0
165.4
85.6
85.6
96.7
126.7
75.5
21.9
30
37.2
49.3
60.3
85.6
85.6
154.4
43.7
43.7
48.3
63.4
77.2
32.7
32.7
38.7
50.8
61.8
55.1
67.8
83.5
109.5
161.9
55.1
75.1
93.2
123.2
150.9
28.3
37.6
46.6
61.6
MCA
1 w/Pwr
Exh
(Amps)
93.8
119.9
172.2
91.1
91.1
103.5
133.6
78.2
23.7
32.3
39.5
51.5
62.6
91.1
91.1
161.3
45.9
45.9
51.1
66.1
80.0
34.5
34.5
41.0
53.0
64.1
60.6
74.7
90.3
116.4
168.7
60.6
82
100
130.1
157.8
30.5
40.3
49.3
64.4
Max Fuse
2
/
Breaker
3
Size
(Amps)
110
125
175
110
110
110
150
90
25
35
40
60
70
110
110
90
40
40
45
175
50
50
60
70
60
70
Max Fuse
2
/
Breaker
3
Size w/ Pwr
Exh
(Amps)
70
80
100
125
175
35
45
50
70
70
90
100
150
175
100
125
175
100
100
100
150
80
25
30
40
50
70
100
100
90
40
40
40
175
50
50
50
70
60
70
35
40
50
70
60
80
100
125
175
60
70
90
110
175
Johnson Controls Unitary Products 25
518674-YIM-E-1210
ZF078-150 Hi Static Motor - With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
078
(6.5)
090
(7.5)
102
(8.5)
208 9.3
230 9.3
460 4.9
575 3.8
68 14.5
68 14.5
34
28
7.7
6
208 11.9
88 18.5
230 11.9
88 18.5
460 5.2
575 4.8
44
36
208 12.2
88
230 12.2
88
460 5.8
575 4.4
44
36
8.1
7.5
19
19
9
5.5
1.5
1.5
0.8
0.6
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
6.8
6.8
3.4
2.7
9.6
9.6
4.8
3.9
9.6
9.6
4.8
3.9
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
Electric Heat Option
FLA Model kW Stages Amps
10
10
5
4
10
10
5
4
10
10
5
4
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
E24
E36
None
E09
E18
E24
E36
None
E09
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
24
34
-
9
18
24
34
34
-
9
18
-
9
18
24
18
24
34
-
6.8
13.5
18
25.5
-
9
18
24
34
-
9
13.5
18
25.5
-
9
18
24
34
24
34
-
6.8
24
34
-
9
18
9
18
24
34
-
9
18
-
6.8
13.5
18
25.5
-
2
2
2
-
1
2
2
1
2
2
-
2
2
-
1
2
2
1
2
2
-
2
2
2
-
1
2
2
-
1
2
2
-
1
2
2
2
2
-
1
2
2
-
1
2
2
2
-
1
2
2
2
1
2
-
2
2
1
2
-
28.9
40.9
-
8.7
17.3
23.1
32.7
-
21.7
43.3
57.7
81.8
-
10.8
21.7
17.3
23.1
32.7
-
18.9
37.5
50.0
70.8
-
10.8
21.7
28.9
40.9
-
8.7
37.5
50.0
70.8
-
21.7
43.3
57.7
81.8
28.9
40.9
-
8.7
17.3
23.1
32.7
-
18.9
21.7
43.3
57.7
81.8
-
10.8
21.7
-
18.9
37.5
50.0
70.8
-
MCA
1
(Amps)
48.3
63.4
20.4
20.7
31.5
38.7
50.8
54.1
54.1
78.6
96.7
126.7
26.1
26.1
39.3
31.5
38.7
50.8
54.1
54.1
71.3
87
113
24.7
25.8
39.3
48.3
63.4
21.3
21.3
71.3
87
113
53.4
53.4
78.6
96.7
126.7
46.6
61.6
16.5
19.2
30
37.2
49.3
53.4
53.4
40.9
44.6
67.8
83.5
109.5
40.9
48.1
75.1
93.2
123.2
21.1
24
37.6
w/Pwr
Exh
(Amps)
51.1
66.1
22.2
23
33.8
41
53
59.6
59.6
85.5
103.5
133.6
28.3
28.5
42.1
33.8
41
53
59.6
59.6
78.2
93.8
119.9
26.9
28.5
42.1
51.1
66.1
23.1
23.1
78.2
93.8
119.9
58.9
58.9
85.5
103.5
133.6
49.3
64.4
18.3
21.5
32.3
39.5
51.5
58.9
58.9
46.4
51.5
74.7
90.3
116.4
46.4
54.9
82
100
130.1
23.3
26.8
40.3
Max Fuse
Breaker
3
2
/
Size
(Amps)
60
70
25
25
35
45
60
70
70
90
110
150
30
30
45
70
80
100
125
35
45
60
70
30
30
45
60
70
25
25
80
100
125
70
70
90
110
150
40
60
70
70
50
70
20
25
35
/
Size w/ Pwr
Exh
(Amps)
50
60
80
100
125
50
60
90
100
150
25
30
45
50
70
25
25
35
40
60
60
60
80
100
150
30
30
40
60
80
90
125
35
40
60
60
25
30
40
50
70
25
25
80
90
125
60
60
80
100
150
40
50
60
60
50
70
20
20
30
50
80
100
125
25
25
40
50
50
70
90
110
50
26 Johnson Controls Unitary Products
518674-YIM-E-1210
ZF078-150 Hi Static Motor - With Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA MCC
OD Fan
Motors
(each)
FLA
120
(10)
150
(12.5)
208 13.9
110 21.7
230 13.9
110 21.7
460 7.4
575 5.6
55 11.5
43
208 23.1
160
230 23.1
160
460 12.2
87
575 8.7
8.7
36
36
19
62 13.5
3.5
3.5
1.6
1.3
3.5
3.5
1.6
1.3
Supply
Blower
Motor
FLA
Pwr
Exh
Motor
FLA
9.6
9.6
4.8
3.9
15.2
15.2
7.6
6.1
5.5
5.5
2.2
1.8
5.5
5.5
2.2
1.8
Pwr
Conv
Outlet
Electric Heat Option
FLA Model kW Stages Amps
10
10
5
4
10
10
5
4
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
18
25.5
40.6
-
18
24
34
54
-
18
24
34
54
-
13.5
54
-
18
24
54
-
18
24
34
34
54
-
18
24
34
-
18
24
34
54
-
13.5
18
25.5
40.6
2
2
2
2
-
2
2
2
-
2
2
2
2
-
2
2
2
2
-
2
2
2
2
2
-
2
2
2
-
2
2
2
-
2
2
2
2
2
-
2
50.0
70.8
112.7
-
43.3
57.7
81.8
65.0
-
17.3
23.1
32.7
52.0
-
37.5
129.9
-
21.7
28.9
40.9
65.0
-
17.3
23.1
32.7
52.0
-
37.5
50.0
70.8
112.7
-
43.3
57.7
81.8
129.9
-
21.7
28.9
40.9
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
MCA
1
(Amps)
94.0
120.0
172.4
91.2
91.2
103.7
133.7
77.2
23.1
31.5
38.7
50.8
61.8
91.2
91.2
161.4
46.5
46.5
51.8
66.9
80.7
34.9
34.9
41.5
53.5
64.6
57.9
71.3
87
113
165.4
57.9
78.6
96.7
126.7
154.4
29.7
39.3
48.3
63.4
MCA
1 w/Pwr
Exh
(Amps)
100.8
126.9
179.2
96.7
96.7
110.5
140.6
80
24.9
33.8
41
53
64.1
96.7
96.7
168.3
48.7
48.7
54.6
69.6
83.5
36.7
36.7
43.7
55.8
66.8
63.4
78.2
93.8
119.9
172.2
63.4
85.5
103.5
133.6
161.3
31.9
42.1
51.1
66.1
Max Fuse
Breaker
3
2
/
Size
(Amps)
110
150
200
110
110
125
150
90
30
35
45
60
70
110
110
90
45
45
45
175
60
60
60
70
60
70
Max Fuse
2
/
Breaker
3
Size w/ Pwr
Exh
(Amps)
70
80
100
125
175
35
45
60
70
70
90
110
150
175
110
125
175
110
110
110
150
90
25
35
40
60
70
110
110
90
40
40
45
175
50
50
60
70
60
70
35
40
50
70
70
80
100
150
175
70
80
90
125
175
Johnson Controls Unitary Products 27
518674-YIM-E-1210
Table 9: ZF078-150 Physical Data
Component
Nominal Tonnage
ARI COOLING PERFORMANCE
Gross Capacity @ ARI A point (Mbh)
ARI net capacity (Mbh)
EER
IEER
IPLV
Nominal CFM
System power (KW)
Refrigerant type
Refrigerant charge (lb-oz)
System 1
System 2
ARI HEATING PERFORMANCE
Heating model
Heat input (K Btu)
Heat output (K Btu)
AFUE %
Steady state efficiency (%)
No. burners
No. stages
Temperature Rise Range (ºF)
Gas Limit Setting (ºF)
Gas piping connection (in.)
DIMENSIONS (inches)
Length
Width
Height
OPERATING WT. (lbs.)
COMPRESSORS
Type
Quantity
Unit Capacity Steps (%)
CONDENSER COIL DATA
Face area (Sq. Ft.)
Rows
Fins per inch
Tube diameter (in.)/mm
Circuitry Type
EVAPORATOR COIL DATA
Face area (Sq. Ft.)
Rows
Fins per inch
Tube diameter
Circuitry Type
Refrigerant control
ZF078
6.5
81000
78000
11.2
13
12.9
2600
6.95
R-410A
ZF090
7.5
90000
88000
11.2
12.1
12.1
2500
7.87
R-410A
Models
ZF102
8.5
104000
101000
11.2
12.5
12.5
3000
8.60
R-410A
ZF120
10
126000
120000
11.2
12.5
12.6
4000
10.70
R-410A
ZF150
12.5
156000
150000
11.2
12.7
13.06
4100
13.40
R-410A
4-12
4-10
4-12
4-10
4-14
5-0
6-8
6-8
7-8
7-8
4
2
1
20-50
165
3/4
10
120
96
-
80
6
2
1
35-65
165
3/4
15
180
144
-
80
4
2
1
15-45
165
3/4
10
120
96
-
80
15
180
144
-
80
6
2
1
30-60
165
3/4
10
120
96
-
80
4
2
1
10-40
215
3/4
15
180
144
-
80
6
2
1
25-55
195
3/4
15
180
144
-
80
6
2
1
20-50
195
3/4
20
240
192
-
80
8
2
1
35-65
160
3/4
15
180
144
-
80
6
2
1
10-40
195
3/4
20
240
192
-
80
8
2
1
25-55
160
3/4
89
59
42
860
Recip
2
50 / 100
18.5
1
23
.71/18
2-pass
Microchannel
89
59
42
880
Recip
2
50 / 100
18.5
1
23
.71/18
2-pass
Microchannel
89
59
50-3/4
1020
Recip
2
50 / 100
18.5
1
23
.71/18
2-pass
Microchannel
89
59
50-3/4
1060
Recip
2
50 / 100
29.0
1
23
.71/18
2-pass
Microchannel
119-1/2
59
50-3/4
1253
Scroll
2
50 / 100
29.0
1
23
1/25
2-pass
Microchannel
10.6
3
15
0.375
Intertwined
TXV
10.6
3
15
0.375
Intertwined
TXV
13.2
3
15
0.375
Intertwined
TXV
13.2
4
15
0.375
Intertwined
TXV
13.2
3
15
0.375
Intertwined
TXV
28 Johnson Controls Unitary Products
518674-YIM-E-1210
Table 9: ZF078-150 Physical Data (Continued)
Component
Quantity of Fans
Fan diameter (Inch)
Type
Drive type
Nominal Tonnage
CONDENSER FAN DATA
Quantity of motors
Motor HP each
No. speeds
RPM
Nominal total CFM
BELT DRIVE EVAP FAN DATA
Quantity
Fan Size (Inch)
Type
Motor Sheave
Blower Sheave
Belt
Motor HP each
RPM
Frame size
FILTERS
Quantity - Size
ZF078
AK74
A49
1-1/2
1725
56
6.5
2
24
Prop
Direct
2
1/3
1
850
6200
1
12 x 12
AK64
A49
2
1725
56
AK74
A49
1725
56
ZF090
7.5
2
24
Prop
Direct
2
3/4
1
1110
7600
1
12 x 12
1-1/2
Models
ZF102
8.5
2
24
Prop
Direct
2
3/4
1
1110
8300
1
15 x 15
ZF120
10
2
24
Prop
Direct
2
3/4
1
1110
9500
56
ZF150
12.5
4
24
Prop
Direct
4
3/4
1
1110
13900
1
15 x 15
Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal
1VM50 1VM50 1VM50 1VM50 1VM50 1VM50 1VM50 1VM50 1VM50 1VP56
AK61
A49
3
1725
56
4 - (24 x 16 x 2) 2, 3
4 - (24 x 16 x 4)
4
4 - (24 x 16 x 2)
1. 1
ST
Stage 60% of 2 nd
Stage
2. 2 In. Throwaway, Standard, MERV (Minimum Efficiency Reporting Value) 3
3. 2 In. Pleated, Optional, MERV 7
4. 4 In. Pleated, Optional, MERV 13
2, 3
4 - (24 x 16 x 4)
4
AK89
A56
2
1725
56
AK74
A54
3
1725
56
4 - (24 x 20 x 2) 2, 3
4 - (24 x 20 x 4)
4
AK84
A56
2
1725
56
1
15 x 15
AK74
A54
3
1725
56
4 - (24 x 20 x 2) 2, 3
4 - (24 x 20 x 4)
4
AK74
A54
3
1725
BK77
BX55
5
1725
184T
4 - (24 x 20 x 2) 2, 3
4 - (24 x 20 x 4)
4
Johnson Controls Unitary Products 29
518674-YIM-E-1210
Optional Electric Heat
The factory-installed heaters are wired for single point power supply. Power supply need only be brought into the single point terminal block.
These CSA approved heaters are located within the central compartment of the unit with the heater elements extending in to the supply air chamber.
Fuses are supplied, where required, by the factory. Some kW
sizes require fuses and others do not. refer to Table 10 for
minimum CFM limitations and to Table 8 for electrical data.
Table 10: Electric Heat Minimum Supply Air
Size
(Tons)
078
(6.5)
090
(7.5)
102
(8.5)
120
(10)
150
(12.5)
Model
ZF
ZF
ZF
ZF
ZF
Voltage
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
9
1950
1950
1950
2250
2250
2250
2550
2550
2550
-
-
-
-
-
-
2550
3000
3000
3000
3750
3750
3750
18
1950
Minimum Supply Air (CFM)
Heater kW
24
1950
1950
1950
36
1950
1950
1950
2250
2250
2250
2550
2550
1950
2250
2250
2250
2550
2550
1950
2250
2250
2250
2550
2550
2550
3000
3000
3000
3750
3750
3750
2550
3000
3000
3000
3750
3750
3750
-
3500
3000
3500
-
-
-
-
54
-
-
-
-
4000
3750
3750
30 Johnson Controls Unitary Products
Optional Gas Heat
These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition.
NOTE: On VAV units, individual VAV boxes must be fully open in heating mode to insure airflow falls within specified
Temperature Rise range.
Gas Piping
Proper sizing of gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas and the length of run. "National Fuel Gas Code" Z223.1 (in U.S.A.) or the current
Gas Installation Codes CSA-B149.1 (in Canada) should be followed in all cases unless superseded by local codes or gas
utility requirements. Refer to the Pipe Sizing Table 11. The
heating value of the gas may differ with locality. The value should be checked with the local gas utility.
518674-YIM-E-1210
OPTIONAL
COIL
GUARD
SHOWN
Figure 25: Side Entry Gas Piping
OPTIONAL
COIL
GUARD
SHOWN
Figure 26: Bottom Entry Gas Piping
Table 11: Gas Pipe Sizing - Capacity of Pipe
Length of
Pipe (ft.)
3/4 in.
Nominal Iron Pipe Size
1 in.
1-1/4 in.
50
60
70
80
10
20
30
40
90
100
115
105
96
90
278
190
152
130
84
79
215
195
180
170
520
350
285
245
160
150
1050
730
590
500
440
400
370
350
320
305
NOTE: Maximum capacity of pipe in cubic feet of gas per hour based upon a pressure drop of 0.3 inch W.C. and 0.6 specific gravity gas.
NOTE: There may be a local gas utility requirement specifying a minimum diameter for gas piping. All units require a 3/4 inch pipe connection at the entrance fitting. Line should not be sized smaller than the entrance fitting size.
Johnson Controls Unitary Products 31
518674-YIM-E-1210
Table 12: Gas Heat Minimum Supply Air
Size
(Tons)
078
(6.5)
090
(7.5)
102
(8.5)
120
(10)
150
(12.5)
Model
ZF
ZF
ZF
ZF
ZF
Supply Air (CFM)
Heat Size
Min
10 1950
15 1950
10 2250
15 2250
10 2550
15 2550
15 3000
20 3000
15 3750
20 3750
Cooling
Max
3250
3250
3750
3750
4250
4250
5000
5000
6250
6250
Min
1950
1950
2250
2250
2550
2550
3000
3000
3750
3750
Heating
Max
3250
3250
3750
3750
4250
4250
5000
5000
6250
6250
Gas Connection
The gas supply line can be routed within the space and roof curb,
exiting through the unit’s basepan. Refer to Figures 8 and 9 for
the gas piping inlet location. Typical supply piping arrangements
are shown in Figures 25 and 26. All pipe nipples, fittings, and the
gas cock are field supplied or may be purchased in UP accessory kit #1GP0405.
Gas piping recommendations:
1.
A drip leg and a ground joint union must be installed in the gas piping.
2.
Where required by local codes, a manual shut-off valve must be installed outside of the unit.
3.
Use wrought iron or steel pipe for all gas lines. Pipe dope should be applied sparingly to male threads only.
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.
Natural gas may contain some propane. Propane 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. Shellac based compounds such as Gaskolac or Stalastic, and compounds such as Rectorseal #5,
Clydes’s or John Crane may be used.
The furnace and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas valve damage resulting in a hazardous condition. If it is subjected to a pressure greater than 1/2 PSIG, the gas valve must be replaced.
The furnace must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG.
4.
All piping should be cleaned of dirt and scale by hammering on the outside of the pipe and blowing out loose particles. Before initial start-up, be sure that all gas lines external to the unit have been purged of air.
5.
The gas supply should be a separate line and installed in accordance with all safety codes as prescribed under
“Limitations”.
6.
A 1/8-inch NPT plugged tapping, accessible for test gage connection, must be installed immediately upstream of the gas supply connection to the unit.
7.
After the gas connections have been completed, open the main shut-off valve admitting normal gas pressure to the mains. Check all joints for leaks with soap solution or other
material suitable for the purpose. NEVER USE A FLAME.
Threaded joints should be coated with a sealing compound that is resistant to the action of liquefied petroleum gases. Do not use Teflon tape.
LP Units, Tanks And Piping
All gas heat units are shipped from the factory equipped for natural gas use only. The unit may be converted in the field for use with LP gas with accessory kit model number 1NP0442.
All LP gas equipment must conform to the safety standards of the National Fire Protection Association.
32 Johnson Controls Unitary Products
518674-YIM-E-1210
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.
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.
Check all connections for leaks when piping is completed using a soap solution. NEVER USE A FLAME. electric heaters are fused and intended for use with single point power supply.
Smoke Detectors
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.
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 configurations. Be aware that the supply air configuration has the sensor component mounted in the blower section, with its control module mounted in the return air compartment.
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.
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.
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
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.
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
Johnson Controls Unitary Products 33
518674-YIM-E-1210 the assembly. Field installed Motorized Outdoor Damper accessories include complete instructions for installation.
Economizer
The Economizer 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 the assembly.
Field installed Economizer accessories include complete instructions for installation.
There are two Economizer options:
1.
Down Flow application with barometric relief hood standard.
2.
Horizontal Flow application that requires the purchase of a barometric relief hood.
Power Exhaust
The Power Exhaust 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 the assembly.
Field installed Power Exhaust accessories include complete instructions for installation.
The Power Exhaust factory installed option is for Down Flow application only.
There are two field installed Power Exhaust accessories:
1.
Down Flow application.
2.
Horizontal Flow application that requires the purchase of a barometric relief hood.
Rain Hood
All of the hood components, including the filters, the gasketing and the hardware for assembling, are packaged and located between the condenser coil section and the main unit cabinet, if the unit has factory installed options. If field installed accessories are being installed all parts necessary for the installation comes in the accessory.
Optional Variable Air Volume (VAV)
A variable air volume (VAV) option using a variable frequency drive (VFD) is available for applications requiring a constant supply-duct static pressure. A differential pressure transducer is used to monitor supply duct static pressure and return a speed reference signal to the VFD to control the output of the indoor blower motor.
Duct Static Pressure Transducer
A 0-5" WC pressure transducer, located in the control box compartment, is used to sense static (gauge) pressure in the supply air duct and convert this pressure measurement to a proportional 0-5 VDC electrical output. Pressure-transmitting plastic tubing (1/4" diameter) must be field supplied and installed from the transducer to both the ductwork and to the atmosphere. Connect the tubing from the 'HIGH' pressure tap of the transducer to a static pressure tap (field supplied) in the supply duct located at a point where constant pressure is expected. To prevent an unstable signal due to air turbulence, there should be no obstructions, turns or VAV terminal boxes up- or down-stream of the sensing tube location for at least a distance of 6-10 times the duct diameter. Tubing must also be run between the 'LOW' pressure tap of the transducer and atmospheric pressure (outside of the unit).
Do not run plastic tubing in the supply or return air ducts as air movement could cause erroneous pressure measurements. If the tubing penetrates through the bottom of the unit be sure openings are sealed to prevent air and water leakage.
VAV Control Board
A VAV control board, located in the control box, is used to convert the pressure transducer input signal into a speed reference signal that the drive uses to control the speed of the blower motor. This modulating speed reference signal is generated using an algorithm which continuously calculates an output value.
A brief description of the VAV board's I/O terminals that are used follows;
Inputs:
• DUCT PRES - a 0-5 VDC analog input provided by a factory-installed duct static pressure transducer located in the unit's control box.
• SAT - analog input provided by a factory-installed 10kohm, type 3 thermistor located in the unit's supply air compartment.
• RAT - analog input provided by a factory-installed 10kohm, type 3 thermistor located in the unit's return air compartment.
• OAT - analog input provided by a factory-installed 10kohm, type 3 thermistor located in the unit’s compressor compartment within the base rail.
• ST - analog input provided by field-installed space temperature sensor.
• OH - a 0-10 VDC analog input provided by a field installed outdoor air relative humidity sensor for single enthalpy economizer configuration.
• RH - a 0-10 VDC analog input provided by a field-installed return air relative humidity sensor for dual enthalpy economizer configuration (used with OH).
• IAQ - a 0-10 VDC analog input provided by a fieldinstalled carbon dioxide sensor which monitors indoor air quality (CO2 concentration) and enables call for Demand
Ventilation mode for units installed with economizer option.
• OAQ - a 0-10 VDC analog input provided by a fieldinstalled carbon dioxide sensor which monitors outdoor air quality (CO
2
concentration) and, along with IAQ, enables
34 Johnson Controls Unitary Products
518674-YIM-E-1210 call for Differential Demand Ventilation mode for units installed with economizer option.
• APS - a 24 VAC binary input provided by a field-installed air proving switch which monitors the pressure difference across the indoor blower.
• PUR - a 24 VAC binary input for building purge calls from an external source.
• OCC - a 24 VAC binary input used to set the building occupancy status for the control.
• LIMIT 2 - a 24 VAC binary input which either confirms
2nd-stage gas heat operation or receives an error signal from the variable frequency drive.
Outputs:
• FAN - a 2-10 VDC analog output signal sent to the VFD to modulate the speed of the indoor blower motor.
• ECON - a 2-10 VDC analog output signal sent to the economizer actuator to modulate position of the return air and outdoor air dampers (optional).
• EXH ~ - a 24 VAC binary output signal used to turn on/off the power exhaust relay (optional).
• VAV BOX (gas/electric heat only) - a normally open relay contact connected to a terminal block, used to drive the building's VAV boxes to full-open during heating operation.
Programmable set points:
The duct static set point is the pressure that the drive will maintain when operating the unit in VAV mode. The set-point is adjustable between 0" WC and 5" WC with the default setting of
1.5" WC.
The duct static high-limit set point is the maximum allowable duct pressure to prevent damage from over-pressurization of the ductwork in the event of either a drive or damper failure.
The high-limit set-point is adjustable between 0" WC and 5" WC with the factory default setting of 4.5" WC. If the duct static pressure reaches the high-limit set point, then the supply fan motor will be shutdown.
NOTE: Either of the set points described above can be changed through the unit control board (UCB) with the use of a USB-to-RS485 converter, personal computer or PDA and a down-loaded copy of the Simplicity® software available at the UPGnet Commercial Product
Catalog website.
Factory-installed VFD
The factory-installed VFD is mounted in the blower access compartment. The drive comes wired from the factory to include both 3-phase power and control connections (run permit signal, speed reference signal & fault signal). All required drive parameters are pre-programmed at the factory, except in the case of 208-volt applications, in which the parameter that defines motor nameplate voltage must be changed to a value of
208.00 and the parameter that defines motor-rated current must be changed to the appropriate value appearing on the motor's nameplate. Refer to the enclosed drive material or access the
UPGnet Commercial Product Catalog website for instructions on changing parameter settings.
For units also equipped with gas/electric heat, a terminal block located in the unit's control box and connected to the VAV board's "VAV BOX" terminal, must be field wired to the building's VAV boxes to ensure fully open dampers during heating operation.
Manual Bypass
An optional, factory-installed manual bypass switch available with factory-installed VFD can be found in the Blower Motor
Access compartment and has the following three positions:
• DRIVE - routes power through the VFD for modulating control of the indoor blower motor.
• LINE (or BYPASS) - routes power directly to the motor which provides full-speed motor operation and complete electrical isolation of the drive.
• TEST - routes power to the VFD but not to the motor to allow for drive programming and/or diagnostics.
If a drive failure occurs, the unit does not automatically switch to bypass mode. The LINE/DRIVE/TEST switch must be manually switched to the LINE (BYPASS) position. If there is a call for the fan, the indoor blower motor will run at full-speed while in the bypass mode.
If the unit is operated with the manual bypass switch in the LINE (BYPASS) position and there are VAV boxes present in the duct system, then boxes must be driven to the full-open position using a customer-supplied power source to prevent over-pressurizing and possible damage to the ductwork.
The customer must be aware of the duct pressure design limit, and what the duct pressure sensor is reading when the peak pressure is reached (i.e. the pressure transducer sensing tube may not be located at the place of highest pressure in the system).
Before beginning any service, disconnect all power to the drive. Be aware that high voltages are present in the drive even after power has been disconnected.
Capacitors within the drive must be allowed to discharge before beginning service.
Johnson Controls Unitary Products 35
518674-YIM-E-1210
Bas-ready VFD
Factory-installed VFD is also available with 'BAS-Ready' models. Terminal blocks are provided in the control box (in place of the VAV control board) for field wiring of a customerinstalled BAS to receive 24 VAC power and to connect to the following control signals:
• a duct static pressure transducer input signal (0-5 VDC)
• an economizer actuator input signal (2-10 VDC)
• an economizer actuator output signal (2-10 VDC)
• a VFD speed reference output signal (2-10 VDC)
The use of shielded cable is recommended for the above control wiring connections.
NOTE: Factory-installed VFD is not available with factoryinstalled BAS options due to space limitations in the control box.
A solid-state, lock-out relay (LR) and 100 microfarad, 50 VDC capacitor must be field-supplied and installed to provide a means to transmit a potential fault signal back to the BAS controller. The specific relay part number required will depend upon the need for either AC-output or DC-output. See price pages for further details.
Once the appropriate relay and capacitor are obtained, install the capacitor across LR terminals '3' & '4' and make the following wiring connections:
• LR '1' to BAS controller
• LR '2' to BAS controller
• LR '3' to UCB 'X'
• LR '4' to UCB 'C'
'VFD-ready' For Customer-installation
Units configured as 'VFD-ready' provide provisions for a customer-installed drive. The physical dimensions of VFDs can vary greatly among manufacturers, horsepower ratings and voltage requirements. Keep in mind that drive manufacturers also require various minimum clearances to allow for adequate internal cooling of the drive during operation.
The unit comes with a mounting bracket installed in the Blower
Access compartment which may accommodate other vendor's drives depending on their size. In order to utilize the unit's mounting bracket, the maximum recommended drive dimensions are limited to approximately 9" H x 5" W x 7.5" D.
If the drive will not fit in the allotted space, then it will need to be mounted elsewhere; either within the building on a perpendicular wall which is not subjected to excessive temperature, vibration, humidity, dust, corrosive gas, explosive gas, etc., or within an appropriate enclosure rated for outside installation to safeguard against moisture, dust and excessive heat.
The power leads to the drive (L1, L2, L3) and from the motor
(T1, T2, T3) have been temporarily spliced together with wire nuts. After removing the wire nuts, connect the wires to the field-installed VFD per the VFD wiring diagram (See Figure 27).
The VFD should also be grounded per the manufacturer's specifications.
TB1
L1 720 / PR
L2 723 / BR
L3 726 / O
FU3
FU4
FU5
722 / BK
725 / BR
728 / Y
ELEMENTARY DIAGRAM
(L1)
(L2)
(L3)
VFD
(T1)
(T2)
(T3)
GND
( ) GRN
118 / BK
119 / BR
120 / Y
GND
T1
1 DMTR
M
T2 3
T3
GRN
GND
SPEED REF
(ANALOG)
(2-10 VDC)
1 2 3 4
RUN PERMIT
(DIGITAL)
5 6
TB8 (IN CONTROL BOX)
Figure 27: Simplified VFD Wiring
Do not connect AC power to the T1, T2, T3 drive terminals to prevent damage to the VFD.
The fuses (FU3, FU4, FU5) supplied with the unit are sized according to the electrical load of the blower motor, but may not provide adequate protection to the customer-installed drive, depending upon its specifications. Once a drive has been selected and installed, refer to the drive manufacturer's recommendations for proper fuse sizing.
A terminal block located in the control box is provided for field connection of the VFD speed reference signal (2-10 VDC) and to the normally-open, run-permit auxiliary contact. The use of shielded cable is recommended for the above control wiring connections. For VFD-ready units also equipped with gas/ electric heat, a terminal block located in the unit's control box and connected to the VAV board's "VAV BOX" terminal, must be field wired to the building's VAV boxes to ensure fully open dampers during heating operation.
Optional Hot Gas Bypass (HGBP)
To allow for low cooling load operation, a direct-acting, pressure-modulating bypass control valve installed on the system #1 discharge line is used to divert high temperature, high pressure refrigerant around the TXV in order to maintain a desired minimum evaporator pressure.
The opening pressure of the bypass valve is adjustable between 95 and 115 psig with a factory-setting of 105 psig.
36 Johnson Controls Unitary Products
518674-YIM-E-1210
HGBP is standard on all units with VAV and optional with CV units.
Standard Economizer And Power Exhaust Set Point
Adjustments
(Not applicable for VFD or INTELLI-Comfort™ options.)
Remove the top rear access panel from the unit. Locate the economizer control module, where the following adjustments will be made.
Extreme care must be exercised in turning all set point, maximum and minimum damper positioning adjustment screws to prevent twisting them off.
Minimum Position Adjustment
• Check that the damper blades move smoothly without binding; carefully turn the Minimum Position Adjust screw
(found on the damper control module) fully clockwise and then set the thermostat indoor fan switch to the ON position and then OFF or energize and de-energize terminals “R” to “G”.
• With the thermostat set to the indoor fan ON position or terminals “R” to “G” energized, turn the Minimum Position
Adjusting screw (located on the damper control module) counterclockwise until the desired minimum damper position has been attained.
Enthalpy Set Point Adjustment
• The enthalpy set point may now be set by selecting the desired set point shown in the Enthalpy Set Point
Adjustment Figure 28. Adjust as follows:
• For a single enthalpy operation carefully turn the set point adjusting screw (found on the damper control module) to the "A", "B", "C" or "D" setting corresponding to the lettered
curve of the Enthalpy Set Point Adjustment Figure 29.
• For a dual enthalpy operation, carefully turn the set point adjusting screw fully clockwise past the "D" setting.
Power Exhaust Damper Set Point (With Or Without Power
Exhaust)
• With no power exhaust option, adjust the Exhaust Air
Adjustment Screw fully clockwise. This will allow 2nd stage cooling to operate.
• With power exhaust option, each building pressurization requirement will be different. The point at which the power exhaust comes on is determined by the economizer damper position (Percent Open). The Exhaust Air
Adjustment Screw should be set at the Percent Open of the economizer damper at which the power exhaust is needed. It can be set from 0 to 100% damper open.
Indoor Air Quality AQ
Indoor Air Quality (indoor sensor input): Terminal AQ accepts a
+2 to +10 Vdc signal with respect to the (AQ1) terminal. When the signal is below it's set point, the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs. When the AQ signal exceeds it's set point setting and there is no call for free cooling, the actuator is proportionately modulated from the 2 to 10 Vdc signal, with 2
Vdc corresponding to full closed and 10 Vdc corresponding to full open. When there is no call for free cooling, the damper position is limited by the IAQ Max damper position setting.
When the signal exceeds it's set point (Demand Control
Ventilation Set Point) setting and there is a call for free cooling, the actuator modulates from the minimum position to the full open position based on the highest call from either the mixed air sensor input or the AQ voltage input.
• Optional CO
2
Space Sensor Kit Part # 2AQ04700324
• Optional CO
2
Sensor Kit Part # 2AQ04700424
Replace the top rear access panel on the unit.
Johnson Controls Unitary Products 37
518674-YIM-E-1210
CONTROL
CURVE
CONTROL POINT
APPROX. 0 F ( 0 C)
AT 50% RH
A
B
C
D
73 (23)
70 (21)
67 (19)
63 (17)
35
(2)
55
(13)
60
(16)
A
65
(18)
40
(4)
45
(7)
50
(10)
D
C
B
70
(21)
75
(24)
80
(27)
85
(29)
90
(32)
95
(35)
100
(38)
105
(41)
110
(43)
D
C B
A
35
(2)
40
(4)
45
(7)
50
(10)
55
(13)
60
(16)
65
(18)
70
(21)
75
(24)
80
(27)
85
(29)
90
(32)
95
(35)
100
(38)
105
(41)
110
(43)
APPROXIMATE DRY BULB TEMPERATURE 0 F ( 0 C)
Figure 28: Enthalpy Set Point Chart
Exhaust Air
Adjustment
Screw
Exhaust Air LED
Damper Min.
Position
Screw
Indoor Air Quality
Max. Adjustment
Screw
N1 N
P1 P
T1 T
EXH
Set
EXH
Min
Pos
TR
24
Vac
HOT
TR1
24
Vac
COM
+
Indoor Air Quality
LED
AQ1 AQ
Indoor Air Quality
Min. Adjustment
Screw
SO+ SO
Free Cooling LED
Economizer Enthalpy
Set Point Adjustment
Screw
Figure 29: Honeywell Economizer Control W7212
SR+ SR
B
A
Phasing
Predator
®
units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the phasing of the Field Line
IAQ
Max
IAQ
IAQ
Min
Free
Cool
C
D
1
3
EF
2
5
4
EF1
Connection at the factory or field supplied disconnect to obtain proper rotation. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or producing a high noise level, the scroll is misphased.)
38 Johnson Controls Unitary Products
518674-YIM-E-1210
Scroll compressors require proper rotation to operate correctly. Units are properly phased at the factory. Do not change the internal wiring to make the blower condenser fans, or compressor rotate correctly.
Blower Rotation
Check for proper supply air blower rotation. If the blower is rotating backwards, the line voltage at the unit point of power connection is misphased (See ‘PHASING’).
Table 13: Supply Air Limitations
Unit Size (Ton)
078 (6.5)
090 (7.5)
102 (8.5)
120 (10)
150 (12.5)
Minimum
1950
2250
2550
3000
3750
Maximum
3250
3750
4250
5000
6250
Belt Tension
The tension on the belt should be adjusted as shown in Figure 30.
A
A
C*
* NEVER LOOSEN
A
Procedure for 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 span as shown. Deflection distance of 4mm (5/32”) is obtained.
To determine the deflection distance from normal position, use a straight edge from sheave to sheave as reference line. The recommended deflection force is as follows:
Tension new belts at the max. deflection force recommended for the belt section. Check the belt tension at least two times during the first 24 hours of operation. Any retensioning should fall between the min. and max. deflection force values.
5. After adjusting retighten nuts (A).
CFM Static Pressure and Power-Altitude and Temperature
Corrections
The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level.
The air flow rates listed in the standard blower performance tables are based on standard air at sea level. As the altitude or temperature increases, the density of air decreases. In order to use the indoor blower tables for high altitude applications, certain corrections are necessary.
A centrifugal fan is a "constant volume" device. This means that, if the rpm remains constant, the CFM delivered is the same regardless of the density of the air. However, since 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
B
SPAN LENGTH
DEFL. FORCE
Figure 30: Belt Adjustment
Johnson Controls Unitary Products 39
518674-YIM-E-1210
Table 14: Altitude/Temperature Correction Factors
Air
Temp.
40
50
60
70
80
90
100
0
1.060
1.039
1.019
1.000
0.982
0.964
0.946
1000
1.022
1.002
0.982
0.964
0.947
0.929
0.912
2000
0.986
0.966
0.948
0.930
0.913
0.897
0.880
3000
0.950
0.931
0.913
0.896
0.880
0.864
0.848
4000
0.916
0.898
0.880
0.864
0.848
0.833
0.817
Altitude (Ft.)
5000
0.882
0.864
0.848
0.832
0.817
0.802
0.787
6000
0.849
0.832
0.816
0.801
0.787
0.772
0.758
7000
0.818
0.802
0.787
0.772
0.758
0.744
0.730
8000
0.788
0.772
0.757
0.743
0.730
0.716
0.703
9000
0.758
0.743
0.729
0.715
0.702
0.689
0.676
10000
0.729
0.715
0.701
0.688
0.676
0.663
0.651
1.100
1.050
1.000
0.950
0.900
0.850
0.800
0.750
0.700
0.650
0.600
Sea Level
1000 ft
2000 ft
3000 ft
4000 ft
5000 ft
6000 ft
7000 ft
8000 ft
9000 ft
10000 ft
40 50 60 70 80
Air Temperature (ºF)
90 100
Figure 31: Altitude/Temperature Correction Factors
The examples below will assist in determining the airflow performance of the product at altitude.
Example 1: What are the corrected CFM, static pressure, and
BHP at an elevation of 5,000 ft. if the blower performance data is 6,000 CFM, 1.5 IWC and 4.0 BHP?
Solution: At an elevation of 5,000 ft. the indoor blower will still
deliver 6,000 CFM if the rpm is unchanged. However, Table 13
must be used to determine the static pressure and BHP. Since no temperature data is given, we will assume an air temperature
of 70°F. Table 15 shows the correction factor to be 0.832.
Corrected static pressure = 1.5 x 0.832 = 1.248 IWC
Corrected BHP = 4.0 x 0.832 = 3.328
Example 2: A system, located at 5,000 feet of elevation, is to deliver 6,000 CFM at a static pressure of 1.5". Use the unit blower tables to select the blower speed and the BHP requirement.
Solution: As in the example above, no temperature information is given so 70°F is assumed.
The 1.5" static pressure given is at an elevation of 5,000 ft. The first step is to convert this static pressure to equivalent sea level conditions.
Sea level static pressure = 1.5 / .832 = 1.80"
Enter the blower table at 6000 sCFM and static pressure of
1.8". The rpm listed will be the same rpm needed at 5,000 ft.
Suppose that the corresponding BHP listed in the table is 3.2.
This value must be corrected for elevation.
BHP at 5,000 ft. = 3.2 x .832 = 2.66
40 Johnson Controls Unitary Products
518674-YIM-E-1210
Drive Selection
1.
Determine side or bottom supply duct Application.
2.
Determine desired airflow.
3.
Calculate or measure the amount of external static pressure.
4.
Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table. (Linear interpolation may be necessary.)
5.
Noting the RPM and BHP from step 4, locate the appropriate motor and, or drive on the RPM selection table.
6.
Review the BHP compared to the motor options available. Select the appropriate motor and, or drive.
7.
Review the RPM range for the motor options available. Select the appropriate drive if multiple drives are available for the chosen motor.
8.
Determine turns open to obtain the desired operation point.
Example
1.
2600 CFM
2.
1.6 iwg
3.
Using the supply air blower performance table below, the following data point was located: 1268 RPM & 1.95 BHP.
4.
Using the RPM selection table below, Size X and Model Y is found.
5.
1.95 BHP exceeds the maximum continuous BHP rating of the 1.5 HP motor. The 2 HP motor is required.
6.
1268 RPM is within the range of the 2 HP drives.
7.
Using the 2 HP motor and drive, .5 turns open will achieve 1268 RPM.
Airflow Performance
Example Supply Air Blower Performance
Air Flow
(CFM)
2200
2400
2600
2800
804 0.50
835 0.66
869 0.84
906 1.03
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 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
1.5 HP & Field Supplied Drive
866 0.71
925 0.90
982
897 0.87
931 1.05
956
990
1.06
1.24
1013
1047
1.06
1.22
1.40
1038
1069
1103
Standard 1.5 HP & Drive
1.21
1.37
1.55
1092
1124
1158
1.35
1.51
1.69
1147
1178
1212
1.48
1.64
1.82
1203
1234
1268
Alternate 2 HP & Drive
1.61
1.77
1.95
1259
1290
1324
1.73
1.90
2.07
968 1.25
1027 1.43
1084 1.60
1139 1.75
1194 1.89
1249 2.02
1304 2.14
1361 2.27
1317
1348
1382
-
1.87
2.03
2.21
-
Table X: RPM Selection
Size
(Tons)
X
Model
Y
HP
1.5
2
Max
BHP
1.73
2.30
Motor
Sheave
1VM50
1VM50
Blower
Sheave
AK74
AK64
6 Turns
Open
N/A
N/A
5 Turns
Open
897
1039
4 Turns
Open
945
1094
3 Turns
Open
991
1150
2 Turns
Open
1035
1207
1 Turn
Open
1079
1256
Fully
Closed
1126
1308
Johnson Controls Unitary Products 41
518674-YIM-E-1210
Table 15: Airflow Performance - Side Duct Application
1800
2000
2200
2400
2600
2800
3000
3200
3400
ZF078 (6.5 Ton) Side Duct
Air Flow
(CFM)
Available External Static Pressure - IWG
1
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
751 0.22
Field Supplied Drive
813 0.43
776
804
835
0.35
0.50
0.66
838
866
897
0.56
0.71
0.87
872 0.62
929 0.78
Standard 1.5 HP & Drive
985 0.93
1040 1.07
1095 1.20
1150
Hi Static 2 HP & Drive
1.33
1206 1.46
1265 1.59
0.92
1010 1.07
1064 1.20
1119 1.33
1175 1.46
1231 1.59
1289 1.72
897 0.75
954
925 0.90
982 1.06
1038 1.21
1092 1.35
1147 1.48
1203 1.61
1259 1.73
1317 1.87
956 1.06
1013 1.22
1069 1.37
1124 1.51
1178 1.64
1234 1.77
1290 1.90
1348 2.03
869 0.84
906 1.03
931
968
1.05
1.25
990
1027
1.24
1.43
1047
1084
1.40
1.60
1103
1139
1.55
1.75
1158
1194
1.69
1.89
1212
1249
1.82
2.02
1268
1304
1.95
2.14
1324
1361
2.07
2.27
1382
-
2.21
-
945 1.25
1007 1.46
1066 1.65
1123 1.81
1179 1.96
1234 2.10
1288 2.23
987 1.48
1048 1.69
1107 1.88
1165 2.04
1220 2.19
-
1030 1.73
1092 1.94
1151 2.12
1208 2.29
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2 HP & Field Supplied Drive
-
-
-
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.
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
ZF090 (7.5 Ton) Side Duct
Air Flow
(CFM)
Available External Static Pressure - IWG
1
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
776 0.35
804 0.50
835 0.66
869
906
Field Supplied Drive
0.84
1.03
838
866
897
0.56
0.71
0.87
897 0.75
954
925 0.90
982
Standard 1.5 HP & Drive
0.92
1010 1.07
1064 1.20
1119 1.33
1175
Hi Static 3 HP & Drive
1.46
1231 1.59
1289 1.72
1.06
1038 1.21
1092 1.35
1147 1.48
1203 1.61
1259 1.73
1317 1.87
956 1.06
1013 1.22
1069 1.37
1124 1.51
1178 1.64
1234 1.77
1290 1.90
1348 2.03
931 1.05
990 1.24
1047 1.40
1103 1.55
1158 1.69
1212 1.82
1268 1.95
1324 2.07
1382 2.21
968 1.25
1027 1.43
1084 1.60
1139 1.75
1194 1.89
1249 2.02
1304 2.14
1361 2.27
1419 2.40
945 1.25
1007 1.46
1066 1.65
1123 1.81
1179 1.96
1234 2.10
1288 2.23
1344 2.36
1400 2.48
1458 2.62
987 1.48
1048 1.69
1107 1.88
1165 2.04
1220 2.19
1275 2.33
1330 2.46
1385 2.59
1442 2.71
1500 2.85
1030 1.73
1092 1.94
1151 2.12
1208 2.29
1264 2.44
1319 2.58
1374 2.71
1429 2.84
1485 2.96
1544 3.10
1076 1.99
1138 2.20
1197 2.39
1254 2.56
1310 2.71
1364 2.84
1419 2.97
1475 3.10
1531 3.23
1589 3.36
1124 2.27
1185 2.48
1245 2.67
1302 2.84
1357 2.99
1412 3.12
1467 3.25
1522 3.38
-
3 HP & Field Supplied Drive
-
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.
2600
2800
3000
3200
3400
3600
3800
4000
4200
ZF102 (8.5 Ton) Side Duct
Air Flow
(CFM)
Field Supplied Drive
628 0.56
678 0.76
648 0.67
666 0.80
698
717
0.87
1.00
684 0.95
702 1.11
721 1.28
742 1.47
765 1.67
789 1.87
735
753
772
793
815
840
1.15
1.31
1.48
1.67
1.86
2.07
Available External Static Pressure - IWG
1
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
730 0.93
781
750
768
786
804
824
844
867
1.04
1.17
1.32
1.48
1.65
1.84
2.04
Standard 2 HP & Drive
801
820
838
856
875
896
918
1.09
1.20
1.33
1.48
1.64
1.81
2.00
2.19
833
853
871
889
907
927
947
970
1.25
1.36
1.49
1.63
1.79
1.97
2.15
883
903
922
940
958
977
998
1.41
1.52
1.65
1.80
1.96
2.13
933 1.59
Hi Static 3 HP & Drive
980 1.80
1025 2.05
1068 2.35
953 1.70
1000 1.91
1046 2.16
1088 2.46
971
989
1007
1027
1.83
1.98
2.14
2.31
1019
1037
1055
1074
2.04
2.19
2.35
2.52
2.32
1047 2.50
1095 2.71
1140 2.96
2.35
1020 2.51
1070 2.70
1117 2.91
1064
1082
1100
1119
---
2.29
2.44
2.60
2.77
---
1106
1124
1142
---
---
---
2.59
2.74
2.90
---
---
---
891 2.24
943 2.40
995 2.56
1045 2.72
1094 2.90
-----------
3 HP & Field Supplied Drive
---
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.
42 Johnson Controls Unitary Products
518674-YIM-E-1210
3800
4000
4200
4400
4600
4800
5000
2600
2800
3000
3200
3400
3600
ZF120 (10 Ton) Side Duct
Air Flow
(CFM)
0.2
0.4
0.6
Available External Static Pressure - IWG
1
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
Field Supplied Drive Standard 2 HP & Drive Hi Static 3 HP & Drive
675 0.53
686 0.63
699 0.75
713 0.88
728 1.02
745 1.18
763 1.36
783 1.55
805 1.77
828 2.00
852 2.25
879 2.52
906 2.81
726 0.74
738 0.84
750 0.96
764 1.09
779 1.23
796 1.39
776 0.94
824
787 1.04
835
800 1.16
847
814 1.28
861
829 1.43
877
846 1.59
893
1.12
1.23
1.34
1.47
1.61
1.77
870
881
893
907
923
939
1.30
1.41
1.52
1.65
1.79
1.95
914
925
938
952
967
984
1.48
1.58
1.70
957 1.65
1000 1.82
1041 1.99
1082 2.17
969 1.76
1011 1.93
1052 2.10
1093 2.27
981 1.87
1024 2.04
1065 2.21
1106 2.39
1.83
995 2.00
1037 2.17
1079 2.34
1119 2.52
1.97
1010 2.14
1053 2.31
1094 2.48
1135 2.66
2.13
1027 2.30
1069 2.47
1111 2.64
1152 2.82
815 1.57
835 1.76
856 1.98
879 2.21
904 2.46
930 2.73
864
884
906
929
953
980
1.76
1.96
2.17
2.41
2.66
2.93
912
932
953
976
1001
1027
1.95
2.15
2.36
2.59
2.85
3.12
958 3.02
1007 3.22
1055 3.41
958
978
999
1022
1047
1073
-
2.13
2.33
2.54
2.77
3.03
3.30
-
1002
1022
1044
1067
1092
-
-
2.31
2.50
2.72
2.95
3.20
-
-
1046
1066
1087
1110
1135
-
-
2.48
2.67
2.89
3.12
3.37
-
-
1088
1108
1129
1152
-
-
-
2.65
2.84
3.06
3.29
-
-
-
1129
1149
1171
-
-
-
-
3 HP & Field Supplied Drive
2.82
3.02
3.23
-
-
-
-
1170
1190
1211
-
-
-
-
3.00
3.19
3.41
-
-
-
-
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.
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
6000
6200
ZF150 (12.5 Ton) Side Duct
Air Flow
(CFM)
0.2
0.4
0.6
Available External Static Pressure - IWG
1
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
684 1.00
709 1.15
734 1.30
761 1.48
789 1.66
3 HP & Field Supplied Drive
741 1.16
794 1.32
844
765 1.30
818 1.46
868
791 1.46
818 1.63
846 1.82
844
871
899
1.62
1.79
1.98
894
921
949
1.48
1.62
1.78
1.95
2.14
892
916
942
969
997
1.65
1.79
940
964
Standard 3 HP & Drive
1.81
988 1.97
1036 2.12
1087 2.27
1141 2.42
1.95
1012 2.11
1061 2.26
1112 2.42
1166 2.56
1.94
990 2.10
1038 2.26
1087 2.42
1137 2.57
1191 2.72
2.12
1017 2.28
1065 2.44
1114 2.59
1164 2.75
1218 2.89
2.31
1045 2.47
1093 2.63
1142 2.78
1192 2.93
1246 3.08
818 1.87
847 2.09
877 2.33
875 2.03
904 2.25
934 2.49
928 2.19
978 2.35
1026 2.51
1074 2.67
1121 2.83
1170 2.99
1221 3.14
1275 3.29
957 2.41
1007 2.57
1055 2.73
1103 2.90
1151 3.06
1199 3.21
1250 3.36
1304 3.51
986 2.65
1036 2.81
1085 2.97
1132 3.14
1180 3.29
1229 3.45
1280 3.60
1334 3.75
907 2.59
937 2.86
963
993
2.75
3.02
1016
1046
2.91
3.18
1066
1096
3.07
3.34
1115
1145
3.23
3.50
1162
1192
3.39
3.66
1210
1240
3.55
3.82
1259
1289
3.71
3.98
1310
1340
3.86
4.13
1364
1394
4.01
4.28
967 3.15
1023 3.31
1076 3.47
1126 3.63
1175 3.79
1222 3.95
1270 4.11
1319 4.27
1370 4.42
1424 4.57
997 3.45
1053 3.61
1106 3.77
1156 3.93
1205 4.09
1252 4.26
1300 4.41
1349 4.57
1400 4.72
1454 4.87
1027 3.77
1083 3.93
1136 4.09
1186 4.25
1235 4.41
1282 4.57
1330 4.73
1379 4.89
1430 5.04
1484 5.19
1057 4.11
1113 4.26
1166 4.42
1216 4.59
1264 4.75
1312 4.91
1360 5.07
1409 5.22
-
1086 4.46
1143 4.61
1196 4.77
1246 4.93
1294 5.10
1342 5.26
1116 4.82
1172 4.98
1225 5.14
Hi Static 5 HP & Drive
1275 5.30
-
-
-
-
-
-
-
5 HP & Field Supplied Drive
-
-
-
-
-
-
-
-
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.
Johnson Controls Unitary Products 43
518674-YIM-E-1210
Table 16: Airflow Performance - Bottom Duct Application
1800
2000
2200
2400
2600
2800
3000
3200
3400
ZF078 (6.5 Ton) Bottom Duct
Air Flow
(CFM)
Available External Static Pressure - IWG
1
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
Field Supplied Drive
775 0.31
850 0.53
803 0.45
838 0.60
878
913
0.67
0.82
Standard 1.5 HP & Drive
924 0.72
998 0.89
1072 1.05
1147
Hi Static 2 HP & Drive
1.20
1224 1.35
1303 1.51
1384 1.69
1469 1.89
952 0.86
1026 1.03
1100 1.19
1175 1.34
1252 1.49
1331 1.65
1412 1.83
1497 2.03
986 1.01
1060 1.19
1134 1.34
1210 1.49
1286 1.65
1365 1.81
1447 1.98
1532 2.18
878 0.78
923 0.98
953 1.00
1027 1.19
1100 1.36
1174 1.52
1250 1.67
1327 1.82
1405 1.98
1487 2.16
997 1.20
1071 1.39
1145 1.56
1219 1.72
1294 1.87
1371 2.02
1450 2.18
-
971 1.20
1046 1.42
1119 1.61
1193 1.78
1267 1.94
1343 2.09
1419 2.24
1023 1.44
1097 1.66
1171 1.85
1245 2.03
1319 2.18
-
-
-
-
-
-
-
-
-
1077 1.71
1151 1.93
1225 2.12
1299 2.29
1133 1.99
1208 2.21
-
-
-
-
-
-
-
-
-
-
-
-
-
2 HP & Field Supplied Drive
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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.
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
ZF090 (7.5 Ton) Bottom Duct
Air Flow
(CFM)
Available External Static Pressure - IWG
1
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
Field Supplied Drive
803 0.45
878 0.67
838 0.60
878 0.78
913 0.82
952
Standard 1.5 HP & Drive
0.86
1026 1.03
1100 1.19
1175
Hi Static 3 HP & Drive
1.34
1252 1.49
1331 1.65
1412 1.83
1497 2.03
986 1.01
1060 1.19
1134 1.34
1210 1.49
1286 1.65
1365 1.81
1447 1.98
1532 2.18
953 1.00
1027 1.19
1100 1.36
1174 1.52
1250 1.67
1327 1.82
1405 1.98
1487 2.16
1572 2.36
923 0.98
997 1.20
1071 1.39
1145 1.56
1219 1.72
1294 1.87
1371 2.02
1450 2.18
1532 2.36
1617 2.56
971 1.20
1046 1.42
1119 1.61
1193 1.78
1267 1.94
1343 2.09
1419 2.24
1498 2.40
1580 2.58
1665 2.78
1023 1.44
1097 1.66
1171 1.85
1245 2.03
1319 2.18
1394 2.33
1471 2.49
1550 2.65
1632 2.82
1717 3.02
1077 1.71
1151 1.93
1225 2.12
1299 2.29
1373 2.45
1448 2.60
1525 2.75
1604 2.91
1686 3.09
1771 3.29
1133 1.99
1208 2.21
1282 2.41
1356 2.58
1430 2.73
1505 2.88
1582 3.04
1661 3.20
1742 3.37
1192 2.30
1267 2.52
1341 2.71
1414 2.88
1489 3.04
1564 3.19
1641 3.34
-
1253 2.63
1327 2.85
1401 3.04
1475 3.21
1549 3.37
-
3 HP & Field Supplied Drive
-
-
-
-
-
-
-
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.
2600
2800
3000
3200
3400
3600
3800
4000
4200
ZF102 (8.5 Ton) Bottom Duct
Air Flow
(CFM)
Available External Static Pressure - IWG
1
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 2 HP & Drive Hi Static 3 HP & Drive
674 0.71
689 0.86
707 1.01
728 1.17
751 1.34
776 1.53
804 1.74
835 1.97
867 2.21
731 0.88
746 1.02
764 1.17
785 1.33
808 1.51
833 1.70
861 1.90
892 2.13
924 2.37
786 1.05
838
801 1.20
854
819 1.35
872
840 1.51
892
1.24
1.38
1.53
1.69
887
903
921
941
1.42
1.56
1.71
1.87
933
948
966
987
1.59
1.73
974 1.74
1010 1.87
1040 1.97
1064 2.03
989 1.88
1025 2.01
1056 2.11
1080 2.17
1.88
1007 2.03
1043 2.16
1074 2.26
1098 2.32
2.04
1028 2.20
1064 2.33
1094 2.42
1118 2.48
863 1.68
915
888 1.87
941
916 2.08
969
947 2.31
999
979
1.87
2.06
2.26
2.49
964
990
1018
1048
2.05
2.24
2.44
2.67
1010
1035
1063
1094
2.22
2.41
2.61
2.84
2.55
1032 2.73
1081 2.91
1127 3.08
1051
1076
1104
1135
---
2.37
2.56
2.77
2.99
---
1087
1112
1140
---
---
2.50
2.69
2.90
---
---
1117
1142
1170
---
---
2.60
2.79
2.99
---
---
3 HP & Field Supplied Drive
1141
1167
1194
---
---
2.66
2.85
---
---
---
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
44 Johnson Controls Unitary Products
518674-YIM-E-1210
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
ZF120 (10 Ton) Bottom Duct
Air Flow
(CFM)
0.2
0.4
0.6
Available External Static Pressure - IWG
1
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
Field Supplied Drive Standard 2 HP & Drive Hi Static 3 HP & Drive
722 0.83
744 0.97
769 1.13
797 1.32
828 1.52
861 1.75
776 0.97
798 1.12
823 1.28
851 1.46
882 1.67
915 1.90
828 1.11
878
850 1.26
900
875 1.42
925
1.25
1.39
1.55
926
949
974
1.37
1.52
973
995
1.50
1.64
1018
1041
1.62
1.76
1063
1085
1.74
1.88
1106
1128
1.86
2.00
1149
1171
1.99
2.13
1.68
1020 1.80
1066 1.92
1110 2.05
1153 2.17
1196 2.29
903 1.60
953
934 1.81
983
1.74
1.94
1001
1032
1.86
2.07
1048
1078
1.99
2.19
1093
1124
2.11
2.32
1138
1168
2.23
2.44
1181
1212
2.35
2.56
1224
1254
2.48
2.68
967 2.04
1017 2.17
1065 2.30
1112 2.42
1157 2.54
1201 2.67
1245 2.79
1287 2.91
897 2.00
935 2.27
951
989
2.15
2.42
1002
1041
2.29
2.56
1052
1091
2.42
2.69
1101
1139
2.55
2.82
1147
1186
2.67
2.95
1193
1231
2.80
3.07
976 2.57
1030 2.72
1082 2.86
1132 2.99
1180 3.12
1227 3.24
1272 3.36
1237
1275
-
2.92
3.19
-
1280
1319
-
3.04
3.31
-
1323
1362
-
3.16
3.43
-
1019 2.88
1073 3.03
1125 3.17
1175 3.30
1223 3.43
1065 3.22
1119 3.36
-
-
-
-
-
3 HP & Field Supplied Drive
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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.
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
ZF150 (12.5 Ton) Bottom Duct
Air Flow
(CFM)
0.2
0.4
0.6
Available External Static Pressure - IWG
1
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
3 HP & Field Supplied Drive
823 1.28
861 1.47
906 1.64
955
Standard 3 HP & Drive Hi Static 5 HP & Drive
1.80
1007 1.95
1059 2.12
1109 2.29
1155 2.50
1194 2.73
1225 3.01
860 1.48
898 1.71
936 1.97
898 1.67
935 1.90
942
980
1.84
2.07
992
1030
2.00
2.23
1044
1081
2.16
2.39
1095
1133
2.32
2.55
1145
1183
2.50
2.73
1191
1229
2.70
2.94
1231
1269
2.94
3.17
1262
1300
3.22
3.45
974 2.16
1019 2.33
1068 2.49
1120 2.64
1172 2.81
1222 2.98
1267 3.19
1307 3.42
1338 3.70
975 2.24
1013 2.43
1057 2.60
1107 2.76
1158 2.92
1210 3.08
1260 3.26
1306 3.46
1346 3.70
1377 3.97
1014 2.54
1052 2.73
1096 2.90
1146 3.05
1197 3.21
1249 3.38
1299 3.55
1345 3.76
1385 3.99
1416 4.27
1053 2.85
1091 3.04
1135 3.21
1185 3.37
1236 3.53
1288 3.69
1338 3.87
1384 4.07
1424 4.31
1455 4.58
1091 3.19
1129 3.38
1174 3.55
1223 3.71
1275 3.86
1327 4.03
1377 4.20
1423 4.41
1462 4.64
1494 4.92
1130 3.54
1168 3.73
1213 3.90
1262 4.06
1314 4.22
1365 4.38
1415 4.56
1461 4.76
1501 5.00
1532 5.27
1168 3.92
1206 4.11
1251 4.28
1300 4.44
1352 4.59
1404 4.76
1454 4.94
1500 5.14
1539 5.37
-
1206 4.31
1244 4.50
1288 4.67
1338 4.83
1389 4.99
1441 5.15
1491 5.33
1537 5.53
1243 4.72
1281 4.91
1326 5.08
1375 5.24
1427 5.40
1479 5.56
-
1280 5.15
1318 5.34
1362 5.51
-
1316 5.60
-
5 HP & Field Supplied Drive
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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.
Table 17: RPM Selection
Size
(Tons)
078
(6.5)
090
(7.5)
102
(8.5)
120
(10)
150
(12.5)
Model
ZF
ZF
ZF
ZF
ZF
HP
3
2
3
2
1.5
2
1.5
3
3
5
Max
BHP
1.73
2.30
1.73
3.45
2.30
3.45
2.30
3.45
3.45
5.75
Motor
Sheave
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VP56
Blower
Sheave
AK74
AK64
AK74
AK61
AK94
AK74
AK84
AK74
AK74
BK77
6 Turns
Open
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1052
5 Turns
Open
887
1039
887
1088
690
887
776
887
887
1095
4 Turns
Open
936
1094
936
1147
728
936
819
936
936
1136
3 Turns
Open
986
1150
986
1205
767
986
863
986
986
1175
2 Turns
Open
1035
1207
1035
1265
805
1035
906
1035
1035
1216
1 Turn
Open
1084
1256
1084
1312
843
1084
949
1084
1084
1272
Fully
Closed
1134
1308
1134
1365
882
1134
992
1134
1134
N/A
Johnson Controls Unitary Products 45
518674-YIM-E-1210
Size
(Tons)
078
(6.5)
090
(7.5)
102
(8.5)
120
(10)
150
(12.5)
Table 18: Indoor Blower Specifications
Model
ZF
ZF
ZF
ZF
ZF
HP RPM
Motor
Eff.
SF
1-1/2 1725 0.8
1.15
2 1725 0.8
1.15
1-1/2 1725 0.8
1.15
3
2
1725
1725
0.8
0.8
1.15
1.15
3
2
1725 0.8
1.15
1725 0.8
1.15
3
3
5
1725 0.8
1.15
1725 0.8
1.15
1725 0.87
1.15
Frame
56
56
56
56
56
56
56
56
56
184T
Motor Sheave
Datum Dia.
(in.)
3.4 - 4.4
3.4 - 4.4
3.4 - 4.4
Bore (in.)
7/8
7/8
Model
1VM50
1VM50
3.4 - 4.4
3.4 - 4.4
7/8
7/8
7/8
1VM50
1VM50
1VM50
3.4 - 4.4
3.4 - 4.4
3.4 - 4.4
3.4 - 4.4
4.3 - 5.3
7/8
7/8
7/8
7/8
1-1/8
1VM50
1VM50
1VM50
1VM50
1VP56
6.0
7.0
Blower Sheave
Datum Dia.
(in.)
7.0
Bore (in.)
1
1
Model
AK74
AK64
5.7
9.0
1
1
1
AK74
AK61
AK94
7.0
8.0
7.0
7.0
6.7
1
1
1
1
1
Belt
AK74
AK84
A49
A49
A49
A49
A56
A54
A56
AK74
AK74
A54
A54
BK77 BX55
Table 19: Power Exhaust Specifications
Model Voltage
2PE04703225 208/230-1-60
2PE04703246 460-1-60
2PE04703258 575-1-60
HP
3/4
3/4
3/4
Motor
RPM
1075
1075
1050
1
1. Motors are multi-tapped and factory wired for high speed.
QTY
1
1
1
LRA
7.8
3.4
2.9
Motor
FLA
5
2.2
1.5
MCA
6.3
2.8
1.9
Fuse Size
10
5
4
CFM @
0.1 ESP
3800
3800
3800
Air Balance
On VAV units be certain that the VFD is set to maximum output, exhaust dampers are closed and individual space damper boxes are full open.
VFD units with manual bypass option must not be in the bypass mode ('LINE" position), unless all individual space dampers are full open.
Start the supply air blower motor. Adjust the resistances in both the supply and the return air duct systems to balance the air distribution throughout the conditioned space. The job specifications may require that this balancing be done by someone other than the equipment installer.
Belt drive blower systems MUST be adjusted to the specific static and CFM requirements for the application.
The Belt drive blowers are NOT set at the factory for any specific static or CFM. Adjustments of the blower speed and belt tension are REQUIRED. Verify proper sheave alignment; tighten blower pulley and motor sheave set screws after these adjustments. Re-checking set screws after 10-12 hrs. run time is recommended.
Checking Air Quantity
Method One
1.
Remove the dot plugs from the duct panel (for location of
the dot plugs see Figures 12 and 13).
2.
Insert eight-inches of 1/4 inch metal tubing into the airflow on both sides of the indoor coil.
NOTE: The tubes must be inserted and held in a position perpendicular to the air flow so that velocity pressure will not affect the static pressure readings.
3.
Use an Inclined Manometer or Magnehelic to determine the pressure drop across a dry evaporator coil. Since the moisture on an evaporator coil can vary greatly, measuring the pressure drop across a wet coil under field conditions could be inaccurate. To assure a dry coil, the compressors should be de-activated while the test is being run.
NOTE: De-energize the compressors before taking any test measurements to assure a dry evaporator coil.
4.
The CFM through the unit can be determined from the pressure drop indicated by the manometer by referring to
Figure 32. In order to obtain an accurate measurement, be
certain that the air filters are clean.
5.
To adjust Measured CFM to Required CFM, see SUPPLY
AIR DRIVE ADJUSTMENT.
6.
After readings have been obtained, remove the tubes and replace the dot plugs.
7.
Tighten blower pulley and motor sheave set screws after any adjustments. Re-check set screws after 10-12 hrs. run time is recommended.
46 Johnson Controls Unitary Products
518674-YIM-E-1210
Failure to properly adjust the total system air quantity can result in extensive blower damage.
Method Two
1.
Drill two 5/16 inch holes, one in the return air duct as close to the inlet of the unit as possible, and another in the supply air duct as close to the outlet of the unit as possible.
2.
Using the whole drilled in step 1, insert eight inches of 1/4 inch metal tubing into the airflow of the return and supply air ducts of the unit.
NOTE: The tubes must be inserted and held in position perpendicular to the airflow so that velocity pressure will not affect the static pressure readings.
3.
Use an Inclined Manometer or Magnehelic to determine the pressure drop across the unit. This is the External
Static Pressure (ESP). In order to obtain an accurate measurement, be certain that the air filters are clean.
4.
Determine the number of turns the variable motor sheave is open.
5.
Select the correct blower performance table for the unit
from Tables 15 and 16. Tables are presented for side and
downflow configuration.
6.
7.
8.
9.
Determine the unit Measured CFM from the Blower
Performance Table, External Static Pressure and the number of turns the variable motor sheave is open.
To adjust Measured CFM to Required CFM, see SUPPLY
AIR DRIVE ADJUSTMENT.
After reading has been obtained, remove the tubes and seal holes.
Tighten blower pulley and motor sheave set screws after any adjustments. Re-check set screws after 10-12 hrs. run time is recommended.
NOTE: With the addition of field installed accessories repeat this procedure.
Failure to properly adjust the total system air quantity can result in extensive blower damage.
0.5
0.45
0.4
0.35
ZF078
ZF090 ZF102
ZF120
ZF150
0.3
0.25
0.2
0.15
0.1
0.05
Figure 32: Dry Coil Delta P
0
1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Airflow (CFM)
Johnson Controls Unitary Products 47
518674-YIM-E-1210
Supply Air Drive Adjustment EXAMPLE
A 12.5 ton unit was selected to deliver 4,000 CFM with a 3 HP motor, but the unit is delivering 3,800 CFM. The variable pitch motor sheave is set at 2 turns open.
Use the equation to determine the required DD for the new motor sheave,
Before making any blower speed changes review the installation for any installation 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 of the blower motor will increase by the cube of the blower speed. Static pressure will increase by the square of the blower speed. Only qualified personnel should make blower speed changes, strictly adhering to the fan laws.
At unit start-up, the measured CFM may be higher or lower than the required CFM. To achieve the required CFM, the speed of the drive may have adjusted by changing the datum diameter
(DD) of the variable pitch motor sheave as described below:
Use the following tables and the DD calculated per the above equation to adjust the motor variable pitch sheave.
Use Table 20 to locate the DD nearest to 4.21 in. Close the
sheave to 1 turn open.
New BHP
= (Speed increase)
3
• BHP at 3,800 CFM
= (Speed increase)
3
• Original BHP
= New BHP
New motor Amps
= (Speed increase)
3
• Amps at 3,800 CFM
= (Speed increase)
3
• Original Amps
= New Amps
Table 20: Motor Sheave Datum Diameters
Turns Open
0
1/2
1
1VM50x7/8
(1-1/2, 2 & 3 HP Motor)
Datum Diameter
4.4
4.3
4.2
1-1/2
2
2-1/2
3
4.1
4.0
3.9
3.8
3-1/2
4
4-1/2
5
3.7
3.6
3.5
3.4
Turns Open
1
1-1/2
2
2-1/2
3
3-1/2
4
4-1/2
5
5-1/2
6
1VP56x1-1/8
(5 HP Motor)
Datum Diameter
5.3
5.2
5.1
5.0
4.9
4.8
4.7
4.6
4.5
4.4
4.3
Belt drive blower systems MUST be adjusted to the specific static and CFM requirements for the application.
The Belt drive blowers are NOT set at the factory for any specific static or CFM. Adjustments of the blower speed and belt tension are REQUIRED. Verify proper sheave alignment; tighten blower pulley and motor sheave set screws after these adjustments. Re-checking set screws after 10-12 hrs. run time is recommended.
48 Johnson Controls Unitary Products
518674-YIM-E-1210
Table 21: Additional Static Resistance
Size
(Tons)
078 (6.5)
090 (7.5)
102 (8.5)
120 (10)
150 (12.5)
Model
ZF
ZF
CFM
3700
3900
4100
4300
4500
4700
4900
5100
2100
2300
2500
2700
2900
3100
3300
3500
5300
5500
5700
5900
6100
6300
3300
3500
3700
3900
4100
4300
4500
1900
1900
2100
2300
2500
2700
2900
3100
Cooling Only
0.00
-0.01
-0.01
-0.02
-0.03
-0.04
-0.05
-0.06
-0.07
-0.08
-0.09
-0.09
-0.10
-0.11
0.06
0.07
0.08
0.09
0.11
0.12
0.14
0.16
0.18
0.20
0.23
0.25
0.28
0.30
0.33
0.36
0.39
0.42
0.45
0.48
0.52
0.56
0.60
1
Economizer
0.07
0.09
0.11
0.13
0.16
0.18
0.20
0.22
0.24
0.27
0.29
0.31
0.30
0.35
0.02
0.02
0.02
0.02
0.03
0.03
0.03
0.03
0.04
0.04
0.04
0.04
0.05
0.05
0.05
0.05
0.06
0.06
0.06
0.06
0.07
0.07
0.07
2
,
3
4” Filter
0.10
0.11
0.12
0.14
0.15
0.16
0.18
0.19
0.20
0.21
0.23
0.24
0.25
0.26
0.12
0.13
0.14
0.16
0.17
0.19
0.20
0.22
0.26
0.27
0.29
0.32
0.35
0.38
0.41
0.44
0.47
0.51
0.55
0.58
0.62
0.67
0.71
2
9
0.05
0.06
0.07
0.08
0.09
0.10
0.12
0.13
0.15
0.17
0.19
0.21
0.23
0.25
0.05
0.06
0.07
0.08
0.09
0.10
0.12
0.13
0.15
0.17
0.19
0.21
0.23
0.25
0.28
0.30
0.33
0.35
0.38
0.41
0.44
0.47
0.50
0.11
0.13
0.14
0.16
0.18
0.20
0.22
0.24
0.22
0.24
0.26
0.06
0.07
0.08
0.09
0.10
0.26
0.29
0.31
0.34
0.37
0.40
0.43
0.46
0.49
0.53
0.09
0.10
0.11
0.13
0.14
0.16
0.18
0.20
18
0.06
0.07
0.08
Electric Heat kW
24
0.07
0.08
0.09
36
0.08
0.09
0.10
0.10
0.12
0.13
0.15
0.17
0.19
0.21
0.23
0.11
0.13
0.14
0.16
0.18
0.20
0.22
0.24
0.25
0.28
0.30
0.07
0.08
0.09
0.10
0.12
0.13
0.15
0.17
0.19
0.21
0.23
0.25
0.28
0.30
0.33
0.35
0.38
0.41
0.44
0.47
0.50
0.53
0.56
0.31
0.34
0.37
0.40
0.43
0.46
0.49
0.53
0.56
0.59
0.14
0.16
0.18
0.20
0.22
0.24
0.26
0.29
0.26
0.29
0.31
0.08
0.09
0.10
0.11
0.13
1. Add these values to the available static resistance in the respective Blower Performance Tables.
2. Deduct these values from the available external static pressure shown in the respective Blower Performance Tables.
3. The pressure drop through the economizer is greater for 100% outdoor air than for 100% return air. If the resistance of the return air duct is less than 0.25 IWG, the unit will deliver less CFM during full economizer operation.
0.26
0.28
0.31
0.34
0.37
0.40
0.43
0.46
0.11
0.13
0.14
0.16
0.18
0.20
0.22
0.24
0.49
0.53
0.56
0.59
0.62
0.65
0.22
0.24
0.26
0.28
0.31
0.34
0.37
0.10
54
0.10
0.11
0.13
0.14
0.16
0.18
0.20
Operation
Cooling Sequence Of Operation
For the Predator
®
series of units, the thermostat makes a circuit between "R" and "Y1" for the first stage of cooling.
The call is passed to the Unit Control Board (UCB), which then determines whether the requested operation is available and, if so, which components to energize.
For gas heating, the UCB monitors the "W1" call but does not handle the operation of the gas furnace. An ignition control board controls the gas heater operation. For electric heat units, the UCB passes the call to the electric heater. In both cases, when the "W1" call is sensed, the indoor air blower is energized following a specified heating delay.
If at any time a call for both heating and cooling are present, the heating operation will be performed. If operating, the cooling system is halted as with a completion of a call for cooling.
Heating always takes priority.
Johnson Controls Unitary Products 49
518674-YIM-E-1210
Continuous Blower
By setting the room thermostat fan switch to "ON," the supply air blower will operate continuously.
Intermittent Blower
With the room thermostat fan switch set to "AUTO" and the system switch set to either the "AUTO" or "HEAT" settings, the blower is energized whenever a cooling or heating operation is requested. The blower is energized after any specified delay associated with the operation.
When energized, the indoor blower has a minimum run time of
30 seconds. Additionally, the indoor blower has a delay of 10 seconds between operations.
Optional VAV Start-up and Control
If the unit is operated with the optional manual bypass switch in the LINE (BYPASS) position and there are
VAV boxes present in the duct system, then boxes must be driven to the full-open position using a customersupplied power source to prevent over-pressurizing and possible damage to the ductwork.
For units with VFD and VAV control, the unit must first be put into the Occupied Mode to start operation. The default setting for all VAV units is 'Unoccupied', therefore the installer must add a jumper wire between terminals R - OCC on the VAV addon board to put the unit into 'Occupied' Mode. Additionally, the unit can be switched between Unoccupied/Occupied mode through network communications with Simplicity™ PC and other BAS control systems.
Figure 33: Occupied Jumper
Once placed into the Occupied Mode, the speed of the indoor blower motor is controlled by duct static pressure. The Duct
Static set point (default = 1.5") is the pressure that the VFD drive will maintain when operating the unit in VAV mode. If the
50 duct static pressure reaches or exceeds the high-limit set-point
(default = 4.5"), then the supply fan motor will be shutdown.
The Supply Air Temperature (SAT) is controlled by staging compressors on and off to satisfy the "Operating Cooling
Supply Air Temp Set point". There are 3 set points that determine the resulting "Operating Cooling Supply Air Temp
Set point".
1.
VAV Cooling Supply Air Temp Upper Set point
(default 60° F)
2.
VAV Cooling Supply Air Temp Lower Set point
(default 55° F)
3.
VAV Supply Air Temp Reset Set point (default 72° F)
When the Return Air Temp (RAT) is above the "VAV Supply Air
Temp Reset Set point" the SAT will be maintained at +/- 5 degrees of the "VAV Cooling Supply Air Temp Lower Set point".
When the Return Air Temp (RAT) is below the "VAV Supply Air
Temp Reset Set point" the SAT will be maintained at +/- 5 degrees of the "VAV Cooling Supply Air Temp Upper Set point".
When the Outdoor air condition is sufficient for free cooling, the economizer will modulate to control the SAT to +/- 1 degrees of the operational set point.
The following components are needed to access the control points in the Simplicity® controller. Installation and operation guide is located on UPGNET.
1.
Computer running Windows software with a standard USB port.
2.
Simplicity® PC Software (http://www.yorkupg.com/
software.asp)
3.
Freenet USB adapter driver, (http://www.yorkupg.com/
software.asp)
4.
Simplicity® Freenet USB Adapter (S1-03101967000)
5.
Freenet service cable (S1-02538682000)
No Outdoor Air Options
When the thermostat calls for the first stage of cooling, the lowvoltage control circuit from “R” to “Y1” and “G” is completed.
The UCB energizes the economizer (if installed and free cooling is available) or the first available compressor * and the condenser fans. For first stage cooling, compressor #1 is energized. If compressor #1 is unavailable, compressor #2 is energized. After completing the specified fan on delay for cooling, the UCB will energize the blower motor.
When the thermostat calls for the second stage of cooling, the low-voltage control circuit from “R” to “Y2” is completed. The control board energizes the first available compressor. If free cooling is being used for the first stage of cooling, compressor
#1 is energized. If compressor #1 is active for first stage cooling or the first compressor is locked-out, compressor #2 is energized. In free-cooling mode, if the call for the second stage of cooling continues for 20 minutes, compressor #2 is energized, provided it has not been locked-out.
Johnson Controls Unitary Products
518674-YIM-E-1210
If there is an initial call for both stages of cooling, the UCB will delay energizing compressor #2 by 30 seconds in order to avoid a power rush.
Once the thermostat has been satisfied, it will de-energize Y1 and Y2. If the compressors have satisfied their minimum run times, the compressors and condenser fans are de-energized.
Otherwise, the unit operates each cooling system until the minimum run times for the compressors have been completed.
Upon the final compressor de-energizing, the blower is stopped following the elapse of the fan off delay for cooling.
* To be available, a compressor must not be locked-out due to a high or low-pressure switch or freezestat trip and the Anti-
Short Cycle Delay (ASCD) must have elapsed.
Economizer With Single Enthalpy Sensor
When the room thermostat calls for "first-stage" cooling, the low voltage control circuit from "R" to "G" and "Y1" is completed.
The UCB energizes the blower motor (if the fan switch on the room thermostat is set in the "AUTO" position) and drives the economizer dampers from fully closed to their minimum position. If the enthalpy of the outdoor air is below the set point of the enthalpy controller (previously determined), "Y1" energizes the economizer. The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor. If the outdoor air enthalpy is above the set point, "Y1" energizes compressor #1.
When the thermostat calls for "second-stage" cooling, the low voltage control circuit from "R" to "Y2" is completed. The UCB energizes the first available compressor. If the enthalpy of the outdoor air is below the set point of the enthalpy controller (i.e. first stage has energized the economizer), "Y2" will energize compressor #1. If the outdoor air is above the set point, "Y2" will energize compressor #2.
Once the thermostat has been satisfied, it will de-energize “Y1” and “Y2”. If the compressors have satisfied their minimum run times, the compressors and condenser fans are de-energized.
Otherwise, the unit operates each cooling system until the minimum run times for the compressors have been completed.
Upon the final compressor de-energizing, the blower is stopped following the elapse of the fan off delay for cooling, and the economizer damper goes to the closed position. If the unit is in continues fan operation, the economizer damper goes to the minimum position.
Economizer With Dual Enthalpy Sensors
The operation with the dual enthalpy sensors is identical to the single sensor except that a second enthalpy sensor is mounted in the return air. This return air sensor allows the economizer to choose between outdoor air and return air, whichever has the lowest enthalpy value, to provide maximum operating efficiency.
Economizer With Power Exhaust
A unit equipped with an economizer (single or dual enthalpy) and a power exhaust operates as specified above with one addition. The power exhaust motor is energized 45 seconds after the actuator position exceeds the exhaust fan set point on
Johnson Controls Unitary Products the economizer control. As always, the "R" to "G" connection provides minimum position but does not provide power exhaust operation.
Economizer With Optional VAV OR Intelli-Comfort™
Control
The position of the outside air and return air dampers are controlled through a 2-10 VDC signal from the VAV or Intelli-
Comfort™ control board. The economizer is enabled only in
Occupied or Recovery mode. When the control is not powered or is in Unoccupied mode, the outside air dampers will be closed. When the supply fan is powered and there is no Y1 call, or if free-cooling is unavailable, the control opens the economizer dampers to the minimum position setting.
Free-cooling is available if the outdoor air temperature meets one of the three criteria discussed below, based upon the unit's configuration.
• Dry Bulb: The control refers to input from the Outside Air
Temperature sensor and will allow free cooling when the outdoor temperature is less than both the First-Stage SAT
Control set point plus 5 °F, and the Economizer OAT
Enable set point.
• Single Enthalpy (optional): A field-installed, Outdoor Air
Humidity sensor is connected to the control. When the measured outdoor enthalpy is below the Outside Air
Enthalpy set point, and the outdoor temperature is less than the First-Stage SAT Control set point plus 5 °F, freecooling is available.
• Dual Enthalpy (optional): Both the field-installed
Outdoor Air Humidity and the Return Air Humidity sensors are connected to the control. When the measured outdoor air enthalpy is less than the measured return air enthalpy, and the outdoor temperature is less than the First-Stage
SAT Control set point plus 5 °F, free-cooling is available.
If free-cooling is available with a Y1 call, then the control modulates the economizer dampers to maintain the First-Stage
SAT Control set point, plus or minus one degree. If free-cooling is unavailable, then 1st-stage mechanical cooling is initiated.
If at anytime the outdoor air temperature rises above the First-
Stage SAT Control set point plus 5 °F, while free-cooling is available, then a Y1 call will also initiate 1st-stage mechanical cooling.
For a Y2 call, free-cooling is available based upon the criteria described above, except a Second-Stage SAT Control set point is used in the determination.
Once the call for cooling has been satisfied, it will de-energize any compressors and condenser fans, after the minimum compressor run times have been satisfied. Otherwise, the unit operates each cooling system until the minimum run times for the compressors have been completed.
Upon de-energizing the final compressor, the blower will continue to run with the economizer damper in its minimum position if in the Occupied mode; otherwise, the blower will stop following the elapse of the fan-off delay for cooling, and the economizer outdoor damper will close.
51
518674-YIM-E-1210
Economizer With Optional VAV Blower With Power
Exhaust
The power exhaust motor is energized via the controller's EXH~ terminal and the M5 contactor, based on the position of the economizer damper parameter settings in the VAV control.
Minimum run time is 10 seconds; minimum off time is 60 seconds. The outlet pressure of the power exhaust fan forces the barometric relief dampers open; gravity closes the dampers when the exhaust fan is off.
Economizer With Optional Intelli-Comfort™ With Power
Exhaust
The power exhaust motor is energized via the M5 contactor based on the position of the economizer actuator's auxiliary switch adjustment screw. The adjustment screw represents the outdoor damper position at which to activate power exhaust, and can be set between 0 to 90 degrees open. The outlet pressure of the power exhaust fan forces the barometric relief dampers open; gravity closes the dampers when the exhaust fan is off.
Motorized Outdoor Air Dampers
This system operation is the same as the units with no outdoor air options with one exception. When the "R" to "G" circuit is complete, the motorized damper drives open to a position set by the thumbwheel on the damper motor. When the "R" to "G" circuit is opened, the damper spring returns fully closed.
Cooling Operation Errors
Each cooling system is monitored for operation outside of the intended parameters. Errors are handled as described below. All system errors override minimum run times for compressors.
High-Pressure Limit Switch
During cooling operation, if a high-pressure limit switch opens, the UCB will de-energize the associated compressor, initiate the ASCD (Anti-short cycle delay), and, if the other compressor is idle, stop the condenser fans. If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the halted compressor.
Should a high-pressure switch open three times within two hours of operation, the UCB will lock-out the associated
compressor and flash a code (see Table 29). If the other
compressor is inactive, the condenser fans will be deenergized.
Low-Pressure Limit Switch
The low-pressure limit switch is not monitored during the initial
30 seconds of a cooling system's operation. For the following
30 seconds, the UCB will monitor the low-pressure switch to ensure it closes. If the low-pressure switch fails to close after the 30-second monitoring phase, the UCB will de-energize the associated compressor, initiate the ASCD, and, if the other compressor is idle, stop the condenser fans.
Once the low-pressure switch has been proven (closed during the 30-second monitor period described above), the UCB will monitor the low-pressure limit switch for any openings. If the low-pressure switch opens for greater than 5 seconds, the UCB will de-energize the associated compressor, initiate the ASCD, and, if the other compressor is idle, stop the condenser fans.
If the call for cooling is still present at the conclusion of the
ASCD, the UCB will re-energize the halted compressor.
Should a low-pressure switch open three times within one hour of operation, the UCB will lock-out the associated compressor
and flash a code (Table 29). If the other compressor is inactive,
the condenser fans will be de-energized.
Freezestat
During cooling operation, if a freezestat opens, the UCB will deenergize the associated compressor, initiate the ASCD, and, if the other compressor is idle, stop the condenser fans. If the call for cooling is still present at the conclusion of the ASCD, the
UCB will re-energize the halted compressor.
Should a freezestat open three times within two hours of operation, the UCB will lock-out the associated compressor and
flash a code (Table 29). If the other compressor is inactive, the
condenser fans will be de-energized.
Low Ambient Cooling
To determine when to operate in low ambient mode, the UCB has a pair of terminals connected to a temperature-activated switch set at 45ºF. When the low ambient switch is closed and the thermostat is 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 cycle. The 5-minute off period is necessary to defrost the indoor coil.
Low ambient mode always begins with compressor operation.
Compressor minimum run time may extend the minutes of compressor operation. The defrost cycle will begin immediately following the elapse of the minimum run time.
When operating in low ambient mode, the UCB will not lockout the compressors due to a freezestat trip. However, a freezestat trip will de-energize the associated compressor. If the call for cooling is still present at the end of the ASCD and the freezestat has closed, the unit will resume operation.
Safety Controls
The unit control board monitors the following inputs for each cooling system:
1.
A suction line freezestat to protect against low evaporator temperatures due to a low airflow or a low return air temperature, (opens at 26 ± 5 °F and resets at 38 ± 5°F).
52 Johnson Controls Unitary Products
518674-YIM-E-1210
2.
A high-pressure switch to protect against excessive discharge pressures due to a blocked condenser coil or a condenser motor failure, (opens at 625 ± 25 psig).
3.
A low-pressure switch to protect against loss of refrigerant charge, (opens at 50 ± 5 psig).
The above pressure switches are hard-soldered to the unit. The refrigeration systems are independently monitored and controlled. On any fault, only the associated system will be affected by any safety/preventive action. The other refrigerant system will continue in operation unless it is affected by the fault as well.
The unit control board monitors the temperature limit switch of electric heat units and the temperature limit switch and the gas valve of gas furnace units.
Compressor Protection
In addition to the external pressure switches, the compressors also have inherent (internal) protection. If there is an abnormal temperature rise in a compressor, the protector will open to shut down the compressor. The UCB incorporates features to minimize compressor wear and damage. An Anti-Short Cycle
Delay (ASCD) is utilized to prevent operation of a compressor too soon after its previous run. Additionally, a minimum run time is imposed any time a compressor is energized.
The ASCD is initiated on unit start-up and on any compressor reset or lock-out.
Flash Codes
The UCB will initiate a flash code associated with errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES
Reset
Remove the call for cooling, by raising thermostat setting higher than the conditioned space temperature. This resets any pressure or freezestat flash codes.
Electric Heating Sequence Of Operations
The following sequence describes the operation of the electric heat section.
For units with VFD and electric heat, the speed of the indoor blower motor continues to be controlled by duct static pressure via the VAV control board.
If there are VAV boxes present in the duct system, the boxes must be driven to the full-open position using a customer-supplied power source to assure adequate airflow across the heating elements.
Two-stage heating: a. Upon a call for first stage heat by the thermostat, the heater relay (RA) will be energized. After completing the specified fan on delay for heating, the UCB will energize the blower motor. If the second stage of heat is required, heater relay (RB) will be energized. After completing the specified fan on delay for heating, the UCB will energize the blower motor.
b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space.
Electric Heat Operation Errors
Temperature Limit
If the UCB senses zero volts from the high temperature limit, the indoor blower motor is immediately energized.
This limit is monitored regardless of unit operation status, i.e. the limit is monitored at all times.
If the temperature limit opens three times within one hour, it will lock-on the indoor blower motor and a flash code is initiated
Safety Controls
The UCB monitors the temperature limit switch of electric heat units.
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 Limit
Setting Tables 22 and 23. It resets automatically. The limit
switch operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shutting down the heater and energizing the blower.
Table 22: Electric Heat Limit Setting 50” Cabinet
UNIT (TONS)
ZF102, 120, 150
(8.5, 10, 12.5)
ZF102, 120, 150
(8.5, 10, 12.5)
ZF102, 120, 150
(8.5, 10, 12.5)
VOLTAGE
HEATER kW
208/230
480
600
54
18
24
34
18
24
34
54
18
24
34
54
LIMIT
SWITCH
OPENS °F
150
150
150
130
150
150
150
130
150
150
150
130
Johnson Controls Unitary Products 53
518674-YIM-E-1210
Table 23: Electric Heat Limit Setting 42” Cabinet
UNIT (TONS)
ZF078, 090 (6.5, 7.5)
ZF078, 090 (6.5, 7.5)
ZF078, 090 (6.5, 7.5)
VOLTAGE
HEATER kW
208/230
480
600
34
9
18
24
9
18
24
34
9
18
24
34
LIMIT
SWITCH
OPENS °F
135
150
165
190
135
150
165
185
135
150
150
185
Flash Codes
The UCB will initiate a flash code associated with errors within the system. Refer to UNIT CONTROL BOARD FLASH CODES
Reset
Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This resets any flash codes.
Electric Heat Anticipator Setpoints
It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the value below the correct setpoint will give shorter “ON” cycles and may result in the lowering of the temperature within the
conditioned space. Refer to Table 24 for the required electric
heat anticipator setting.
Table 24: Electric Heat Anticipator Setpoints
SETTING, AMPS
W1
0.13
W2
0.1
Gas Heating Sequence Of Operations
For units with VFD and gas heat, the speed of the indoor blower motor continues to be controlled by duct static pressure via the VAV control board.
If there are VAV boxes present in the duct system, the boxes must be driven to the full-open position using a customer-supplied power source to assure adequate airflow across the heat exchanger tubes.
When the thermostat calls for the first stage of heating, the lowvoltage control circuit from “R” to “W1” is completed. A call for heat passes through the UCB to the Ignition Control Board
(ICB). The UCB monitors the “W1” call and acts upon any call for heat by monitoring the Gas Valve (GV). Once voltage has been sensed at the GV, the UCB will initiate the fan on delay for heating, energizing the indoor blower the specified delay has elapsed.
When the thermostat has been satisfied, heating calls are ceased. The GV is immediately closed. The blower is deenergized after the fan off delay for heating has elapsed. The draft motor performs a 30-second post purge.
Ignition Control Board
First Stage Of Heating
When the ICB receives a call for first stage of heating, “W1,” the draft motor is energized. Once the draft motor has been proven, a 30-second purge is initiated. At the end of the purge, the GV is opened, and the spark ignitor is energized for 10 seconds.
The ICB then checks for the presence of flame. If flame is detected, the ICB enters a flame stabilization period. If flame was not detected, the GV closes, and a retry operation begins.
During the flame stabilization period, a loss of the flame for 2 seconds will cause the GV to close and the retry operation to begin. After the flame stabilization period, a loss of flame for 3/4 second will cause the GV to close and the retry operation to begin.
At the conclusion of the flame stabilization period, the ICB will operate the gas heat in high fire for an additional 60 seconds
(for a total for 120 seconds of high fire operation). After this 60 seconds, the ICB will then use the call for the second stage of heat to control second stage operation of the GV.
When “W1” is satisfied, both valves are closed.
Second Stage Of Heating
When the ICB receives a call for the second stage of heating,
“W2,” the ICB conducts a complete first stage ignition sequence. If this sequence is satisfied, the second main valve of the GV is opened.
When “W2” is satisfied, the second main valve is closed.
Retry Operation
When a flame is lost or is not detected during an attempt to achieve ignition, a retry operation occurs. A 30-second purge is performed between ignition attempts.
If the unit fails after three ignition attempts, the furnace is locked-out for one hour. The furnace is monitored during this one-hour period for unsafe conditions.
54 Johnson Controls Unitary Products
518674-YIM-E-1210
Recycle Operation
When a flame is lost after the flame stabilization period, a recycle operation occurs. If the unit fails after five recycle attempts, the furnace is locked-out for one hour.
Gas Heating Operation Errors
Lock-Out
A one-hour lockout occurs following three retries or five recycles. During the one-hour lockout, flame detection, limit conditions, and main valves are tested. Any improper results will cause the appropriate action to occur. Recycling the low voltage power cancels the lock-out.
Temperature Limit
If the UCB senses zero volts from the high temperature limit, the indoor blower motor is immediately energized. When the
UCB again senses 24 volts from the temperature limit, the draft motor will perform a 15-second post-purge and the indoor blower will be de-energized following the elapse of the fan off delay for heating.
This limit is monitored regardless of unit operation status, i.e. this limit is monitored at all times.
If the temperature limit opens three times within one hour, it will lock-on the indoor blower motor and flash code is initiated (See
Flame Sense
Flame sensing occurs at all times. If “W1” is not present and a flame is sensed for 2 seconds, the draft motor is energized and the GV is kept off. The ICB halts any operation until a flame is not detected. Once the flame detection is lost, the ICB performs a post-purge. Normal operation is allowed concurrently with the purge (i.e. this purge can be considered the purge associated with a call for “W1”).
If “W1” is present, a flame is sensed, but the GV is not energized, the draft motor is energized until the flame detection is lost. Normal operation is now allowed.
The flame detection circuitry continually tests itself. If the ICB finds the flame detection circuitry to be faulty, the ICB will not permit an ignition sequence and the draft motor is energized. If this failure should occur during an ignition cycle the failure is counted as a recycle.
Gas Valve
The UCB and ICB continuously monitor the GV.
If the ICB senses voltage at the GV when not requested, the
ICB will energize the draft motor. The ICB will not operate the furnace until voltage is no longer sensed at the GV. The draft motor is stopped when voltage is not sensed at the GV.
Any time the UCB senses voltage at the GV without a call for heat for a continuous five-minute period, the UCB will lock-on
the indoor blower and a flash code is initiated (Table 29). When
voltage is no longer sensed at the GV, the UCB will de-energize the indoor blower following the elapse of the fan off delay for heating.
If voltage has been sensed at the GV for at least 15 seconds during the fan on delay for heating and GV voltage or “W1” is lost, the indoor blower is forced on for the length of the fan off delay for heating.
During a call for heat, if the UCB does not sense voltage at the
GV for a continuous five-minute period the UCB will initiate a
flash code (Table 29). The indoor blower motor will not be
locked-on while there is no GV voltage.
Safety Controls
The UCB monitors the temperature limit switch of gas heat units.
The control circuit includes the following safety controls:
Limit Switch (LS)
This control is located inside the gas heat compartment and is set to open at the temperature indicated in the Gas Heat Limit
Control Settings Table 25. It resets automatically. The limit
switch operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shutting down the heater and energizing the blower.
Auxiliary Limit Switch (ALS)
This control is located inside the supply air compartment and is set to open at the temperature indicated in the Gas Heat Limit
Control Settings Table 25. It resets manually. The limit switch
operates when a high temperature condition, caused by inadequate supply air flow occurs, thus shutting down the heater and energizing the blower.
The auxiliary limit switch is wired in series with the limit switch.
As such, the UCB cannot distinguish the auxiliary limit and the gas heat limit switch operation except the auxiliary is manual reset. Consequently, the control will respond in the same manner as outlined above under “Limit Switch”.
Table 25: Gas Heat Limit Control Settings
1
Unit
Size
ZF078
ZF090
ZF102
ZF120
ZF150
10
15
15
20
15
20
Opt.
10
15
10
15
1. Rollout = 300°F, Auxiliary Limit = 200°F.
Main Limit Setting
°F
165
165
165
165
215
195
195
160
195
160
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The ICB monitors the Pressure and Rollout switches of gas heat units.
The control circuit includes the following safety controls:
Pressure Switch (PS)
Once the draft motor has reached full speed and closes the pressure switch during a normal ignition sequence, if the pressure sw opens for 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 switch closes or
“W1” is lost.
Rollout Switch (ROS)
The rollout switch is wired in series with the pressure switch. As such, the ICB cannot distinguish the rollout switch operation from that of the pressure switch.
Consequently, the control will only respond in the same manner as outlined above under “Pressure Switch”. An open rollout will inhibit the gas valve from actuating.
Internal Microprocessor Failure
If the ICB detects an internal failure, it will cease all outputs, ignore inputs, and display the proper flash code for control replacement. The ICB remains in this condition until replaced.
Flash Codes
The ICB will initiate a flash code associated with errors within the system. Refer to IGNITION CONTROL FLASH CODES
Resets
Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. This resets any flash codes.
Gas Heat Anticipator Setpoints
It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the value below the correct setpoint will give shorter “ON cycles and may result in the lowering of the temperature within the
conditioned space. Refer to Table 26 for the required gas heat
anticipator setting.
Table 26: Gas Heat Anticipator Setpoints
SETTING, AMPS
W1
0.65
W2
0.1
Start-Up (Cooling)
Prestart Check List
After installation has been completed:
1.
Check the electrical supply voltage being supplied. Be sure that it is the same as listed on the unit nameplate.
2.
Set the room thermostat to the off position.
3.
Turn unit electrical power on.
4.
Set the room thermostat fan switch to on.
5.
Check indoor blower rotation.
• If blower rotation is in the wrong direction. Refer to
Phasing Section in general information section.
Check blower drive belt tension.
6.
Check the unit supply air (CFM).
7.
Measure evaporator fan motor's amp draw.
8.
Set the room thermostat fan switch to off.
9.
Turn unit electrical power off.
Operating Instructions
1.
Turn unit electrical power on.
NOTE: Prior to each cooling season, the crankcase heaters must be energized at least 10 hours before the system is put into operation.
2.
Set the room thermostat setting to lower than the room temperature.
3.
First stage compressors will energize after the built-in time delay (five minutes).
4.
The second stage of the thermostat will energize second stage compressor if needed.
Post Start Check List
1.
Verify proper system pressures for both circuits.
2.
Measure the temperature drop across the evaporator coil.
Start-Up (Gas Heat)
Pre-Start Check List
Complete the following checks before starting the unit.
1.
Check the type of gas being supplied. Be sure that it is the same as listed on the unit nameplate.
2.
Make sure that the vent outlet and combustion air inlet are free of any debris or obstruction.
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Operating Instructions
This furnace is equipped with an automatic re-ignition system. DO NOT attempt to manually light the pilot.
Lighting The Main Burners
1.
Turn “OFF” electric power to unit.
2.
Turn room thermostat to lowest setting.
3.
Turn gas valve counter-clockwise to “ON” position (See
4.
Turn “ON” electric power to unit.
5.
If thermostat set temperature is above room temperature, the main burners will ignite. If a second stage of heat is called for, the main burners for second stage heat will ignite for the second stage heat.
Post Start Checklist
After the entire control circuit has been energized and the heating section is operating, make the following checks:
1.
Check for gas leaks in the unit piping as well as the supply piping.
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.
2.
Check 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 appliances in the building at full fire. At no 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 supplier for corrective action.
Shut Down
1.
Set the thermostat to the lowest temperature setting.
2.
Turn “OFF” all electric power to unit.
3.
Open gas heat access panel.
4.
Turn gas valve clockwise to “OFF” position (See Figure 35).
Checking Gas Heat Input
This unit has two stages of gas heat. The first stage is 60% of the full fire input and is considered the minimum input for the furnace. The intended input for each furnace is shown in
Table 28. The table applies to units operating on 60 Hz power
only.
To determine the rate of gas flow (Second Stage).
1.
Turn off all other gas appliances connected to the gas meter.
2.
Turn on the furnace and make sure the thermostat is calling for Second stage (100% input) heat.
3.
Measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter has a 1/
2 or a 1 cubic foot test dial.
4.
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).
5.
If necessary, adjust the high pressure regulator as discussed in the section “Manifold Gas Pressure
Adjustment”. Be sure not to over-fire the furnace on
Second stage. If in doubt, it is better to leave the Second stage of the furnace slightly under-fired. Repeat Steps 1-5.
To determine the rate of gas flow (First Stage)
1.
Turn off all other gas appliances connected to the gas meter.
2.
Turn on the furnace and make sure the thermostat is calling for first stage (60% input) heat.
3.
Even when the thermostat is calling for first stage heat, the unit will light on second stage and will run on Second stage for 1 minute. Allow this one-minute time period to expire and be certain the unit is running on first stage.
4.
Measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter has a 1/
2 or 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 pressure regulator as discussed in the section “Manifold Gas Pressure
Adjustment”. Be sure not to under-fire the furnace on first stage. If in doubt, it is better to leave the first stage of the furnace slightly over-fired (greater than 60% input). Repeat
Steps 1-6.
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518674-YIM-E-1210
46
48
50
52
38
40
42
44
54
56
58
60
Seconds for
One Rev.
10
12
14
16
18
20
30
32
34
36
22
24
26
28
Table 27: Gas Rate Cubic Feet Per Hour
39
37
36
35
47
45
43
41
34
32
31
30
60
56
53
50
82
75
69
64
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
180
150
360
300
129
113
100
90
257
225
200
180
164
150
138
129
120
113
106
100
78
75
72
69
95
90
86
82
67
64
62
60
NOTE: To find the Btu input, multiply the number of cubic feet of gas consumed per hour by the Btu content of the gas in your particular locality (contact your gas company for this information as it varies widely from area to area).
EXAMPLE
By actual measurement, it takes 19 seconds for the hand on a 1 cubic foot dial to make a revolution with a 192,000 Btuh furnace running. To determine rotations per minute, divide 60 by 19 =
3.16. To calculate rotations per hour, multiply 3.16
60 = 189.6.
Multiply 189.6
1 (0.5 if using a 1/2 cubic foot dial) = 189.6.
Multiply 189.6
(the Btu rating of the gas). For this example, assume the gas has a Btu rating of 1050 Btu/ft.
3 . The result of
199,000 Btuh is within 5% of the 192,000 Btuh rating of the furnace.
Manifold Gas Pressure Adjustment
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” marking on the valve and the first stage
(60% input) adjustment screw is located adjacent to the “LO”
marking on the valve (See Figure 35).
Manifold pressure adjustment procedure.
Adjust second stage (100% input) pressure first, then adjust first stage (60% input) pressure.
1.
Turn off all power to the unit.
2.
Using the outlet pressure port on the gas valve, connect a manometer to monitor the manifold pressure.
3.
Remove plastic cap covering HI and LO pressure adjustment screws.
4.
Turn on power to the unit.
5.
Set thermostat to call for second stage heat and start furnace.
6.
If necessary, using a screwdriver, turn the second stage adjustment screw (adjacent to the “HI” marking on the valve) clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure. Be sure
not to over-fire the unit on second stage.
7.
After the high manifold pressure has been checked, adjust the thermostat to call for first stage heat.
8.
If necessary, using a screwdriver, turn the first stage adjustment screw (adjacent to the “LO” marking on the valve) clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure. Be sure
not to under-fire the 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% input) should be 3.5 IWG ± 0.3.
The manifold pressure for first stage (60% input) when using natural gas should be 1.5 IWG ± 0.3.
Table 28: Gas Heat Stages
# of Burner Tubes
4
6
8
2nd Stage Input
(100% Btuh)
120,000
180,000
240,000
1st Stage Input
(60% Btuh)
72,000
108,000
144,000
58 Johnson Controls Unitary Products
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Adjustment Of Temperature Rise
The temperature rise (the difference of temperature between the return air and the heated air from the furnace) must lie within the
range shown on the CSA rating plate and the data in Table 9.
After the temperature rise has been determined, the CFM can be calculated as follows:
HIGH & LOW GAS ADJUSTMENT
HI
LO
After about 20 minutes of operation, determine the furnace temperature rise. Take readings of both the return air and the heated air in the ducts (about 6 feet from the furnace) where they will not be affected by radiant heat. Increase the blower
CFM to decrease the temperature rise; decrease the blower
CFM to increase the rise (See SUPPLY AIR DRIVE
ADJUSTMENT).
NOTE: Each gas heat exchanger size has a minimum allowable CFM. Below this CFM, the limit will open.
Burners/Orifices Inspection/Servicing
Before checking or changing burners, pilot or orifices, CLOSE
MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL
POWER TO THE UNIT.
1.
Open the union fitting just upstream of the unit gas valve and downstream from the main manual shut-off valve in the gas supply line.
2.
Remove the screws holding each end of the manifold to the manifold supports.
3.
Disconnect wiring to the gas valves and spark igniter(s).
Remove the manifold & gas valve assembly. Orifices can now be inspected and/or replaced.
To service burners, complete step 4.
4.
Remove the heat shield on top of the manifold supports.
Burners are now accessible for 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.
INLET
PRESSURE
TAP
ON
OFF
MATE-N-LOCK
CONNECTORS
OUTLET
PRESSURE
TAP
MV
C
HI
Figure 35: Typical Gas Valve
Charging The Unit
All ZF units use Thermal Expansion Devices. Charge the unit to nameplate charge or 10° subcooling.
Troubleshooting
Troubleshooting of components may require opening the electrical control box with the power connected to the unit. Use extreme care when working with live
circuits! Check the unit nameplate for the correct line voltage and set the voltmeter to the correct range before making any connections with line terminals.
For troubleshooting of optional VFD, disconnect all power to the drive. Be aware that high voltages are present in the drive even after power has been disconnected. Capacitors within the drive must be allowed to discharge before beginning service.
When not necessary, shut off all electric power to the unit prior to any of the following maintenance procedures so as to prevent personal injury.
HEAT EXCHANGER TUBE
GAS
SUPPLY
PIPE
BURNER
BURNER BRACKET
IGNITOR
Figure 34: Typical Flame
BURNER FLAME
(BLUE ONLY)
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation which could cause injury to person and/or damage unit components. Verify proper operation after servicing.
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Predator
®
Flash Codes
Various flash codes are utilized by the unit control board (UCB) to aid in troubleshooting. Flash codes are distinguished by the short on and off cycle used (approximately 200ms on and
200ms off). To show normal operation, the control board flashes a 1 second on, 1 second off "heartbeat" during normal operation. This is to verify that the UCB is functioning correctly.
Do not confuse this with an error flash code. To prevent confusion, a 1-flash, flash code is not used.
Alarm condition codes are flashed on the UCB lower left Red
LED, See Figure 36. While the alarm code is being flashed, it
will also be shown by the other LEDs: lit continuously while the alarm is being flashed. The total of the continuously lit LEDs
Table 29: Unit Control Board Flash Codes equates to the number of flashes, and is shown in the table.
Pressing and releasing the LAST ERROR button on the UCB can check the alarm history. The UCB will cycle through the last five (5) alarms, most recent to oldest, separating each alarm flash code by approximately 2 seconds. In all cases, a flashing
Green LED will be used to indicate non-alarm condition.
In some cases, it may be necessary to "zero" the ASCD for the compressors in order to perform troubleshooting. To reset all
ASCDs for one cycle, press and release the UCB TEST/
RESET button once.
Flash codes that do and do not represent alarms are listed in
Flash Code Description
On Steady
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
11 Flashes
12 Flashes
13 Flashes
14 Flashes
OFF
This is a Control Failure
Not Applicable
Control waiting ASCD
1
HPS1 Compressor Lockout
HPS2 Compressor Lockout
LPS1 Compressor Lockout
LPS2 Compressor Lockout
FS1 Compressor Lockout
FS2 Compressor Lockout
Ignition Control Locked Out / Ignition Control Failure
Compressors Locked Out on Low Outdoor Air Temperature
1
Compressors locked out because the Economizer is using free
Cooling
1
Unit Locked Out due to Fan Overload Switch Failure
Compressor Held Off due to Low Voltage
EEPROM Storage Failure
No Power or Control Failure
1. Non-alarm condition.
1
Green
LED
16
-
-
Flashing
Off
Off
Off
Off
Off
Off
Off
Flashing
Flashing
Off
Flashing
Off
Off
Red
LED
8
-
-
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
Off
Red
LED
4
-
-
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
Off
Red
LED
2
-
-
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
Off
Red
LED
1
-
-
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
Off
60 Johnson Controls Unitary Products
518674-YIM-E-1210
Check
Alarm
History
Reset All
ASCDs for
One Cycle
Non Alarm
Condition Green
LED Flashing
Current Alarm
Flashed
Red LED
Figure 36: Unit Control Board
Unit Control Board Option Setup
Option Byte Setup
• Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2 seconds.
• The green status LED (Option Byte) will be turned on and the red status LED (Heat Delay) is turned off.
• The 8, 4, 2 and 1 LEDs will then show the status of the 4 labeled options ((8) Fan Off at Heat Start, (4) Low
Ambient Lockout, (2) Free Cooling Lockout, and (1)
Lead / Lag).
• Press the UP or Down button to change the LED status to correspond to the desired Option Setup.
• To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2 seconds.
When the value is saved, the green LED will flash a few times and then normal display will resume.
NOTE: While in either Setup mode, if no buttons are pushed for
60 seconds, the display will revert to its normal display, exiting the Option Setup mode. When saving, the control board only saves the parameters for the currently displayed mode (Option Byte or Heat
Delay).
Heat Delay Setup
• Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2 seconds.
• The green status LED (Option Byte) will be turned on and the red status LED (Heat Delay) is turned off.
• Press the COMM SETUP / SELECT button to toggle into the Heat Delay Setup, the green LED will turn off and the red LED for Heat Delay will turn on.
• The 8, 4, 2 and 1 LEDs will then show the status of the
Heat Delay, (See Table 30). Press the UP or Down button
to change the LED status to correspond to the desired
Heat Delay Value.
• To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2 seconds.
When the value is saved, the red LED will flash a few times and then normal display will resume.
NOTE: While in either Setup mode, if no buttons are pushed for
60 seconds, the display will revert to its normal display, exiting the Option Setup mode. When saving, the control board only saves the parameters for the currently displayed mode (Option Byte or Heat
Delay).
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Table 30: Heat Delay
30
30
30
0
45
45
45
30
Heat
Fan On
Delay
60
60
60
60
45
0
0
Non-std
90
60
30
60
90
60
30
180
Heat
Fan Off
Delay
180
90
60
30
180
30
10
Non-std
Red
LED 8
Off
Off
Off
Off
Off
On
Off
Off
Off
On
On
On
On
On
On
On
Red
LED 4
On
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
Off
Off
Off
Red
LED 2
Off
On
On
Off
Off
Off
On
On
Off
On
On
Off
Off
On
On
Off
Red
LED 1
Off
On
Off
On
Off
Off
On
Off
On
On
Off
On
Off
On
Off
On
Table 31: Ignition Control Flash Codes
Flashes Fault Conditions
STEADY ON Control Failure
HEARTBEAT Normal Operation
1 Not Applicable
2
3
Pressure Switch
Stuck Closed
Pressure Switch Failed
To Close
4
5
6
Control
Check
Pressure Switch
Limit Switch Open
Ignition Lockout
Venter Pressure Switch
Vent Blocked
Main Limit
AUX Limit
Flame Present With Gas
Off First Stage Gas Valve
Energized With W1 Off
Second Stage Gas Valve
Energized With First
Stage
Gas Valve Off
Gas Valve
Gas Flow
Gas Pressure
Gas Valve
Flame Sensor
STEADY OFF
No Power Or Control
Failure
24VAC or Control
Table 32: VAV Control Board Flash Codes
Flash Codes
On Steady
1 Flash
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
11 Flashes
12 Flashes
13 Flashes
14 Flashes
15 Flashes
16 Flashes
17 Flashes
18 Flashes
19 Flashes
20 Flashes
Description
This is a Control Failure
Not Applicable
Loss of Communications with UCB
Space Sensor Failed
SAT Sensor Failed
RAT Sensor Failed
OAT Sensor Failed
OAH Sensor Failed
RAH Sensor Failed
IAQ Sensor Failed
OAQ Sensor Failed
APS Switch Failed
Limit 2 Switch Open
Purge
VFD Input Failure
Dirty Filter Switch
Econ Minimum Position Alarm
Space Temp/Time Alarm
Water Coil Freeze Stat Alarm
SAT Alarm for Cooling
SAT Alarm for Heating
62 Johnson Controls Unitary Products
Monitor
Monitored
Systems
Problem?
Yes
No
Trip/Failure
Programming?
No
Yes
Program
Unit
Control
Board
Turn off ID
Blower Motor
Yes
No
Fan on
>30 secs?
Yes
No
Lossof Call for ID Blower?
Figure 37: Basic Troubleshooting Flowchart
Call for
Heating?
Yes
Call for
Heat
Energize ID
Blower Motor
Yes
No
Fan off
>10 secs?
No
Yes
Call for
ID Blower?
No Loss of
Call for
Heating?
No
Yes
Heat Off
Call for
Cooling?
Yes
No
Call for 2nd
Stage
Cooling
No
First
Stage?
Yes
Call for 1st
Stage
Cooling
No
Loss of Call for Cooling?
Yes
Cool Off
Power to
Unit
Call for heat?
Yes
No
Voltage @
Gas Valve?
No
Yes
518674-YIM-E-1210
Initialize ASCD
Energize ID
Blower
Montior
Figure 38: Power On Flow Chart
Johnson Controls Unitary Products 63
518674-YIM-E-1210
Figure 39: Trip Failure Flow Chart
64 Johnson Controls Unitary Products
518674-YIM-E-1210
Cooling Troubleshooting Guide
NOTE: For units with optional VFD without manual bypass, the
M3 contactor has been replaced with an "ice cube" relay (designated 'VFDR') located in the control box.
The relay is energized by "FAN" output from the UCB.
Normally-open relay contacts provide a run-permit signal to the VFD.
On calls for cooling, if the compressors are operating but the supply air blower motor does not energize after a short delay
(the room thermostat fan switch is in the “AUTO” position):
1.
Turn the thermostat fan switch to the ON position. If the supply air blower motor does not energize, go to Step 3.
2.
If the blower motor runs with the fan switch in the ON position but will not run after the first compressor has energized when the fan switch is in the AUTO position, check the room thermostat for contact between R and G in the AUTO position during calls for cooling.
3.
If the supply air blower motor does not energize when the fan switch is set to ON, check that line voltage is being supplied to the contacts of the M3, contactor, and that the contactor is pulled in. Check for loose wiring between the contactor and the supply air blower motor.
4.
If M3 is pulled in and voltage is supplied to M3, lightly touch the supply air blower motor housing. If it is hot, the motor may be off on internal protection. Cancel any thermostat calls and set the fan switch to AUTO. Wait for the internal overload to reset. Test again when cool.
5.
If M3 is not pulled in, check for 24 volts at the M3 coil. If 24 volts are present at M3 but M3 is not pulled in, replace the contactor.
6.
Failing the above, if there is line voltage supplied at M3, M3 is pulled in, and the supply air blower motor still does not operate, replace the motor.
7.
If 24 volts is not present at M3, check that 24 volts is present at the UCB supply air blower motor terminal,
“FAN”. If 24 volts is present at the FAN, check for loose wiring between the UCB and M3.
8.
If 24 volts is not present at the “FAN” terminal, check for 24 volts from the room thermostat. If 24 volts are not present from the room thermostat, check for the following: a. Proper operation of the room thermostat (contact between R and G with the fan switch in the ON position and in the AUTO position during operation calls).
b. Proper wiring between the room thermostat and the
UCB, and c. Loose wiring from the room thermostat to the UCB
9.
If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat and the UCB, i.e. that the thermostat G terminal is connected to the G terminal of the UCB, and for loose wiring.
10. If the thermostat and UCB are properly wired, replace the
UCB.
On calls for cooling, the supply air blower motor is operating but compressor #1 is not (the room thermostat fan switch is in the
“AUTO” position):
1.
If installed, check the position of the economizer blades. If the blades are open, the economizer is providing free cooling and the compressors will not immediately operate.
If both stages of cooling are requested simultaneously and the economizer provides free cooling, following a short delay compressor #1 will be energized unless it is locked out. If compressor #1 is locked out, compressor #2 is energized. Compressor #2 is always energized in place of compressor #1 when compressor #1 is requested but locked out.
2.
If no economizer is installed or the economizer is not opening to provide free cooling and compressor #1 does not energize on a call for cooling, check for line voltage at the compressor contactor, M1, and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor.
3.
If M1 is pulled in and voltage is supplied at M1, lightly touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool.
4.
If M1 is not pulled in, check for 24 volts at the M1 coil. If 24 volts are present and M1 is not pulled in, replace the contactor.
5.
Failing the above, if voltage is supplied at M1, M1 is pulled in, and the compressor still does not operate, replace the compressor.
6.
If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose wiring between C1 and the compressor contactor.
7.
If 24 volts is not present at the C1 terminal, check for 24 volts from the room thermostat at the UCB Y1 terminal. If
24 volts is not present from the room thermostat, check for the following: a. 24 volts at the thermostat Y1 terminal b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and c. Loose wiring from the room thermostat to the UCB
8.
If 24 volts is present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat. Check for 24 volts at the HPS1, LPS1, and FS1 terminals of the UCB. If a switch has opened, there should be a voltage potential between the UCB terminals, e.g. if LPS1 has opened, there will be a 24-volt potential between the LPS1 terminals.
9.
If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened, the UCB may have locked out the compressor for repeat trips. The UCB should be flashing an alarm code. If not, press and release the ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked
Johnson Controls Unitary Products 65
518674-YIM-E-1210 out, cancel any call for cooling. This will reset any compressor lock outs.
NOTE: While the above step will reset any lockouts, compressor #1 may be held off for the ASCD. See the next step.
10. If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and release the TEST button to reset all ASCDs.
11. If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip, repeat trip lock out, or ASCD, the economizer terminals of the
UCB may be improperly wired. Check for 24 volts at the Y1
“OUT” terminal of the UCB. If 24 volts is present, trace the wiring from Y1 “OUT” for incorrect wiring. If 24 volts is not present at the Y1 “OUT” terminal, the UCB must be replaced.
12. For units without economizers: If 24 volts is present at the
Y1 OUT terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, the jumper in the Mate-N-Lock plug, and in the wiring from the
Mate-N-Lock plug to the Y1 “ECON” terminal.
13. For units with economizers: If 24 volts is present at the Y1
“OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, a poor connection between the UCB and economizer Mate-
N-Lock plugs, loose wiring from the Mate-N-Lock plug to the economizer, back to the Mate-N-Lock plug, and from the Mate-N-Lock plug to the Y1 “ECON” terminal. If nothing is found, the economizer control may have faulted and is failing to return the 24-volt “call” to the Y1 “ECON” terminal even though the economizer is not providing free cooling.
To test, disconnect the Mate-N-Locks and jumper between the WHITE and YELLOW wires of the UCB’s Mate-N-Lock plug. If compressor #1 energizes, there is a fault in the economizer wiring or the economizer control.
14. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions. These options are not enabled by default. Local distributors can test the UCB for this programming.
For units with factory installed economizers, the UCB is programmed to lock out compressor operation when the
LAS set point is reached.
For units without factory installed or with field installed economizers, the UCB allows compressor operation all the time. This programming can be checked or changed by the local distributor.
15. If none of the above corrected the error, test the integrity of the UCB. Disconnect the C1 terminal wire and jumper it to the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If the compressor engages, the UCB has faulted.
16. If none of the above correct the error, replace the UCB.
On calls for the second stage of cooling, the supply air blower motor and compressor #1 are operating but compressor #2 is not (the room thermostat fan switch is in the “AUTO” position):
1.
If installed, check the position of the economizer blades. If the blades are open, the economizer is providing free cooling. If the second stage of cooling is requested, following a short delay, compressor #1 will be energized unless it is locked out. Typically, compressor #2 is energized only during free cooling if the call for the second stage of cooling persists for 20 minutes.
2.
Compressor #2 will not energize simultaneously with compressor #1 if a call for both stages of cooling is received. The UCB delays compressor #2 by 30 seconds to prevent a power surge. If after the delay compressor #2 does not energize on a second stage call for cooling, check for line voltage at the compressor contactor, M2, and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor.
3.
If M2 is pulled in and voltage is supplied at M2, lightly touch the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool.
4.
If M2 is not pulled in, check for 24 volts at the M2 coil. If 24 volts is present and M2 is not pulled in, replace the contactor.
5.
Failing the above, if voltage is supplied at M2, M2 is pulled in, and the compressor still does not operate, replace the compressor.
6.
If 24 volts is not present at M2, check for 24 volts at the
UCB terminal, C2. If 24 volts are present, check for loose wiring between C2 and the compressor contactor.
7.
If 24 volts is not present at the C2 terminal, check for 24 volts from the room thermostat at the UCB Y2 terminal. If
24 volts is not present from the room thermostat, check for the following: a. 24 volts at the thermostat Y2 terminal b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and c. Loose wiring from the room thermostat to the UCB
8.
If 24 volts is present at the UCB Y2 terminal, the compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat. Check for 24 volts at the HPS2, LPS2, and FS2 terminals of the UCB. If a switch has opened, there should be a voltage potential between the UCB terminals, e.g. if LPS2 has opened, there will be 24 volts of potential between the LPS2 terminals.
9.
If 24 volts is present at the UCB Y2 terminal and none of the protection switches have opened, the UCB may have locked out the compressor for repeat trips. The UCB should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked out,
66 Johnson Controls Unitary Products
518674-YIM-E-1210 remove any call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y2 UCB terminal. This will reset any compressor lock outs.
NOTE: While the above step will reset any lock outs, compressor #1 will be held off for the ASCD, and compressor #2 may be held off for a portion of the
ASCD. See the next step.
10. If 24 volts is present at the UCB Y2 terminal and none of the switches are open and the compressor is not locked out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and release the TEST button to reset all ASCDs.
11. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions. These options are not enabled by default. Local distributors can test the UCB for this programming.
For units with factory installed economizers, the UCB is programmed to lock out compressor operation when the
LAS set point is reached.
For units without factory installed or with field installed economizers, the UCB allows compressor operation all the time. This programming can be checked or changed by the local distributor.
12. If none of the above corrected the error, test the integrity of the UCB. Disconnect the C2 terminal wire and jumper it to the Y2 terminal. DO NOT jump the Y2 to C2 terminals. If the compressor engages, the UCB has faulted.
13. If none of the above correct the error, replace the UCB.
On a call for cooling, the supply air blower motor and compressor #2 are operating but compressor #1 is not (the room thermostat fan switch is in the “AUTO” position):
7.
If 24 volts is not present at the C1 terminal, check for 24 volts from the room thermostat at the UCB Y1 terminal. If
24 volts are not present at the UCB Y1 terminal, the UCB may have faulted. Check for 24 volts at the Y1 ECON terminal. If 24 volts is not present at Y1 “ECON”, the UCB has faulted. The UCB should de-energize all compressors on a loss of call for the first stage of cooling, i.e. a loss if 24 volts at the Y1 terminal.
8.
If 24 volts are present at the UCB Y1 terminal, the compressor may be out due to an open high-pressure switch, low-pressure switch, or freezestat. Check for 24 volts at the HPS1, LPS1, and FS1 terminals of the UCB. If a switch has opened, there should be a voltage potential between the UCB terminals, e.g. if LPS1 has opened, there will be a 24-volt potential between the LPS1 terminals.
9.
If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened, the UCB may have locked out the compressor for repeat trips. The UCB should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last five alarms on the LED. If the compressor is locked out, remove any call for cooling. This will reset any compressor lock outs.
NOTE: While the above step will reset any lock outs, compressor #2 will be held off for the ASCD, and compressor #1 may be held off for a portion of the
ASCD. See the next step.
1.
Compressor #2 is energized in place of compressor #1
2.
Check for line voltage at the compressor contactor, M1,
3.
If M1 is pulled in and voltage is supplied at M1, lightly touch
4.
5.
6.
when compressor #1 is unavailable for cooling calls. Check the UCB for alarms indicating that compressor #1 is locked out. Press and release the ALARMS button if the LED is not flashing an alarm.
and that the contactor is pulled in. Check for loose wiring between the contactor and the compressor.
the compressor housing. If it is hot, the compressor may be off on inherent protection. Cancel any calls for cooling and wait for the internal overload to reset. Test again when cool.
If M1 is not pulled in, check for 24 volts at the M1 coil. If 24 volts is present and M1 is not pulled in, replace the contactor.
Failing the above, if voltage is supplied at M1, M1 is pulled in, and the compressor still does not operate, replace the compressor.
If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose wiring between C1 and the compressor contactor.
10. If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and release the TEST button to reset all ASCDs.
11. If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip, repeat trip lock out, or ASCD, the economizer terminals of the UCB may be improperly wired. Check for 24 volts at the Y1 “OUT” terminal of the UCB. If 24 volts is present, trace the wiring from Y1 “OUT” for incorrect wiring. If 24 volts is not present at the Y1 “OUT” terminal, the UCB must be replaced.
12. For units without economizers: If 24 volts is present at the
Y1 “OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, the jumper in the Mate-N-Lock plug, and in the wiring from the
Mate-N-Lock plug to the Y1 “ECON” terminal.
For units with economizers: If 24 volts is present at the Y1
“OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, a poor connection between the UCB and economizer Mate-
N-Lock plugs, loose wiring from the Mate-N-Lock plug to the economizer, back to the Mate-N-Lock plug, and from the Mate-N-Lock plug to the Y1 “ECON” terminal. The economizer control may have faulted and is not returning the 24 volts to the Y1 “ECON” terminal even though the
Johnson Controls Unitary Products 67
518674-YIM-E-1210 economizer is not providing free cooling. To test the economizer control, disconnect the Mate-N-Locks and jumper between the WHITE and YELLOW wires of the
UCB’s Mate-N-Lock plug.
13. The UCB can be programmed to lock out compressor operation during free cooling and in low ambient conditions. These options are not enabled by default. They can be checked by local distributors.
For units with factory installed economizers, the UCB is programmed to lock out compressor operation when the
LAS set point is reached.
For units without factory installed or with field installed economizers, the UCB allows compressor operation all the time. This programming can be checked or changed by the local distributor.
14. If none of the above corrected the error, test the integrity of the UCB. Disconnect the C1 terminal wire and jumper it to the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If the compressor engages, the UCB has faulted.
15. If none of the above correct the error, replace the UCB.
Gas Heat Troubleshooting Guide
NOTE: For units with optional VFD without manual bypass, the
M3 contactor has been replaced with an "ice cube" relay (designated 'VFDR') located in the control box.
The relay is energized by "FAN" output from the UCB.
Normally-open relay contacts provide a run-permit signal to the VFD.
On calls for heating, the draft motor operates and the furnace lights but the supply air blower motor does not energize after a short delay (the room thermostat fan switch is in “AUTO” position).
1.
3.
The furnace may shut down on a high temperature condition during the procedure. If this occurs, the UCB energize the supply air blower motor until the high temperature limit has reset. Caution should be used at all times as the supply air blower may energize regardless of the room thermostat fan switch position.
Place the thermostat fan switch in the “ON” position. If the
supply air blower motor energizes, go to Step 9.
2.
If the supply air blower motor does not energize when the fan switch is set to “ON,” check that line voltage is being supplied to the contacts of the M3 contactor, and that the contactor is pulled in. Check for loose wiring between the contactor and the supply air blower motor.
If M3 is pulled in and voltage is supplied at M3, lightly touch the supply air blower motor housing. If it is hot, the motor may be off on inherent protection. Cancel any thermostat calls and set the fan switch to “AUTO”, wait for the internal overload to reset. Test again when cool.
4.
If M3 is not pulled in, check for 24 volts at the M3 coil. If 24 volts is present at M3 but M3 is not pulled in, replace the contactor.
5.
Failing the above, if there is line voltage supplied at M3, M3 is pulled in, and the supply air blower motor still does not operate, replace the motor.
6.
If 24 volts is not present at M3, check that 24 volts is present at the supply air blower motor terminal on the UCB.
If 24 volts is present at the UCB terminal, check for loose wiring between the UCB and M3.
a. If 24 volts is not present at the UCB supply air blower motor terminal, check for 24 volts from the room thermostat. If 24 volts is not present from the room thermostat, check for the following:
• Proper operation of the room thermostat (contact between R and G with the fan switch in the “ON” position and in the “AUTO” position during operation calls.)
• Proper wiring between the room thermostat and the
UCB, and
• Loose wiring from the room thermostat to the UCB
7.
If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat and the UCB, i.e. that the thermostat G terminal is connected to the G terminal of the UCB, and for loose wiring.
8.
If the thermostat and UCB are properly wired, replace the
UCB.
9.
If the blower motor runs with the fan switch in the “ON” position but does not run shortly after the furnace has ignited when the fan switch is in the “AUTO” position, check the room thermostat for contact between R and G during “W1” calls.
On calls for heating, the supply air blower operates but the draft motor does not (the room thermostat fan switch is in the
“AUTO” position).
1.
The draft motor has inherent protection. If the motor shell is hot to the touch, wait for the internal overload to reset.
2.
If the motor shell is cold with the room thermostat calling for heat, check for line voltage at the motor leads. If line voltage is present, replace the draft motor.
3.
If line voltage is not present, check for line voltage on the ignition control at the “inducer” terminal draft motor relay
(DMR or DMC) contacts in the main control box and check to see if the (DMR or DMC) is pulled in.
The draft motor runs but the furnace does not light and the spark ignitor does not spark.
1.
Check for 24 volts at the spark ignitor from the ignition control board (ICB). Check the 24-volt wiring from the ICB to the spark ignitor. Check for 24 volts at the ICB spark ignitor terminal.
2.
Check the ground wiring for the ICB and the gas valve is intact and making good electrical connection. Check the ceramic insulator on the spark ignitor for breaks or cracks.
Replace the spark ignitor if damaged.
68 Johnson Controls Unitary Products
518674-YIM-E-1210
3.
With the draft motor running, check for 24 volts at the pressure switch terminal on the ICB. If not present, check for 24 volts on the terminal from the pressure switch. If present, go to step 4. If 24 volts is not present, the either pressure or rollout switch is not closed. Or the draft motor is not sufficiently evacuating the heat exchanger tubes or the pressure switch has failed. Check the operation of the pressure switch. Check the line voltage to the unit; if line voltage is low, call the local power company. If the problem persists, the draft motor may need replacement.
4.
If the furnace is hot, it may be out on a high temperature limit open; wait for limit reset.
5.
If all are intact replace the ICB.
The draft motor runs and the spark ignitor sparks at the burner, but the burner does not ignite and a gas odor is not detected at the draft motor outlet.
1.
Check to ensure gas is being supplied to the unit. Confirm that the gas pressure to the unit is within the proper limits as described in the “POST START CHECKLIST”.
2.
Check the voltage at the gas valve and at the gas valve terminals on the ICB. Check all wiring between the ICB and the gas valve. Check to make sure the ground connections are intact.
3.
If 24 volts is present, remove the pilot burner and the orifice. The removal procedure is described in “BURNER/
ORIFICE INSPECTION/SERVICING.” Inspect the orifice for obstruction. If it is clear, replace the gas valve.
Main burners light but exhibit erratic flame characteristics.
1.
Check the main burner orifices for obstruction and alignment. The removal procedure is described in
“BURNER/ORIFICE INSPECTION/SERVICING”. Clean or replace burner orifices and burners as needed.
Johnson Controls Unitary Products 69
Subject to change without notice. Printed in U.S.A.
Copyright © 2011 by Johnson Controls, Inc. All rights reserved.
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
518674-YIM-E-1210
Supersedes: 518674-YIM-D-0810
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