York | ZJ300 | Specifications | York ZJ300 Specifications

York ZJ300 Specifications
R-410A
ZJ SERIES
15 - 25 Ton
60 Hertz
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 14
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Economizer And Power Exhaust Set Point Adjustments . 29
Optional BAS-Ready Economizer Power Exhaust
Damper Set Point Adjustment. . . . . . . . . . . . . . . . . . . . . . 30
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . 30
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . 32
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . .
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . .
Electric Heating Sequence Of Operations . . . . . . . . . . . .
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . .
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . .
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . .
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . .
Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional VAV Control Board Flash Codes . . . . . . . . . . . .
43
45
45
45
47
48
48
49
50
51
51
52
54
55
62
62
62
62
LIST OF TABLES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
ZJ180-300 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
ZJ180-300 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9
Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Supply Fan VFD Weights, In Lbs. . . . . . . . . . . . . . . . . . . . 9
ZJ180-300 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 11
Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ZJ180-300 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 25
Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 26
Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Gas Pipe Sizing - CapacIty of Pipe . . . . . . . . . . . . . . . . . 27
Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 27
Altitude/Temperature Correction Factors . . . . . . . . . . . . 35
1
2
3
4
5
6
7
8
9
10
11
ZJ180-300 Component Location . . . . . . . . . . . . . . . . . . . 6
Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ZJ180-300 Unit Dimensions Front View . . . . . . . . . . . . . 9
ZJ180-300 Unit Dimensions Rear View . . . . . . . . . . . . . 10
ZJ180-300 Unit Dimensions Rain Hood . . . . . . . . . . . . . 11
ZJ180-300 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fixed Outdoor Air Damper . . . . . . . . . . . . . . . . . . . . . . . 13
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Field Wiring Disconnect - Cooling Unit With/
Without Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . 15
External Supply Connection External Shut-Off . . . . . . . 27
Bottom Supply Connection External Shut-Off . . . . . . . . 27
Vent and Combustion Air Hood . . . . . . . . . . . . . . . . . . . 29
15
16
17
18
19
20
21
22
23
24
25
26
27
Air Flow Performance - Side Duct Application . . . . . . . .
Air Flow Performance - Bottom Duct Application . . . . . .
RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . .
Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . .
Limit Control Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Heat Anticipator Setpoint . . . . . . . . . . . . . . . . . .
Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . . . . .
Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . .
Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . .
Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . .
Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VAV Control Board Flash Codes . . . . . . . . . . . . . . . . . .
37
40
43
43
43
48
49
50
51
52
61
62
62
LIST OF FIGURES
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . .
Honeywell Economizer Control W7212 . . . . . . . . . . . . .
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Altitude/Temperature Correction Factors . . . . . . . . . . . .
Pressure Drop Across A Dry Indoor Coil Vs. Supply
Air CFM For All Unit Tonnages . . . . . . . . . . . . . . . . . . .
Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Valve and Controls . . . . . . . . . . . . . . . . . . . . . . . . .
Proper Pilot Flame Adjustment . . . . . . . . . . . . . . . . . . .
Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ZJ180 (15 Ton) Charging Chart . . . . . . . . . . . . . . . . . . .
ZJ210 (17.5 Ton) Charging Chart . . . . . . . . . . . . . . . . .
ZJ240 (20 Ton) Charging Chart . . . . . . . . . . . . . . . . . . .
ZJ300 (25 Ton) Charging Chart . . . . . . . . . . . . . . . . . . .
Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
34
35
44
50
51
53
53
53
54
54
54
54
61
284810-YIM-F-1210
284810-YIM-F-1210
General
YORK® Model ZJ units are either single package air conditions
equipped with optional factory installed electric heaters, or single
package gas-fired central heating furnaces with cooling unit.
Both are designed for outdoor installation on a rooftop or slab.
The 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 connection, duct connections, installation of
combustion air inlet hood, flue gas outlet hoods and fixed
outdoor air intake damper (units without economizer or
motorized damper option only) at the point of installation.
The supplemental electric heaters have nickel-chrome
elements and utilize single point power connection.
These gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark ignition with
proven pilot. All gas heaters are shipped from the factory equipped
for natural gas use, but can be field converted to L.P./Propane with
Kit Model # 1NP0418. See Gas Heat Application Data Table.
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.
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.
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.
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.
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.
2
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 CSAB149.1- latest edition.
Johnson Controls Unitary Products
284810-YIM-F-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.
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.
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.
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.
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.
Reference
Additional information is available in the following reference
forms:
• Technical Guide - ZJ180-300, 251934
• General Installation - ZJ180-300, 284810
Johnson Controls Unitary Products
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.
3
284810-YIM-F-1210
Nomenclature
15-25 Ton Sunline Magnum™ Model Number Nomenclature
Z J 180 N24 A 2 A AA 1 0 1 2 4 A
Product Category
Product Style
Z = A/C, Single Pkg., R-410A
A = Style A
Product Identifier
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
J = 11.0+ EER A/C
SS Drain Pan
CPC Controller, DFS, APS
Nominal Cooling Capacity
Johnson Controller UNT 1126 (N2 protocol), DFS, APS
Honeywell Controller, DFS, APS
180 = 15 Ton
210 = 17.5 Ton
240 = 20 Ton
300 = 25 Ton
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller Simplicity™LINC
York Commercial Comfort System (YCCS) Rtu Controller
Heat Type and Nominal Heat Capacity
Hot Gas Bypass (Standard on VAV, Optional on CV)
C00 = Cooling Only. No field installed
electric heat
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)
Gas Heat Options
Variable Air Volume, VFD and Manual Bypass with Simplicity™LINC (not available with factory installed BAS options)
Variable Air Volume, VFD (BAS ready)
N24 = 240 MBH Output Aluminized Steel
N32 = 320 MBH Output Aluminized Steel
S24 = 240 MBH Output Stainless Steel
S32 = 320 MBH Output Stainless Steel
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
Electric Heat Options
4" Pleated filters
E18 = 18 KW
E36 = 36 KW
E54 = 54 KW
E72 = 72 KW
BAS Ready Economizer (2-10 V.D.C. Actuator without a controller)
Double Wall Construction
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
Product Generation
Airflow
A = Std. Motor
B = Std. Motor/Economizer
C = Std. Motor/Economizer/Power Exhaust
(Downflow Only)
D = Std. Motor/Motorized Damper
E = Std. Motor/Motorized Damper/Barometric Relief
J = Std. Motor/Economizer/Barometric Relief
N = Hi Static
P = Hi Static/Economizer
Q = Hi Static/Economizer/Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper
K = Hi Static/Motorized Damper/Barometric Relief
S = Hi Static/Economizer/Barometric Relief
2 = Low Static
3 = Low Static/Economizer
4 = Low Static/Economizer/Power Exhaust
(Downflow Only)
5 = Low Static/Motorized Damper
6 = Low Static/Motorized Damper/Barometric Relief
7 = Low Static/Economizer/Barometric Relief
Voltage
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
1 = First Generation
Additional Options
Standard Cabinet
Hinged Filter Door & Tool Free Access Cabinet
AA = None
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
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
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
BA = Hinged Filter Door & Tool Free Access Panels
BB = Phase Monitor, Hinged Filter Door & Tool Free
Access Panels
BC = Coil Guard, Hinged Filter Door & Tool Free
Access Panels
BD = Dirty Filter Switch, Hinged Filter Door &
Tool Free Access Panels
BE = Phase Monitor & Coil Guard, Hinged Filter
Door & Tool Free Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged
Filter Door & Tool Free Access Panels
BG = Coil Guard & Dirty Filter Switch, Hinged Filter
Door & Tool Free Access Panels
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged Filter Door & Tool Free Access Panels
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
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
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Johnson Controls Unitary Products
284810-YIM-F-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.
4.
5.
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
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, 28 and 52 of these instructions.
In Canada:
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 27 of these instructions.
This equipment is not to be used for temporary heating of
buildings or structures under construction.
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.
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.
6.
If a factory option convenience outlet is installed, the
weatherproof outlet cover must be field installed. The cover
shall be located in the unit control box. 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.
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 @ 1877-UPG-SERV for guidance. Additional
accessories may be needed for stable operation at
temperatures below 30°F.
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
284810-YIM-F-1210
Simplicity® Control Board
Slide In/ Plug In
Internal Economizer
(Optional)
110 Volt Convenience
Outlet (“Powered” or
“Non-Powered” Optional)
2” Disposable Filters
(4” Filters Optional)
Disconnect Location
(Optional Disconnect Switch)
Bottom Power and
Control Wiring Entry
Power Ventor Motor
Electric Heater Location
(Optional Electric/Electric Units)
Location of VFD (Optional)
Location of VFD Bypass (Optional)
Belt Drive
Blower Motor
Copper Tube/
Aluminum Fin Thermal
1” NPT
Evaporator Expansion
Valve
Condensate Drain
Coils
Filter Drier
(Solid Core)
14 Gauge
Base Rails
with Lifting Holes
Copper Tube/Aluminum Fin
Condenser Coils
4-High Efficiency Scroll Compressors
Figure 1: ZJ180-300 Component Location
6
Johnson Controls Unitary Products
284810-YIM-F-1210
Table 1:
ZJ180-300 Unit Limitations
Unit Limitations
Size
(Tons)
180
(15)
210
(17.5)
240
(20)
300
(25)
Unit Voltage
Applied Voltage
Outdoor DB Temp
Min
Max
Max (°F)
208/230-3-60
187
252
125
460-3-60
432
504
125
575-3-60
540
630
125
208/230-3-60
187
252
125
460-3-60
432
504
125
575-3-60
540
630
125
208/230-3-60
187
252
125
460-3-60
432
504
125
575-3-60
540
630
125
208/230-3-60
187
252
125
460-3-60
432
504
125
575-3-60
540
630
125
Location
Clearances
Use the following guidelines to select a suitable location for
these units:
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 6 for clearances required for combustible
construction, servicing, and proper unit operation.
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.
Johnson Controls Unitary Products
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.
7
284810-YIM-F-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.
C
LENGTH OF FORKS MUST BE A MINIMUM OF 90 INCHES.
B
E
D
A
All panels must be secured in place when the unit is
lifted.
F
The condenser coils should be protected from rigging
cable damage with plywood or other suitable material.
Figure 3: Unit 6 Point Load Weight
Y
X
FRONT
LEFT
Figure 4: Center of Gravity
B
C
A
D
Figure 2: Unit 4 Point Load Weight
Table 2:
Weights and Dimensions
Weight (lbs.)
Center of Gravity
Size
(Tons) Shipping Operating
X
Y
180
2614
2609
85.25
44
(15)
210
2670
2665
85.25
44
(17.5)
240
2702
2697
85.05
44
(20)
300
2788
2783
85.25
44
(25)
8
4 Point Load Location (lbs.)
A
B
C
D
A
6 Point Load Location (lbs.)
B
C
D
E
F
467
781
852
510
287
392
568
620
428
313
477
797
870
520
293
401
580
633
437
320
485
805
878
529
298
406
585
638
443
326
498
833
908
544
306
419
606
661
457
334
Johnson Controls Unitary Products
284810-YIM-F-1210
Table 3:
ZJ180-300 Unit Accessory Weights
Weight (lbs.)
Unit Accessory
Shipping
165
90
40
240
260
150
50
60
95
220
190
10
Economizer
Power Exhaust
Electric Heat1
Gas Heat2
Double Wall
Motorized Damper
Barometric Damper
Econ./Motorized Damper Rain Hood
Econ./Power Exhaust Rain Hood
Wood Skid
Roof Curb
Hot Gas Bypass
Supply Fan VFD
Operating
160
85
40
240
260
150
45
55
90
220
185
10
See Table 5
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).
ECONOMIZER / MOTORIZED DAMPER
FIXED OUTDOOR INTAKE AIR AND
POWER EXHAUST RAIN HOODS
(See detail Y)
BLOWER MOTOR
ACCESS (Location
of Optional VFD Bypass)
BLOWER
COMPARTMENT
ACCESS
(Auxiliary)
DOT PLUG
(For pressure
drop reading)
BLOWER ACCESS
(Location of
Optional VFD)
COMPRESSOR ACCESS
180-19/32
52-5/8
GAS OR ELECTRIC
HEAT
ACCESS
COIL
GUARD
KIT
VENT AIR
OUTLET
HOODS
COMBUSTION
AIR INLET HOOD
21.00
(C) GAS
SUPPLY
ENTRY
9-3/4
CONDENSER
COILS
7-1/8
136-1/4
(A) CONTROL WIRING
ENTRY
92
6-3/8
5
DISCONNECT
SWITCH
LOCATION
46-5/8
11-1/2
CONTROL BOX
ACCESS
5-7/8
(B) POWER
WIRING
ENTRY
35
BOTTOM SUPPLY
AND RETURN
AIR OPENINGS
(See Note)
35-1/4
33
2-3/4
RETURN
AIR
SUPPLY
AIR
3-3/4
21-1/2
UNIT BASE RAILS
Shown separately to illustrate
Bottom Duct openings. Power
and Gas Piping Connection
location.
(D)
GAS SUPPLY
ENTRY
NOTE:
For curb mounted units, refer to the curb hanger
dimensions of the curb for proper size of the
supply and return air duct connections.
(B) POWER WIRING
ENTRY
11-1/8
8-1/8
12-1/2
(A) CONTROL WIRING
ENTRY
46-5/8
9-1/4
9-3/4
Figure 5: ZJ180-300 Unit Dimensions Front View
Table 4:
Hole
A
B
C
D
Table 5:
Utilities Entry
Opening Size
Diameter
1-1/8” KO
3/4” NPS (Fem.)
3-5/8” KO
3” NPS (Fem.)
2-3/8” KO
1-11/16” Hole
Used For
Front
Bottom
Front
Power Wiring
Bottom
Gas Piping (Front)1
Gas Piping (Bottom)1,2
Control Wiring
1. One-inch Gas Piping NPT Required.
2. Opening in the bottom to the unit can be located by the slice in the
insulation.
Supply Fan VFD Weights, In Lbs.
Supply Fan Motor
230V
460V
575V
W/O Manual Bypass
5.0 hp
7.5 hp
10.0 hp
15.0 hp
25
30
30
30
25
30
30
30
30
30
35
40
W/Manual Bypass
5.0 hp
7.5 hp
10.0 hp
15.0 hp
30
35
35
40
30
35
35
35
35
35
40
45
Note: All entry holes should be sealed to prevent rain water entry
into building.
Johnson Controls Unitary Products
9
284810-YIM-F-1210
Dot Plug
(for Pressure
Drop Reading)
Evaporator
Section
40-3/8”
Supply
Air
Outdoor
Air
Return
Air
18-5/8”
Supply Air
Access
40-1/2”
27-3/4”
Filter
Access
5-1/8”
Dimensions listed are for side duct
flange opening; see Field Accessories
for Side Duct Flange Kit.
39-5/8”
Return Air
Access
Outdoor Air
Compartment
Access
1” NPT Female
Cond. Drain
Connector
Figure 6: ZJ180-300 Unit Dimensions Rear View
NOTE: Units are shipped with the bottom duct openings
covered. An accessory flange kit is available for
connecting side ducts.
For bottom duct applications:
For side duct applications:
1.
Remove the side panels from the supply and return air
compartments to gain access to the bottom supply and
return air duct covers.
1.
Replace the side panels on the supply and return air
compartments with the accessory flange kit panels.
2.
Connect ductwork to the flanges on those panels.
2.
Remove and discard the bottom duct covers. Duct
openings are closed with sheet metal covers except when
the unit includes a power exhaust option. The covering
consists of a heavy black paper composition.
3.
Replace the side supply and return air compartment
panels.
10
Johnson Controls Unitary Products
284810-YIM-F-1210
Supply Air
Compartment
Power Exhaust
Rain Hood
(on Return
Air Compartment)
Economizer Motorized
Damper Rain Hood
(on Outdoor
Air Compartment)
Economizer/Motorized Damper
and Power Exhaust Rain Hood
Fixed
Outdoor Air
Intake Hood
(Located on
Return Air
Compartment)
36-5/8”
1” Condensate
Drain (Must be
Trapped)
16-1/8”
5”
28-3/16”
92”
Rear View
LH View
Detail “Y”
Unit with Rain Hoods
Figure 7: ZJ180-300 Unit Dimensions Rain Hood
Table 6:
ZJ180-300 Unit Clearances
Direction
Top1
Front
Rear
Distance (in.)
72 With 36 Maximum
Horizontal Overhang (For
Condenser Air Discharge)
36
24 (W/O Economizer)
49 (W/Economizer)
Direction
Distance (in.)
Right
36
Bottom2
0
24 (W/O Economizer)
36 (W/Economizer)3
Left
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.
3. If economizer is factory installed, the unassembled rain hood must be removed from its ride along position in front of
the evaporator coil, or in the outdoor air compartment, prior to final installation.
Note: ELEC/ELEC Models: Units and ductwork are approved for zero clearance to combustible material when
equipped with electric heaters.
GAS/ELEC Models: A 1" clearance must be provided between any combustible material and the supply air
ductwork for a distance of 3 feet from the unit.
The products of combustion must not be allowed to accumulate within a confined space and recirculate.
Locate unit so that the vent air outlet hood is at least:
• Three (3) feet above any force air inlet located within 10 horizontal feet (excluding those integral to the unit).
• Four (4) feet below, four horizontal feet from, or one foot above any door or gravity air inlet into the building.
• Four (4) feet from electric and gas meters, regulators and relief equipment.
Johnson Controls Unitary Products
11
284810-YIM-F-1210
25-1/4"
Figure 8: ZJ180-300 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 5 for bottom air duct openings. Refer to Figure 6
for side air duct openings.
NOTE: It is recommended that, in Canada, the outlet duct be
provided with a removable access panel. It is
recommended that this opening be accessible when
the unit is installed in service, and of a size such that
smoke or reflected light may be observed inside the
casing to indicate the presence of leaks in the heat
exchanger. The cover should be attached in a
manner adequate to prevent leakage.
Gasketing and mounting screws are provided in a parts bag
attached to the hood assembly. Apply gasketing to the three
flange surfaces on the hood prior to installing the hood. Extend
gasketing 1/4 inch beyond the top and bottom of the two side
flanges to insure adequate sealing.
Adjusting the damper to the desired air flow may be done
before mounting the hood into position or after installation by
removing the front hood panel or the screen on the bottom of
the hood. Damper baffle in position 1 will allow approximately
10% outdoor air flow, position 2 approximately 15% and, to
allow approximately 25%, remove the damper baffle.
On units with bottom return air application install the damper
assembly over the opening in the side return air access panel.
Remove and discard the opening cover and the covering over
the hood mounting holes (used for shipping) before installing.
Secure with the screws provided.
On units with side return air applications, install the damper
assembly on the return air ductwork as close to the unit as
possible. Cut an opening 16 inches high by 18 inches wide in the
ductwork to accommodate the damper. Using the holes in the
hood flanges as a template, drill 9/64 inch diameter (#26 drill)
holes into the ductwork and secure with the screws provided.
Fixed Outdoor Air Intake Damper
This damper is shipped inside the return air compartment. It is
completely assembled and ready for installation. A damper
baffle inside of the hood is adjustable to provide variable
amounts of outdoor air intake on units that are not provided with
an economizer or a motorized damper option. Refer to the
Fixed Outdoor Damper Figure 9.
12
If outdoor air intake will not be required on units with
bottom return air applications, the damper assembly
should still be mounted on the side return air access
panel, per the instructions above, to insure moisture is
not drawn into the unit during operation. The covering
over the mounting holes only need be removed. Do not
remove the opening cover.
Johnson Controls Unitary Products
284810-YIM-F-1210
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.
Side Supply
Air Access
Panel
*
Damper
Baffle
Hood
Screen
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
Side Return Air
Access Panel
Outdoor Air
Opening Cover
Rear View
1
2
* Gasketed
Flange
POE (polyolester) compressor lubricants are known to cause
long term damage to some synthetic roofing materials.
Figure 9: Fixed Outdoor Air Damper
Condensate Drain
Plumbing must conform to local codes. Use a sealing compound
on male pipe threads. Install a condensate drain line from the
one-inch NPT female connection on the unit to an open drain.
NOTE: The condensate drain operates in a negative pressure
in the cabinet. The condensate drain line MUST be
trapped to provide proper drainage. See Figure 10.
Base
Pan
Unit Condensate
Connection
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.
3” Min.
2”
Base
Rails
Drain
Plug
Do not loosen compressor mounting bolts.
Figure 10: Condensate Drain
Filters
Compressors
Two-inch filters are supplied with each unit, but units can be
converted easily to four-inch filters. Filters must always be
installed ahead of the evaporator coil and must be kept clean or
replaced with same size and type. Dirty filters will reduce the
capacity of the unit and will result in frosted coils or safety
shutdown. Minimum filter area and required sizes are shown in
Physical Data Table 9.
The scroll compressor used in this product is specifically
designed to operate with R-410A Refrigerant and cannot be
interchanged.
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
Make sure that panel latches are properly positioned on
the unit to maintain an airtight seal.
13
284810-YIM-F-1210
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.
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.
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 2083-60 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 1 for the recommended mounting location.
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 11 and 12 for typical field wiring and to the
appropriate unit wiring diagram mounted inside control doors
for control circuit and power wiring information.
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.
Power wiring is brought into the unit through the side of the unit
or the basepan inside the curb.
TERMINAL BLOCK TB1
GROUND
LUG
FACTORY OR FIELD
SUPPLIED DISCONNECT
THREE
PHASE
POWER
SUPPLY
Figure 11: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat
14
Johnson Controls Unitary Products
284810-YIM-F-1210
Thermostat Wiring
Space Sensor
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.
The space sensor, if used, should be located on an inside wall
approximately 56 inches above the floor where it will not be
subject to drafts, sun exposure or heat from electrical fixtures or
appliances. Follow manufacturer's instructions enclosed with
sensor for general installation procedure.
Table 7:
Control Wire Sizes
Wire Size
18 AWG
Maximum Length1
150 Feet
1. From the unit to the thermostat and back to the unit.
CONTROL
TERMINAL
BLOCK
THERMOSTAT
TERMINALS
W1
W1
W2
W2
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 2083-60 or 380-3-50 operation. See unit wiring diagram.
Y1
1
G
Y1
OCC
Y2
P
Y3
P1
Y4
Y2
X
G
Smoke
Detector
R
R
SD
C
C
R
Jumper
2
SD
EXPANSION
BOARD
TERMINAL
BLOCK
3
RC
4
OCC
X
SD
C
24 VAC
Class 2
Y3
5
Y4
TERMINALS ON
A LIMITED
NUMBER OF
THERMOSTATS
1
Second stage heating not required on single stage heating units.
2
Jumper is required if there is no Smoke Detector circuit.
3
Jumper is required for any combination of R, RC, or RH.
4
OCC is an output from the thermostat to indicate the Occupied condition.
5
X is an input to the thermostat to display Error Status conditions.
Figure 12: Typical Field Wiring 24 Volt Thermostat
Johnson Controls Unitary Products
15
284810-YIM-F-1210
Table 8:
Electrical Data
ZJ180-300 - Standard Drive Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 14.7
115
23.0
2.1
15.4
0.0
230-3-60 14.7
115
23.0
2.1
14.4
0.0
460-3-60 7.7
50
12.0
1.1
7.2
0.0
575-3-60 6.4
40
10.0
0.9
5.9
0.0
208-3-60 16.7
120
26.0
2.1
15.4
0.0
230-3-60 16.7
120
26.0
2.1
14.4
0.0
460-3-60 8.7
60
15.5
1.1
7.2
0.0
575-3-60 6.7
42
10.5
0.9
5.9
0.0
208-3-60 17.9
120
28.0
3.7
15.4
0.0
230-3-60 17.9
120
28.0
3.7
14.4
0.0
460-3-60 9.6
70
15.0
1.9
7.2
0.0
575-3-60 7.4
53
11.5
1.5
5.9
0.0
180
(15)
210
(17.5)
240
(20)
16
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
86.5
86.5
112.9
160.1
169.4
85.3
85.3
126.3
147.9
191.2
44.3
44.3
63.1
74.0
95.6
36.7
36.7
50.7
59.3
76.7
94.8
94.8
112.9
160.1
169.4
93.8
93.8
126.3
147.9
191.2
48.6
48.6
63.1
74.0
95.6
38.0
38.0
50.7
59.3
76.7
106.3
106.3
112.9
160.1
169.4
105.3
105.3
126.3
147.9
191.2
55.6
55.6
63.1
74.0
95.6
43.4
43.4
50.7
59.3
76.7
Max Fuse2/
Breaker3
Size
(Amps)
100
100
125
175
200
90
90
150
175
225
50
50
70
90
110
40
40
60
70
90
110
110
125
175
200
110
110
150
175
225
50
50
70
90
110
40
40
60
70
90
110
110
125
175
200
110
110
150
175
225
60
60
70
90
110
50
50
60
70
90
Johnson Controls Unitary Products
284810-YIM-F-1210
ZJ180-300 - Standard Drive Without Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 23.0
160
31.5
3.7
28.0
0.0
230-3-60 23.0
160
31.5
3.7
26.0
0.0
460-3-60 12.2
87
17.1
1.9
13.0
0.0
575-3-60 8.7
62
13.5
1.5
10.3
0.0
300
(25)
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
141.8
141.8
141.8
175.9
185.2
139.3
139.3
140.8
162.4
205.7
72.7
72.7
72.7
81.2
102.9
53.7
53.7
56.2
64.8
82.2
Max Fuse2/
Breaker3
Size
(Amps)
150
150
150
200
200
150
150
150
175
225
80
80
80
90
110
60
60
60
70
90
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
17
284810-YIM-F-1210
ZJ180-300 - Standard Drive With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 14.7
115
23.0
2.1
15.4
10.0
230-3-60 14.7
115
23.0
2.1
14.4
10.0
460-3-60 7.7
50
12.0
1.1
7.2
5.0
575-3-60 6.4
40
10.0
0.9
5.9
4.0
208-3-60 16.7
120
26.0
2.1
15.4
10.0
230-3-60 16.7
120
26.0
2.1
14.4
10.0
460-3-60 8.7
60
15.5
1.1
7.2
5.0
575-3-60 6.7
42
10.5
0.9
5.9
4.0
208-3-60 17.9
120
28.0
3.7
15.4
10.0
230-3-60 17.9
120
28.0
3.7
14.4
10.0
460-3-60 9.6
70
15.0
1.9
7.2
5.0
575-3-60 7.4
53
11.5
1.5
5.9
4.0
180
(15)
210
(17.5)
240
(20)
18
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages Amps
1
37.5
2
74.9
2
112.7
2
150.2
1
43.3
2
86.6
2
129.9
2
173.2
1
21.7
2
43.3
2
65.0
2
86.6
1
17.3
2
34.6
2
52.0
2
69.3
1
37.5
2
74.9
2
112.7
2
150.2
1
43.3
2
86.6
2
129.9
2
173.2
1
21.7
2
43.3
2
65.0
2
86.6
1
17.3
2
34.6
2
52.0
2
69.3
1
37.5
2
74.9
2
112.7
2
150.2
1
43.3
2
86.6
2
129.9
2
173.2
1
21.7
2
43.3
2
65.0
2
86.6
1
17.3
2
34.6
2
52.0
2
69.3
MCA1
(Amps)
96.5
96.5
125.4
172.6
181.9
95.3
95.3
138.8
160.4
203.7
49.3
49.3
69.4
80.2
101.9
40.7
40.7
55.7
64.3
81.7
104.8
104.8
125.4
172.6
181.9
103.8
103.8
138.8
160.4
203.7
53.6
53.6
69.4
80.2
101.9
42.0
42.0
55.7
64.3
81.7
116.3
116.3
125.4
172.6
181.9
115.3
115.3
138.8
160.4
203.7
60.6
60.6
69.4
80.2
101.9
47.4
47.4
55.7
64.3
81.7
Max Fuse2/
Breaker3
Size
(Amps)
110
110
150
175
200
100
100
150
175
225
50
50
70
90
110
45
45
60
70
90
110
110
150
175
200
110
110
150
175
225
60
60
70
90
110
45
45
60
70
90
125
125
150
175
200
125
125
150
175
225
70
70
70
90
110
50
50
60
70
90
Johnson Controls Unitary Products
284810-YIM-F-1210
ZJ180-300 - Standard Drive With Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 23.0
160
31.5
3.7
28.0
10.0
230-3-60 23.0
160
31.5
3.7
26.0
10.0
460-3-60 12.2
87
17.1
1.9
13.0
5.0
575-3-60 8.7
62
13.5
1.5
10.3
4.0
300
(25)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages Amps
1
37.5
2
74.9
2
112.7
2
150.2
1
43.3
2
86.6
2
129.9
2
173.2
1
21.7
2
43.3
2
65.0
2
86.6
1
17.3
2
34.6
2
52.0
2
69.3
MCA1
(Amps)
151.8
151.8
151.8
188.4
197.7
149.3
149.3
153.3
174.9
218.2
77.7
77.7
77.7
87.5
109.1
57.7
57.7
61.2
69.8
87.2
Max Fuse2/
Breaker3
Size
(Amps)
175
175
175
200
200
175
175
175
175
225
90
90
90
90
110
60
60
70
70
90
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
19
284810-YIM-F-1210
ZJ180-300 - High Static Drive Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 14.7
115
23.0
2.1
15.4
0.0
230-3-60 14.7
115
23.0
2.1
14.4
0.0
460-3-60 7.7
50
12.0
1.1
7.2
0.0
575-3-60 6.4
40
10.0
0.9
5.9
0.0
208-3-60 16.7
120
26.0
2.1
20.0
0.0
230-3-60 16.7
120
26.0
2.1
20.0
0.0
460-3-60 8.7
60
15.5
1.1
10.0
0.0
575-3-60 6.7
42
10.5
0.9
8.2
0.0
208-3-60 17.9
120
28.0
3.7
15.4
0.0
230-3-60 17.9
120
28.0
3.7
14.4
0.0
460-3-60 9.6
70
15.0
1.9
7.2
0.0
575-3-60 7.4
53
11.5
1.5
5.9
0.0
180
(15)
210
(17.5)
240
(20)
20
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
86.5
86.5
112.9
160.1
169.4
85.3
85.3
126.3
147.9
191.2
44.3
44.3
63.1
74.0
95.6
36.7
36.7
50.7
59.3
76.7
100.2
100.2
118.7
165.9
175.2
100.2
100.2
133.3
154.9
198.2
51.7
51.7
66.6
77.5
99.1
40.7
40.7
53.6
62.2
79.5
106.3
106.3
112.9
160.1
169.4
105.3
105.3
126.3
147.9
191.2
55.6
55.6
63.1
74.0
95.6
43.4
43.4
50.7
59.3
76.7
Max Fuse2/
Breaker3
Size
(Amps)
100
100
125
175
200
90
90
150
175
225
50
50
70
90
110
40
40
60
70
90
110
110
125
175
200
110
110
150
175
225
60
60
70
90
110
45
45
60
70
90
110
110
125
175
200
110
110
150
175
225
60
60
70
90
110
50
50
60
70
90
Johnson Controls Unitary Products
284810-YIM-F-1210
ZJ180-300 - High Static Drive Without Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 23.0
160
31.5
3.7
38.6
0.0
230-3-60 23.0
160
31.5
3.7
38.6
0.0
460-3-60 12.2
87
17.1
1.9
19.3
0.0
575-3-60 8.7
62
13.5
1.5
15.4
0.0
300
(25)
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
155.1
155.1
155.1
189.1
198.4
155.1
155.1
156.5
178.2
221.5
80.5
80.5
80.5
89.1
110.7
60.1
60.1
62.6
71.2
88.5
Max Fuse2/
Breaker3
Size
(Amps)
175
175
175
200
225
175
175
175
200
250
90
90
90
100
125
70
70
70
80
100
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
21
284810-YIM-F-1210
ZJ180-300 - High Static Drive With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 14.7
115
23.0
2.1
15.4
10.0
230-3-60 14.7
115
23.0
2.1
14.4
10.0
460-3-60 7.7
50
12.0
1.1
7.2
5.0
575-3-60 6.4
40
10.0
0.9
5.9
4.0
208-3-60 16.7
120
26.0
2.1
20.0
10.0
230-3-60 16.7
120
26.0
2.1
20.0
10.0
460-3-60 8.7
60
15.5
1.1
10.0
5.0
575-3-60 6.7
42
10.5
0.9
8.2
4.0
208-3-60 17.9
120
28.0
3.7
15.4
10.0
230-3-60 17.9
120
28.0
3.7
14.4
10.0
460-3-60 9.6
70
15.0
1.9
7.2
5.0
575-3-60 7.4
53
11.5
1.5
5.9
4.0
180
(15)
210
(17.5)
240
(20)
22
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
96.5
96.5
125.4
172.6
181.9
95.3
95.3
138.8
160.4
203.7
49.3
49.3
69.4
80.2
101.9
40.7
40.7
55.7
64.3
81.7
110.2
110.2
131.2
178.4
187.7
110.2
110.2
145.8
167.4
210.7
56.7
56.7
72.9
83.7
105.4
44.7
44.7
58.6
67.2
84.5
116.3
116.3
125.4
172.6
181.9
115.3
115.3
138.8
160.4
203.7
60.6
60.6
69.4
80.2
101.9
47.4
47.4
55.7
64.3
81.7
Max Fuse2/
Breaker3
Size
(Amps)
110
110
150
175
200
100
100
150
175
225
50
50
70
90
110
45
45
60
70
90
125
125
150
200
200
125
125
150
175
225
60
60
80
90
110
50
50
60
70
90
125
125
150
175
200
125
125
150
175
225
70
70
70
90
110
50
50
60
70
90
Johnson Controls Unitary Products
284810-YIM-F-1210
ZJ180-300 - High Static Drive With Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 23.0
160
31.5
3.7
38.6
10.0
230-3-60 23.0
160
31.5
3.7
38.6
10.0
460-3-60 12.2
87
17.1
1.9
19.3
5.0
575-3-60 8.7
62
13.5
1.5
15.4
4.0
300
(25)
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
165.1
165.1
165.1
201.6
210.9
165.1
165.1
169.0
190.7
234.0
85.5
85.5
85.5
95.3
117.0
64.1
64.1
67.6
76.2
93.5
Max Fuse2/
Breaker3
Size
(Amps)
200
200
200
225
225
200
200
200
225
250
100
100
100
110
125
70
70
70
90
100
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
23
284810-YIM-F-1210
ZJ300 - Low Static Drive Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 23.0
160
31.5
3.7
20.0
0.0
230-3-60 23.0
160
31.5
3.7
20.0
0.0
460-3-60 12.2
87
17.1
1.9
10.0
0.0
575-3-60 8.7
62
13.5
1.5
8.2
0.0
300
(25)
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
132.6
132.6
132.6
165.9
175.2
132.6
132.6
133.3
154.9
198.2
69.5
69.5
69.5
77.5
99.1
51.2
51.2
53.6
62.2
79.5
Max Fuse2/
Breaker3
Size
(Amps)
150
150
150
175
200
150
150
150
175
225
80
80
80
90
110
60
60
60
70
90
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
ZJ300 - Low Static Drive With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
FLA
Supply
Blower
Motor
FLA
Pwr
Conv
Outlet
FLA
208-3-60 23.0
160
31.5
3.7
20.0
10.0
230-3-60 23.0
160
31.5
3.7
20.0
10.0
460-3-60 12.2
87
17.1
1.9
10.0
5.0
575-3-60 8.7
62
13.5
1.5
8.2
4.0
300
(25)
MCA1
(Amps)
Electric Heat Option
Model
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
kW
13.5
27.0
40.6
54.1
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
18.0
36.0
54.0
72.0
Stages
1
2
2
2
1
2
2
2
1
2
2
2
1
2
2
2
Amps
37.5
74.9
112.7
150.2
43.3
86.6
129.9
173.2
21.7
43.3
65.0
86.6
17.3
34.6
52.0
69.3
142.6
142.6
142.6
178.4
187.7
142.6
142.6
145.8
167.4
210.7
74.5
74.5
74.5
83.7
105.4
55.2
55.2
58.6
67.2
84.5
Max Fuse2/
Breaker3
Size
(Amps)
150
150
150
200
200
150
150
150
175
225
80
80
80
90
110
60
60
60
70
90
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
24
Johnson Controls Unitary Products
284810-YIM-F-1210
Table 9:
ZJ180-300 Physical Data
Models
Component
ZJ180
ZJ210
ZJ240
ZJ300
15
17.5
20
25
Gross Capacity @ ARI A point (Btu)
183500
213700
242000
312000
ARI net capacity (Btu)
178500
206000
235000
295000
12.4
12.1
11.6
10.4
SEER
-
-
-
-
IPLV
13.9
13.2
12.9
10.6
10000
Nominal Tonnage
ARI COOLING PERFORMANCE
EER
Nominal CFM
6000
7000
8000
System power (KW)
14.40
17.10
20.10
28.50
R-410a
R-410a
R-410a
R-410a
System 1
12-8
12-8
12-0
12-8
System 2
12-8
13-8
12-0
13-8
System 3
12-8
12-8
12-0
13-0
System 4
12-8
12-8
12-0
12-8
Refrigerant type
Refrigerant charge (lb-oz)
ARI HEATING PERFORMANCE
Heating model
24
32
24
32
24
32
24
32
Heat input (K Btu)
300
400
300
400
300
400
300
400
Heat output (K Btu)
240
320
240
320
240
320
240
320
-
-
-
-
-
-
-
-
Steady state efficiency (%)
80
80
80
80
80
80
80
80
No. burners
6
8
6
8
6
8
6
8
No. stages
2
2
2
2
2
2
2
2
20-50
30-60
20-50
30-60
20-50
30-60
20-50
30-60
195
195
195
195
195
195
195
195
1
1
1
1
1
1
1
1
AFUE%
Temperature Rise Range (ºF)
Gas Limit Setting (ºF)
Gas piping connection (in.)
DIMENSIONS (inches)
Length
180-19/32
Width
92
Height
52-5/8
OPERATING WT. (lbs.)
2609
2665
2697
2783
Scroll
Scroll
Scroll
Scroll
4
4
4
4
25 / 50 / 75 / 100
25 / 50 / 75 / 100
25 / 50 / 75 / 100
25 / 50 / 75 / 100
63.8
COMPRESSORS
Type
Quantity
Unit Capacity Steps (%)
CONDENSER COIL DATA
Face area (Sq. Ft.)
63.8
63.8
63.8
Rows
2
2
2
2
Fins per inch
20
20
20
20
Tube diameter (in.)
3/8
3/8
3/8
3/8
Split-face
Split-face
Split-face
Split-face
Face area (Sq. Ft.)
25
25
25
25
Rows
4
4
4
4
13.5
13.5
13.5
13.5
Circuitry Type
EVAPORATOR COIL DATA
Fins per inch
Tube diameter
3/8
3/8
3/8
3/8
Circuitry Type
Split-face
Split-face
Split-face
Split-face
TXV
TXV
TXV
TXV
Refrigerant control
Johnson Controls Unitary Products
25
284810-YIM-F-1210
Table 9:
ZJ180-300 Physical Data (Continued)
Models
Component
ZJ180
ZJ210
ZJ240
ZJ300
15
17.5
20
25
4
4
4
4
Nominal Tonnage
CONDENSER FAN DATA
Quantity
Fan diameter (Inch)
24
24
30
30
Type
Prop
Prop
Prop
Prop
Drive type
Direct
Direct
Direct
Direct
No. speeds
1
1
1
1
Number of motors
4
4
4
4
1/3
1/3
1/3
1/3
Motor HP each
RPM
850
850
870
870
Nominal total CFM
4000
4000
5000
5000
BELT DRIVE EVAP FAN DATA
Quantity
Fan Size (Inch)
Type
1
1
1
1
15 X 15
18 X 15
18 X 15
18 X 15
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Motor Sheave
1VP65
1VP65
1VP60
1VP60
1VP60
1VP60
1VP60
Blower Sheave
BK110
BK090
BK110
BK090
BK110
BK090
1B5V94 1B5V110 1B5V94
Belt
BX85
BX81
BX78
BX75
BX78
BX75
BX78
5
5
5
7.5
5
7.5
7.5
Motor HP each
1VP75X 1VP75X
5VX840 5VX860
10
15
RPM
1725
1725
1725
1725
1725
1725
1725
1725
1725
Frame size
184T
184T
184T
213T
184T
213T
213T
215T
254T
FILTERS
Quantity - Size
12 - 12 x 24 x 2
12 - 12 x 24 x 2
Optional Electric Heat
12 - 12 x 24 x 2
12 - 12 x 24 x 2
These CSA approved heaters are located within the central
compartment of the unit with the heater elements extending in
to the supply air chamber.
The factory-installed heaters are wired for single point power
supply. Power supply need only be brought into the single point
terminal block.
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)
180
(15)
210
(17.5)
240
(20)
300
(25)
26
Minimum Supply Air (CFM)
Voltage
Heater kW
9
18
54
72
208/230-3-60
4500
4500
5000
5000
460-3-60
4500
4500
5000
4500
600-3-60
4500
4500
4500
4500
208/230-3-60
6000
6000
6000
6000
460-3-60
6000
6000
6000
6000
600-3-60
6000
6000
6000
6000
208/230-3-60
6000
6000
6000
6000
460-3-60
6000
6000
6000
6000
600-3-60
6000
6000
6000
6000
208/230-3-60
7500
7500
7500
7500
460-3-60
7500
7500
7500
7500
600-3-60
7500
7500
7500
7500
Johnson Controls Unitary Products
284810-YIM-F-1210
Optional Gas Heat
These gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark ignition with
proven pilot.
Table 11: Gas Application Data
Unit
Size
180
210
240
300
Opt.
24
32
24
32
24
32
24
32
Input
(MBH)
300
400
300
400
300
400
300
400
Output (MBH)
240
320
240
320
240
320
240
320
Temp Rise
(°F)1
20-50
30-60
20-50
30-60
20-50
30-60
20-50
30-60
1. On VAV units, individual VAV boxes must be full open in
heating mode to insure airflow falls within 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 12. The
heating value of the gas may differ with locality. The value
should be checked with the local gas utility.
NOTE: There may be a local gas utility requirement specifying
a minimum diameter for gas piping. All units require a
one-inch pipe connection at the entrance fitting.
Main
Manual
Shut-off
Valve
Drip Leg
Figure 14: Bottom Supply Connection External Shut-Off
Table 12: Gas Pipe Sizing - CapacIty of Pipe
Nominal Iron Pipe Size
1 in.
1-1/4 in.
520
1050
350
730
285
590
245
500
215
440
195
400
180
370
170
350
160
320
150
305
Length of
Pipe (ft.)
10
20
30
40
50
60
70
80
90
100
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.
Table 13: Gas Heat Minimum Supply Air
Main
Manual
Shut-off
Valve
Size
(Tons)
Heat Size
180
(15)
210
(17.5)
240
(20)
300
(25)
24
32
24
32
24
32
24
32
Supply Air (CFM)
Cooling
Heating
Min
Max
Min
Max
4500
7000
4500
7000
4500
7000
4500
7000
6000
8750
6000
8750
6000
8750
6000
8750
6000
9400
6000
9400
6000
9400
6000
9400
7500
12500
7500
12500
7500
12500
7500
12500
Drip Leg
Figure 13: External Supply Connection External Shut-Off
Johnson Controls Unitary Products
27
284810-YIM-F-1210
Gas Connection
The gas supply line can be routed within the space and roof curb,
exiting through the unit’s basepan. Refer to Figure 5 for the gas
piping inlet location. Typical supply piping arrangements are
shown in Figures 13 and 14. All pipe nipples, fittings, and the gas
cock are field supplied.
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.
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.
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.
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.
FIRE OR EXPLOSION HAZARD
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.
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 1NP0418.
All LP gas equipment must conform to the safety standards of
the National Fire Protection Association.
For satisfactory operation, LP gas pressure must be 10.0 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.
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.
28
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.
Johnson Controls Unitary Products
284810-YIM-F-1210
Check all connections for leaks when piping is completed using
a soap solution. NEVER USE A FLAME.
Options/Accessories
Electric Heat
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
Two vent hoods and a combustion air hood (with screens) are
shipped attached to the blower housing in the blower
compartment. For units with factory installed VFD option, the
hoods and accompanying hardware are shipped inside the
gas heat section. These hoods must be installed to assure
proper unit function. All hoods must be fastened to the
outside of the gas heat access panel with the screws
provided in the bag also attached to the blower housing.
The screen for the combustion air intake hood is secured to
the inside of the access panel opening with four fasteners and
the screws used for mounting the hood to the panel. The top
flange of this hood slips in under the top of the access panel
opening when installing. Refer to Vent and Combustion Air
Hood Figure 15.
Electric heaters are available as a factory-installed option.
These heaters mount in the heat compartment with the
heating elements extending into the supply air chamber. All
electric heaters are fused and intended for use with single
point power supply.
Economizer/Motorized Outdoor Damper Rain Hood
The instruction for the optional economizer/motorized damper
rain hood can be found in the rain hood kit. Use these
instructions when field assembling an economizer rain hood
onto a unit. The outdoor and return air dampers, the damper
actuator, the damper linkage, the outdoor and return air divider
baffles, and all the control sensors are factory mounted as part
of the “Factory installed” economizer option.
Power Exhaust/Barometric Relief Damper and Rain Hood
The instructions for the power exhaust/barometric relief damper
and rain hood can be found in the rain hood kit. The exhaust
fan, all supporting brackets, angles, and the wiring are factory
installed as part of the power exhaust option.
Economizer And Power Exhaust Set Point
Adjustments
Remove the top rear access panel from the unit. Locate the
economizer control module, where the following adjustments
will be made.
Each vent hood is installed by inserting the top flange of the
hood into the slotted opening in the access panel and securing
in place.
The products of combustion are discharged horizontally
through these two screened, hooded vent openings on the
upper gas heat access panel.
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
Slotted Openings in
Access Panel
Vent Air
Outlet Hoods
• 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.
Combustion Air
Intake Hood
Gas Heat
Access Panels
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 16. Adjust as follows:
Figure 15: Vent and Combustion Air Hood
Johnson Controls Unitary Products
• 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
29
284810-YIM-F-1210
to the lettered curve of the Enthalpy Set Point
Adjustment Figure 17.
• For a dual enthalpy operation, carefully turn the set point
adjusting screw fully clockwise past the "D" setting.
Power Exhaust Damper Set Point
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 CO2 Space Sensor Kit Part # 2AQ04700324
• Optional CO2 Sensor Kit Part # 2AQ04700424
Replace the top rear access panel on the unit.
Optional BAS-Ready Economizer Power Exhaust
Damper Set Point Adjustment
Remove the economizer access panel from the unit. Loosen,
but do not remove the two panel latches. Locate the
economizer actuator, where the following adjustment can be
made.
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's outdoor
damper position. The actuator's auxiliary switch adjustment
screw should be set at the damper position at which the power
exhaust is needed. The adjustment screw can be set between
25 to 85 degrees open.
Replace the economizer access panel.
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
30
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 top-left corner of 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 internal 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
10k-ohm, type 3 thermistor located in the unit's supply
air compartment.
• RAT - analog input provided by a factory-installed 10k-ohm,
type 3 thermistor located in the unit's return air compartment.
• OAT - analog input provided by a factory-installed 10k-ohm,
type 3 thermistor located in the outdoor air compartment or
mounted within the evaporator base rail for units without the
installed economizer option.
• ST - analog input provided by field-installed space
temperature sensor.
Johnson Controls Unitary Products
284810-YIM-F-1210
• 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).
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.
• IAQ - a 0-10 VDC analog input provided by a field-installed
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 (CO2 concentration) and, along with IAQ, enables
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.
Johnson Controls Unitary Products
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).
Factory-installed VFD
The factory-installed VFD is mounted in the Blower Access
Compartment above the blower assembly. 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.
31
284810-YIM-F-1210
'VFD-Ready' For Customer-installation
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.
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.
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:
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 as follows:
For 5-hp motor applications ........................13" H x 6" W x 7" D
For 7.5 thru 15-hp motor applications .........13" H x 8" W x 8" 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) along with the respective ground wires are supplied
with the unit and need to be connected after the drive is
installed.
• 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-F, 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'
32
Do not connect AC power to the T1, T2, T3 drive
terminals to prevent damage to the VFD.
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 fully adjustable
between 0 and 80 psig with a factory-setting of 60 psig. HGBP
is standard on all units with VAV and optional with CV units.
Johnson Controls Unitary Products
284810-YIM-F-1210
CONTROL
CURVE
CONTROL POINT
APPROX. 0F (0C)
AT 50% RH
A
73 (23)
B
C
70 (21)
67 (19)
D
63 (17)
85 90 95 100 105 110
(29) (32) (35) (38) (41) (43)
80
(27)
75
(24)
70
(21)
65
(18)
60
(16)
55
(13)
50
(10)
45
(7)
35
(2)
A
B
C
D
40
(4)
B A
D C
35
(2)
40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
(4) (7) (10) (13) (16) (18) (21) (24) (27) (29) (32) (35) (38) (41) (43)
APPROXIMATE DRY BULB TEMPERATURE - 0F (0C)
Figure 16: Enthalpy Set Point Chart
Exhaust Air
Adjustment
Screw
Exhaust Air LED
Damper Min.
Position
Screw
Indoor Air Quality
Max. Adjustment
Screw
N1
N
EXH
Set
TR
P1
P
EXH
24
Vac
HOT
T1
T
Min
Pos
IAQ
Max
Indoor Air Quality
LED
AQ1
AQ
IAQ
SO
IAQ
Min
TR1
24
Vac
COM
+
1
2
5
Indoor Air Quality
Min. Adjustment
Screw
Free Cooling LED
SO+
3
4
EF
EF1
Free
Cool
SR+
SR
B
A
C
D
Economizer Enthalpy
Set Point Adjustment
Screw
Figure 17: Honeywell Economizer Control W7212
Johnson Controls Unitary Products
33
284810-YIM-F-1210
Phasing
York® Model ZJ 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 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.)
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’).
Belt Tension
The tension on the belt should be adjusted as shown in Figure 18.
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.
Span Length
Defl Force
(B)
*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).
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
in Table 14 and Figure 19.
(C)*
Figure 18: Belt Adjustment
34
Johnson Controls Unitary Products
284810-YIM-F-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
Correction Factor
1.000
Sea Level
0.950
1000 ft
0.900
2000 ft
0.850
3000 ft
0.800
5000 ft
0.750
6000 ft
7000 ft
4000 ft
8000 ft
0.700
9000 ft
10000 ft
0.650
0.600
40
50
60
70
80
90
100
Air Temperature (ºF)
Figure 19: Altitude/Temperature Correction Factors
The examples below will assist in determining the airflow
performance of the product at altitude.
blower tables to select the blower speed and the BHP
requirement.
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: As in the example above, no temperature
information is given so 70°F is assumed.
Solution: At an elevation of 5,000 ft. the indoor blower will still
deliver 6,000 CFM if the rpm is unchanged. However, Table 14
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 14 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
Johnson Controls Unitary Products
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
35
284810-YIM-F-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.
6800 CFM
2.
2.0 iwg
3.
Using the supply air blower performance table below, the following data point was located: 1020 RPM & 5.92 BHP.
4.
Using the RPM selection table below, Size X and Model Y is found.
5.
5.92 BHP exceeds the maximum continuous BHP rating of the 5.0 HP motor. The 7.5 HP motor is required.
6.
1020 RPM is within the range of the 7.5 HP drives.
7.
Using the 7.5 HP motor and drive, 3.5 turns open will achieve 1020 RPM.
Example Supply Air Blower Performance
Air Flow
(CFM)
6400
6800
7200
7600
Available External Static Pressure - IWG
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard
5 HP & Field
Supplied
Drive
719 2.55
742 3.02
765 3.54
790 4.11
Standard 5 HP & Drive
756
778
802
827
3.03
3.51
4.03
4.60
792
814
838
863
3.49
3.97
4.49
5.06
828
850
874
899
3.92
4.40
4.92
5.49
864
886
910
935
High Static 7.5 HP & Drive
4.32
4.79
5.32
5.88
899
921
945
970
4.67 933
5.15 955
5.67 979
6.24 1004
4.98 966 5.24 998 5.45 1028
5.46 988 5.72 1020 5.92 1050
5.98 1012 6.24 1044 6.44 1074
6.55 1037 6.81 1069 7.01 1099
5.59
6.07
6.59
7.16
1056 5.67 1083 5.68
1078 6.15 1105 6.16
1102 6.67 1129 6.68
1127 7.24 1154 7.25
7.5 HP & Field
Supplied Drive
Table X: RPM Selection
Size
(Tons)
Model
HP
X
Y
5
7.5
36
Max
BHP
5.75
8.63
Motor
Sheave
1VP60
1VP60
Blower
Sheave
BK110
BK090
6 Turns
Open
730
905
5 Turns
Open
765
950
4 Turns
Open
800
990
3 Turns
Open
835
1035
2 Turns
Open
870
1075
1 Turn
Open
905
1120
Fully
Closed
N/A
N/A
Johnson Controls Unitary Products
284810-YIM-F-1210
Table 15: Air Flow Performance - Side Duct Application
ZJ180 (15 Ton) Side Duct
Air Flow
(CFM)
4000
4400
4800
5200
5600
6000
6400
6800
7200
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard 5 HP & Field Supplied Drive
727 1.14 765 1.47 806 1.77
753 1.51 792 1.84 832 2.14
781 1.92 820 2.25 861 2.55
812 2.37 850 2.70 891 3.00
844 2.86 882 3.19 923 3.49
877 3.39 916 3.72 957 4.02
912 3.96 951 4.29 992 4.59
949 4.56 988 4.89 1028 5.19
986 5.20 1025 5.53
-
848
874
903
933
965
999
1034
1070
-
2.04
2.41
2.82
3.27
3.76
4.29
4.86
5.46
-
Standard 5 HP & Drive
891 2.29 934 2.52
917 2.66 960 2.88
946 3.06 989 3.29
976 3.52 1019 3.74
1008 4.01 1051 4.23
1042 4.54 1085 4.76
1077 5.10 1120 5.33
1113 5.71
-
977
1004
1032
1062
1094
1128
1163
-
2.73
3.09
3.50
3.95
4.45
4.98
5.54
-
1020
1046
1074
1105
1137
1170
1205
-
2.93
3.29
3.70
4.15
4.64
5.17
5.74
-
1061
1087
1116
1146
1178
1212
-
High Static 5 HP & Drive
3.12 1101 3.30 1138 3.48 1174 3.67
3.48 1127 3.67 1165 3.85 1200 4.03
3.89 1155 4.08 1193 4.26 1228 4.44
4.34 1186 4.53 1223 4.71 1259 4.89
4.83 1218 5.02 1255 5.20 1291 5.39
5.36 1251 5.55 1289 5.73
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 0.898.
ZJ210 (17.5 Ton) Side Duct
Air Flow
(CFM)
4400
4800
5200
5600
6000
6400
6800
7200
7600
8000
8400
8800
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard 5 HP & Field Supplied Drive
636 0.65 672 1.14 709 1.60
649 0.99 685 1.48 721 1.94
663 1.34 700 1.83 736 2.29
680 1.71 717 2.20 753 2.66
699 2.11 735 2.60 772 3.06
719 2.55 756 3.03 792 3.49
742 3.02 778 3.51 814 3.97
765 3.54 802 4.03 838 4.49
790 4.11 827 4.60 863 5.06
817 4.72 853 5.21 890 5.67
845 5.38 881 5.87 918 6.33
874 6.09 911 6.58 947 7.04
745
757
772
789
808
828
850
874
899
926
954
983
2.03 780
2.37 793
2.72 808
3.09 825
3.49 844
3.92 864
4.40 886
4.92 910
5.49 935
6.10 962
6.76 990
7.47 1019
Standard 5 HP & Drive
2.43 815 2.78 849
2.77 828 3.12 862
3.11 843 3.47 877
3.48 860 3.84 894
3.88 879 4.24 913
4.32 899 4.67 933
4.79 921 5.15 955
5.32 945 5.67 979
5.88 970 6.24 1004
6.50 997 6.85 1031
7.16 1025 7.51 1059
7.86 1054 8.22 1088
3.09
3.43
3.78
4.15
4.55
4.98
5.46
5.98
6.55
7.16
7.82
8.53
882
895
910
927
946
966
988
1012
1037
1064
1092
-
3.35
3.69
4.04
4.41
4.80
5.24
5.72
6.24
6.81
7.42
8.08
-
914
927
942
959
977
998
1020
1044
1069
1095
1123
-
3.55
3.89
4.24
4.61
5.01
5.45
5.92
6.44
7.01
7.62
8.28
-
High Static 7.5 HP & Drive
944 3.70 973 3.78 999 3.79
957 4.04 985 4.12 1012 4.13
972 4.39 1000 4.47 1027 4.48
989 4.76 1017 4.84 1044 4.85
1007 5.15 1036 5.24 1062 5.25
1028 5.59 1056 5.67 1083 5.68
1050 6.07 1078 6.15 1105 6.16
1074 6.59 1102 6.67 1129 6.68
1099 7.16 1127 7.24 1154 7.25
1125 7.77 1154 7.85 1180 7.86
1153 8.43 1182 8.51 1208 8.52
7.5 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 0.838.
Johnson Controls Unitary Products
37
284810-YIM-F-1210
ZJ240 (20 Ton) Side Duct
Air Flow
(CFM)
5200
5600
6000
6400
6800
7200
7600
8000
8400
8800
9200
9600
10000
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard 5 HP & Field
Supplied Drive
663 1.34 700 1.83 736
680 1.71 717 2.20 753
699 2.11 735 2.60 772
719 2.55 756 3.03 792
742 3.02 778 3.51 814
765 3.54 802 4.03 838
790 4.11 827 4.60 863
817 4.72 853 5.21 890
845 5.38 881 5.87 918
874 6.09 911 6.58 947
905 6.85 941 7.33 977
936 7.65 973 8.13 1009
969 8.49
-
Standard 5 HP & Drive
2.29 772
2.66 789
3.06 808
3.49 828
3.97 850
4.49 874
5.06 899
5.67 926
6.33 954
7.04 983
7.79 1014
8.59
-
2.72 808 3.11 843 3.47
3.09 825 3.48 860 3.84
3.49 844 3.88 879 4.24
3.92 864 4.32 899 4.67
4.40 886 4.79 921 5.15
4.92 910 5.32 945 5.67
5.49 935 5.88 970 6.24
6.10 962 6.50 997 6.85
6.76 990 7.16 1025 7.51
7.47 1019 7.86 1054 8.22
8.22 1049 8.62
-
High Static 7.5 HP & Drive
877
894
913
933
955
979
1004
1031
1059
1088
-
3.78
4.15
4.55
4.98
5.46
5.98
6.55
7.16
7.82
8.53
-
910
927
946
966
988
1012
1037
1064
1092
-
4.04
4.41
4.80
5.24
5.72
6.24
6.81
7.42
8.08
-
942
959
977
998
1020
1044
1069
1095
1123
-
4.24
4.61
5.01
5.45
5.92
6.44
7.01
7.62
8.28
-
972 4.39 1000 4.47 1027 4.48
989 4.76 1017 4.84 1044 4.85
1007 5.15 1036 5.24 1062 5.25
1028 5.59 1056 5.67 1083 5.68
1050 6.07 1078 6.15 1105 6.16
1074 6.59 1102 6.67 1129 6.68
1099 7.16 1127 7.24 1154 7.25
1125 7.77 1154 7.85 1180 7.86
1153 8.43 1182 8.51 1208 8.52
7.5 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 0.838.
38
Johnson Controls Unitary Products
284810-YIM-F-1210
ZJ300 (25 Ton) Side Duct
Air Flow
(CFM)
Low Static 7.5 HP &
Field Supplied Drive
760 2.51 793 3.11
775 2.99 808 3.60
792 3.51 824 4.11
809 4.07 841 4.67
826 4.66 859 5.27
845 5.30 877 5.90
864 5.97 896 6.57
884 6.68 916 7.28
Low Static 7.5 HP & Drive
824
839
856
873
890
909
928
948
3.68
4.17
4.69
5.24
5.84
6.47
7.14
7.86
856
871
887
904
922
940
960
980
4.23
4.71
5.23
5.78
6.38
7.01
7.69
8.40
887
902
918
935
953
972
991
1011
4.74
5.22
5.74
6.30
6.89
7.53
8.20
8.91
919
934
950
967
985
1003
1022
1042
5.23
5.72
6.24
6.79
7.39
8.02
8.69
9.41
950
966
982
999
1016
1035
1054
1074
5.70
6.19
6.70
7.26
7.86
8.49
9.16
9.88
983
998
1014
1031
1049
1067
1087
1107
6.15
6.64
7.16
7.71
8.31
8.94
9.61
10.33
9800
905 7.43 937 8.04 969 8.61 1000 9.15 1032 9.67 1063 10.16 1095 10.63 1127 11.08
10200
10600
11000
11400
11800
12200
12600
926
948
970
993
1017
1040
1065
Air Flow
(CFM)
6600
7000
7400
7800
8200
8600
9000
9400
9800
10200
10600
11000
11400
11800
12200
12600
8.22
9.05
9.92
10.82
11.76
12.74
13.75
958
980
1003
1025
1049
1073
1097
8.83
9.66
10.52
11.43
12.37
13.34
14.35
990
1012
1034
1057
1081
1104
1129
9.40
10.23
11.09
12.00
12.94
13.91
14.92
1021 9.94 1053 10.46 1084
1043 10.77 1075 11.29 1106
1066 11.64 1097 12.15 1128
1089 12.54 1120 13.06 1151
1112 13.48 1143 14.00 1175
1136 14.46 1167 14.97 1199
1160 15.47 1192 15.98 1223
High Static 15 HP & Drive
10.95
11.78
12.64
13.55
14.49
15.46
16.47
1116
1138
1160
1183
1207
1231
1255
11.42
12.25
13.11
14.02
14.96
15.93
16.94
1148
1170
1193
1216
1239
1263
-
Standard 10 HP & Drive
6600
7000
7400
7800
8200
8600
9000
9400
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
11.87
12.70
13.56
14.47
15.41
16.38
-
Available External Static Pressure - IWG1
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
1016
1031
1047
1064
1082
1101
1120
1140
1160
1182
1204
1226
1249
1272
1296
-
6.59
7.07
7.59
8.14
8.74
9.37
10.05
10.76
11.51
12.30
13.13
14.00
14.90
15.84
16.82
-
1050
1065
1081
1098
1116
1135
1154
1174
1195
1216
1238
1260
1283
1306
1330
-
Standard 10 HP & Drive
7.00 1086 7.41 1123
7.49 1101 7.89 1138
8.01 1117 8.41 1154
8.56 1134 8.97 1171
9.16 1152 9.56 1189
9.79 1170 10.20 1207
10.46 1189 10.87 1226
11.18 1209 11.58 1246
11.93 1230 12.33 1267
12.72 1251 13.12 1288
13.55 1273 13.95 1310
14.41 1296 14.82 1332
15.32 1318 15.72 1355
16.26 1342 16.66 1379
17.23 -
7.81
8.29
8.81
9.36
9.96
10.59
11.27
11.98
12.73
13.52
14.35
15.22
16.12
17.06
-
High Static 15 HP & Drive
1161 8.19 1202 8.58 1244 8.95 1289 9.33
1176 8.68 1217 9.06 1259 9.44 1304 9.82
1192 9.20 1233 9.58 1275 9.96 1320 10.34
1209 9.75 1250 10.13 1292 10.51 1337 10.89
1227 10.35 1268 10.73 1310 11.11 1355 11.49
1246 10.98 1286 11.36 1329 11.74 1374 12.12
1265 11.65 1305 12.04 1348 12.41 1393 12.79
1285 12.37 1325 12.75 1368 13.13 1413 13.51
1306 13.12 1346 13.50 1389 13.88 1434 14.26
1327 13.91 1367 14.29 1410 14.67 1455 15.05
1349 14.74 1389 15.12 1432 15.50 1477 15.88
1371 15.60 1412 15.99 1454 16.36 1499 16.74
1394 16.51 1434 16.89 15 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 0.82.
Johnson Controls Unitary Products
39
284810-YIM-F-1210
Table 16: Air Flow Performance - Bottom Duct Application
ZJ180 (15 Ton) Bottom Duct
Air Flow
(CFM)
4000
4400
4800
5200
5600
6000
6400
6800
7200
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard 5 HP &
Standard 5 HP & Drive
Field Supplied Drive
768 1.24 806 1.55 846 1.83 888 2.09 930 2.32
797 1.65 835 1.96 875 2.24 916 2.49 959 2.72
828 2.09 866 2.40 906 2.68 947 2.93 989 3.16
860 2.57 898 2.88 938 3.16 980 3.41 1022 3.65
894 3.09 932 3.40 972 3.68 1014 3.93 1056 4.16
930 3.64 968 3.95 1008 4.23 1049 4.48 1091 4.71
966 4.22 1005 4.53 1045 4.81 1086 5.06 1128 5.30
1005 4.84 1043 5.14 1083 5.42 1124 5.68
1044 5.48
-
High Static 5 HP & Drive
972
1001
1032
1064
1098
1134
1171
-
2.53
2.93
3.38
3.86
4.38
4.93
5.51
-
1015
1043
1074
1107
1141
1176
1213
-
2.73
3.13
3.58
4.06
4.57
5.12
5.71
-
1056
1085
1116
1148
1182
1218
-
2.91
3.32
3.76
4.24
4.76
5.31
-
1097
1126
1157
1189
1223
1259
-
3.09
3.50
3.94
4.42
4.94
5.49
-
1136 3.27 1173 3.44 1208
1165 3.67 1202 3.84 1237
1196 4.11 1233 4.28 1267
1228 4.59 1265 4.77 1300
1262 5.11 1299 5.28 1334
1298 5.66
5 HP & Field Supplied Drive
3.61
4.02
4.46
4.94
5.46
-
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 0.898.
ZJ210 (17.5 Ton) Bottom Duct
Air Flow
(CFM)
4400
4800
5200
5600
6000
6400
6800
7200
7600
8000
8400
8800
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard 5 HP &
Field Supplied Drive
661 0.74 697 1.19
677 1.07 712 1.53
694 1.43 730 1.89
713 1.82 749 2.27
734 2.25 770 2.70
757 2.71 793 3.17
781 3.22 817 3.68
807 3.78 843 4.23
834 4.38 870 4.83
862 5.02 898 5.48
892 5.71 928 6.17
923 6.45 959 6.91
Standard 5 HP & Drive
733
748
766
785
806
829
853
878
905
934
963
994
1.62 768
1.96 784
2.32 801
2.71 820
3.13 841
3.60 864
4.11 888
4.66 914
5.26 941
5.91 969
6.60 999
7.34 1030
2.03 803 2.40 838
2.36 819 2.73 853
2.72 836 3.09 871
3.11 856 3.48 890
3.53 877 3.90 911
4.00 899 4.37 934
4.51 923 4.88 958
5.07 949 5.44 983
5.67 976 6.04 1010
6.31 1004 6.68 1039
7.00 1034 7.37 1069
7.74 1065 8.11 1099
2.73
3.06
3.42
3.81
4.23
4.70
5.21
5.77
6.37
7.01
7.70
8.44
High Static 7.5 HP & Drive
871
887
904
923
944
967
991
1017
1044
1072
1102
-
3.02
3.35
3.71
4.10
4.52
4.99
5.50
6.06
6.66
7.30
7.99
-
904
919
937
956
977
1000
1024
1049
1076
1105
1134
-
3.26
3.59
3.95
4.34
4.77
5.23
5.74
6.30
6.90
7.55
8.24
-
935 3.45 964 3.59 992 3.66
950 3.79 980 3.92 1008 4.00
968 4.14 997 4.28 1025 4.35
987 4.53 1017 4.67 1045 4.74
1008 4.96 1038 5.09 1066 5.17
1031 5.42 1060 5.56 1088 5.64
1055 5.94 1085 6.07 1112 6.15
1081 6.49 1110 6.63 1138 6.70
1108 7.09 1137 7.23 1165 7.30
1136 7.74 1166 7.87 1194 7.95
1166 8.43 1195 8.56
7.5 HP & Field Supplied Drive
1018
1034
1051
1071
1092
1114
1139
1164
1191
1220
-
3.67
4.01
4.37
4.75
5.18
5.65
6.16
6.71
7.31
7.96
-
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 0.838.
40
Johnson Controls Unitary Products
284810-YIM-F-1210
ZJ240 (20 Ton) Bottom Duct
Air Flow
(CFM)
5200
5600
6000
6400
6800
7200
7600
8000
8400
8800
9200
9600
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Standard 5
HP & Field
Supplied
Drive
694 1.43 730
713 1.82 749
734 2.25 770
757 2.71 793
781 3.22 817
807 3.78 843
834 4.38 870
862 5.02 898
892 5.71 928
923 6.45 959
955 7.23 991
988 8.05 1024
Standard 5 HP & Drive
1.89 766
2.27 785
2.70 806
3.17 829
3.68 853
4.23 878
4.83 905
5.48 934
6.17 963
6.91 994
7.68 1026
8.51
-
2.32 801 2.72 836 3.09 871
2.71 820 3.11 856 3.48 890
3.13 841 3.53 877 3.90 911
3.60 864 4.00 899 4.37 934
4.11 888 4.51 923 4.88 958
4.66 914 5.07 949 5.44 983
5.26 941 5.67 976 6.04 1010
5.91 969 6.31 1004 6.68 1039
6.60 999 7.00 1034 7.37 1069
7.34 1030 7.74 1065 8.11 1099
8.11 1062 8.52
-
High Static 7.5 HP & Drive
3.42
3.81
4.23
4.70
5.21
5.77
6.37
7.01
7.70
8.44
-
904
923
944
967
991
1017
1044
1072
1102
-
3.71
4.10
4.52
4.99
5.50
6.06
6.66
7.30
7.99
-
937
956
977
1000
1024
1049
1076
1105
1134
-
3.95
4.34
4.77
5.23
5.74
6.30
6.90
7.55
8.24
-
968 4.14 997 4.28 1025 4.35
987 4.53 1017 4.67 1045 4.74
1008 4.96 1038 5.09 1066 5.17
1031 5.42 1060 5.56 1088 5.64
1055 5.94 1085 6.07 1112 6.15
1081 6.49 1110 6.63 1138 6.70
1108 7.09 1137 7.23 1165 7.30
1136 7.74 1166 7.87 1194 7.95
1166 8.43 1195 8.56
7.5 HP & Field Supplied Drive
1051
1071
1092
1114
1139
1164
1191
1220
-
4.37
4.75
5.18
5.65
6.16
6.71
7.31
7.96
-
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 0.838.
Johnson Controls Unitary Products
41
284810-YIM-F-1210
ZJ300 (25 Ton) Bottom Duct
Air Flow
(CFM)
Low Static
7.5 HP &
Field
Supplied
Drive
787 2.67
804 3.18
821 3.72
839 4.30
858 4.92
877 5.58
898 6.28
918 7.01
Low Static 7.5 HP & Drive
819
835
853
871
890
909
929
950
3.23
3.74
4.28
4.86
5.48
6.14
6.84
7.57
850
867
884
902
921
940
960
981
3.76
4.27
4.82
5.40
6.02
6.68
7.37
8.10
881
898
915
933
952
971
991
1012
4.27
4.78
5.32
5.90
6.52
7.18
7.88
8.61
912
928
946
964
983
1002
1022
1043
4.75
5.26
5.80
6.39
7.01
7.66
8.36
9.09
943
959
977
995
1013
1033
1053
1074
5.21
5.72
6.26
6.85
7.47
8.12
8.82
9.55
974
991
1008
1026
1045
1064
1084
1105
5.65
6.16
6.70
7.28
7.90
8.56
9.26
9.99
9800
940 7.78 972 8.34 1003 8.87 1034 9.38 1064 9.86 1095 10.32 1127 10.76
10200
10600
11000
11400
11800
12200
12600
962
984
1007
1031
1055
1080
1104
Air Flow
(CFM)
6600
7000
7400
7800
8200
8600
9000
9400
9800
10200
10600
11000
11400
11800
12200
12600
8.58
9.42
10.30
11.20
12.14
13.11
14.12
994
1016
1039
1063
1087
1111
1136
9.14
9.98
10.86
11.76
12.70
13.68
14.68
1025
1047
1070
1094
1118
1142
1167
9.68 1056 10.18 1086 10.67
10.52 1078 11.02 1109 11.51
11.39 1101 11.90 1132 12.38
12.30 1125 12.80 1156 13.29
13.24 1149 13.74 1180 14.23
14.21 1173 14.72 1204 15.20
15.21 1198 15.72 1229 16.20
High Static 15 HP & Drive
1117
1140
1163
1187
1211
1235
1260
11.13
11.96
12.84
13.75
14.69
15.66
16.66
1149
1171
1194
1218
1242
1266
1291
Standard 10 HP & Drive
6600
7000
7400
7800
8200
8600
9000
9400
Available External Static Pressure - IWG1
0.4
0.6
0.8
1.0
1.2
1.4
1.6
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
11.56
12.40
13.28
14.18
15.12
16.10
17.10
Available External Static Pressure - IWG1
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
1006
1023
1040
1058
1077
1096
1116
1137
1159
1181
1203
1226
1250
1274
1298
-
6.07
6.58
7.12
7.71
8.33
8.98
9.68
10.41
11.18
11.99
12.82
13.70
14.61
15.55
16.52
-
1039
1055
1072
1090
1109
1129
1149
1170
1191
1213
1236
1259
1282
1307
1331
-
Standard 10 HP & Drive
6.48 1072 6.87 1107
6.98 1089 7.37 1124
7.53 1106 7.92 1141
8.11 1124 8.50 1159
8.73 1143 9.12 1178
9.39 1162 9.78 1197
10.08 1183 10.47 1218
10.82 1203 11.21 1238
11.59 1225 11.98 1260
12.39 1247 12.78 1282
13.23 1269 13.62 1304
14.10 1293 14.49 1327
15.01 1316 15.40 1351
15.95 1340 16.34 1375
16.92 -
7.25
7.75
8.30
8.88
9.50
10.16
10.85
11.59
12.35
13.16
14.00
14.87
15.78
16.72
-
1144
1160
1177
1195
1214
1234
1254
1275
1296
1318
1341
1364
1387
1411
-
High Static 15 HP & Drive
7.62 1182 7.98 1221 8.33 1263 8.68 1307
8.12 1198 8.48 1238 8.84 1280 9.19 1324
8.67 1215 9.03 1255 9.38 1297 9.74 1341
9.25 1233 9.61 1273 9.97 1315 10.32 1359
9.87 1252 10.23 1292 10.59 1334 10.94 1378
10.53 1272 10.89 1311 11.24 1353 11.60 1397
11.22 1292 11.58 1332 11.94 1373 12.29 1418
11.95 1313 12.32 1352 12.67 1394 13.02 1438
12.72 1334 13.09 1374 13.44 1416 13.79 1460
13.53 1356 13.89 1396 14.25 1438 14.60 1482
14.37 1379 14.73 1418 15.08 1460 15.44 1504
15.24 1402 15.60 1441 15.96 1483 16.31 1528
16.15 1425 16.51 1465 16.87 1507 17.22 17.09 15 HP & Field Supplied Drive
9.04
9.54
10.09
10.67
11.29
11.95
12.64
13.37
14.14
14.95
15.79
16.66
-
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 0.82.
42
Johnson Controls Unitary Products
284810-YIM-F-1210
Table 17: RPM Selection
Size
(Tons)
180
(15)
Model
HP
5
5
5
7.5
5
7.5
7.5
10
15
ZJ
210
(17.5)
ZJ
240
(20)
ZJ
300
(25)
ZJ
Max
BHP
5.75
5.75
5.75
8.63
5.75
8.63
8.63
11.50
17.25
Motor
Sheave
1VP65
1VP65
1VP60
1VP60
1VP60
1VP60
1VP60
1VP75X
1VP75X
Blower
Sheave
BK110
BK090
BK110
BK090
BK110
BK090
1B5V94
1B5V110
1B5V94
6 Turns
Open
815
1010
730
905
730
905
810
975
1140
5 Turns
Open
850
1055
765
950
765
950
850
1005
1180
4 Turns
Open
885
1095
800
990
800
990
885
1040
1215
3 Turns
Open
920
1135
835
1035
835
1035
920
1070
1255
2 Turns
Open
950
1180
870
1075
870
1075
960
1100
1290
1 Turn
Open
985
1220
905
1120
905
1120
1000
1135
1330
Fully
Closed
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1165
1365
Table 18: Indoor Blower Specifications
Size
(Tons)
Motor
Model
180
(15)
210
(17.5)
240
(20)
300
(25)
ZJ
ZJ
ZJ
ZJ
HP
RPM
Eff.
SF
5
5
5
7.5
5
7.5
7.5
10
15
1725
1725
1725
1725
1725
1725
1725
1725
1725
0.89
0.89
0.89
0.91
0.89
0.91
0.91
0.89
0.91
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
Motor Sheave
Blower Sheave
Belt
Datum Dia.
Datum Dia.
Bore (in.) Model
Bore (in.) Model
Frame
(in.)
(in.)
184T
5.2 - 6.4
1 1/8
1VP65
10.4
1
BK110
BX85
184T
5.2 - 6.4
1 1/8
1VP65
8.4
1
BK090
BX81
184T
4.2 - 5.5
1 1/8
1VP60
10.4
1 3/16
BK110
BX78
213T
4.2 - 5.5
1 3/8
1VP60
8.4
1 3/16
BK090
BX75
184T
4.2 - 5.5
1 1/8
1VP60
10.4
1 3/16
BK110
BX78
213T
4.2 - 5.5
1 3/8
1VP60
8.4
1 3/16
BK090
BX75
213T
4.2 - 5.5
1 3/8
1VP60
9.5
1 7/16
1B5V94
BX78
215T
5.8 - 7.0
1 3/8
1VP75X
11.1
1 7/16 1B5V110 5VX840
254T
6.2 - 7.4
1 5/8
1VP75X
9.5
1 7/16
1B5V94 5VX860
Table 19: Power Exhaust Specifications
Voltage
208/230-1-60
460-1-60
575-1-60
HP
3/4
3/4
3/4
Motor
RPM1
1075
1075
1050
QTY
1
1
1
LRA
7.7
4.1
2.84
Motor
FLA
5.0
2.2
1.5
MCA
6.25
2.75
1.875
CFM @
0.1 ESP
5250
5250
5250
1. Motors are multi-tapped and factory wired for high speed.
Air Balance
To check the supply air CFM after the initial balancing has been
completed:
1.
Remove the two 5/16” dot plugs from the blower motor and
the filter access panels shown in the Unit Dimensions and
Rear View Clearances Figure 6.
On VAV units be certain that the VFD drive is set to
maximum output, exhaust dampers are closed and
individual space damper boxes are full open.
2.
Insert at least 8" of 1/4 inch tubing into each of these holes
for sufficient penetration into the air flow on both sides of
the indoor coil.
VFD units with bypass must not be in bypass mode
(‘LINE’ position) unless all individual space dampers are
full open.
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.
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.
Johnson Controls Unitary Products
3.
Using an inclined manometer, determine the pressure drop
across a dry evaporator coil. Since the moisture on an
evaporator coil may vary greatly, measuring the pressure
drop across a wet coil under field conditions would be
inaccurate. To assure a dry coil, the compressors should
be deactivated while the test is being run.
43
284810-YIM-F-1210
Supply Air Drive Adjustment
Pressure Drop Across A Dry Indoor Coil VS Supply Air CFM
0.45
The RPM of the supply air blower will depend on the required
CFM, the unit accessories or options and the static resistances
of both the supply and the return air duct systems. With this
information, the RPM for the supply air blower and the motor
pulley adjustment (turns open) can be determined from the
Blower Performance Data Tables.
Pressure Drop (IWG)
0.4
0.35
0.3
0.25
0.2
0.15
0.1
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. Tighten blower pulley
and motor sheave set screws after these adjustments.
Re-checking set screws after 10-12 hours run time is
recommended.
0.05
0
4000
5000
6000
7000
8000
9000
10000
11000
12000
Nominal Air Flow (CFM)
Figure 20: Pressure Drop Across A Dry Indoor Coil Vs.
Supply Air CFM For All Unit Tonnages
4.
Knowing the pressure drop across a dry coil, the actual
CFM through the unit can be determined from the curve in
Pressure Drop vs. Supply Air CFM Figure 20.
Failure to properly adjust the total system air quantity
can result in extensive blower damage.
High speed drive accessories (containing a smaller blower
pulley and a shorter belt) are available for applications requiring
the supply air blower to produce higher CFM's and/or higher
static pressures. Use Model 1LD0460 for 15 ton units, Model
1LD0417 for 17.5 and 20 ton units, and Model 1LD0435 for 25
ton units. Refer to the Blower Motor and Drive Data Table 18.
Note the following:
After readings have been obtained, remove the tubes and
reinstall the two 5/16” dot plugs that were removed in Step 1.
NOTE: De-energize the compressors before taking any test
measurements to assure a dry indoor coil.
1.
The supply air CFM must be within the limitations shown in
the Blower Performance Tables 15 and 16.
2.
Pulleys can be adjusted in half turn increments.
3.
The tension on the belt should be adjusted as shown in the
Bet Adjustment, Figure 18.
4.
Tighten blower pulley and motor sheave set screws after
any adjustments. Re-check set screws after 10-12 hours
run time recommended.
Additional Static Resistance
Size
(Tons)
Model
180
(15)
ZJ
210 (17.5)
240 (20)
300 (25)
ZJ
CFM
Cooling Only1
Economizer2 3
4500
6000
7500
6000
7500
9000
10500
12000
0.10
0.10
0.10
0.10
0.10
0.15
0.15
0.20
0.10
0.10
0.10
0.10
0.10
0.15
0.15
0.20
18
0.10
0.10
0.10
0.10
0.10
0.10
0.20
0.30
Electric Heat kW2
36
54
0.10
0.20
0.20
0.30
0.30
0.40
0.10
0.20
0.20
0.30
0.30
0.40
0.40
0.60
0.50
0.70
72
0.20
0.40
0.60
0.20
0.40
0.60
0.80
0.90
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.
44
Johnson Controls Unitary Products
284810-YIM-F-1210
Operation
Cooling Sequence Of Operation
For ZJ 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.
Continuous Blower
By setting the room thermostat fan switch to "ON," the supply
air blower will operate continuously.
Intermittent Blower
Figure 21: 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
duct static pressure reaches or exceeds the high-limit set-point
(default = 4.5"), then the supply fan motor will be shutdown.
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.
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".
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.
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)
Optional VAV Startup and Control
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".
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.
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.
Johnson Controls Unitary Products
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)
45
284810-YIM-F-1210
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.
Compressor #2 is energized, provided it has not been locked
out, and condenser fan motor #1, and condenser fan motor #2
remain energized. (If the ambient temperature is above 60ºF.)
If there is an initial call for more than one stage of cooling, the
UCB will delay energizing compressors #2, #3 & #4 by 30
seconds each, depending on how many stages are called for, in
order to avoid a power in-rush.
Once the thermostat has been satisfied, it will de-energize Y1,
Y2, Y3 and Y4. If the compressors have satisfied their minimum
run times, the compressors and condenser fans are deenergized. 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 AntiShort Cycle Delay (ASCD) must have elapsed.
These units utilize a lead-lag feature that results in an equal
amount of run hours on all compressors, thereby extending the
life of the compressors. This feature works as follows: If the
thermostat requires for more than one stage of cooling, the
currently off compressor with the least number of run hours will
be the next to be energized. When the thermostat requires
fewer stages of cooling, the currently running compressor with
the most run hours will be the first to be de-energized.
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.
46
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. If Y2 brings on compressor #1 and
this condition remains for more than 20 minutes, then
compressor #2 will be energized until the thermostat is
satisfied.
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
the economizer control. When the power exhaust is operating,
the second stage of mechanical cooling will not operate. 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 IntelliComfort™ 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 setpoint plus 5 °F, and the Economizer OAT
Enable setpoint.
Johnson Controls Unitary Products
284810-YIM-F-1210
• 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 setpoint, and the outdoor temperature is less
than the First-Stage SAT Control setpoint 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 setpoint 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 FirstStage SAT Control setpoint, plus or minus one degree. If freecooling is unavailable, then 1st-stage mechanical cooling is
initiated.
If at anytime the outdoor air temperature rises above the FirstStage SAT Control setpoint 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 setpoint
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.
Economizer With Optional VAV Blower With Power Exhaust
The power exhaust motor is energized via the controller's
EXH~ terminal and the ER relay, 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 exhaust relay 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 25 to 85 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.
Johnson Controls Unitary Products
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 25). 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. If the LPS is still
open after the ASCD, the compressor will not be energized for
30 seconds. The second and third times that the UCB sees an
open LPS will count towards the three occurrences that will
cause a UCB lock-out.
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 25). 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
47
284810-YIM-F-1210
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 25). If the other compressor is inactive, the
condenser fans will be de-energized.
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.
Low Ambient Cooling
Flash Codes
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).
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 and
resets 500 ± 25 psig).
3.
A low-pressure switch to protect against loss of refrigerant
charge, (opens at 50 ± 5 psig and resets at 71 ± 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
48
The UCB will initiate a flash code associated with errors within
the system. Refer to UNIT CONTROL BOARD FLASH CODES
Table 25.
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.
Single-stage heating: (applies only to 18 KW heater, all other
heaters MUST use a two-stage thermostat)
a. Upon a call for heat by the thermostat, the heater
contactor (6M) 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.
Two-stage heating: (applies to all heaters except 18 KW)
a. Upon a call for first-stage heat by the thermostat, the
heater contactor (6M) (6M & 7M on 72 KW, 240V) 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 contactor
(7M) will be energized. Note that on the 54 KW, 240V
heater, heater contactors (7M & 8M) will be energized and
on the 72 KW, 240V heater, heater contactors (8M & 9M)
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.
Johnson Controls Unitary Products
284810-YIM-F-1210
NOTE: All 240 & 480V heaters are provided with manual reset
backup protection limits. These will de-energize the
heaters should the primary limit fail to open or the
contactors fail to open in a failure mode.
Table 20: Limit Control Setting
Unit
(Tons)
Voltage
Electric Heat Operation Errors
Temperature Limit
15, 17.5,
20 and 25
460
15, 17.5,
20 and 25
600
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
(See Table 25).
Safety Controls
Heater
Kw
18
36
54
72
18
36
54
72
Temperature,
Limit Switch
1, 2
Opens, °F
120
120
120
120
120
120
120
120
Temperature,
Limit Switch
3, 4, 5, 6
Opens, °F
170
170
170
170
-
Flash Codes
The UCB will initiate a flash code associated with errors within
the system. Refer to UNIT CONTROL BOARD FLASH CODES
Table 25.
The UCB monitors the temperature limit switch of electric heat
units.
Reset
The control circuit includes the following safety controls:
Remove the call for heating by lowering the thermostat setting
lower than the conditioned space temperature.This resets any
flash codes.
Temperature Limit Switch (TLs)
1.
Electric Heat Anticipator Setpoints
Temperature Limit Switch (TLS 1, 2).
This control is located inside the heater compartment and
is set to open at the temperature indicated in the Limit
Control Setting Table 20. 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.
2.
Temperature Limit Switch (TLS 3, 4, 5 and 6).
This control is located inside the heater compartment and
is set to open at the temperature indicated in the Limit
Control Setting Table 20. It is a manual reset limit. These
limit switches will de-energize the heaters should the
primary limit fail to open or the contactors fail to open in a
failure mode.
Table 20: Limit Control Setting
Unit
(Tons)
Voltage
15
240
17.5, 20
and 25
240
Heater
Kw
18
36
54
72
18
36
54
72
Temperature,
Limit Switch
1, 2
Opens, °F
120
120
120
120
140
140
140
140
Johnson Controls Unitary Products
Temperature,
Limit Switch
3, 4, 5, 6
Opens, °F
170
170
170
170
200
200
200
200
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 21 for the required electric
heat anticipator setting.
Table 21: Electric Heat Anticipator Setpoint
Heater
Kw
18
36
54
72
18
36
54
72
18
36
54
72
Voltage
208/230-3-60
460-3-60
575-3-60
Th1
0.29
0.29
0.29
0.29
0.29
0.29
0.29
0.29
0.29
0.29
0.29
0.29
Setting, Amps
Th2
0.29
0.58
0.58
0.29
0.29
0.29
0.29
0.29
0.29
Gas Heating Sequence Of Operations
The following sequence describes the operation of the gas heat
section.
49
284810-YIM-F-1210
operation for five minutes or until 24V power is removed from
the module either at the unit or by resetting the room
thermostat.
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.
NOTE: That the second stage furnace can operate even if first
stage has locked out.
When the thermostat satisfies de-energizing the “RW2”and
“RW1”, thus opening all gas valves. The blower motor will
continue to run after the furnace is shut down until the specified
fan off delay for heating has been satisfied. The UCB will deenergize the blower motor.
Redundant valve
Main valve
When the thermostat calls for the first stage of heating, the lowvoltage control circuit from “R” to “W1” and “G” is completed,
thru the UCB. The heat relay “RW1” is energized. The “RW1-2”
contacts close energizing the draft motor control. The draft
motor control contacts close and start the draft motor. As the
speed of the draft motor reaches approximately 2500 RPM, the
centrifugal switch contact, located on the end of the draft motor
shaft, closes to power the first stage ignition module “IC1”, thru
the “RW1-1” contacts.
Figure 22: Gas Valve Piping
Ignition module “IC1” will immediately start the first stage igniter
sparking and will open the redundant valve located inside the
first stage main gas valve “GV1” to allow a flow of gas to only
the first stage carryover tube. Only after the pilot flame has
been ignited and the presence of pilot flame detected at the
“IC1” by a signal sent back through the flame sensor is sparking
terminated and the first stage main gas valve opened.
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. Once voltage has been sensed at “W1”, the UCB will
initiate the fan on delay for heating, energizing the indoor
blower after the specified delay has elapsed.
Gas flows into each of the main burners and is ignited from the
carryover tube flame.
When the thermostat has been satisfied, heating calls are
ceased. The GV is immediately de-energized. The blower is deenergized after the fan off delay for heating has elapsed. The
draft motor performs a 25-second post purge.
After completing the specified fan on delay for heating, the UCB
will energize the blower motor.
Gas main
To main burner
Gas Valve
To pilot burner
Gas Heating Operation Errors
If “IC1” fails to detect a pilot flame, it will continue to try for a
maximum of 85 seconds to ignite the pilot tube. If the pilot flame
is not detected, then “IC1” will lock out first stage furnace
operation for five minutes or until 24V power is removed from
the module either at the unit or by resetting the room
thermostat.
When the thermostat calls for the second stage of heating, the
low-voltage control circuit from “R” to “W2” is completed, thru
the UCB. Heat relay “RW2” is energized. The “RW2-1” contact
is closed energizing the second stage ignition module “IC2”.
“IC2” will immediately start the second stage igniter sparking
and will open the redundant valve located inside the second
stage main gas valve “GV2” to allow a flow of gas to the second
stage carryover tube. Only after the pilot flame has been ignited
and the presence of pilot flame detected at “IC2” by a signal
sent back through the flame sensor is sparking terminated and
the main gas valve opened.
Gas flows into each of the second stage main burners and is
ignited from the carryover tube flame.
If “IC2” fails to detect a pilot flame, it will continue to try for a
maximum of 85 seconds to ignite the pilot tube. If the pilot flame
is not detected, then “IC2” will lock out first stage furnace
50
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 25-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
Table 25).
Gas Valve
The UCB continuously monitors 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 25). 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.
Johnson Controls Unitary Products
284810-YIM-F-1210
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.
Safety Controls
The UCB monitors the temperature limit switch of gas heat units.
The control circuit includes the following safety controls:
Table 22: Gas Heat Limit Control Setting
Capacity, MBH
Units
(Tons)
Input
Output
Limit Control
Opens, ºF
15, 17.5, 20 & 25
300
240
195
15, 17.5, 20 & 25
400
320
195
The ICB monitors the Pressure and Rollout switches 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 22. 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.
Ignitor Control #2
Ignitor Control #1
Centrifugal Switch (CS)
If the draft motor should fail, the centrifugal switch attached to
the shaft of the motor prevents the ignition controls and gas
valves from being energized.
Redundant Gas Valve
This switch is located above the main burners in the control
compartment, which in the event of a sustained main burner
rollout shuts off and locks out both ignition controls closing both
gas valves. The ignition controls lock out furnace operation until
24V power is removed from the controls either at the unit or by
resetting the room thermostat.
Auxiliary Limit Switch (AUX)
This control is located inside the heat exchanger compartment
and is set to open at 190°F. It is a manual reset switch. If AUX
trips, then the primary limit has not functioned correctly.
Replace the primary limit.
Johnson Controls Unitary Products
Ignitor #1
Sensor #2
Ignitor #2
Burner Compartment
Flame Sensor Rod / 100% Ignition Control Lock-Out.
Rollout Switch
GV1
Gas
Valve
GV2
Gas
Valve
There are two separate gas valves in the furnace. Each valve
contains a main and a redundant valve. The redundant valves
are located upstream of the main gas valves. Should either or
both of the main gas valves fail in the open position the
redundant valves serve as back-ups and shut off the flow of gas.
The flame rods and controls are located per Proper Flame
Adjustment Figure 24. If an ignition control fails to detect a
signal from the flame sensor indicating the pilot flame is
properly ignited, then the main gas valve will not open. It will
continue to try and ignite the pilot for a maximum of 85 seconds,
then if the pilot flame is not detected, the ignition control will
lock out furnace operation until 24V power is removed from the
module either at the unit or by resetting the room thermostat.
Rollout
Switch
Sensor #1
Figure 23: Gas Valve and Controls
Flash Codes
The UCB will initiate a flash code associated with errors within
the system. Refer to UNIT CONTROL BOARD FLASH CODES
Table 25.
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 23 for the required gas heat
anticipator setting.
51
284810-YIM-F-1210
Operating Instructions
Table 23: Gas Heat Anticipator Setpoints
Gas Valve
Honeywell VR8440
White-Rodgers
36C68
Anticipator Setpoint
1st Stage
2nd Stage
0.30 amp
0.11 amp
This furnace is equipped with an intermittent pilot and
automatic re-ignition system. DO NOT attempt to
manually light the pilot.
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.
Lighting The Main Burners
1.
Turn “OFF” electric power to unit.
2.
Turn room thermostat to lowest setting.
3.
Turn gas valve knob or switch to “ON” position (See
Figure 26).
4.
Turn “ON” electric power to unit.
5.
Set room thermostat to desired temperature (If thermostat
“set” temperature is above room temperature, pilot burner
ignition will occur and, after an interval to prove pilot flame,
main burners will ignite).
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.
Operating Instructions
1.
Turn unit electrical power on.
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.
3.
Measure the system amperage draw across all legs of 3
phase power wires.
4.
Measure the condenser fan amperage draw.
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 13 in. or
the operating pressure drop below 5.0 in for natural gas
units. If gas pressure is outside these limits, contact the
local gas utility or propane supplier for corrective action.
Start-Up (Gas Heat)
Shut Down
Pre-Start Check List
1.
Set the thermostat to the lowest temperature setting.
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.
Turn “OFF” all electric power to unit.
3.
Open gas heat access panel.
2.
4.
Turn gas valve clockwise to “OFF” position (See Figure 26).
52
Make sure that the vent and combustion hoods have been
properly installed.
Johnson Controls Unitary Products
284810-YIM-F-1210
Checking Gas Heat Input
Table 24: Gas Rate Cubic Feet Per Hour
1.
Turn off all other gas appliances connected to the gas meter.
2.
With the furnace turned on, measure the time needed for
one revolution of the hand on the smallest dial on the
meter. A typical gas meter usually has a 1/2 or a 1 cubic
foot test dial.
3.
Using the number of seconds for each revolution and the
size of the test dial increment, find the cubic feet of gas
consumed per hour from the Gas Rate - Cubic Feet Per
Hour Table 24.
If the actual input is not within 5% of the furnace rating (with
allowance being made for the permissible range of the regulator
setting), replace the orifice spuds with spuds of the proper size.
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 - it varies widely from city to city.).
Table 24: Gas Rate Cubic Feet Per Hour
Seconds for
One Rev.
4
6
8
10
12
14
16
18
20
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
450
300
228
180
150
129
113
100
90
Johnson Controls Unitary Products
900
600
450
360
300
257
225
200
180
Seconds for
One Rev.
22
24
26
28
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
82
75
69
64
164
150
138
129
EXAMPLE
By actual measurement, it takes 13 seconds for the hand on the
1-cubic foot dial to make a revolution with just a 300,000 Btuh
furnace running. Read across to the column in the table above,
headed “1 Cubic Foot”, where you will see that 278 cubic feet of
gas per hour are consumed by the furnace at that rate. Multiply
278 x 1050 (the Btu rating of the gas obtained from the local
gas company). The result is 292,425 Btuh, which is close to the
300,000 Btuh rating of the furnace.
Manifold Gas Pressure Adjustment
Small adjustments to the high-fire gas flow may be made by
turning the pressure regulator adjusting screw on the automatic
gas valve.
Adjust as follows:
1.
Remove the cap on the regulator. It's located next to the
push-on electrical terminals.
2.
To decrease the gas pressure, turn the adjusting screw
counterclockwise.
3.
To increase the gas pressure, turn the adjusting screw
clockwise.
NOTE: The correct manifold pressure for these furnaces is
3.65 IWG ± 0.3.
53
284810-YIM-F-1210
Adjustment Of Temperature Rise
Burner Instruction
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 11.
To check or change burners, pilot or orifices, CLOSE MAIN
MANUAL SHUT-OFF VALVE AND SHUT OFF ALL ELECTRIC
POWER TO THE UNIT.
After the temperature rise has been determined, the CFM can
be calculated as follows:
1.
Remove the screws holding either end of the manifold to
the burner supports.
2.
Open the union fitting in the gas supply line just upstream
of the unit gas valve and downstream from the main
manual shut-off valve.
3.
Remove the gas piping closure panel.
4.
Disconnect wiring to the gas valves and spark ignitors.
Remove the manifold-burner gas valve assembly by lifting
up and pulling back.
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).
Burner
Heat Tube
Exchanger
Pilot Tube
Burner Flame
(Blue Only)
Adjustable Shutter
NOTE: Each gas heat exchanger size has a minimum
allowable CFM. Below this CFM, the limit will open.
Burner Assembly Bracket
Gas Supply Pipe
Figure 25: Typical Flame
Flame Sensor Bulb
Burners are now accessible for service.
Reverse the above procedure to replace the assemblies. Make
sure that burners are level and seat at the rear of the heat
exchanger.
Burner Air Shutter Adjustment
1/8” Gap Between
Carry-over Tube
and Flame Sensor Bulb
Adjust burner shutters so no yellow flame is observed in the
heat exchanger tubes.
Carry-over Tube
Figure 24: Proper Pilot Flame Adjustment
Pilot Checkout
The pilot flame should envelope the end of the flame sensor. To
adjust pilot flame, (1) remove pilot adjustment cover screw, (2)
increase or decrease the clearance for air to the desired level,
(3) be sure to replace cover screw after adjustment to prevent
possible gas leakage.
Put the system into operation and observe through complete
cycle to be sure all controls function properly.
54
Figure 26: Typical Gas Valve
Johnson Controls Unitary Products
284810-YIM-F-1210
Charging The Unit
15 Ton Charging Chart
20 Ton Charging Chart
500
500
480
460
460
440
440
Discharge Pressure (psig)
400
380
95°F
Outdoor
360
340
85°F
Outdoor
320
300
260
240
220
105°F
Outdoor
420
Discharge Pressure (psig)
105°F
Outdoor
420
280
115°F
Outdoor
480
115°F
Outdoor
75°F
Outdoor
400
380
95°F
Outdoor
360
340
85°F
Outdoor
320
300
75°F
Outdoor
280
260
65°F
Outdoor
240
65°F
Outdoor
220
200
110 115 120 125 130 135 140 145 150 155 160 165 170
200
110 115 120 125 130 135 140 145 150 155 160 165 170
Suction Pressure (psig)
Suction Pressure (psig)
Figure 27: ZJ180 (15 Ton) Charging Chart
Figure 29: ZJ240 (20 Ton) Charging Chart
17.5 Ton Charging Chart
25 Ton Charging Chart
530
500
115°F
Outdoor
480
490
460
420
400
95°F
Outdoor
380
360
340
85°F
Outdoor
320
300
75°F
Outdoor
105°F
Outdoor
450
430
410
95°F
Outdoor
390
370
85°F
Outdoor
350
330
75°F
Outdoor
310
290
260
240
470
105°F
Outdoor
Discharge Pressure (psig)
Discharge Pressure (psig)
440
280
115°F
Outdoor
510
65°F
Outdoor
270
220
250
200
110 115 120 125 130 135 140 145 150 155 160 165 170
230
Suction Pressure (psig)
Figure 28: ZJ210 (17.5 Ton) Charging Chart
Johnson Controls Unitary Products
65°F
Outdoor
95
100 105 110 115 120 125 130 135 140 145 150 155
Suction Pressure (psig)
Figure 30: ZJ300 (25 Ton) Charging Chart
55
284810-YIM-F-1210
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.
the drive and for any fault/warning messages displayed on
the drive's digital display (refer to the drive user manual for
full descriptions, if necessary). Clear any fault by pressing
'RESET' on the drive's keypad and take any corrective
action as needed. If the 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 UCB supply air blower motor terminal,
“FAN”. If 24 volts is present at the FAN, check for loose
wiring between the UCB and M3.
7.
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
8.
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.
9.
If the thermostat and UCB are properly wired, replace the
UCB.
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.
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.
Cooling Troubleshooting Guide
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.
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 2.
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. For units with VFD, check that line
voltage is being supplied to the M3-Auxiliary contacts.
Check for loose wiring between the contactor and the
supply air blower motor.
3.
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.
4.
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.
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.
5.
Failing the above, if voltage is supplied at M1, M1 is pulled
in, and the compressor still does not operate, replace the
compressor.
For units with VFD, if there is line voltage supplied at M3,
M3 is pulled in, and the blower motor does not operate,
check all power & control wiring connections to and from
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.
56
Johnson Controls Unitary Products
284810-YIM-F-1210
7.
8.
9.
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
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.
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 out, cancel
any call for cooling. This will reset any compressor lock outs.
If the LPS is still open after the ASCD, the compressor will
not be energized for 30 seconds. The second and third
times that the UCB sees an open LPS will count towards the
three occurrences that will cause a UCB lock-out.
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 MateN-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
Johnson Controls Unitary Products
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
57
284810-YIM-F-1210
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.
9.
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.
2.
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.
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.
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 is present and M1 is not pulled in, replace the
contactor.
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,
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.
remove any call for cooling at the thermostat or by
disconnecting the thermostat wiring at the Y1, Y2, Y3 and
Y4 on the UCB terminal. This will reset any compressor
lock outs, except LPS lockouts these can only be reset by
cycling power to UCB.
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, except LPS lockouts. These can only be reset by
cycling power to the UCB.
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):
1.
58
Compressor #2 is energized in place of compressor #1
when compressor #1 is unavailable for cooling calls. Check
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.
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”
Johnson Controls Unitary Products
284810-YIM-F-1210
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 MateN-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
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.
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.
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.
1.
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. For units with VFD, check that line
voltage is being supplied to the M3-Auxiliary contacts.
Check for loose wiring between the contactor and the
supply air blower motor.
3.
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.
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
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).
Johnson Controls Unitary Products
For units with VFD, if there is line voltage supplied at M3,
M3 is pulled in, and the blower motor does not operate,
check all power & control wiring connections to and from
the drive and for any fault/warning messages displayed on
the drive's digital display (refer to the drive user manual for
full descriptions, if necessary). Clear any fault by pressing
'RESET' on the drive's keypad and take any corrective
action as needed. If the motor still does not operate,
replace the motor.
59
284810-YIM-F-1210
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.
2.
Check all 24 volt connections from the relay board to and in
the gas heat section. Check low voltage connections to the
(ETD) located in the control box.
3.
If the furnace is hot, it may be out on an over-temperature
condition, wait for limit reset.
4.
If the furnace is cold, check for 24 volts at wire 241
attached to the electrical time delay (ETD) located in the
main control box. If 24 volts is not found, replace the ETD.
5.
24 volts is found at wire 241, remove the wires attached to the
(TDR) and with a VOM, check for continuity across contacts 1
and 2. If none is found, the (TDR) is open and must be
replaced. If there is continuity, re-attach the wires.With the
draft motor running, check for 24 volts at terminal 4 of (RW12) and (RW2-1). If 24 volts is not present, the centrifugal
switch (CS) has not closed or has gone bad. Check the line
voltage to the unit - if it is correct, replace the draft motor. If
line voltage is low, call the power company.
6.
Check for 24V at terminal 2 of (RW1-2 and RW2-1). If 24V
is not present, check for 24V at (RW1 and RW2) relay
coils. If these relays are pulled in, then check for a loose
connection at terminal 2 and terminal 4 of each relay. If no
problem is found, then replace (RW1 and/or RW2) as
required.
7.
If 24 volts is present at the ignitor controls, check all control
wiring at the ignitor controls and the high tension wire to
the ignitors. Check that the ground wires from the ignitor
controls, the gas valves and pilot burners are all intact and
making good electrical connection. Check to make sure
that the ceramic insulator on the pilot ignitors or sensors is
not broken or cracked, if all are intact, replace the ignition
control IC1 or IC2.
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's Mate-N-Lok
connector attached to the evaporator partition. If line
voltage is present, replace the draft motor.
3.
If line voltage is not present, check for line voltage at the
heat relay (RW1) contacts in the main control box and
check to see if the (RW1) is pulled in.
4.
If the (RW1) relay is pulled in, check for a loose line voltage
connection.
5.
If the (RW1) relay is not pulled in, check for 24 volts at the
(RW1) coil. If 24 volts is present, replace the (RW1) relay. If
24 volts is not present, check for a loose 24 volt connection
back to the relay board and check the connections from the
room thermostat to the relay board. If all connections are
correct, replace the relay board.
The draft motor runs and the ignitor sparks at the pilot burner
but the pilot does not ignite and a gas odor is not detected at
the draft motor outlet.
1.
Check to make sure gas is being supplied to the unit. Make
sure that the gas pressure to the unit is within the proper
limits as described in the “POST START CHECK LIST”
page 52 and that the pilot adjust screw is allowing some
flow of gas as described in “PILOT CHECKOUT” page 54.
2.
Check all wiring between the ignitor control and the gas
valve. Check to make sure the ground connections are
intact.
3.
If the wiring is intact, check for 24 volts across terminals
“PV” and “COMMON” on the ignitor control. If 24 volts is
not present, replace the ignitor control.
4.
If 24 volts is present, remove the pilot burner and remove
the pilot orifice from the pilot burner. The orifice is removed
in the direction opposite the flow of gas. Inspect the orifice
for obstruction. If it is clear, replace the main gas valve.
The draft motor runs but the furnace does not light and the
sparker does not spark.
1.
60
The ignition control (IC1, IC2) may be locked out due to
either a flame roll out or 100% shut off. These safety features
are described above. If lock-out has occurred, 24V must be
removed from the ignition controls. This is done at the unit or
by resetting the room thermostat. After resetting 24V, check
for proper furnace operation. If lock-out continues to occur,
locate the source of the problem and correct.
The ignitor sparks at the pilot burner but the pilot does not ignite
and a gas odor is detected at the draft motor outlet.
1.
Adjust the pilot adjust screw on the gas valve as described
in “PILOT CHECKOUT” page 54.
2.
Check the supply pressure as described in “POST START
CHECK LIST” page 52. Make adjustments as necessary.
Johnson Controls Unitary Products
284810-YIM-F-1210
3.
Check the pilot orifice for obstruction as described in
paragraph above. Clean as needed but the problem should
not be the gas valve.
The pilot burner ignites but the ignitor continues to spark and
the main burners do not ignite.
1.
2.
Make the same checks and adjustment as described in
“PILOT CHECKOUT” page 54.
Check the supply pressure as described in “POST START
CHECK LIST” page 52. Make adjustments as necessary.
3.
Make sure that the pilot burner is not bent or damaged.
4.
Make sure that the ground connections at the pilot burner,
gas valve and ignitor control are intact. Check the high
tension wire for good electrical connection. If all are intact,
replace the ignitor module.
The pilot burner lights and the spark stops but the main burners
do not light.
1.
Check electrical connections between the ignitor control
and the gas valve. If intact, check for 24 volts across
terminals “MV” and “COMMON” terminals. If no voltage
detected, replace ignitor control. If voltage is present,
replace gas valve.
Furnace lights with roll-out or one burner has delayed ignition.
1.
Make sure that the pilot burner is aligned properly with the
carryover as described in “PILOT CHECKOUT” page 54.
2.
Make sure that the carryovers on adjoining burners are
screwed fast and are level with respect to one another.
Main burners light but exhibit erratic flame characteristics.
1.
Adjust air shutters as described in “BURNER AIR
SHUTTER ADJUSTMENT” page 54.
Johnson Controls Unitary Products
2.
Check the main burner orifices for obstruction and
alignment. Removal procedure is described in BURNER
INSTRUCTIONS page 54. Clean or replace burner orifices
and burners as needed.
Unit Control Board 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 31. 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
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. Flash code 21 is a nonalarm condition but due to the space constraints of the UCB,
will be indicated by the Red LED. In all other cases, a flashing
Green LED will be used to indicate non-alarm conditions.
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
Table 25.
61
284810-YIM-F-1210
Table 25: Unit 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
21 Flashes
OFF
Description
This is a Control Failure
Not Applicable
Control waiting ASCD1
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 Temperature1
Compressors locked out because the Economizer is using free Cooling1
Unit Locked Out due to Fan Overload Switch Failure
Compressor Held Off due to Low Voltage1
EEPROM Storage Failure
HPS3 Compressor Lockout
HPS4 Compressor Lockout
LPS3 Compressor Lockout
LPS4 Compressor Lockout
FS3 Compressor Lockout
FS4 Compressor Lockout
Compressor Off due to Low SAT1
No Power or Control Failure
Green
LED 16
Flashing
Off
Off
Off
Off
Off
Off
Off
Flashing
Flashing
Off
Flashing
Off
Off
On
On
On
On
On
On
Off
Red
LED 8
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Red
LED 4
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
Off
Red
Led 2
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
Off
Red
LED 1
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
1. Non-alarm conditions.
Check
Alarm
History
Reset All ASCDs
For One Cycle
Non Alarm Condition
Green LED Flashing
Current Alarm
Flashed Red LED
Figure 31: Unit Control Board
62
Johnson Controls Unitary Products
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.
Table 26: Heat Delay
Heat
Fan On
Delay
60
60
60
60
45
45
45
45
30
30
30
30
0
0
0
Non-std
Heat
Fan Off
Delay
180
90
60
30
180
90
60
30
180
90
60
30
60
30
10
Non-std
Red
LED 8
Red
LED 4
Red
LED 2
Red
LED 1
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
Optional VAV Control Board Flash Codes
Flash codes are also utilized by the VAV add-on board to aid in
troubleshooting optional VAV applications. Flash codes are
displayed by a red LED located near the center of the board
using a short on/off cycle (approximately 200-ms on and 200ms off).
To verify that the board is functioning correctly, the LED will
display a repetitive 1 second on, 1 second off "heartbeat". Do
not confuse this "heartbeat" with the error flash codes shown in
the table below. To prevent confusion, a 1-flash, flash code is
not used.
Table 27: VAV Control Board Flash Codes
FLASH CODE
DESCRIPTION
• The 8, 4, 2 and 1 LEDs will then show the status of the
Heat Delay, (See Table 26). Press the UP or Down button
to change the LED status to correspond to the desired
Heat Delay Value.
On Steady
Control Failure
1 Flash
Not Applicable
• 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.
4 Flashes
SAT Sensor Failure
5 Flashes
RAT Sensor Failure
6 Flashes
OAT Sensor Failure
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).
2 Flashes
Loss of Communication with UCB
3 Flashes
Space Sensor Failure
7 Flashes
OH Sensor Failure
8 Flashes
RH Sensor Failure
9 Flashes
IAQ Sensor Failure
10 Flashes
OAQ Sensor Failure
11 Flashes
APS Sensor Failure
12 Flashes
Limit 2 Switch Open
13 Flashes
Purge
14 Flashes
VFD Input Failure
15 Flashes
OFF
Subject to change without notice. Printed in U.S.A.
Copyright © 2010 by Johnson Controls, Inc. All rights reserved.
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
Dirty Filter Switch
No Power or Control Failure
284810-YIM-F-1210
Supersedes: 284810-YIM-E-0910
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