r-410a zs series
R-410A
ZS SERIES
6-1/2 - 12-1/2 Ton
60 Hertz
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . . 36
Standard Economizer And Power Exhaust Set Point 
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 53
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54
Ignition Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 55
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . . . . . 61
Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LIST OF TABLES
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ZS-06 thru -12 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7
Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ZS-06 thru -12 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9
ZS-06 thru -12 Unit Physical Dimensions . . . . . . . . . . . . . . . 11
ZS-06 thru -12 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . 11
Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ZS-06 thru -12 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 28
Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 30
Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 31
Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 32
Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 40
Airflow Performance - Side Duct Application . . . . . . . . . . . . . 42
Airflow Performance - Bottom Duct Application . . . . . . . . . . 44
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ZS Component Location (ZS-10 Shown) . . . . . . . . . . . . . . . . 6
Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ZS-06 thru -10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ZS-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ZS-06 thru -12 Unit Bottom Duct Openings . . . . . . . . . . . . . 12
ZS-06 thru -12 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13
ZS-06 thru -10 Unit Side Duct Openings . . . . . . . . . . . . . . . 13
ZS-12 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . . 14
ZS-06 thru -12 Unit Left Duct Opening . . . . . . . . . . . . . . . . 14
ZS-06 thru -12 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ZS-06 thru -12 Transition Roof Curb . . . . . . . . . . . . . . . . . . 15
Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16
Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . 16
Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Field Wiring Disconnect - Cooling Unit With/Without Electric
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . .
Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . .
Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Heat Limit Setting 50” Cabinet . . . . . . . . . . . . . . . . .
Electric Heat Limit Setting 42” Cabinet . . . . . . . . . . . . . . . . .
Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . .
Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . .
Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . .
Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . .
Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . .
Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . .
VAV Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . .
45
46
46
48
49
53
54
54
55
56
58
58
60
62
62
62
LIST OF FIGURES
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . 18
22 Field Wiring Disconnect - Cooling Unit With Gas Heat Without
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
23 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . . 19
24 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . . . . 19
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
28 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
29 Honeywell Economizer Control W7212 . . . . . . . . . . . . . . . . 38
30 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
31 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 40
32 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
33 Occupied Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
34 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
35 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
36 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
37 Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . 63
38 Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
39 Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
518676-BIM-E-1210
518676-BIM-E-1210
General
UP ZS units are single package air conditioners with optional
gas heating designed for outdoor installation on a rooftop or
slab and for non-residential use. These units can be equipped
with factory or field installed electric heaters for heating
applications.
These units are completely assembled on rigid, permanently
attached base rails. All piping, refrigerant charge, and electrical
wiring is factory installed and tested. The units require electric
power, gas supply (where applicable), and duct connections.
The electric heaters have nickel-chrome elements and utilize
single-point power connection.
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.
Safety Considerations
This is a safety alert symbol. When you see this symbol
on labels or in manuals, be alert to the potential for
personal injury.
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal injury.
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.
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.
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
c. Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
d. If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
Due to system pressure, moving parts, and electrical
components, installation and servicing of air conditioning
equipment can be hazardous. Only qualified, trained service
personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions
of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags
accompanying the equipment whenever working on air
conditioning equipment. Be sure to follow all other applicable
safety precautions and codes including ANSI Z223.1 or CSAB149.1- latest edition.
Johnson Controls Unitary Products
518676-BIM-E-1210
Wear safety glasses and work gloves. Use quenching cloth and
have a fire extinguisher available during brazing operations.
• Gas Heat High Altitude Kit (Natural Gas)
Inspection
• –60F Gas Heat Kit
• Gas Heat High Altitude Kit (Propane)
• Electric Heater Accessory 50” cabinet
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.
• Electric Heater Accessory 42” cabinet
Renewal Parts
Contact your local UP parts distribution center for authorized
replacement parts.
Approvals
This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state and national codes including, but not limited
to, building, electrical, and mechanical codes.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system during
any pressure testing at pressures in excess of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas valve
damage resulting in a hazardous condition. If it is
subjected to a pressure greater than 1/2 PSIG, the gas
valve must be replaced.
The furnace must be isolated from the gas supply piping
system by closing its individual manual shut-off valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
Reference
Design certified by CSA as follows:
1.
For use as a cooling only unit, cooling unit with
supplemental electric heat or a forced air furnace.
2.
For outdoor installation only.
3.
For installation on combustible material and may be
installed directly on combustible flooring or, in the U.S., on
wood flooring or Class A, Class B or Class C roof covering
materials.
4.
For use with natural gas (convertible to LP with kit).
This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state, and national codes including, but not limited
to, building, electrical, and mechanical codes.
Additional information is available in the following reference
forms:
• Technical Guide - ZS-06 thru -12, 528197
• General Installation - ZS-06 thru -12, 518676
• Pre-start & Post-start Check List
• Economizer Accessory Downflow Factory Installed
Downflow Field Installed
Horizontal Field Installed
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage.
• Motorized Outdoor Air Damper
• Manual Outdoor Air Damper (0-100%)
• Manual Outdoor Air Damper (0-35%)
• Gas Heat Propane Conversion Kit
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
518676-BIM-E-1210
Nomenclature
6.5-12.5 Ton Single Package Model Number Nomenclature
Z S -10 N18 A T A AA 5 0 1 2 4 A
Product Category
Product Style
Z = A/C, Single Pkg., R-410A
A = Style A
B = Style B
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
Product Identifier
S = 11.2 + EER A/C
SS Drain Pan
CPC Controller, DFS, APS
Johnson Controller UNT 1126 (N2 protocol), DFS, APS
Nominal Cooling Capacity
Honeywell Controller, DFS, APS
-06 = 6.5 Ton
-07 = 7.5 Ton
-08 = 8.5 Ton
-10 = 10.0 Ton
-12 = 12.5 Ton
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/Simplicity®LINC
Hot Gas Bypass (Standard on VAV, Optional on CV)
Variable Air Volume, VFD (not available with factory installed BAS options)
Variable Air Volume, VFD with Simplicity®LINC (not available with factory installed BAS options)
Heat Type and Nominal Heat Capacity
Variable Air Volume, VFD and Manual Bypass
(not available with factory installed BAS options)
C00 = Cooling Only. No heat installed
Variable Air Volume, VFD and Manual Bypass with Simplicity®LINC
(not available with factory installed BAS options)
Gas Heat Options
Variable Air Volume, VFD (BAS ready)
Variable Air Volume, VFD and Manual Bypass (BAS ready)
N12 = 120 MBH Input Aluminized Steel
N18 = 180 MBH Input Aluminized Steel
N24 = 240 MBH Input Aluminized Steel
S12 = 120 MBH Input Stainless Steel
S18 = 180 MBH Input Stainless Steel
S24 = 240 MBH Input Stainless Steel
Variable Air Volume, VFD Ready (for customer-provided, field-installed drive)
Variable Air Volume, VFD Ready with Simplicity®LINC
(for customer-provided, field-installed drive)
2" Pleated filters
4" Pleated filters
BAS Ready Economizer (2-10 V.D.C. Actuator without a Controller)
Shipping Bag
Electric Heat Options
E09 = 9 KW
E18 = 18 KW
E24 = 24 KW
E36 = 36 KW
E54 = 54 KW
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
Product Generation
5 = Fifth Generation
Airflow
Additional Options
A = Std. Motor
B = Std. Motor/Econo./Barometric Relief (Downflow
Only)
C = Std. Motor/Econo./Power Exhaust (Downflow Only)
D = Std. Motor/Motorized Damper (Downflow Only)
E = Std. Motor/Horizontal Economizer (No Baro.)
F = Std. Motor/Slab Econo./Power Exhaust
(Downflow Only)
G = Std. Motor/Slab Econo./Barometric Relief
(Downflow Only)
N = Hi Static
P = Hi Static/Econo./Barometric Relief
(Downflow Only)
Q = Hi Static/Econo./Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper (Downflow Only)
S = Hi Static/Horizontal Economizer (No Baro.)
T = Hi Static/Slab Econo./Power Exhaust
(Downflow Only)
U = Hi Static/Slab Econo./Barometric Relief
(Downflow only)
Voltage
T = 208/230-3-60
W = 460-3-60
X = 575-3-60
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
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
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 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
4
Johnson Controls Unitary Products
518676-BIM-E-1210
Installation
3.
Remove the condenser coil external protective covering
prior to operation.
Installation Safety Information
4.
Remove the toolless doorknobs and instruction packet
prior to installation.
Read these instructions before continuing this appliance
installation. This is an outdoor combination heating and cooling
unit. The installer must assure that these instructions are made
available to the consumer and with instructions to retain them
for future reference.
1.
Refer to the unit rating plate for the approved type of gas
for this product.
2.
Install this unit only in a location and position as specified
on Page 7 of these instructions.
3.
Never test for gas leaks with an open flame. Use
commercially available soap solution made specifically for
the detection of leaks when checking all connections, as
specified on Pages 5, 32, 33 and 57 of these instructions.
4.
Always install furnace to operate within the furnace's
intended temperature-rise range with the duct system and
within the allowable external static pressure range, as
specified on the unit name/rating plate, specified on
Page 59 of these instructions.
5.
This equipment is not to be used for temporary heating of
buildings or structures under construction.
Condenser
Coil External
Protective
Covering
Barometric
Relief Hood
in Shipping
Location
(if Included)
Figure 2: Condenser Covering
Toolless
Doorknobs
FIRE OR EXPLOSION HAZARD
Installation
Instruction
Packet
Failure to follow the safety warning exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
Preceding Installation
1.
Remove the two screws holding the brackets in the front,
rear and compressor side fork-lift slots.
Bracket
Screws
Turn down
Figure 1: Unit Shipping Bracket
2.
Figure 3: Compressor Section
5.
If a factory option convenience outlet is installed, the
weatherproof outlet cover must be field installed. The cover
shall be located behind the filter access panel. To install
the cover, remove the shipping label covering the
convenience outlet, follow the instructions on the back of
the weatherproof cover box, and attach the cover to the
unit using the (4) screws provided.
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.
Turn each bracket toward the ground and the protective
plywood covering will drop to the ground.
Johnson Controls Unitary Products
5
518676-BIM-E-1210
Limitations
These units must be installed in accordance with the following:
In U.S.A.:
1.
National Electrical Code, ANSI/NFPA No. 70 - Latest
Edition
2.
National Fuel Gas Code, ANSI Z223.1 - Latest Edition
3.
Gas-Fired Central Furnace Standard, ANSI Z21.47a. Latest Edition
4.
Local building codes, and
5.
Local gas utility requirements
In Canada:
1.
Canadian Electrical Code, CSA C22.1
2.
Installation Codes, CSA - B149.1.
3.
Local plumbing and waste water codes, and
4.
Other applicable local codes.
Refer to unit application data found in this document.
After installation, gas fired units must be adjusted to obtain a
temperature rise within the range specified on the unit rating
plate.
If components are to be added to a unit to meet local codes,
they are to be installed at the dealer’s and/or customer’s
expense.
Size of unit for proposed installation should be based on heat
loss/heat gain calculation made according to the methods of Air
Conditioning Contractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings
or structures under construction.
The Simplicity® control board used in this product will
effectively operate the cooling system down to 0°F when
this product is applied in a comfort cooling application
for people. An economizer is typically included in this
type of application. When applying this product for
process cooling applications (computer rooms,
switchgear, etc.), please reference applications bulletin
AE-011-07 or call the applications department for
Unitary Products @ 1-877-UPG-SERV for guidance.
Additional accessories may be needed for stable
operation at temperatures below 30° F.
Simplicity® control board
Filter access
Disconnect location
w/screw connector for T-stat
(2” or 4” Filter Options)
(optional
disconnect
switch)
wiring and network connections
Terminal block for
hi-voltage connection
Filter drier
(solid core)
Micro-Channel Aluminum Tube
Aluminum Fin Condenser
Second model
nameplate
inside hinged
access panel
Slide-out motor and
blower assembly for
easy adjustment
and service
Dual stage
cooling for
maximum
comfort
Belt-drive
blower motor
VFD Location (Optional)
Power ventor motor
Compressor #2
access (highefficiency
compressor
w/crankcase
heater)
20-gauge aluminized steel tubular
heat exchanger for
long life (stainless
steel option)
Base rails w/forklift
slots (three sides)
and lifting holes
Two-stage gas
heating to maintain
warm, comfortable
temperature
Roof curbs in eight- and
fourteen-inch heights. Roof
curbs for transitioning from
DHB/DUC/HC/DUS footprint to
the ZS Series footprints are
also available (field-installed
accessory)
Slide-out drain pan
with 3/4” NPT,
female connection
Toolless
door latch
Side entry power
and control wiring
knockouts
Intelligent control
board for safe and
efficient operation
Compressor #1 access
(high-efficiency compressor
w/crankcase heater)
Figure 4: ZS Component Location (ZS-10 Shown)
6
Johnson Controls Unitary Products
518676-BIM-E-1210
Table 1:
ZS-06 thru -12 Unit Limitations
Unit Limitations
Size
(Tons)
-06
(6.5)
-07
(7.5)
-08
(8.5)
-10
(10)
-12
(12.5)
Model
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
208/230-3-60
187
252
125
460-3-60
432
504
125
575-3-60
540
630
125
ZS
ZS
ZS
ZS
ZS
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 5 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 UP
roof curb, gasketing must be applied to all surfaces that
come in contact with the unit underside.
7
518676-BIM-E-1210
Before lifting, make sure the unit weight is distributed
equally on the rigging cables so it will lift evenly.
Units may be moved or lifted with a forklift. Slotted openings in
the base rails are provided for this purpose.
LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES.
FRONT
LEFT
All panels must be secured in place when the unit is
lifted.
D
C
B
A
E
F
The condenser coils should be protected from rigging
cable damage with plywood or other suitable material.
Figure 6: Unit 6 Point Load Weight
Y
X
FRONT
LEFT
Figure 7: Center of Gravity
FRONT
LEFT
B
C
A
D
Figure 5: Unit 4 Point Load Weight
Table 2:
Weights and Dimensions
Weight (lbs.)
Center of Gravity
Size
Model
(Tons)
Shipping Operating
X
Y
-06
ZS
865
860
38
24
(6.5)
-07
ZS
885
860
38
24
(7.5)
-08
ZS
1025
1020
38
24
(8.5)
-10
ZS
1065
1060
38
24
(10)
-12
ZS
1258
1253
47
25
(12.5)
8
4 Point Load Location (lbs.)
A
B
C
D
A
6 Point Load Location (lbs.)
B
C
D
E
F
200
149
218
292
140
114
95
138
167
205
205
153
223
299
144
117
97
142
171
210
238
177
258
347
167
136
113
164
198
243
247
184
268
360
173
141
117
171
206
253
251
280
381
341
164
176
190
259
240
223
Johnson Controls Unitary Products
518676-BIM-E-1210
Table 3:
ZS-06 thru -12 Unit Accessory Weights
Unit Accessory
Economizer
Power Exhaust
Electric Heat1
Gas Heat2
Variable Frequency Drive3
Weight (lbs.)
Shipping
Operating
90
85
40
35
49
49
110
110
30
30
1. Weight given is for the maximum heater size available
(54KW).
2. Weight given is for the maximum number of tube heat
exchangers available (8 tube).
3. Weight includes mounting hardware, controls and manual
bypass option.
29.69
15.25
15.38
59.00
15.38
Ø 24.47 TYP. 2 PL.
B
See detail A for gas inlet
A
C
D
E
11 3/8
F
See detail B for drain location
LEFT
4 3/16
FRONT
59
21 3/16
27 5/16
89
Figure 8: ZS-06 thru -10
Johnson Controls Unitary Products
9
518676-BIM-E-1210
30.11
29.95
45.64
14.92
14.92
58.09
14.92
Ø 24.47 TYP. 4 PL.
B
See detail A for gas inlet
A
C
D
E
11 3/8
F
LEFT
59
See detail B for drain location
4 3/16
21 3/16
FRONT
27 5/16
89
Figure 9: ZS-12
10
Johnson Controls Unitary Products
518676-BIM-E-1210
Table 4:
ZS-06 thru -12 Unit Physical Dimensions
Unit Model Number
A
42
42
50 3/4
50 3/4
50 3/4
ZS-06
ZS-07
ZS-08
ZS-10
ZS-12
B
89
89
89
89
119 1/2
Dimension (in.)
C
D
22 1/8
18 3/16
22 1/8
18 3/16
30 3/16
24 3/16
30 3/16
24 3/16
30 3/16
24 3/16
E
15 3/16
15 3/16
17 3/16
17 3/16
17 3/16
F
6 3/16
6 3/16
6 3/16
6 3/16
6 3/16
Detail A
3.184
3.184
Gas Pipe Inlet
Gas Pipe Inlet
Ø 2.000
Ø 2.000
Gas Exhaust Vent
Gas Exhaust Vent
Ø 3.126
Ø 3.126
17.541
14.594
7.715
7.705
4.737
4.727
42” CABINET
50 3/4” CABINET
Detail B
5-3/8
3/4” FPT
Table 5:
ZS-06 thru -12 Unit Clearances
Direction
Top1
Front
Rear
Distance (in.)
72
36
36
Direction
Right
Left
Bottom2
Distance (in.)
12
36
0
1. Units must be installed outdoors. Over hanging structure or shrubs should not obscure condenser air discharge outlet.
2. Units may be installed on combustable floors made from wood or class A, B or C roof covering materials.
Johnson Controls Unitary Products
11
518676-BIM-E-1210
89
32 11/16
6 13/16
RETURN
AIR
SUPPLY
AIR
6 13/16
27 1/2
LEFT
Bottom power, control
and convenience outlet
wiring entry
24
RIGHT
21
18
20 1/8 19 1/8
17 1/8
12 5/16
Bottom condensate drain
14 1/2
Bottom gas
supply entry
25 9/16
16 3/8
18 1/16
FRONT
TOP VIEW
3X Ø 0.875
Ø 2.469
Figure 10: ZS-06 thru -12 Unit Bottom Duct Openings
12
Johnson Controls Unitary Products
518676-BIM-E-1210
Disconnect Swith Cover
Power Entry Ø 2-1/2
Control Entry Ø 7/8
Power Entry Ø 2-1/2
Convenience Outlet Cover
Convenience Outlet
Power Entry Ø 7/8
FRONT
Figure 11: ZS-06 thru -12 Unit Electrical Entry
18-1/4
Dot Plugs
A
Return
Air
Supply
Air
D
B
2-31/32
5-5/32
C
31-11/16
Figure 12: ZS-06 thru -10 Unit Side Duct Openings
Johnson Controls Unitary Products
13
518676-BIM-E-1210
Dot Plugs
18-1/4
A
D
B
5-5/32
2-7/8
31-5/8
C
Figure 13: ZS-12 Unit Side Duct Openings
Table 6:
Side Duct Dimensions
Unit Model Number
Dimension (in.)
A
B
C
D
ZS-06
27 3/4
12 1/16
27 1/2
16
ZS-07
27 3/4
12 1/16
27 1/2
16
ZS-08
28 1/4
18 1/16
28 1/4
18 1/4
ZS-10
28 1/4
18 1/16
28 1/4
18 1/4
ZS-12
28 1/4
18 1/16
28 1/4
18 1/4
30-3/8
4-5/16
Figure 14: ZS-06 thru -12 Unit Left Duct Opening
14
Johnson Controls Unitary Products
518676-BIM-E-1210
RIGHT
80-5/8
INSULATED DECK UNDER
CONDENSER SECTION
20
SUPPLY
20
6
RETURN
2 TYP.
30
INSULATED DECK UNDER
COMPRESSOR SECTION
50-1/2
FRONT
8 or 14
Figure 15: ZS-06 thru -12 Roof Curb
2 TYP
50-1/2
30-1/2
23 4
80-5/8
26
RETURN
SUPPLY
10
76-5/8
94
FRONT
59-1/4
64-1/4
RIGHT
Figure 16: ZS-06 thru -12 Transition Roof Curb
Ductwork
Ductwork should be designed and sized according to the
methods in Manual D of the Air Conditioning Contractors of
America (ACCA) or as recommended by any other recognized
authority such as ASHRAE or SMACNA.
A closed return duct system should be used. This will not
preclude use of economizers or outdoor fresh air intake. The
Johnson Controls Unitary Products
supply and return air duct connections at the unit should be
made with flexible joints to minimize noise.
The supply and return air duct systems should be designed for
the CFM and static pressure requirements of the job. They
should NOT be sized to match the dimensions of the duct
connections on the unit.
Refer to Figure 10 for bottom air duct openings. Refer to
Figures 12, 13 and Table 6 for side air duct openings.
15
518676-BIM-E-1210
Duct Covers
Units are shipped with the side duct openings covered and a
covering over the bottom of the unit. For bottom duct
application, no duct cover changes are necessary. For side
duct application, remove the side duct covers and install over
the bottom duct openings. The panels removed from the side
duct connections are designed to be reused by securing each
panel to its respective downflow opening. But keep in mind that
the supply panel is installed with the painted surface UP, facing
the heat exchanger, while the return panel is installed with the
painted surface DOWN, facing the downflow duct opening. The
supply panel is secured with the bracket (already in place from
the factory) and two screws. It’s a snug fit for the panel when
sliding it between the heat exchanger and unit bottom, but there
is room. The return panel is secured with four screws.
When fastening ductwork to side duct flanges on unit,
insert screws through duct flanges only. DO NOT insert
screws through casing. Outdoor ductwork must be
insulated and water-proofed.
Figure 19: Discharge Panel In Place
Condensate Drain
The side condensate drain is reversible and maybe re-oriented to
the rear of the cabinet to facilitate condensate piping. A
condensate drain connection is available through the base pan
for piping inside the roof curb. Trap the connection per Figure 20.
The trap and drain lines should be protected from freezing.
Plumbing must conform to local codes. Use a sealing compound
on male pipe threads. Install condensate drain line from the 3/4
inch NPT female connection on the unit to an open drain.
OPTIONAL COIL
GUARD
3" Minimum
Figure 17: Side Panels With Hole Plugs
NOTE: Orientation. Panel is “insulation” side up.
Figure 20: Condensate Drain
Compressors
The scroll compressor used in this product is specifically
designed to operate with R-410A Refrigerant and cannot be
interchanged.
Figure 18: Return Downflow Plenum With Panel
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.
The compressor also uses a polyolester (POE oil), Mobil 3MA
POE. This oil is extremely hygroscopic, meaning it absorbs water
readily. POE oil can absorb 15 times as much water as other oils
designed for HCFC and CFC refrigerants. Take all necessary
precautions to avoid exposure of the oil to the atmosphere.
16
Johnson Controls Unitary Products
518676-BIM-E-1210
Voltage tolerances which must be maintained at the
compressor terminals during starting and running conditions are
indicated on the unit Rating Plate and Table 1.
Do not leave the system open to the atmosphere. Unit
damage could occur due to moisture being absorbed by
the POE oil in the system. This type of oil is highly
susceptible to moisture absorption
POE (polyolester) compressor lubricants are known to cause
long term damage to some synthetic roofing materials.
Exposure, even if immediately cleaned up, may cause
embrittlement (leading to cracking) to occur in one year
or more. When performing any service that may risk
exposure of compressor oil to the roof, take precautions
to protect roofing.
Procedures which risk oil leakage include, but are not limited to,
compressor replacement, repairing refrigerant leaks, replacing
refrigerant components such as filter drier, pressure switch,
metering device or coil.
Units are shipped with compressor mountings which are
factory-adjusted and ready for operation.
Do not loosen compressor mounting bolts.
Filters
Two-inch filters are supplied with each unit. One-inch filters may
be used with no modification to the filter racks. Filters must
always be installed ahead of evaporator coil and must be kept
clean or replaced with same size and type. Dirty filters reduce
the capacity of the unit and result in frosted coils or safety
shutdown. Refer to physical data tables, for the number and
size of filters needed for the unit. The unit should not be
operated without filters properly installed.
Make sure that panel latches are properly positioned on
the unit to maintain an airtight seal.
Power And Control Wiring
Field wiring to the unit, fuses, and disconnects must conform to
provisions of National Electrical Code (NEC), ANSI/NFPA No.
70 – Latest Edition (in U.S.A.), current Canadian Electrical
Code C221, and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC as
specified above and/or local codes.
Johnson Controls Unitary Products
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 Unitary Products supplied accessory), refer to
Figure 4 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 21, 22, 23 and 24 for typical field wiring and to
the appropriate unit wiring diagram mounted inside control
doors for control circuit and power wiring information.
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.
17
518676-BIM-E-1210
Power wiring is brought into the unit through the side of the unit
or the basepan inside the curb.
TERMINAL BLOCK TB1
FACTORY OR FIELD
SUPPLIED DISCONNECT
GROUND
LUG
THREE
PHASE
POWER
SUPPLY
Figure 21: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat and All Units With VFD Option
CONTACTOR 1M
GROUND
LUG
T1
T2
T3
L1
L2
L3
FACTORY OR FIELD
SUPPLIED DISCONNECT
THREE
PHASE
POWER
SUPPLY
Figure 22: Field Wiring Disconnect - Cooling Unit With Gas Heat Without VFD Option
18
Johnson Controls Unitary Products
518676-BIM-E-1210
Thermostat Wiring (Not applicable to units with VFD)
thermostat to the unit. Refer to Table 7 for control wire sizing
and maximum length.
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
THERMOSTAT1
TERMINALS
Control Wire Sizes
Wire Size
Maximum Length1
18 AWG
150 Feet
1. From the unit to the thermostat and back to the unit.
UNIT TERMINALS
STRIP TB1
RC
RH
R
Y1
Y1
Y2
Y2
W1
W1
W2
W2
G
G
C
C
X1
X
X3
Table 7:
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.
24 Volt
Transformer
OCC
2
X4
A1
A2
T
T
TO REMOTE SENSOR
2ET04701324 IF USED
1
2
Electronic programmable Thermostat 2ET0770010024 (includes subbase).
Terminals A1 and A2 provide a relay output to close the outdoor economizer
dampers when the thermostat switches to the set-back position.
Figure 23: Typical Electronic Thermostat Field Wiring
T-STAT
W1
W1
W2
W2
Y1
Y1
G
G
Y2
OCC
RH
RC
REMOTE
MIN POS
C
UNIT CONTROL
BOARD
Y2
X
R
SD
C
Figure 24: Typical Field Wiring 24 Volt Thermostat
Johnson Controls Unitary Products
19
518676-BIM-E-1210
Table 8:
Electrical Data
ZS-06 thru -12 Standard Motor - Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
9.3
68
14.5
1.5
6.0
5.5
0
230
9.3
68
14.5
1.5
6.0
5.5
0
460
4.9
34
7.7
0.8
3.0
2.2
0
575
3.8
28
6
0.6
2.4
1.8
0
208
11.9
88
18.5
3.5
6.0
5.5
0
230
11.9
88
18.5
3.5
6.0
5.5
0
460
5.2
44
8.1
1.6
3.0
2.2
0
575
4.8
36
7.5
1.3
2.4
1.8
0
208
12.2
88
19
3.5
6.8
5.5
0
230
12.2
88
19
3.5
6.8
5.5
0
460
5.8
44
9
1.6
3.4
2.2
0
575
4.4
36
5.5
1.3
2.7
1.8
0
-06
(6.5)
-07
(7.5)
-08
(8.5)
20
Electric Heat Option
Model
kW
Stages
Amps
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
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
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
MCA1
(Amps)
MCA1
w/Pwr
Exh
(Amps)
29.9
31.1
54.3
70
96
29.9
34.6
61.6
79.7
109.7
15.6
17.3
30.8
39.8
54.9
12.2
13.8
24.7
31.9
43.9
39.8
39.8
54.3
70
96
39.8
39.8
61.6
79.7
109.7
17.9
17.9
30.8
39.8
54.9
15.8
15.8
24.7
31.9
43.9
41.3
41.3
55.3
71
97
41.3
41.3
62.6
80.7
110.7
19.7
19.7
31.3
40.3
55.4
15.2
15.2
25
32.2
44.3
35.4
38
61.2
76.8
102.9
35.4
41.4
68.5
86.5
116.6
17.8
20
33.6
42.6
57.6
14
16.1
26.9
34.1
46.1
45.3
45.3
61.2
76.8
102.9
45.3
45.3
68.5
86.5
116.6
20.1
20.1
33.6
42.6
57.6
17.6
17.6
26.9
34.1
46.1
46.8
46.8
62.2
77.8
103.9
46.8
46.8
69.5
87.5
117.6
21.9
21.9
34.1
43.1
58.1
17
17
27.3
34.5
46.5
2
Max Fuse2/ Max Fuse3 /
Breaker3 Breaker
Size w/
Size
Pwr Exh
(Amps)
(Amps)
35
40
35
40
60
70
70
80
100
110
35
40
35
45
70
70
80
90
110
125
20
20
20
20
35
35
40
45
60
60
15
15
15
20
25
30
35
35
45
50
50
50
50
50
60
70
70
80
100
110
50
50
50
50
70
70
80
90
110
125
20
25
20
25
35
35
40
45
60
60
20
20
20
20
25
30
35
35
45
50
50
50
50
50
60
70
80
80
100
110
50
50
50
50
70
70
90
90
125
125
25
25
25
25
35
35
45
45
60
60
20
20
20
20
25
30
35
35
45
50
Johnson Controls Unitary Products
518676-BIM-E-1210
ZS-06 thru -12 Standard Motor - Without Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
13.9
110
21.7
3.5
6.8
5.5
0
230
13.9
110
21.7
3.5
6.8
5.5
0
460
7.4
55
11.5
1.6
3.4
2.2
0
575
5.6
43
8.7
1.3
2.7
1.8
0
208
23.1
160
36
3.5
9.6
5.5
0
230
23.1
160
36
3.5
9.6
5.5
0
460
12.2
87
19
1.6
4.8
2.2
0
575
8.7
62
13.5
1.3
3.9
1.8
0
-10
(10)
-12
(12.5)
Electric Heat Option
MCA
(Amps)
MCA1
w/Pwr
Exh
(Amps)
45.1
55.3
71
97
149.4
45.1
62.6
80.7
110.7
138.4
23.3
31.3
40.3
55.4
69.2
17.9
25
32.2
44.3
55.3
75.6
75.6
75.6
100.5
152.9
75.6
75.6
84.2
114.2
141.9
38.7
38.7
42.1
57.1
71.0
28.7
28.7
33.7
45.8
56.8
50.6
62.2
77.8
103.9
156.2
50.6
69.5
87.5
117.6
145.3
25.5
34.1
43.1
58.1
72
19.7
27.3
34.5
46.5
57.6
81.1
81.1
81.3
107.4
159.7
81.1
81.1
91.0
121.1
148.8
40.9
40.9
44.8
59.9
73.7
30.5
30.5
36.0
48.0
59.1
1
Model
kW
Stages
Amps
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
2
Max Fuse2/ Max Fuse3 /
Breaker3 Breaker
Size w/
Size
Pwr Exh
(Amps)
(Amps)
50
60
60
70
80
80
100
110
150
175
50
60
70
70
90
90
125
125
150
175
30
30
35
35
45
45
60
60
80
80
20
25
25
30
35
35
45
50
60
60
90
100
90
100
90
100
110
110
175
175
90
100
90
100
90
100
125
125
175
175
50
50
50
50
50
50
60
60
80
80
35
35
35
35
35
40
50
50
70
70
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
21
518676-BIM-E-1210
ZS-06 thru -12 Hi Static Motor - Without Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
9.3
68
14.5
1.5
6.8
5.5
0
230
9.3
68
14.5
1.5
6.8
5.5
0
460
4.9
34
7.7
0.8
3.4
2.2
0
575
3.8
28
6
0.6
2.7
1.8
0
208
11.9
88
18.5
3.5
9.6
5.5
0
230
11.9
88
18.5
3.5
9.6
5.5
0
460
5.2
44
8.1
1.6
4.8
2.2
0
575
4.8
36
7.5
1.3
3.9
1.8
0
208
12.2
88
19
3.5
9.6
5.5
0
230
12.2
88
19
3.5
9.6
5.5
0
460
5.8
44
9
1.6
4.8
2.2
0
575
4.4
36
5.5
1.3
3.9
1.8
0
-06
(6.5)
-07
(7.5)
-08
(8.5)
22
Electric Heat Option
Model
kW
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
MCA1
(Amps)
MCA1
w/Pwr
Exh
(Amps)
30.7
32.1
55.3
71
97
30.7
35.6
62.6
80.7
110.7
16
17.8
31.3
40.3
55.4
12.5
14.2
25
32.2
44.3
43.4
43.4
58.8
74.5
100.5
43.4
43.4
66.1
84.2
114.2
19.7
19.7
33.1
42.1
57.1
17.3
17.3
26.5
33.7
45.8
44.1
44.1
58.8
74.5
100.5
44.1
44.1
66.1
84.2
114.2
21.1
21.1
33.1
42.1
57.1
16.4
16.4
26.5
33.7
45.8
36.2
39
62.2
77.8
103.9
36.2
42.4
69.5
87.5
117.6
18.2
20.5
34.1
43.1
58.1
14.3
16.5
27.3
34.5
46.5
48.9
48.9
65.7
81.3
107.4
48.9
48.9
73
91
121.1
21.9
22.3
35.8
44.8
59.9
19.1
19.1
28.8
36
48
49.6
49.6
65.7
81.3
107.4
49.6
49.6
73
91
121.1
23.3
23.3
35.8
44.8
59.9
18.2
18.2
28.8
36
48
Stages Amps
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
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
2
Max Fuse2/ Max Fuse3 /
Breaker
Breaker3
Size w/ Pwr
Size
Exh
(Amps)
(Amps)
40
45
40
45
60
70
80
80
100
110
40
45
40
45
70
70
90
90
125
125
20
20
20
25
35
35
45
45
60
60
15
15
15
20
25
30
35
35
45
50
50
60
50
60
60
70
80
90
110
110
50
60
50
60
70
80
90
100
125
125
20
25
20
25
35
40
45
45
60
60
20
20
20
20
30
30
35
40
50
50
50
60
50
60
60
70
80
90
110
110
50
60
50
60
70
80
90
100
125
125
25
25
25
25
35
40
45
45
60
60
20
20
20
20
30
30
35
40
50
50
Johnson Controls Unitary Products
518676-BIM-E-1210
ZS-06 thru -12 Hi Static Motor - Without Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
13.9
110
21.7
3.5
9.6
5.5
0
230
13.9
110
21.7
3.5
9.6
5.5
0
460
7.4
55
11.5
1.6
4.8
2.2
0
575
5.6
43
8.7
1.3
3.9
1.8
0
208
23.1
160
36
3.5
15.2
5.5
0
230
23.1
160
36
3.5
15.2
5.5
0
460
12.2
87
19
1.6
7.6
2.2
0
575
8.7
62
13.5
1.3
6.1
1.8
0
-10
(10)
-12
(12.5)
Electric Heat Option
Model
kW
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
MCA
(Amps)
MCA1
w/Pwr
Exh
(Amps)
47.9
58.8
74.5
100.5
152.9
47.9
66.1
84.2
114.2
141.9
24.7
33.1
42.1
57.1
71
19.1
26.5
33.7
45.8
56.8
81.2
81.2
81.5
107.5
159.9
81.2
81.2
91.2
121.2
148.9
41.5
41.5
45.6
60.6
74.5
30.9
30.9
36.5
48.5
59.6
53.4
65.7
81.3
107.4
159.7
53.4
73
91
121.1
148.8
26.9
35.8
44.8
59.9
73.7
20.9
28.8
36
48
59.1
86.7
86.7
88.3
114.4
166.7
86.7
86.7
98.0
128.1
155.8
43.7
43.7
48.3
63.4
77.2
32.7
32.7
38.7
50.8
61.8
1
Stages Amps
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
2
Max Fuse2/ Max Fuse3 /
Breaker
3
Breaker
Size w/ Pwr
Size
Exh
(Amps)
(Amps)
60
60
60
70
80
90
110
110
175
175
60
60
70
80
90
100
125
125
175
175
30
30
35
40
45
45
60
60
80
80
20
25
30
30
35
40
50
50
70
70
100
100
100
100
100
100
110
125
175
175
100
100
100
100
100
100
125
150
175
175
50
50
50
50
50
50
70
70
90
90
35
40
35
40
40
40
50
60
70
70
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
23
518676-BIM-E-1210
ZS-06 thru -12 Standard Motor - With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
9.3
68
14.5
1.5
6.0
5.5
10
230
9.3
68
14.5
1.5
6.0
5.5
10
460
4.9
34
7.7
0.8
3.0
2.2
5
575
3.8
28
6
0.6
2.4
1.8
4
208
11.9
88
18.5
3.5
6.0
5.5
10
230
11.9
88
18.5
3.5
6.0
5.5
10
460
5.2
44
8.1
1.6
3.0
2.2
5
575
4.8
36
7.5
1.3
2.4
1.8
4
208
12.2
88
19
3.5
6.8
5.5
10
230
12.2
88
19
3.5
6.8
5.5
10
460
5.8
44
9
1.6
3.4
2.2
5
575
4.4
36
5.5
1.3
2.7
1.8
4
-06
(6.5)
-07
(7.5)
-08
(8.5)
24
Electric Heat Option
Model
kW
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
MCA1
(Amps)
MCA1
w/Pwr
Exh
(Amps)
40.1
43.6
66.8
82.5
108.5
40.1
47.1
74.1
92.2
122.2
20.7
23.5
37.1
46.1
61.1
16.2
18.8
29.7
36.9
48.9
49.8
49.8
66.8
82.5
108.5
49.8
49.8
74.1
92.2
122.2
22.9
23.5
37.1
46.1
61.1
19.8
19.8
29.7
36.9
48.9
51.3
51.3
67.8
83.5
109.5
51.3
51.3
75.1
93.2
123.2
24.7
24.7
37.6
46.6
61.6
19.2
19.2
30
37.2
49.3
45.6
50.5
73.7
89.3
115.4
45.6
53.9
81
99
129.1
22.9
26.3
39.8
48.8
63.9
18
21.1
31.9
39.1
51.1
55.3
55.3
73.7
89.3
115.4
55.3
55.3
81
99
129.1
25.1
26.3
39.8
48.8
63.9
21.6
21.6
31.9
39.1
51.1
56.8
56.8
74.7
90.3
116.4
56.8
56.8
82
100
130.1
26.9
26.9
40.3
49.3
64.4
21
21.5
32.3
39.5
51.5
Stages Amps
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
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
2
Max Fuse2/ Max Fuse3 /
Breaker
Breaker3
Size w/ Pwr
Size
Exh
(Amps)
(Amps)
50
50
50
60
70
80
90
90
110
125
50
50
50
60
80
90
100
100
125
150
25
25
25
30
40
40
50
50
70
70
20
20
20
25
30
35
40
40
50
60
60
60
60
60
70
80
90
90
110
125
60
60
60
60
80
90
100
100
125
150
25
30
25
30
40
40
50
50
70
70
20
25
20
25
30
35
40
40
50
60
60
60
60
60
70
80
90
100
110
125
60
60
60
60
80
90
100
100
125
150
30
30
30
30
40
45
50
50
70
70
20
25
20
25
30
35
40
40
50
60
Johnson Controls Unitary Products
518676-BIM-E-1210
ZS-06 thru -12 Standard Motor - With Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
13.9
110
21.7
3.5
6.8
5.5
10
230
13.9
110
21.7
3.5
6.8
5.5
10
460
7.4
55
11.5
1.6
3.4
2.2
5
575
5.6
43
8.7
1.3
2.7
1.8
4
208
23.1
160
36
3.5
9.6
5.5
10
230
23.1
160
36
3.5
9.6
5.5
10
460
12.2
87
19
1.6
4.8
2.2
5
575
8.7
62
13.5
1.3
3.9
1.8
4
-10
(10)
-12
(12.5)
Electric Heat Option
Model
kW
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
MCA
(Amps)
MCA1
w/Pwr
Exh
(Amps)
55.1
67.8
83.5
109.5
161.9
55.1
75.1
93.2
123.2
150.9
28.3
37.6
46.6
61.6
75.5
21.9
30
37.2
49.3
60.3
85.6
85.6
87.0
113.0
165.4
85.6
85.6
96.7
126.7
154.4
43.7
43.7
48.3
63.4
77.2
32.7
32.7
38.7
50.8
61.8
60.6
74.7
90.3
116.4
168.7
60.6
82
100
130.1
157.8
30.5
40.3
49.3
64.4
78.2
23.7
32.3
39.5
51.5
62.6
91.1
91.1
93.8
119.9
172.2
91.1
91.1
103.5
133.6
161.3
45.9
45.9
51.1
66.1
80.0
34.5
34.5
41.0
53.0
64.1
1
Stages Amps
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
2
Max Fuse2/ Max Fuse3 /
Breaker
3
Breaker
Size w/ Pwr
Size
Exh
(Amps)
(Amps)
60
70
70
80
90
100
110
125
175
175
60
70
80
90
100
100
125
150
175
175
35
35
40
45
50
50
70
70
80
90
25
25
30
35
40
40
50
60
70
70
100
110
100
110
100
110
125
125
175
175
100
110
100
110
100
110
150
150
175
175
50
50
50
50
50
60
70
70
90
90
40
40
40
40
40
45
60
60
70
70
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
25
518676-BIM-E-1210
ZS-06 thru -12 Hi Static Motor - With Powered Convenience Outlet
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
9.3
68
14.5
1.5
6.8
5.5
10
230
9.3
68
14.5
1.5
6.8
5.5
10
460
4.9
34
7.7
0.8
3.4
2.2
5
575
3.8
28
6
0.6
2.7
1.8
4
208
11.9
88
18.5
3.5
9.6
5.5
10
230
11.9
88
18.5
3.5
9.6
5.5
10
460
5.2
44
8.1
1.6
4.8
2.2
5
575
4.8
36
7.5
1.3
3.9
1.8
4
208
12.2
88
19
3.5
9.6
5.5
10
230
12.2
88
19
3.5
9.6
5.5
10
460
5.8
44
9
1.6
4.8
2.2
5
575
4.4
36
5.5
1.3
3.9
1.8
4
-06
(6.5)
-07
(7.5)
-08
(8.5)
26
Electric Heat Option
Model
kW
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
None
E09
E18
E24
E36
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
6.8
13.5
18
25.5
9
18
24
34
9
18
24
34
9
18
24
34
MCA1
(Amps)
MCA1
w/Pwr
Exh
(Amps)
40.9
44.6
67.8
83.5
109.5
40.9
48.1
75.1
93.2
123.2
21.1
24
37.6
46.6
61.6
16.5
19.2
30
37.2
49.3
53.4
53.4
71.3
87
113
53.4
53.4
78.6
96.7
126.7
24.7
25.8
39.3
48.3
63.4
21.3
21.3
31.5
38.7
50.8
54.1
54.1
71.3
87
113
54.1
54.1
78.6
96.7
126.7
26.1
26.1
39.3
48.3
63.4
20.4
20.7
31.5
38.7
50.8
46.4
51.5
74.7
90.3
116.4
46.4
54.9
82
100
130.1
23.3
26.8
40.3
49.3
64.4
18.3
21.5
32.3
39.5
51.5
58.9
58.9
78.2
93.8
119.9
58.9
58.9
85.5
103.5
133.6
26.9
28.5
42.1
51.1
66.1
23.1
23.1
33.8
41
53
59.6
59.6
78.2
93.8
119.9
59.6
59.6
85.5
103.5
133.6
28.3
28.5
42.1
51.1
66.1
22.2
23
33.8
41
53
Stages Amps
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
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
18.9
37.5
50.0
70.8
21.7
43.3
57.7
81.8
10.8
21.7
28.9
40.9
8.7
17.3
23.1
32.7
2
Max Fuse2/ Max Fuse3 /
Breaker
Breaker3
Size w/ Pwr
Size
Exh
(Amps)
(Amps)
50
50
50
60
70
80
90
100
110
125
50
50
50
60
80
90
100
100
125
150
25
25
25
30
40
45
50
50
70
70
20
20
20
25
30
35
40
40
50
60
60
70
60
70
80
80
90
100
125
125
60
70
60
70
80
90
100
110
150
150
25
30
30
30
40
45
50
60
70
70
25
25
25
25
35
35
40
45
60
60
60
70
60
70
80
80
90
100
125
125
60
70
60
70
80
90
100
110
150
150
30
30
30
30
40
45
50
60
70
70
25
25
25
25
35
35
40
45
60
60
Johnson Controls Unitary Products
518676-BIM-E-1210
ZS-06 thru -12 Hi Static Motor - With Powered Convenience Outlet (Continued)
Size
(Tons)
Volt
Compressors
(each)
RLA LRA
MCC
OD Fan
Motors
(each)
Supply
Blower
Motor
Pwr
Exh
Motor
Pwr
Conv
Outlet
FLA
FLA
FLA
FLA
208
13.9
110
21.7
3.5
9.6
5.5
10
230
13.9
110
21.7
3.5
9.6
5.5
10
460
7.4
55
11.5
1.6
4.8
2.2
5
575
5.6
43
8.7
1.3
3.9
1.8
4
208
23.1
160
36
3.5
15.2
5.5
10
230
23.1
160
36
3.5
15.2
5.5
10
460
12.2
87
19
1.6
7.6
2.2
5
575
8.7
62
13.5
1.3
6.1
1.8
4
-10
(10)
-12
(12.5)
Electric Heat Option
Model
kW
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
None
E18
E24
E36
E54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
13.5
18
25.5
40.6
18
24
34
54
18
24
34
54
18
24
34
54
MCA
(Amps)
MCA1
w/Pwr
Exh
(Amps)
57.9
71.3
87
113
165.4
57.9
78.6
96.7
126.7
154.4
29.7
39.3
48.3
63.4
77.2
23.1
31.5
38.7
50.8
61.8
91.2
91.2
94.0
120.0
172.4
91.2
91.2
103.7
133.7
161.4
46.5
46.5
51.8
66.9
80.7
34.9
34.9
41.5
53.5
64.6
63.4
78.2
93.8
119.9
172.2
63.4
85.5
103.5
133.6
161.3
31.9
42.1
51.1
66.1
80
24.9
33.8
41
53
64.1
96.7
96.7
100.8
126.9
179.2
96.7
96.7
110.5
140.6
168.3
48.7
48.7
54.6
69.6
83.5
36.7
36.7
43.7
55.8
66.8
1
Stages Amps
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
37.5
50.0
70.8
112.7
43.3
57.7
81.8
129.9
21.7
28.9
40.9
65.0
17.3
23.1
32.7
52.0
2
Max Fuse2/ Max Fuse3 /
Breaker
3
Breaker
Size w/ Pwr
Size
Exh
(Amps)
(Amps)
70
70
80
80
90
100
125
125
175
175
70
70
80
90
100
110
150
150
175
175
35
35
40
45
50
60
70
70
90
90
25
30
35
35
40
45
60
60
70
70
110
110
110
110
110
110
125
150
175
200
110
110
110
110
110
125
150
150
175
175
50
60
50
60
60
60
70
70
90
90
40
45
40
45
45
45
60
60
70
70
1. Minimum Circuit Ampacity.
2. Dual Element, Time Delay Type.
3. HACR type per NEC.
Johnson Controls Unitary Products
27
518676-BIM-E-1210
Table 9:
ZS-06 thru -12 Physical Data
Models
Component
ZS-06
ZS-07
ZS-08
ZS-10
ZS-12
6.5
7.5
8.5
10
12.5
Gross Capacity @ ARI A point (Mbh)
81000
90000
104000
126000
156000
ARI net capacity (Mbh)
78000
88000
101000
120000
150000
EER
11.2
11.2
11.2
11.2
11.2
IEER
13
12.1
12.5
12.5
12.7
IPLV
12.9
12.1
12.5
12.6
13.06
Nominal CFM
2600
2500
3000
4000
4100
System power (KW)
6.95
7.87
8.60
10.70
13.40
R-410A
R-410A
R-410A
R-410A
R-410A
System 1
4-12
4-12
4-14
6-8
7-8
System 2
4-10
4-10
5-0
6-8
7-8
Nominal Tonnage
ARI COOLING PERFORMANCE
Refrigerant type
Refrigerant charge (lb-oz)
ARI HEATING PERFORMANCE
Heating model
12
18
12
18
12
18
18
24
18
24
Heat input (K Btu)
120
180
120
180
120
180
180
240
180
240
Heat output (K Btu)
96
144
96
144
96
144
144
192
144
192
-
-
-
-
-
-
-
-
-
-
80
80
80
80
80
80
80
80
80
80
AFUE %
Steady state efficiency (%)
No. burners
4
6
4
6
4
6
6
8
6
8
No. stages
21
21
21
21
21
21
21
21
21
21
Temperature Rise Range (ºF)
20-50
35-65
15-45
30-60
10-40
25-55
20-50
35-65
10-40
25-55
Gas Limit Setting (ºF)
165
165
165
165
215
195
195
160
195
160
Gas piping connection (in.)
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
3/4
DIMENSIONS (inches)
Length
89
89
89
89
Width
59
59
59
59
59
Height
42
42
50-3/4
50-3/4
50-3/4
860
880
1020
1060
1253
Recip
Recip
Recip
Recip
Scroll
OPERATING WT. (lbs.)
119-1/2
COMPRESSORS
Type
Quantity
Unit Capacity Steps (%)
2
2
2
2
2
50 / 100
50 / 100
50 / 100
50 / 100
50 / 100
29.0
CONDENSER COIL DATA
Face area (Sq. Ft.)
18.5
18.5
18.5
29.0
Rows
1
1
1
1
1
Fins per inch
23
23
23
23
23
Tube diameter (in.)/mm
Circuitry Type
.71/18
.71/18
.71/18
.71/18
1/25
2-pass
Microchannel
2-pass
Microchannel
2-pass
Microchannel
2-pass
Microchannel
2-pass
Microchannel
13.2
EVAPORATOR COIL DATA
Face area (Sq. Ft.)
10.6
10.6
13.2
13.2
Rows
3
3
3
4
3
Fins per inch
15
15
15
15
15
Tube diameter
0.375
0.375
0.375
0.375
0.375
Circuitry Type
Intertwined
Intertwined
Intertwined
Intertwined
Intertwined
TXV
TXV
TXV
TXV
TXV
Refrigerant control
28
Johnson Controls Unitary Products
518676-BIM-E-1210
Table 9:
ZS-06 thru -12 Physical Data (Continued)
Models
Component
ZS-06
ZS-07
ZS-08
ZS-10
ZS-12
6.5
7.5
8.5
10
12.5
2
2
2
2
4
Nominal Tonnage
CONDENSER FAN DATA
Quantity of Fans
Fan diameter (Inch)
24
24
24
24
24
Type
Prop
Prop
Prop
Prop
Prop
Drive type
Direct
Direct
Direct
Direct
Direct
2
2
2
2
4
1/3
3/4
3/4
3/4
3/4
Quantity of motors
Motor HP each
No. speeds
1
1
1
1
1
RPM
850
1110
1110
1110
1110
Nominal total CFM
6200
7600
8300
9500
13900
BELT DRIVE EVAP FAN DATA
Quantity
Fan Size (Inch)
Type
1
1
1
1
1
12 x 12
12 x 12
15 x 15
15 x 15
15 x 15
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Motor Sheave
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VP56
Blower Sheave
AK74
AK64
AK74
AK61
AK89
AK74
AK84
AK74
AK74
BK77
Belt
A49
A49
A49
A49
A56
A54
A56
A54
A54
BX55
Motor HP each
1-1/2
2
1-1/2
3
2
3
2
3
3
5
RPM
1725
1725
1725
1725
1725
1725
1725
1725
1725
1725
56
56
56
56
56
56
56
56
56
184T
Frame size
FILTERS
Quantity - Size
4 - (24 x 16 x 2)2, 3 4 - (24 x 16 x 2)2, 3 4 - (24 x 20 x 2)2, 3 4 - (24 x 20 x 2)2, 3 4 - (24 x 20 x 2)2, 3
4 - (24 x 16 x 4)4
1.
2.
3.
4.
4 - (24 x 16 x 4)4
4 - (24 x 20 x 4)4
4 - (24 x 20 x 4)4
4 - (24 x 20 x 4)4
1ST Stage 60% of 2nd Stage
2 In. Throwaway, Standard, MERV (Minimum Efficiency Reporting Value) 3
2 In. Pleated, Optional, MERV 7
4 In. Pleated, Optional, MERV 13
Johnson Controls Unitary Products
29
518676-BIM-E-1210
Optional Electric Heat
The factory-installed heaters are wired for single point power
supply. Power supply need only be brought into the single point
terminal block.
These CSA approved heaters are located within the central
compartment of the unit with the heater elements extending in
to the supply air chamber.
Fuses are supplied, where required, by the factory. Some kW
sizes require fuses and others do not. refer to Table 10 for
minimum CFM limitations and to Table 8 for electrical data.
Table 10: Electric Heat Minimum Supply Air
Size
(Tons)
30
Model
-06
(6.5)
ZS
-07
(7.5)
ZS
-08
(8.5)
ZS
-10
(10)
ZS
-12
(12.5)
ZS
Voltage
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
208/230-3-60
460-3-60
600-3-60
9
1950
1950
1950
2250
2250
2250
2550
2550
2550
-
Minimum Supply Air (CFM)
Heater kW
18
24
36
1950
1950
1950
1950
1950
1950
1950
1950
1950
2250
2250
2250
2250
2250
2250
2250
2250
2250
2550
2550
2550
2550
2550
2550
2550
2550
2550
3000
3000
3000
3000
3000
3000
3000
3000
3000
3750
3750
3750
3750
3750
3750
3750
3750
3750
54
3500
3000
3500
4000
3750
3750
Johnson Controls Unitary Products
518676-BIM-E-1210
Optional Gas Heat
These gas-fired heaters have aluminized-steel or optional
stainless steel, tubular heat exchangers with spark ignition.
OPTIONAL
COIL
GUARD
SHOWN
NOTE: On VAV units, individual VAV boxes must be fully open
in heating mode to insure airflow falls within specified
Temperature Rise range.
Gas Piping
Proper sizing of gas piping depends on the cubic feet per hour
of gas flow required, specific gravity of the gas and the length of
run. "National Fuel Gas Code" Z223.1 (in U.S.A.) or the current
Gas Installation Codes CSA-B149.1 (in Canada) should be
followed in all cases unless superseded by local codes or gas
utility requirements. Refer to the Pipe Sizing Table 11. The
heating value of the gas may differ with locality. The value
should be checked with the local gas utility.
OPTIONAL
COIL
GUARD
SHOWN
Figure 25: Side Entry Gas Piping
Figure 26: Bottom Entry Gas Piping
Table 11: Gas Pipe Sizing - Capacity of Pipe
Nominal Iron Pipe Size
Length of
Pipe (ft.)
3/4 in.
1 in.
1-1/4 in.
10
278
520
1050
20
190
350
730
30
152
285
590
40
130
245
500
50
115
215
440
60
105
195
400
70
96
180
370
80
90
170
350
90
84
160
320
100
79
150
305
NOTE: Maximum capacity of pipe in cubic feet of gas per hour
based upon a pressure drop of 0.3 inch W.C. and 0.6
specific gravity gas.
NOTE: There may be a local gas utility requirement specifying a
minimum diameter for gas piping. All units require a 3/4
inch pipe connection at the entrance fitting. Line should
not be sized smaller than the entrance fitting size.
Johnson Controls Unitary Products
31
518676-BIM-E-1210
Table 12: Gas Heat Minimum Supply Air
Size
(Tons)
-06
(6.5)
-07
(7.5)
-08
(8.5)
-10
(10)
-12
(12.5)
Supply Air (CFM)
Model
ZS
ZS
ZS
ZS
ZS
Heat Size
12
18
12
18
12
18
18
24
18
24
Cooling
Min
1950
1950
2250
2250
2550
2550
3000
3000
3750
3750
Heating
Max
3250
3250
3750
3750
4250
4250
5000
5000
6250
6250
Min
1950
1950
2250
2250
2550
2550
3000
3000
3750
3750
Max
3250
3250
3750
3750
4250
4250
5000
5000
6250
6250
Gas Connection
The gas supply line can be routed within the space and roof curb,
exiting through the unit’s basepan. Refer to Figures 8 and 9 for
the gas piping inlet location. Typical supply piping arrangements
are shown in Figures 25 and 26. All pipe nipples, fittings, and the
gas cock are field supplied or may be purchased in UP accessory
kit #1GP0405.
Gas piping recommendations:
1.
A drip leg and a ground joint union must be installed in the
gas piping.
2.
Where required by local codes, a manual shut-off valve
must be installed outside of the unit.
3.
Use wrought iron or steel pipe for all gas lines. Pipe dope
should be applied sparingly to male threads only.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
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.
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.
32
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.
Threaded joints should be coated with a sealing
compound that is resistant to the action of liquefied
petroleum gases. Do not use Teflon tape.
LP Units, Tanks And Piping
All gas heat units are shipped from the factory equipped for
natural gas use only. The unit may be converted in the field for
use with LP gas with accessory kit model number 1NP0442.
All LP gas equipment must conform to the safety standards of
the National Fire Protection Association.
Johnson Controls Unitary Products
518676-BIM-E-1210
For satisfactory operation, LP gas pressure must be 10.5 inch
W.C. at the unit under full load. Maintaining proper gas
pressure depends on three main factors:
1.
The vaporization rate which depends on the temperature of
the liquid and the “wetted surface” area of the container(s).
2.
The proper pressure regulation. (Two-stage regulation is
recommended).
3.
The pressure drop in the lines between regulators and
between the second stage regulator and the appliance.
Pipe size required will depend on the length of the pipe run
and the total load of all appliances.
Complete information regarding tank sizing for vaporization,
recommended regulator settings, and pipe sizing is available
from most regulator manufacturers and LP gas suppliers.
LP gas is an excellent solvent and will quickly dissolve
white lead and most standard commercial compounds. A
special pipe dope must be used when assembling
wrought iron or steel pipe for LP. Shellac base
compounds such as Gaskolac or Stalastic, and
compounds such as Rectorseal #5, Clyde’s, or John
Crane may be used.
Check all connections for leaks when piping is completed using
a soap solution. NEVER USE A FLAME.
electric heaters are fused and intended for use with single point
power supply.
Smoke Detectors
The use of duct smoke detectors have specific limitations
as established by the National Fire Protection
Association. Duct smoke detectors are; NOT a substitute
for an open area smoke detector, NOT a substitute for
early warning detection, and NOT a replacement for a
building's regular fire detection system. Refer to NFPA
Code 72 and Standard 90A for additional information.
The factory-installed smoke detector will shut down operation of
the unit by interrupting power to the UCB when smoke is
detected within its mounting compartment. The smoke detector
option is available for both supply and/or return air configurations. Be aware that the supply air configuration has the sensor
component mounted in the blower section, with its control module mounted in the return air compartment.
Factory-installed smoke detectors may be subjected to
extreme temperatures during "off" times due to outside air
infiltration. These smoke detectors have an operational
limit of -4°F to 158°F. Smoke detectors installed in areas
that could be outside this range will have to be relocated to
prevent false alarms.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
Vent And Combustion Air
Venting slots in the heating compartment access panel remove
the need for a combustion air hood. The gas heat flue exhaust
is routed through factory installed exhaust piping with screen. If
necessary, a flue exhaust extension may be installed at the
point of installation.
Options/Accessories
Electric Heat
Electric heaters are available as factory-installed options or
field-installed accessories. Refer to electric heat instructions for
installation. These heaters mount in the heat compartment with
the heating elements extending into the supply air chamber. All
Johnson Controls Unitary Products
To assure adequate airflow reaches the smoke detector's
sensor, make sure that the holes of the sampling tube
face into the air stream, and that the far-end of the
sampling tube is sealed with the plastic end cap.
In addition, the unit's supply airflow must be adjusted to
provide a pressure differential across the smoke
detector's sampling and exhaust ports of at least 0.01
inches of water and no more than 1.11 inches of water, as
measured by a manometer.
The detector must be tested and maintained on a regular basis
according to NFPA 72 requirements and cleaned at least once
a year. For specific troubleshooting and maintenance
procedures, please refer to the smoke detector's installation
instructions which accompanies the unit.
Motorized Outdoor Damper
The Motorized Outdoor Damper can be a factory installed
option or a field installed accessory. If factory installed, refer to
the instructions included with the outdoor air hood to complete
33
518676-BIM-E-1210
the assembly. Field installed Motorized Outdoor Damper
accessories include complete instructions for installation.
Economizer
The Economizer can be a factory installed option or a field
installed accessory. If factory installed, refer to the instructions
included with the outdoor air hood to complete the assembly.
Field installed Economizer accessories include complete
instructions for installation.
There are two Economizer options:
1. Down Flow application with barometric relief hood standard.
2.
Horizontal Flow application that requires the purchase of a
barometric relief hood.
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.
Power Exhaust
VAV Control Board
The Power Exhaust can be a factory installed option or a field
installed accessory. If factory installed, refer to the instructions
included with the outdoor air hood to complete the assembly.
Field installed Power Exhaust accessories include complete
instructions for installation.
A VAV control board, located in the control box, is used to
convert the pressure transducer input signal into a speed
reference signal that the drive uses to control the speed of the
blower motor. This modulating speed reference signal is
generated using an algorithm which continuously calculates an
output value.
The Power Exhaust factory installed option is for Down Flow
application only.
There are two field installed Power Exhaust accessories:
1. Down Flow application.
2.
Horizontal Flow application that requires the purchase of a
barometric relief hood.
Rain Hood
All of the hood components, including the filters, the gasketing
and the hardware for assembling, are packaged and located
between the condenser coil section and the main unit cabinet, if
the unit has factory installed options. If field installed
accessories are being installed all parts necessary for the
installation comes in the accessory.
Optional Variable Air Volume (VAV)
A variable air volume (VAV) option using a variable frequency
drive (VFD) is available for applications requiring a constant
supply-duct static pressure. A differential pressure transducer is
used to monitor supply duct static pressure and return a speed
reference signal to the VFD to control the output of the indoor
blower motor.
Duct Static Pressure Transducer
A 0-5" WC pressure transducer, located in the control box
compartment, is used to sense static (gauge) pressure in the
supply air duct and convert this pressure measurement to a
proportional 0-5 VDC electrical output. Pressure-transmitting
plastic tubing (1/4" diameter) must be field supplied and
installed from the transducer to both the ductwork and to the
atmosphere. Connect the tubing from the 'HIGH' pressure tap of
the transducer to a static pressure tap (field supplied) in the
supply duct located at a point where constant pressure is
expected. To prevent an unstable signal due to air turbulence,
34
A brief description of the VAV board's I/O terminals that are
used follows;
Inputs:
• DUCT PRES - a 0-5 VDC analog input provided by a
factory-installed duct static pressure transducer located in
the unit's control box.
• SAT - analog input provided by a factory-installed 10kohm, type 3 thermistor located in the unit's supply air
compartment.
• RAT - analog input provided by a factory-installed 10kohm, type 3 thermistor located in the unit's return air
compartment.
• OAT - analog input provided by a factory-installed 10kohm, type 3 thermistor located in the unit’s compressor
compartment within the base rail.
• ST - analog input provided by field-installed space
temperature sensor.
• OH - a 0-10 VDC analog input provided by a field installed
outdoor air relative humidity sensor for single enthalpy
economizer configuration.
• RH - a 0-10 VDC analog input provided by a field-installed
return air relative humidity sensor for dual enthalpy
economizer configuration (used with OH).
• IAQ - a 0-10 VDC analog input provided by a fieldinstalled carbon dioxide sensor which monitors indoor air
quality (CO2 concentration) and enables call for Demand
Ventilation mode for units installed with economizer
option.
• OAQ - a 0-10 VDC analog input provided by a fieldinstalled carbon dioxide sensor which monitors outdoor air
quality (CO2 concentration) and, along with IAQ, enables
Johnson Controls Unitary Products
518676-BIM-E-1210
call for Differential Demand Ventilation mode for units
installed with economizer option.
• APS - a 24 VAC binary input provided by a field-installed
air proving switch which monitors the pressure difference
across the indoor blower.
• PUR - a 24 VAC binary input for building purge calls from
an external source.
• OCC - a 24 VAC binary input used to set the building
occupancy status for the control.
• LIMIT 2 - a 24 VAC binary input which either confirms
2nd-stage gas heat operation or receives an error signal
from the variable frequency drive.
Outputs:
• FAN - a 2-10 VDC analog output signal sent to the VFD to
modulate the speed of the indoor blower motor.
• ECON - a 2-10 VDC analog output signal sent to the
economizer actuator to modulate position of the return air
and outdoor air dampers (optional).
• EXH ~ - a 24 VAC binary output signal used to turn on/off
the power exhaust relay (optional).
• VAV BOX (gas/electric heat only) - a normally open
relay contact connected to a terminal block, used to drive
the building's VAV boxes to full-open during heating
operation.
Programmable set points:
The duct static set point is the pressure that the drive will
maintain when operating the unit in VAV mode. The set-point is
adjustable between 0" WC and 5" WC with the default setting of
1.5" WC.
The duct static high-limit set point is the maximum allowable
duct pressure to prevent damage from over-pressurization of
the ductwork in the event of either a drive or damper failure.
The high-limit set-point is adjustable between 0" WC and 5" WC
with the factory default setting of 4.5" WC. If the duct static
pressure reaches the high-limit set point, then the supply fan
motor will be shutdown.
NOTE: Either of the set points described above can be
changed through the unit control board (UCB) with the
use of a USB-to-RS485 converter, personal computer
or PDA and a down-loaded copy of the Simplicity®
software available at the UPGnet Commercial Product
Catalog website.
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).
Johnson Controls Unitary Products
Factory-installed VFD
The factory-installed VFD is mounted in the blower access
compartment. The drive comes wired from the factory to include
both 3-phase power and control connections (run permit signal,
speed reference signal & fault signal). All required drive
parameters are pre-programmed at the factory, except in the
case of 208-volt applications, in which the parameter that
defines motor nameplate voltage must be changed to a value of
208.00 and the parameter that defines motor-rated current must
be changed to the appropriate value appearing on the motor's
nameplate. Refer to the enclosed drive material or access the
UPGnet Commercial Product Catalog website for instructions
on changing parameter settings.
For units also equipped with gas/electric heat, a terminal block
located in the unit's control box and connected to the VAV
board's "VAV BOX" terminal, must be field wired to the
building's VAV boxes to ensure fully open dampers during
heating operation.
Manual Bypass
An optional, factory-installed manual bypass switch available
with factory-installed VFD can be found in the Blower Motor
Access compartment and has the following three positions:
• DRIVE - routes power through the VFD for modulating
control of the indoor blower motor.
• LINE (or BYPASS) - routes power directly to the motor
which provides full-speed motor operation and complete
electrical isolation of the drive.
• TEST - routes power to the VFD but not to the motor to
allow for drive programming and/or diagnostics.
If a drive failure occurs, the unit does not automatically switch to
bypass mode. The LINE/DRIVE/TEST switch must be manually
switched to the LINE (BYPASS) position. If there is a call for the
fan, the indoor blower motor will run at full-speed while in the
bypass mode.
If the unit is operated with the manual bypass switch in
the LINE (BYPASS) position and there are VAV boxes
present in the duct system, then boxes must be driven to
the full-open position using a customer-supplied power
source to prevent over-pressurizing and possible
damage to the ductwork.
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.
35
518676-BIM-E-1210
Bas-ready VFD
Factory-installed VFD is also available with 'BAS-Ready'
models. Terminal blocks are provided in the control box (in
place of the VAV control board) for field wiring of a customerinstalled BAS to receive 24 VAC power and to connect to the
following control signals:
• a duct static pressure transducer input signal (0-5 VDC)
• an economizer actuator input signal (2-10 VDC)
nuts. After removing the wire nuts, connect the wires to the
field-installed VFD per the VFD wiring diagram (See Figure 27).
The VFD should also be grounded per the manufacturer's
specifications.
ELEMENTARY DIAGRAM
TB1
L1
720 / PR
FU3
722 / BK
(L1)
(T1)
L2
723 / BR
FU4
725 / BR
(L2)
(T2)
L3
726 / O
FU5
728 / Y
T1
118 / BK
1 DMTR
M
VFD
119 / BR
T2 3
120 / Y
T3
(T3)
(L3)
• an economizer actuator output signal (2-10 VDC)
GND( )
GRN
GND
GRN
GND
• a VFD speed reference output signal (2-10 VDC)
The use of shielded cable is recommended for the above
control wiring connections.
NOTE: Factory-installed VFD is not available with factoryinstalled BAS options due to space limitations in the
control box.
A solid-state, lock-out relay (LR) and 100 microfarad, 50 VDC
capacitor must be field-supplied and installed to provide a
means to transmit a potential fault signal back to the BAS
controller. The specific relay part number required will depend
upon the need for either AC-output or DC-output. See price
pages for further details.
SPEED REF
(ANALOG)
(2-10 VDC)
RUN PERMIT
(DIGITAL)
1
2
3
4
5
6
TB8 (IN CONTROL BOX)
Figure 27: Simplified VFD Wiring
Do not connect AC power to the T1, T2, T3 drive
terminals to prevent damage to the VFD.
Once the appropriate relay and capacitor are obtained, install
the capacitor across LR terminals '3' & '4' and make the
following wiring connections:
• LR '1' to BAS controller
• LR '2' to BAS controller
• LR '3' to UCB 'X'
• LR '4' to UCB 'C'
'VFD-ready' For Customer-installation
Units configured as 'VFD-ready' provide provisions for a
customer-installed drive. The physical dimensions of VFDs can
vary greatly among manufacturers, horsepower ratings and
voltage requirements. Keep in mind that drive manufacturers
also require various minimum clearances to allow for adequate
internal cooling of the drive during operation.
The unit comes with a mounting bracket installed in the Blower
Access compartment which may accommodate other vendor's
drives depending on their size. In order to utilize the unit's
mounting bracket, the maximum recommended drive
dimensions are limited to approximately 9" H x 5" W x 7.5" D.
The fuses (FU3, FU4, FU5) supplied with the unit are
sized according to the electrical load of the blower
motor, but may not provide adequate protection to the
customer-installed drive, depending upon its
specifications. Once a drive has been selected and
installed, refer to the drive manufacturer's
recommendations for proper fuse sizing.
A terminal block located in the control box is provided for field
connection of the VFD speed reference signal (2-10 VDC) and
to the normally-open, run-permit auxiliary contact. The use of
shielded cable is recommended for the above control wiring
connections. For VFD-ready units also equipped with gas/
electric heat, a terminal block located in the unit's control box
and connected to the VAV board's "VAV BOX" terminal, must
be field wired to the building's VAV boxes to ensure fully open
dampers during heating operation.
Optional Hot Gas Bypass (HGBP)
If the drive will not fit in the allotted space, then it will need to be
mounted elsewhere; either within the building on a
perpendicular wall which is not subjected to excessive
temperature, vibration, humidity, dust, corrosive gas, explosive
gas, etc., or within an appropriate enclosure rated for outside
installation to safeguard against moisture, dust and excessive
heat.
The power leads to the drive (L1, L2, L3) and from the motor
(T1, T2, T3) have been temporarily spliced together with wire
36
To allow for low cooling load operation, a direct-acting,
pressure-modulating bypass control valve installed on the
system #1 discharge line is used to divert high temperature,
high pressure refrigerant around the TXV in order to maintain a
desired minimum evaporator pressure.
The opening pressure of the bypass valve is adjustable
between 95 and 115 psig with a factory-setting of 105 psig.
Johnson Controls Unitary Products
518676-BIM-E-1210
HGBP is standard on all units with VAV and optional with CV
units.
Standard Economizer And Power Exhaust Set Point
Adjustments
(Not applicable for VFD or INTELLI-Comfort™ options.)
Remove the top rear access panel from the unit. Locate the
economizer control module, where the following adjustments
will be made.
Extreme care must be exercised in turning all set point,
maximum and minimum damper positioning adjustment
screws to prevent twisting them off.
Minimum Position Adjustment
• Check that the damper blades move smoothly without
binding; carefully turn the Minimum Position Adjust screw
(found on the damper control module) fully clockwise and
then set the thermostat indoor fan switch to the ON
position and then OFF or energize and de-energize
terminals “R” to “G”.
• With the thermostat set to the indoor fan ON position or
terminals “R” to “G” energized, turn the Minimum Position
Adjusting screw (located on the damper control module)
counterclockwise until the desired minimum damper
position has been attained.
Enthalpy Set Point Adjustment
• The enthalpy set point may now be set by selecting the
desired set point shown in the Enthalpy Set Point
Adjustment Figure 28. Adjust as follows:
• For a single enthalpy operation carefully turn the set point
adjusting screw (found on the damper control module) to
Johnson Controls Unitary Products
the "A", "B", "C" or "D" setting corresponding to the lettered
curve of the Enthalpy Set Point Adjustment Figure 29.
• For a dual enthalpy operation, carefully turn the set point
adjusting screw fully clockwise past the "D" setting.
Power Exhaust Damper Set Point (With Or Without Power
Exhaust)
• With no power exhaust option, adjust the Exhaust Air
Adjustment Screw fully clockwise. This will allow 2nd
stage cooling to operate.
• With power exhaust option, each building pressurization
requirement will be different. The point at which the power
exhaust comes on is determined by the economizer
damper position (Percent Open). The Exhaust Air
Adjustment Screw should be set at the Percent Open of
the economizer damper at which the power exhaust is
needed. It can be set from 0 to 100% damper open.
Indoor Air Quality AQ
Indoor Air Quality (indoor sensor input): Terminal AQ accepts a
+2 to +10 Vdc signal with respect to the (AQ1) terminal. When
the signal is below it's set point, the actuator is allowed to
modulate normally in accordance with the enthalpy and mixed
air sensor inputs. When the AQ signal exceeds it's set point
setting and there is no call for free cooling, the actuator is
proportionately modulated from the 2 to 10 Vdc signal, with 2
Vdc corresponding to full closed and 10 Vdc corresponding to
full open. When there is no call for free cooling, the damper
position is limited by the IAQ Max damper position setting.
When the signal exceeds it's set point (Demand Control
Ventilation Set Point) setting and there is a call for free cooling,
the actuator modulates from the minimum position to the full
open position based on the highest call from either the mixed
air sensor input or the AQ voltage input.
• Optional CO2 Space Sensor Kit Part # 2AQ04700324
• Optional CO2 Sensor Kit Part # 2AQ04700424
Replace the top rear access panel on the unit.
37
518676-BIM-E-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 28: 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 29: Honeywell Economizer Control W7212
Phasing
ZS 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
38
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.)
Johnson Controls Unitary Products
518676-BIM-E-1210
Scroll compressors require proper rotation to operate
correctly. Units are properly phased at the factory. Do
not change the internal wiring to make the blower
condenser fans, or compressor rotate correctly.
Blower Rotation
Check for proper supply air blower rotation. If the blower is
rotating backwards, the line voltage at the unit point of power
connection is misphased (See ‘PHASING’).
Table 13: Supply Air Limitations
Unit Size (Ton)
Minimum
Maximum
-06 (6.5)
1950
3250
-07 (7.5)
2250
3750
-08 (8.5)
2550
4250
-10 (10)
3000
5000
-12 (12.5)
3750
6250
Procedure for adjusting belt tension:
1. Loosen six nuts (top and bottom) A.
2. Adjust by turning (B).
3. Never loosen nuts (C).
4. Use belt tension checker to apply a perpendicular
force to one belt at the midpoint of the span as
shown. Deflection distance of 4mm (5/32”) is
obtained.
To determine the deflection distance from normal
position, use a straight edge from sheave to sheave as
reference line. The recommended deflection force is as
follows:
Tension new belts at the max. deflection force
recommended for the belt section. Check the belt
tension at least two times during the first 24 hours of
operation. Any retensioning should fall between the min.
and max. deflection force values.
5. After adjusting retighten nuts (A).
CFM Static Pressure and Power-Altitude and Temperature
Corrections
Belt Tension
The tension on the belt should be adjusted as shown in Figure 30.
A
A
C*
* NEVER LOOSEN
A
The information below should be used to assist in application of
product when being applied at altitudes at or exceeding 1000
feet above sea level.
The air flow rates listed in the standard blower performance
tables are based on standard air at sea level. As the altitude or
temperature increases, the density of air decreases. In order to
use the indoor blower tables for high altitude applications,
certain corrections are necessary.
A centrifugal fan is a "constant volume" device. This means
that, if the rpm remains constant, the CFM delivered is the
same regardless of the density of the air. However, since the air
at high altitude is less dense, less static pressure will be
generated and less power will be required than a similar
application at sea level. Air density correction factors are shown
in Table 14 and Figure 31.
B
SPAN LENGTH
DEFL. FORCE
Figure 30: Belt Adjustment
Johnson Controls Unitary Products
39
518676-BIM-E-1210
Table 14: Altitude/Temperature Correction Factors
Air
Temp.
40
50
60
70
80
90
100
0
1.060
1.039
1.019
1.000
0.982
0.964
0.946
1000
1.022
1.002
0.982
0.964
0.947
0.929
0.912
2000
0.986
0.966
0.948
0.930
0.913
0.897
0.880
3000
0.950
0.931
0.913
0.896
0.880
0.864
0.848
4000
0.916
0.898
0.880
0.864
0.848
0.833
0.817
Altitude (Ft.)
5000
0.882
0.864
0.848
0.832
0.817
0.802
0.787
6000
0.849
0.832
0.816
0.801
0.787
0.772
0.758
7000
0.818
0.802
0.787
0.772
0.758
0.744
0.730
8000
0.788
0.772
0.757
0.743
0.730
0.716
0.703
9000
0.758
0.743
0.729
0.715
0.702
0.689
0.676
10000
0.729
0.715
0.701
0.688
0.676
0.663
0.651
1.100
1.050
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 31: 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 13
must be used to determine the static pressure and BHP. Since
no temperature data is given, we will assume an air temperature
of 70°F. Table 15 shows the correction factor to be 0.832.
Corrected static pressure = 1.5 x 0.832 = 1.248 IWC
Corrected BHP = 4.0 x 0.832 = 3.328
Example 2: A system, located at 5,000 feet of elevation, is to
deliver 6,000 CFM at a static pressure of 1.5". Use the unit
40
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
Johnson Controls Unitary Products
518676-BIM-E-1210
Drive Selection
1.
Determine side or bottom supply duct Application.
2.
Determine desired airflow.
3.
Calculate or measure the amount of external static pressure.
4.
Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance
table. (Linear interpolation may be necessary.)
5.
Noting the RPM and BHP from step 4, locate the appropriate motor and, or drive on the RPM selection table.
6.
Review the BHP compared to the motor options available. Select the appropriate motor and, or drive.
7.
Review the RPM range for the motor options available. Select the appropriate drive if multiple drives are available for the
chosen motor.
8.
Determine turns open to obtain the desired operation point.
Example
1.
2600 CFM
2.
1.6 iwg
3.
Using the supply air blower performance table below, the following data point was located: 1268 RPM & 1.95 BHP.
4.
Using the RPM selection table below, Size X and Model Y is found.
5.
1.95 BHP exceeds the maximum continuous BHP rating of the 1.5 HP motor. The 2 HP motor is required.
6.
1268 RPM is within the range of the 2 HP drives.
7.
Using the 2 HP motor and drive, .5 turns open will achieve 1268 RPM.
Airflow Performance
Example Supply Air Blower Performance
Air Flow
(CFM)
2200
2400
2600
2800
Available External Static Pressure - IWG
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
804
835
869
906
0.50
0.66
0.84
1.03
1.5 HP & Field Supplied Drive
866
0.71
925
0.90
982
897
0.87
956
1.06 1013
931
1.05
990
1.24 1047
968
1.25 1027 1.43 1084
1.06
1.22
1.40
1.60
1038
1069
1103
1139
Standard 1.5 HP & Drive
1.21 1092 1.35 1147
1.37 1124 1.51 1178
1.55 1158 1.69 1212
1.75 1194 1.89 1249
1.48
1.64
1.82
2.02
1203
1234
1268
1304
Alternate 2 HP & Drive
1.61 1259 1.73 1317
1.77 1290 1.90 1348
1.95 1324 2.07 1382
2.14 1361 2.27
-
1.87
2.03
2.21
-
Table X: RPM Selection
Size
(Tons)
Model
HP
Max
BHP
Motor
Sheave
Blower
Sheave
6 Turns
Open
5 Turns
Open
4 Turns
Open
3 Turns
Open
2 Turns
Open
1 Turn
Open
Fully
Closed
X
Y
1.5
2
1.73
2.30
1VM50
1VM50
AK74
AK64
N/A
N/A
897
1039
945
1094
991
1150
1035
1207
1079
1256
1126
1308
Johnson Controls Unitary Products
41
518676-BIM-E-1210
Table 15: Airflow Performance - Side Duct Application
ZS-06 (6.5 Ton) Side Duct
Air Flow
(CFM)
1800
2000
2200
2400
2600
2800
3000
3200
3400
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
751
776
804
835
869
906
945
987
1030
Field Supplied Drive
0.22
813
0.43
872
0.35
838
0.56
897
0.50
866
0.71
925
0.66
897
0.87
956
0.84
931
1.05
990
1.03
968
1.25 1027
1.25 1007 1.46 1066
1.48 1048 1.69 1107
1.73 1092 1.94 1151
0.62
0.75
0.90
1.06
1.24
1.43
1.65
1.88
2.12
929
954
982
1013
1047
1084
1123
1165
1208
0.78
0.92
1.06
1.22
1.40
1.60
1.81
2.04
2.29
Standard 1.5 HP & Drive
985
0.93 1040 1.07
1010 1.07 1064 1.20
1038 1.21 1092 1.35
1069 1.37 1124 1.51
1103 1.55 1158 1.69
1139 1.75 1194 1.89
1179 1.96 1234 2.10
1220 2.19
-
1095
1119
1147
1178
1212
1249
1288
-
1.20
1.33
1.48
1.64
1.82
2.02
2.23
-
1150
1175
1203
1234
1268
1304
-
Hi Static 2 HP & Drive
1.33 1206 1.46 1265
1.46 1231 1.59 1289
1.61 1259 1.73 1317
1.77 1290 1.90 1348
1.95 1324 2.07 1382
2.14 1361 2.27
2 HP & Field Supplied Drive
1.59
1.72
1.87
2.03
2.21
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
ZS-07 (7.5 Ton) Side Duct
Air Flow
(CFM)
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Drive
776
0.35
838
0.56
804
0.50
866
0.71
835
0.66
897
0.87
869
0.84
931
1.05
906
1.03
968
1.25
945
1.25 1007 1.46
987
1.48 1048 1.69
1030 1.73 1092 1.94
1076 1.99 1138 2.20
1124 2.27 1185 2.48
897
925
956
990
1027
1066
1107
1151
1197
1245
0.75
0.90
1.06
1.24
1.43
1.65
1.88
2.12
2.39
2.67
954
982
1013
1047
1084
1123
1165
1208
1254
1302
Standard 1.5 HP & Drive
0.92 1010 1.07 1064
1.06 1038 1.21 1092
1.22 1069 1.37 1124
1.40 1103 1.55 1158
1.60 1139 1.75 1194
1.81 1179 1.96 1234
2.04 1220 2.19 1275
2.29 1264 2.44 1319
2.56 1310 2.71 1364
2.84 1357 2.99 1412
1.20
1.35
1.51
1.69
1.89
2.10
2.33
2.58
2.84
3.12
1119
1147
1178
1212
1249
1288
1330
1374
1419
1467
Hi Static 3 HP & Drive
1.33 1175 1.46 1231 1.59 1289
1.48 1203 1.61 1259 1.73 1317
1.64 1234 1.77 1290 1.90 1348
1.82 1268 1.95 1324 2.07 1382
2.02 1304 2.14 1361 2.27 1419
2.23 1344 2.36 1400 2.48 1458
2.46 1385 2.59 1442 2.71 1500
2.71 1429 2.84 1485 2.96 1544
2.97 1475 3.10 1531 3.23 1589
3.25 1522 3.38
3 HP & Field Supplied Drive
1.72
1.87
2.03
2.21
2.40
2.62
2.85
3.10
3.36
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
ZS-08 (8.5 Ton) Side Duct
Air Flow
(CFM)
2600
2800
3000
3200
3400
3600
3800
4000
4200
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Drive
628
0.56
678
0.76
648
0.67
698
0.87
666
0.80
717
1.00
684
0.95
735
1.15
702
1.11
753
1.31
721
1.28
772
1.48
742
1.47
793
1.67
765
1.67
815
1.86
789
1.87
840
2.07
730
750
768
786
804
824
844
867
891
0.93
1.04
1.17
1.32
1.48
1.65
1.84
2.04
2.24
Standard 2 HP & Drive
781
1.09
833
1.25
801
1.20
853
1.36
820
1.33
871
1.49
838
1.48
889
1.63
856
1.64
907
1.79
875
1.81
927
1.97
896
2.00
947
2.15
918
2.19
970
2.35
943
2.40
995
2.56
883
903
922
940
958
977
998
1020
1045
1.41
1.52
1.65
1.80
1.96
2.13
2.32
2.51
2.72
933
953
971
989
1007
1027
1047
1070
1094
1.59
1.70
1.83
1.98
2.14
2.31
2.50
2.70
2.90
Hi Static 3 HP & Drive
980
1.80 1025 2.05 1068
1000 1.91 1046 2.16 1088
1019 2.04 1064 2.29 1106
1037 2.19 1082 2.44 1124
1055 2.35 1100 2.60 1142
1074 2.52 1119 2.77
--1095 2.71 1140 2.96
--1117 2.91
----------------3 HP & Field Supplied Drive
2.35
2.46
2.59
2.74
2.90
---------
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
42
Johnson Controls Unitary Products
518676-BIM-E-1210
ZS-10 (10 Ton) Side Duct
Air Flow
(CFM)
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
675
686
699
713
728
745
763
783
805
828
852
879
906
Field Supplied Drive
0.53
726
0.74
776
0.63
738
0.84
787
0.75
750
0.96
800
0.88
764
1.09
814
1.02
779
1.23
829
1.18
796
1.39
846
1.36
815
1.57
864
1.55
835
1.76
884
1.77
856
1.98
906
2.00
879
2.21
929
2.25
904
2.46
953
2.52
930
2.73
980
2.81
958
3.02 1007
0.94
1.04
1.16
1.28
1.43
1.59
1.76
1.96
2.17
2.41
2.66
2.93
3.22
824
835
847
861
877
893
912
932
953
976
1001
1027
1055
1.12
1.23
1.34
1.47
1.61
1.77
1.95
2.15
2.36
2.59
2.85
3.12
3.41
Standard 2 HP & Drive
870
1.30
914
1.48
881
1.41
925
1.58
893
1.52
938
1.70
907
1.65
952
1.83
923
1.79
967
1.97
939
1.95
984
2.13
958
2.13 1002 2.31
978
2.33 1022 2.50
999
2.54 1044 2.72
1022 2.77 1067 2.95
1047 3.03 1092 3.20
1073 3.30
-
957
969
981
995
1010
1027
1046
1066
1087
1110
1135
-
Hi Static 3 HP & Drive
1.65 1000 1.82 1041 1.99 1082
1.76 1011 1.93 1052 2.10 1093
1.87 1024 2.04 1065 2.21 1106
2.00 1037 2.17 1079 2.34 1119
2.14 1053 2.31 1094 2.48 1135
2.30 1069 2.47 1111 2.64 1152
2.48 1088 2.65 1129 2.82 1170
2.67 1108 2.84 1149 3.02 1190
2.89 1129 3.06 1171 3.23 1211
3.12 1152 3.29
3.37
3 HP & Field Supplied Drive
2.17
2.27
2.39
2.52
2.66
2.82
3.00
3.19
3.41
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
ZS-12 (12.5 Ton) Side Duct
Air Flow
(CFM)
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
6000
6200
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
684
709
734
761
789
818
847
877
907
937
967
997
1027
1057
1086
1116
1.00
1.15
1.30
1.48
1.66
1.87
2.09
2.33
2.59
2.86
3.15
3.45
3.77
4.11
4.46
4.82
3 HP & Field Supplied Drive
741
1.16
794
1.32
765
1.30
818
1.46
791
1.46
844
1.62
818
1.63
871
1.79
846
1.82
899
1.98
875
2.03
928
2.19
904
2.25
957
2.41
934
2.49
986
2.65
963
2.75 1016 2.91
993
3.02 1046 3.18
1023 3.31 1076 3.47
1053 3.61 1106 3.77
1083 3.93 1136 4.09
1113 4.26 1166 4.42
1143 4.61 1196 4.77
1172 4.98 1225 5.14
Hi Static 5 HP & Drive
844
868
894
921
949
978
1007
1036
1066
1096
1126
1156
1186
1216
1246
1275
1.48
1.62
1.78
1.95
2.14
2.35
2.57
2.81
3.07
3.34
3.63
3.93
4.25
4.59
4.93
5.30
892
916
942
969
997
1026
1055
1085
1115
1145
1175
1205
1235
1264
1294
-
1.65
1.79
1.94
2.12
2.31
2.51
2.73
2.97
3.23
3.50
3.79
4.09
4.41
4.75
5.10
-
940
964
990
1017
1045
1074
1103
1132
1162
1192
1222
1252
1282
1312
1342
-
Standard 3 HP & Drive
1.81
988
1.97 1036 2.12
1.95 1012 2.11 1061 2.26
2.10 1038 2.26 1087 2.42
2.28 1065 2.44 1114 2.59
2.47 1093 2.63 1142 2.78
2.67 1121 2.83 1170 2.99
2.90 1151 3.06 1199 3.21
3.14 1180 3.29 1229 3.45
3.39 1210 3.55 1259 3.71
3.66 1240 3.82 1289 3.98
3.95 1270 4.11 1319 4.27
4.26 1300 4.41 1349 4.57
4.57 1330 4.73 1379 4.89
4.91 1360 5.07 1409 5.22
5.26
5 HP & Field Supplied Drive
1087
1112
1137
1164
1192
1221
1250
1280
1310
1340
1370
1400
1430
-
2.27
2.42
2.57
2.75
2.93
3.14
3.36
3.60
3.86
4.13
4.42
4.72
5.04
-
1141
1166
1191
1218
1246
1275
1304
1334
1364
1394
1424
1454
1484
-
2.42
2.56
2.72
2.89
3.08
3.29
3.51
3.75
4.01
4.28
4.57
4.87
5.19
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
Johnson Controls Unitary Products
43
518676-BIM-E-1210
Table 16: Airflow Performance - Bottom Duct Application
ZS-06 (6.5 Ton) Bottom Duct
Air Flow
(CFM)
1800
2000
2200
2400
2600
2800
3000
3200
3400
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Drive
775
0.31
850
0.53
803
0.45
878
0.67
838
0.60
913
0.82
878
0.78
953
1.00
923
0.98
997
1.20
971
1.20 1046 1.42
1023 1.44 1097 1.66
1077 1.71 1151 1.93
1133 1.99 1208 2.21
924
952
986
1027
1071
1119
1171
1225
-
Standard 1.5 HP & Drive
0.72
998
0.89 1072
0.86 1026 1.03 1100
1.01 1060 1.19 1134
1.19 1100 1.36 1174
1.39 1145 1.56 1219
1.61 1193 1.78 1267
1.85 1245 2.03 1319
2.12 1299 2.29
-
1.05
1.19
1.34
1.52
1.72
1.94
2.18
-
1147
1175
1210
1250
1294
1343
-
Hi Static 2 HP & Drive
1.20 1224 1.35 1303 1.51
1.34 1252 1.49 1331 1.65
1.49 1286 1.65 1365 1.81
1.67 1327 1.82 1405 1.98
1.87 1371 2.02 1450 2.18
2.09 1419 2.24
2 HP & Field Supplied Drive
1384
1412
1447
1487
-
1.69
1.83
1.98
2.16
-
1469
1497
1532
-
1.89
2.03
2.18
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
ZS-07 (7.5 Ton) Bottom Duct
Air Flow
(CFM)
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Drive
803
0.45
878
0.67
838
0.60
913
0.82
878
0.78
953
1.00
923
0.98
997
1.20
971
1.20 1046 1.42
1023 1.44 1097 1.66
1077 1.71 1151 1.93
1133 1.99 1208 2.21
1192 2.30 1267 2.52
1253 2.63 1327 2.85
952
986
1027
1071
1119
1171
1225
1282
1341
1401
Standard 1.5 HP & Drive
0.86 1026 1.03 1100
1.01 1060 1.19 1134
1.19 1100 1.36 1174
1.39 1145 1.56 1219
1.61 1193 1.78 1267
1.85 1245 2.03 1319
2.12 1299 2.29 1373
2.41 1356 2.58 1430
2.71 1414 2.88 1489
3.04 1475 3.21 1549
1.19
1.34
1.52
1.72
1.94
2.18
2.45
2.73
3.04
3.37
Hi Static 3 HP & Drive
1175 1.34 1252 1.49 1331
1210 1.49 1286 1.65 1365
1250 1.67 1327 1.82 1405
1294 1.87 1371 2.02 1450
1343 2.09 1419 2.24 1498
1394 2.33 1471 2.49 1550
1448 2.60 1525 2.75 1604
1505 2.88 1582 3.04 1661
1564 3.19 1641 3.34
3 HP & Field Supplied Drive
1.65
1.81
1.98
2.18
2.40
2.65
2.91
3.20
-
1412
1447
1487
1532
1580
1632
1686
1742
-
1.83
1.98
2.16
2.36
2.58
2.82
3.09
3.37
-
1497
1532
1572
1617
1665
1717
1771
-
2.03
2.18
2.36
2.56
2.78
3.02
3.29
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
ZS-08 (8.5 Ton) Bottom Duct
Air Flow
(CFM)
2600
2800
3000
3200
3400
3600
3800
4000
4200
1.
2.
3.
4.
44
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
4
FS
674
0.71
689
0.86
707
1.01
728
1.17
751
1.34
776
1.53
804
1.74
835
1.97
867
2.21
731
746
764
785
808
833
861
892
924
0.88
1.02
1.17
1.33
1.51
1.70
1.90
2.13
2.37
786
801
819
840
863
888
916
947
979
Standard 2 HP & Drive
1.05
838
1.24
887
1.20
854
1.38
903
1.35
872
1.53
921
1.51
892
1.69
941
1.68
915
1.87
964
1.87
941
2.06
990
2.08
969
2.26 1018
2.31
999
2.49 1048
2.55 1032 2.73 1081
1.42
1.56
1.71
1.87
2.05
2.24
2.44
2.67
2.91
933
948
966
987
1010
1035
1063
1094
1127
1.59
1.73
1.88
2.04
2.22
2.41
2.61
2.84
3.08
974
989
1007
1028
1051
1076
1104
1135
---
Hi Static 3 HP & Drive
1.74 1010 1.87 1040 1.97
1.88 1025 2.01 1056 2.11
2.03 1043 2.16 1074 2.26
2.20 1064 2.33 1094 2.42
2.37 1087 2.50 1117 2.60
2.56 1112 2.69 1142 2.79
2.77 1140 2.90 1170 2.99
2.99
------------------3 HP & Field Supplied Drive
1064
1080
1098
1118
1141
1167
1194
-----
2.03
2.17
2.32
2.48
2.66
2.85
-------
Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
kW = BHP x 0.932.
Field Supplied Drive
Johnson Controls Unitary Products
518676-BIM-E-1210
ZS-10 (10 Ton) Bottom Duct
Air Flow
(CFM)
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
Field Supplied Drive
722
0.83
776
0.97
744
0.97
798
1.12
769
1.13
823
1.28
797
1.32
851
1.46
828
1.52
882
1.67
861
1.75
915
1.90
897
2.00
951
2.15
935
2.27
989
2.42
976
2.57 1030 2.72
1019 2.88 1073 3.03
1065 3.22 1119 3.36
828
850
875
903
934
967
1002
1041
1082
1125
-
1.11
1.26
1.42
1.60
1.81
2.04
2.29
2.56
2.86
3.17
-
Standard 2 HP & Drive
878
1.25
926
1.37
973
1.50 1018
900
1.39
949
1.52
995
1.64 1041
925
1.55
974
1.68 1020 1.80 1066
953
1.74 1001 1.86 1048 1.99 1093
983
1.94 1032 2.07 1078 2.19 1124
1017 2.17 1065 2.30 1112 2.42 1157
1052 2.42 1101 2.55 1147 2.67 1193
1091 2.69 1139 2.82 1186 2.95 1231
1132 2.99 1180 3.12 1227 3.24 1272
1175 3.30 1223 3.43
3 HP & Field Supplied Drive
Hi Static 3 HP & Drive
1.62 1063 1.74 1106
1.76 1085 1.88 1128
1.92 1110 2.05 1153
2.11 1138 2.23 1181
2.32 1168 2.44 1212
2.54 1201 2.67 1245
2.80 1237 2.92 1280
3.07 1275 3.19 1319
3.36
-
1.86
2.00
2.17
2.35
2.56
2.79
3.04
3.31
-
1149
1171
1196
1224
1254
1287
1323
1362
-
1.99
2.13
2.29
2.48
2.68
2.91
3.16
3.43
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
ZS-12 (12.5 Ton) Bottom Duct
Air Flow
(CFM)
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
Available External Static Pressure - IWG1
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP
3 HP & Field Supplied Drive
823
1.28
861
1.47
860
1.48
898
1.67
898
1.71
935
1.90
936
1.97
974
2.16
975
2.24 1013 2.43
1014 2.54 1052 2.73
1053 2.85 1091 3.04
1091 3.19 1129 3.38
1130 3.54 1168 3.73
1168 3.92 1206 4.11
1206 4.31 1244 4.50
1243 4.72 1281 4.91
1280 5.15 1318 5.34
1316 5.60
-
906
942
980
1019
1057
1096
1135
1174
1213
1251
1288
1326
1362
-
1.64
1.84
2.07
2.33
2.60
2.90
3.21
3.55
3.90
4.28
4.67
5.08
5.51
-
955
992
1030
1068
1107
1146
1185
1223
1262
1300
1338
1375
-
Standard 3 HP & Drive
1.80 1007 1.95 1059 2.12
2.00 1044 2.16 1095 2.32
2.23 1081 2.39 1133 2.55
2.49 1120 2.64 1172 2.81
2.76 1158 2.92 1210 3.08
3.05 1197 3.21 1249 3.38
3.37 1236 3.53 1288 3.69
3.71 1275 3.86 1327 4.03
4.06 1314 4.22 1365 4.38
4.44 1352 4.59 1404 4.76
4.83 1389 4.99 1441 5.15
5.24 1427 5.40 1479 5.56
5 HP & Field Supplied Drive
1109
1145
1183
1222
1260
1299
1338
1377
1415
1454
1491
-
2.29
2.50
2.73
2.98
3.26
3.55
3.87
4.20
4.56
4.94
5.33
-
1155
1191
1229
1267
1306
1345
1384
1423
1461
1500
1537
-
Hi Static 5 HP & Drive
2.50 1194 2.73 1225
2.70 1231 2.94 1262
2.94 1269 3.17 1300
3.19 1307 3.42 1338
3.46 1346 3.70 1377
3.76 1385 3.99 1416
4.07 1424 4.31 1455
4.41 1462 4.64 1494
4.76 1501 5.00 1532
5.14 1539 5.37
5.53
-
3.01
3.22
3.45
3.70
3.97
4.27
4.58
4.92
5.27
-
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications.
2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.
3. kW = BHP x 0.932.
Table 17: RPM Selection
Size
(Tons)
-06
(6.5)
Model
ZS
-07
(7.5)
ZS
-08
(8.5)
ZS
-10
(10)
ZS
-12
(12.5)
ZS
HP
1.5
2
1.5
3
2
3
2
3
3
5
Max
BHP
1.73
2.30
1.73
3.45
2.30
3.45
2.30
3.45
3.45
5.75
Johnson Controls Unitary Products
Motor
Sheave
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VP56
Blower
Sheave
AK74
AK64
AK74
AK61
AK94
AK74
AK84
AK74
AK74
BK77
6 Turns
Open
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
1052
5 Turns
Open
887
1039
887
1088
690
887
776
887
887
1095
4 Turns
Open
936
1094
936
1147
728
936
819
936
936
1136
3 Turns
Open
986
1150
986
1205
767
986
863
986
986
1175
2 Turns
Open
1035
1207
1035
1265
805
1035
906
1035
1035
1216
1 Turn
Open
1084
1256
1084
1312
843
1084
949
1084
1084
1272
Fully
Closed
1134
1308
1134
1365
882
1134
992
1134
1134
N/A
45
518676-BIM-E-1210
Table 18: Indoor Blower Specifications
Size
(Tons)
Motor
Model
-06
(6.5)
-07
(7.5)
-08
(8.5)
-10
(10)
-12
(12.5)
ZS
ZS
ZS
ZS
ZS
HP
RPM
Eff.
SF
Frame
1-1/2
2
1-1/2
3
2
3
2
3
3
5
1725
1725
1725
1725
1725
1725
1725
1725
1725
1725
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.87
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
1.15
56
56
56
56
56
56
56
56
56
184T
Motor Sheave
Datum Dia.
Bore (in.)
(in.)
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
3.4 - 4.4
7/8
4.3 - 5.3
1-1/8
Model
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VM50
1VP56
Blower Sheave
Datum Dia.
Bore (in.)
(in.)
7.0
1
6.0
1
7.0
1
5.7
1
9.0
1
7.0
1
8.0
1
7.0
1
7.0
1
6.7
1
Model
AK74
AK64
AK74
AK61
AK94
AK74
AK84
AK74
AK74
BK77
Belt
A49
A49
A49
A49
A56
A54
A56
A54
A54
BX55
Table 19: Power Exhaust Specifications
Model
Voltage
2PE04703225
2PE04703246
2PE04703258
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
7.8
3.4
2.9
Motor
FLA
5
2.2
1.5
MCA
6.3
2.8
1.9
Fuse Size
10
5
4
CFM @
0.1 ESP
3800
3800
3800
1. Motors are multi-tapped and factory wired for high speed.
Air Balance
Checking Air Quantity
Method One
1.
Remove the dot plugs from the duct panel (for location of
the dot plugs see Figures 12 and 13).
On VAV units be certain that the VFD is set to maximum
output, exhaust dampers are closed and individual
space damper boxes are full open.
2.
Insert eight-inches of 1/4 inch metal tubing into the airflow
on both sides of the indoor coil.
VFD units with manual bypass option must not be in the
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.
3.
Use an Inclined Manometer or Magnehelic to determine
the pressure drop across a dry evaporator coil. Since the
moisture on an evaporator coil can vary greatly, measuring
the pressure drop across a wet coil under field conditions
could be inaccurate. To assure a dry coil, the compressors
should be de-activated while the test is being run.
NOTE: De-energize the compressors before taking any test
measurements to assure a dry evaporator coil.
Belt drive blower systems MUST be adjusted to the
specific static and CFM requirements for the application.
The Belt drive blowers are NOT set at the factory for any
specific static or CFM. Adjustments of the blower speed
and belt tension are REQUIRED. Verify proper sheave
alignment; tighten blower pulley and motor sheave set
screws after these adjustments. Re-checking set screws
after 10-12 hrs. run time is recommended.
46
4.
The CFM through the unit can be determined from the
pressure drop indicated by the manometer by referring to
Figure 32. In order to obtain an accurate measurement, be
certain that the air filters are clean.
5.
To adjust Measured CFM to Required CFM, see SUPPLY
AIR DRIVE ADJUSTMENT.
6.
After readings have been obtained, remove the tubes and
replace the dot plugs.
7.
Tighten blower pulley and motor sheave set screws after
any adjustments. Re-check set screws after 10-12 hrs. run
time is recommended.
Johnson Controls Unitary Products
518676-BIM-E-1210
Failure to properly adjust the total system air quantity
can result in extensive blower damage.
Method Two
1.
Drill two 5/16 inch holes, one in the return air duct as close
to the inlet of the unit as possible, and another in the supply
air duct as close to the outlet of the unit as possible.
2.
Using the whole drilled in step 1, insert eight inches of 1/4
inch metal tubing into the airflow of the return and supply
air ducts of the unit.
NOTE: The tubes must be inserted and held in position
perpendicular to the airflow so that velocity pressure
will not affect the static pressure readings.
3.
4.
Use an Inclined Manometer or Magnehelic to determine
the pressure drop across the unit. This is the External
Static Pressure (ESP). In order to obtain an accurate
measurement, be certain that the air filters are clean.
5.
Select the correct blower performance table for the unit
from Tables 15 and 16. Tables are presented for side and
downflow configuration.
6.
Determine the unit Measured CFM from the Blower
Performance Table, External Static Pressure and the
number of turns the variable motor sheave is open.
7.
To adjust Measured CFM to Required CFM, see SUPPLY
AIR DRIVE ADJUSTMENT.
8.
After reading has been obtained, remove the tubes and
seal holes.
9.
Tighten blower pulley and motor sheave set screws after
any adjustments. Re-check set screws after 10-12 hrs. run
time is recommended.
NOTE: With the addition of field installed accessories repeat
this procedure.
Failure to properly adjust the total system air quantity
can result in extensive blower damage.
Determine the number of turns the variable motor sheave
is open.
0.5
ZS-06
ZS-07
0.45
ZS-08
ZS-10
ZS-12
Dry Coil Delta P (iwg)
0.4
0.35
0.3
0.25
0.2
0.15
0.1
0.05
0
1500
2000
2500
3000
3500 4000 4500
Airflow (CFM)
5000
5500
6000
6500
Figure 32: Dry Coil Delta P
Johnson Controls Unitary Products
47
518676-BIM-E-1210
Supply Air Drive Adjustment
EXAMPLE
A 12.5 ton unit was selected to deliver 4,000 CFM with a 3 HP
motor, but the unit is delivering 3,800 CFM. The variable pitch
motor sheave is set at 2 turns open.
Before making any blower speed changes review the
installation for any installation errors, leaks or undesirable
systems effects that can result in loss of airflow.
Even small changes in blower speed can result in
substantial changes in static pressure and BHP. BHP
and AMP draw of the blower motor will increase by the
cube of the blower speed. Static pressure will increase
by the square of the blower speed. Only qualified
personnel should make blower speed changes, strictly
adhering to the fan laws.
Use the equation to determine the required DD for the new
motor sheave,
Use Table 20 to locate the DD nearest to 4.21 in. Close the
sheave to 1 turn open.
New BHP
= (Speed increase)3 • BHP at 3,800 CFM
At unit start-up, the measured CFM may be higher or lower than
the required CFM. To achieve the required CFM, the speed of
the drive may have adjusted by changing the datum diameter
(DD) of the variable pitch motor sheave as described below:
= (Speed increase)3 • Original BHP
= New BHP
New motor Amps
= (Speed increase)3 • Amps at 3,800 CFM
Use the following tables and the DD calculated per the above
equation to adjust the motor variable pitch sheave.
= (Speed increase)3 • Original Amps
= New Amps
Table 20: Motor Sheave Datum Diameters
1VM50x7/8
(1-1/2, 2 & 3 HP Motor)
Turns Open
Datum Diameter
0
4.4
1/2
4.3
1
4.2
1-1/2
4.1
2
4.0
2-1/2
3.9
3
3.8
3-1/2
3.7
4
3.6
4-1/2
3.5
5
3.4
1VP56x1-1/8
(5 HP Motor)
Turns Open
Datum Diameter
1
5.3
1-1/2
5.2
2
5.1
2-1/2
5.0
3
4.9
3-1/2
4.8
4
4.7
4-1/2
4.6
5
4.5
5-1/2
4.4
6
4.3
Belt drive blower systems MUST be adjusted to the
specific static and CFM requirements for the application.
The Belt drive blowers are NOT set at the factory for any
specific static or CFM. Adjustments of the blower speed
and belt tension are REQUIRED. Verify proper sheave
alignment; tighten blower pulley and motor sheave set
screws after these adjustments. Re-checking set screws
after 10-12 hrs. run time is recommended.
48
Johnson Controls Unitary Products
518676-BIM-E-1210
Table 21: Additional Static Resistance
Size
(Tons)
Model
-06 (6.5)
-07 (7.5)
ZS
-08 (8.5)
-10 (10)
-12 (12.5)
ZS
CFM
Cooling Only1
Economizer2,3
4” Filter2
1900
2100
2300
2500
2700
2900
3100
3300
3500
3700
3900
4100
4300
4500
1900
2100
2300
2500
2700
2900
3100
3300
3500
3700
3900
4100
4300
4500
4700
4900
5100
5300
5500
5700
5900
6100
6300
0.00
-0.01
-0.01
-0.02
-0.03
-0.04
-0.05
-0.06
-0.07
-0.08
-0.09
-0.09
-0.10
-0.11
0.06
0.07
0.08
0.09
0.11
0.12
0.14
0.16
0.18
0.20
0.23
0.25
0.28
0.30
0.33
0.36
0.39
0.42
0.45
0.48
0.52
0.56
0.60
0.07
0.09
0.11
0.13
0.16
0.18
0.20
0.22
0.24
0.27
0.29
0.31
0.30
0.35
0.02
0.02
0.02
0.02
0.03
0.03
0.03
0.03
0.04
0.04
0.04
0.04
0.05
0.05
0.05
0.05
0.06
0.06
0.06
0.06
0.07
0.07
0.07
0.10
0.11
0.12
0.14
0.15
0.16
0.18
0.19
0.20
0.21
0.23
0.24
0.25
0.26
0.12
0.13
0.14
0.16
0.17
0.19
0.20
0.22
0.26
0.27
0.29
0.32
0.35
0.38
0.41
0.44
0.47
0.51
0.55
0.58
0.62
0.67
0.71
9
0.05
0.06
0.07
0.08
0.09
0.10
0.12
0.13
0.15
0.17
0.19
0.21
0.23
0.25
0.05
0.06
0.07
0.08
0.09
0.10
0.12
0.13
0.15
0.17
0.19
0.21
0.23
0.25
0.28
0.30
0.33
0.35
0.38
0.41
0.44
0.47
0.50
Electric Heat kW2
18
24
36
0.06
0.07
0.08
0.07
0.08
0.09
0.08
0.09
0.10
0.09
0.10
0.11
0.10
0.12
0.13
0.11
0.13
0.14
0.13
0.15
0.16
0.14
0.17
0.18
0.16
0.19
0.20
0.18
0.21
0.22
0.20
0.23
0.24
0.22
0.25
0.26
0.24
0.28
0.29
0.26
0.30
0.31
0.06
0.07
0.08
0.07
0.08
0.09
0.08
0.09
0.10
0.09
0.10
0.11
0.10
0.12
0.13
0.11
0.13
0.14
0.13
0.15
0.16
0.14
0.17
0.18
0.16
0.19
0.20
0.18
0.21
0.22
0.20
0.23
0.24
0.22
0.25
0.26
0.24
0.28
0.29
0.26
0.30
0.31
0.29
0.33
0.34
0.31
0.35
0.37
0.34
0.38
0.40
0.37
0.41
0.43
0.40
0.44
0.46
0.43
0.47
0.49
0.46
0.50
0.53
0.49
0.53
0.56
0.53
0.56
0.59
54
0.10
0.11
0.13
0.14
0.16
0.18
0.20
0.22
0.24
0.26
0.28
0.31
0.34
0.37
0.10
0.11
0.13
0.14
0.16
0.18
0.20
0.22
0.24
0.26
0.28
0.31
0.34
0.37
0.40
0.43
0.46
0.49
0.53
0.56
0.59
0.62
0.65
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.
Operation
Cooling Sequence Of Operation
For the ZS series of units, the thermostat makes a circuit
between "R" and "Y1" for the first stage of cooling.
The call is passed to the Unit Control Board (UCB), which
then determines whether the requested operation is available
and, if so, which components to energize.
Johnson Controls Unitary Products
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.
49
518676-BIM-E-1210
Continuous Blower
By setting the room thermostat fan switch to "ON," the supply
air blower will operate continuously.
Intermittent Blower
With the room thermostat fan switch set to "AUTO" and the
system switch set to either the "AUTO" or "HEAT" settings, the
blower is energized whenever a cooling or heating operation is
requested. The blower is energized after any specified delay
associated with the operation.
duct static pressure reaches or exceeds the high-limit set-point
(default = 4.5"), then the supply fan motor will be shutdown.
The Supply Air Temperature (SAT) is controlled by staging
compressors on and off to satisfy the "Operating Cooling
Supply Air Temp Set point". There are 3 set points that
determine the resulting "Operating Cooling Supply Air Temp
Set point".
1.
VAV Cooling Supply Air Temp Upper Set point
(default 60° F)
2.
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.
VAV Cooling Supply Air Temp Lower Set point
(default 55° F)
3.
VAV Supply Air Temp Reset Set point (default 72° F)
Optional VAV Start-up 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 optional manual bypass
switch in the LINE (BYPASS) position and there are
VAV boxes present in the duct system, then boxes must
be driven to the full-open position using a customersupplied power source to prevent over-pressurizing and
possible damage to the ductwork.
For units with VFD and VAV control, the unit must first be put
into the Occupied Mode to start operation. The default setting
for all VAV units is 'Unoccupied', therefore the installer must
add a jumper wire between terminals R - OCC on the VAV addon board to put the unit into 'Occupied' Mode. Additionally, the
unit can be switched between Unoccupied/Occupied mode
through network communications with Simplicity™ PC and
other BAS control systems.
When the Return Air Temp (RAT) is below the "VAV Supply Air
Temp Reset Set point" the SAT will be maintained at +/- 5
degrees of the "VAV Cooling Supply Air Temp Upper Set point".
When the Outdoor air condition is sufficient for free cooling, the
economizer will modulate to control the SAT to +/- 1 degrees of
the operational set point.
The following components are needed to access the control
points in the Simplicity® controller. Installation and operation
guide is located on UPGNET.
1.
Computer running Windows software with a standard USB
port.
2.
Simplicity® PC Software (http://www.yorkupg.com/
software.asp)
3.
Freenet USB adapter driver, (http://www.yorkupg.com/
software.asp)
4.
Simplicity® Freenet USB Adapter (S1-03101967000)
5.
Freenet service cable (S1-02538682000)
No Outdoor Air Options
When the thermostat calls for the first stage of cooling, the lowvoltage control circuit from “R” to “Y1” and “G” is completed.
The UCB energizes the economizer (if installed and free cooling
is available) or the first available compressor* and the
condenser fans. For first stage cooling, compressor #1 is
energized. If compressor #1 is unavailable, compressor #2 is
energized. After completing the specified fan on delay for
cooling, the UCB will energize the blower motor.
Figure 33: Occupied Jumper
Once placed into the Occupied Mode, the speed of the indoor
blower motor is controlled by duct static pressure. The Duct
Static set point (default = 1.5") is the pressure that the VFD
drive will maintain when operating the unit in VAV mode. If the
50
When the thermostat calls for the second stage of cooling, the
low-voltage control circuit from “R” to “Y2” is completed. The
control board energizes the first available compressor. If free
cooling is being used for the first stage of cooling, compressor
#1 is energized. If compressor #1 is active for first stage cooling
or the first compressor is locked-out, compressor #2 is
energized. In free-cooling mode, if the call for the second stage
of cooling continues for 20 minutes, compressor #2 is
energized, provided it has not been locked-out.
Johnson Controls Unitary Products
518676-BIM-E-1210
If there is an initial call for both stages of cooling, the UCB will
delay energizing compressor #2 by 30 seconds in order to
avoid a power rush.
the economizer control. As always, the "R" to "G" connection
provides minimum position but does not provide power exhaust
operation.
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.
Economizer With Optional VAV OR Intelli-Comfort™
Control
* 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.
Economizer With Single Enthalpy Sensor
When the room thermostat calls for "first-stage" cooling, the low
voltage control circuit from "R" to "G" and "Y1" is completed.
The UCB energizes the blower motor (if the fan switch on the
room thermostat is set in the "AUTO" position) and drives the
economizer dampers from fully closed to their minimum
position. If the enthalpy of the outdoor air is below the set point
of the enthalpy controller (previously determined), "Y1"
energizes the economizer. The dampers will modulate to
maintain a constant supply air temperature as monitored by the
discharge air sensor. If the outdoor air enthalpy is above the set
point, "Y1" energizes compressor #1.
When the thermostat calls for "second-stage" cooling, the low
voltage control circuit from "R" to "Y2" is completed. The UCB
energizes the first available compressor. If the enthalpy of the
outdoor air is below the set point of the enthalpy controller (i.e.
first stage has energized the economizer), "Y2" will energize
compressor #1. If the outdoor air is above the set point, "Y2" will
energize compressor #2.
Once the thermostat has been satisfied, it will de-energize “Y1”
and “Y2”. If the compressors have satisfied their minimum run
times, the compressors and condenser fans are de-energized.
Otherwise, the unit operates each cooling system until the
minimum run times for the compressors have been completed.
Upon the final compressor de-energizing, the blower is stopped
following the elapse of the fan off delay for cooling, and the
economizer damper goes to the closed position. If the unit is in
continues fan operation, the economizer damper goes to the
minimum position.
Economizer With Dual Enthalpy Sensors
The operation with the dual enthalpy sensors is identical to the
single sensor except that a second enthalpy sensor is mounted
in the return air. This return air sensor allows the economizer to
choose between outdoor air and return air, whichever has the
lowest enthalpy value, to provide maximum operating
efficiency.
Economizer With Power Exhaust
A unit equipped with an economizer (single or dual enthalpy)
and a power exhaust operates as specified above with one
addition. The power exhaust motor is energized 45 seconds
after the actuator position exceeds the exhaust fan set point on
Johnson Controls Unitary Products
The 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 set point plus 5 °F, and the Economizer OAT
Enable set point.
• Single Enthalpy (optional): A field-installed, Outdoor Air
Humidity sensor is connected to the control. When the
measured outdoor enthalpy is below the Outside Air
Enthalpy set point, and the outdoor temperature is less
than the First-Stage SAT Control set point plus 5 °F, freecooling is available.
• Dual Enthalpy (optional): Both the field-installed
Outdoor Air Humidity and the Return Air Humidity sensors
are connected to the control. When the measured outdoor
air enthalpy is less than the measured return air enthalpy,
and the outdoor temperature is less than the First-Stage
SAT Control set point plus 5 °F, free-cooling is available.
If free-cooling is available with a Y1 call, then the control
modulates the economizer dampers to maintain the First-Stage
SAT Control set point, plus or minus one degree. If free-cooling
is unavailable, then 1st-stage mechanical cooling is initiated.
If at anytime the outdoor air temperature rises above the FirstStage SAT Control set point plus 5 °F, while free-cooling is
available, then a Y1 call will also initiate 1st-stage mechanical
cooling.
For a Y2 call, free-cooling is available based upon the criteria
described above, except a Second-Stage SAT Control set point
is used in the determination.
Once the call for cooling has been satisfied, it will de-energize
any compressors and condenser fans, after the minimum
compressor run times have been satisfied. Otherwise, the unit
operates each cooling system until the minimum run times for
the compressors have been completed.
Upon de-energizing the final compressor, the blower will
continue to run with the economizer damper in its minimum
position if in the Occupied mode; otherwise, the blower will stop
following the elapse of the fan-off delay for cooling, and the
economizer outdoor damper will close.
51
518676-BIM-E-1210
Economizer With Optional VAV Blower With Power
Exhaust
The power exhaust motor is energized via the controller's EXH~
terminal and the M5 contactor, based on the position of the
economizer damper parameter settings in the VAV control.
Minimum run time is 10 seconds; minimum off time is 60
seconds. The outlet pressure of the power exhaust fan forces
the barometric relief dampers open; gravity closes the dampers
when the exhaust fan is off.
Economizer With Optional Intelli-Comfort™ With Power
Exhaust
The power exhaust motor is energized via the M5 contactor
based on the position of the economizer actuator's auxiliary
switch adjustment screw. The adjustment screw represents the
outdoor damper position at which to activate power exhaust,
and can be set between 0 to 90 degrees open. The outlet
pressure of the power exhaust fan forces the barometric relief
dampers open; gravity closes the dampers when the exhaust
fan is off.
Motorized Outdoor Air Dampers
This system operation is the same as the units with no outdoor
air options with one exception. When the "R" to "G" circuit is
complete, the motorized damper drives open to a position set
by the thumbwheel on the damper motor. When the "R" to "G"
circuit is opened, the damper spring returns fully closed.
Cooling Operation Errors
Each cooling system is monitored for operation outside of the
intended parameters. Errors are handled as described below. All
system errors override minimum run times for compressors.
High-Pressure Limit Switch
During cooling operation, if a high-pressure limit switch opens,
the UCB will de-energize the associated compressor, initiate
the ASCD (Anti-short cycle delay), and, if the other compressor
is idle, stop the condenser fans. If the call for cooling is still
present at the conclusion of the ASCD, the UCB will re-energize
the halted compressor.
Once the low-pressure switch has been proven (closed during
the 30-second monitor period described above), the UCB will
monitor the low-pressure limit switch for any openings. If the
low-pressure switch opens for greater than 5 seconds, the UCB
will de-energize the associated compressor, initiate the ASCD,
and, if the other compressor is idle, stop the condenser fans.
If the call for cooling is still present at the conclusion of the
ASCD, the UCB will re-energize the halted compressor.
Should a low-pressure switch open three times within one hour
of operation, the UCB will lock-out the associated compressor
and flash a code (Table 29). If the other compressor is inactive,
the condenser fans will be de-energized.
Freezestat
During cooling operation, if a freezestat opens, the UCB will deenergize the associated compressor, initiate the ASCD, and, if
the other compressor is idle, stop the condenser fans. If the call
for cooling is still present at the conclusion of the ASCD, the
UCB will re-energize the halted compressor.
Should a freezestat open three times within two hours of
operation, the UCB will lock-out the associated compressor and
flash a code (Table 29). If the other compressor is inactive, the
condenser fans will be de-energized.
Low Ambient Cooling
To determine when to operate in low ambient mode, the UCB
has a pair of terminals connected to a temperature-activated
switch set at 45ºF. When the low ambient switch is closed and
the thermostat is calling for cooling, the UCB will operate in the
low ambient mode.
Low ambient mode operates the compressors in this manner:
10 minutes on, 5 minutes off. The indoor blower is operated
throughout the cycle. The 5-minute off period is necessary to
defrost the indoor coil.
Low ambient mode always begins with compressor operation.
Compressor minimum run time may extend the minutes of
compressor operation. The defrost cycle will begin immediately
following the elapse of the minimum run time.
Should a high-pressure switch open three times within two
hours of operation, the UCB will lock-out the associated
compressor and flash a code (see Table 29). If the other
compressor is inactive, the condenser fans will be deenergized.
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.
Low-Pressure Limit Switch
Safety Controls
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.
The unit control board monitors the following inputs for each
cooling system:
52
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).
Johnson Controls Unitary Products
518676-BIM-E-1210
2.
3.
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).
A low-pressure switch to protect against loss of refrigerant
charge, (opens at 50 ± 5 psig).
The above pressure switches are hard-soldered to the unit. The
refrigeration systems are independently monitored and
controlled. On any fault, only the associated system will be
affected by any safety/preventive action. The other refrigerant
system will continue in operation unless it is affected by the
fault as well.
The unit control board monitors the temperature limit switch of
electric heat units and the temperature limit switch and the gas
valve of gas furnace units.
Compressor Protection
In addition to the external pressure switches, the compressors
also have inherent (internal) protection. If there is an abnormal
temperature rise in a compressor, the protector will open to shut
down the compressor. The UCB incorporates features to
minimize compressor wear and damage. An Anti-Short Cycle
Delay (ASCD) is utilized to prevent operation of a compressor
too soon after its previous run. Additionally, a minimum run time
is imposed any time a compressor is energized.
The ASCD is initiated on unit start-up and on any compressor
reset or lock-out.
Two-stage heating:
a. Upon a call for first stage heat by the thermostat, the
heater relay (RA) will be energized. After completing the
specified fan on delay for heating, the UCB will energize
the blower motor. If the second stage of heat is required,
heater relay (RB) will be energized. After completing the
specified fan on delay for heating, the UCB will energize
the blower motor.
b The thermostat will cycle the electric heat to satisfy the
heating requirements of the conditioned space.
Electric Heat Operation Errors
Temperature Limit
If the UCB senses zero volts from the high temperature limit,
the indoor blower motor is immediately energized.
This limit is monitored regardless of unit operation status, i.e.
the limit is monitored at all times.
If the temperature limit opens three times within one hour, it will
lock-on the indoor blower motor and a flash code is initiated
(See Table 29).
Safety Controls
The UCB monitors the temperature limit switch of electric heat
units.
The control circuit includes the following safety controls:
Flash Codes
Limit Switch (Ls)
The UCB will initiate a flash code associated with errors within
the system. Refer to UNIT CONTROL BOARD FLASH CODES
Table 29.
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
This control is located inside the heater compartment and is set
to open at the temperature indicated in the Electric Heat Limit
Setting Tables 22 and 23. It resets automatically. The limit
switch operates when a high temperature condition, caused by
inadequate supply air flow occurs, thus shutting down the
heater and energizing the blower.
Table 22: Electric Heat Limit Setting 50” Cabinet
UNIT (TONS)
VOLTAGE
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.
Johnson Controls Unitary Products
ZS-08, -10, -12
(8.5, 10, 12.5)
208/230
ZS-08, -10, -12
(8.5, 10, 12.5)
480
ZS-08, -10, -12
(8.5, 10, 12.5)
600
HEATER
kW
18
24
34
54
18
24
34
54
18
24
34
54
LIMIT
SWITCH
OPENS °F
150
150
150
130
150
150
150
130
150
150
150
130
53
518676-BIM-E-1210
Table 23: Electric Heat Limit Setting 42” Cabinet
UNIT (TONS)
VOLTAGE
ZS-06, -07 (6.5, 7.5)
208/230
ZS-06, -07 (6.5, 7.5)
480
ZS-06, -07 (6.5, 7.5)
600
HEATER
kW
9
18
24
34
9
18
24
34
9
18
24
34
LIMIT
SWITCH
OPENS °F
135
150
165
190
135
150
165
185
135
150
150
185
Flash Codes
The UCB will initiate a flash code associated with errors within
the system. Refer to UNIT CONTROL BOARD FLASH CODES
Table 29.
Reset
Remove the call for heating by lowering the thermostat setting
lower than the conditioned space temperature.This resets any
flash codes.
Electric Heat Anticipator Setpoints
When the thermostat calls for the first stage of heating, the lowvoltage control circuit from “R” to “W1” is completed. A call for
heat passes through the UCB to the Ignition Control Board
(ICB). The UCB monitors the “W1” call and acts upon any call
for heat by monitoring the Gas Valve (GV). Once voltage has
been sensed at the GV, the UCB will initiate the fan on delay for
heating, energizing the indoor blower the specified delay has
elapsed.
When the thermostat has been satisfied, heating calls are
ceased. The GV is immediately closed. The blower is deenergized after the fan off delay for heating has elapsed. The
draft motor performs a 30-second post purge.
Ignition Control Board
First Stage Of Heating
When the ICB receives a call for first stage of heating, “W1,” the
draft motor is energized. Once the draft motor has been proven,
a 30-second purge is initiated. At the end of the purge, the GV
is opened, and the spark ignitor is energized for 10 seconds.
The ICB then checks for the presence of flame. If flame is
detected, the ICB enters a flame stabilization period. If flame
was not detected, the GV closes, and a retry operation begins.
During the flame stabilization period, a loss of the flame for 2
seconds will cause the GV to close and the retry operation to
begin. After the flame stabilization period, a loss of flame for 3/4
second will cause the GV to close and the retry operation to
begin.
It is important that the anticipator setpoint be correct. Too high
of a setting will result in longer heat cycles and a greater
temperature swing in the conditioned space. Reducing the
value below the correct setpoint will give shorter “ON” cycles
and may result in the lowering of the temperature within the
conditioned space. Refer to Table 24 for the required electric
heat anticipator setting.
At the conclusion of the flame stabilization period, the ICB will
operate the gas heat in high fire for an additional 60 seconds
(for a total for 120 seconds of high fire operation). After this 60
seconds, the ICB will then use the call for the second stage of
heat to control second stage operation of the GV.
Table 24: Electric Heat Anticipator Setpoints
Second Stage Of Heating
SETTING, AMPS
W1
W2
0.13
0.1
Gas Heating Sequence Of Operations
When “W1” is satisfied, both valves are closed.
When the ICB receives a call for the second stage of heating,
“W2,” the ICB conducts a complete first stage ignition
sequence. If this sequence is satisfied, the second main valve
of the GV is opened.
When “W2” is satisfied, the second main valve is closed.
Retry Operation
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.
54
When a flame is lost or is not detected during an attempt to
achieve ignition, a retry operation occurs. A 30-second purge is
performed between ignition attempts.
If the unit fails after three ignition attempts, the furnace is
locked-out for one hour. The furnace is monitored during this
one-hour period for unsafe conditions.
Johnson Controls Unitary Products
518676-BIM-E-1210
Recycle Operation
When a flame is lost after the flame stabilization period, a recycle operation occurs. If the unit fails after five recycle attempts,
the furnace is locked-out for one hour.
Gas Heating Operation Errors
Lock-Out
A one-hour lockout occurs following three retries or five
recycles. During the one-hour lockout, flame detection, limit
conditions, and main valves are tested. Any improper results
will cause the appropriate action to occur. Recycling the low
voltage power cancels the lock-out.
the indoor blower and a flash code is initiated (Table 29). When
voltage is no longer sensed at the GV, the UCB will de-energize
the indoor blower following the elapse of the fan off delay for
heating.
If voltage has been sensed at the GV for at least 15 seconds
during the fan on delay for heating and GV voltage or “W1” is
lost, the indoor blower is forced on for the length of the fan off
delay for heating.
During a call for heat, if the UCB does not sense voltage at the
GV for a continuous five-minute period the UCB will initiate a
flash code (Table 29). The indoor blower motor will not be
locked-on while there is no GV voltage.
Safety Controls
Temperature Limit
If the UCB senses zero volts from the high temperature limit,
the indoor blower motor is immediately energized. When the
UCB again senses 24 volts from the temperature limit, the draft
motor will perform a 15-second post-purge and the indoor
blower will be de-energized following the elapse of the fan off
delay for heating.
This limit is monitored regardless of unit operation status, i.e.
this limit is monitored at all times.
If the temperature limit opens three times within one hour, it will
lock-on the indoor blower motor and flash code is initiated (See
Table 29).
The UCB monitors the temperature limit switch of gas heat
units.
The control circuit includes the following safety controls:
Limit Switch (LS)
This control is located inside the gas heat compartment and is
set to open at the temperature indicated in the Gas Heat Limit
Control Settings Table 25. It resets automatically. The limit
switch operates when a high temperature condition, caused by
inadequate supply air flow occurs, thus shutting down the
heater and energizing the blower.
Auxiliary Limit Switch (ALS)
Flame Sense
Flame sensing occurs at all times. If “W1” is not present and a
flame is sensed for 2 seconds, the draft motor is energized and
the GV is kept off. The ICB halts any operation until a flame is
not detected. Once the flame detection is lost, the ICB performs
a post-purge. Normal operation is allowed concurrently with the
purge (i.e. this purge can be considered the purge associated
with a call for “W1”).
If “W1” is present, a flame is sensed, but the GV is not
energized, the draft motor is energized until the flame detection
is lost. Normal operation is now allowed.
The flame detection circuitry continually tests itself. If the ICB
finds the flame detection circuitry to be faulty, the ICB will not
permit an ignition sequence and the draft motor is energized. If
this failure should occur during an ignition cycle the failure is
counted as a recycle.
Gas Valve
This control is located inside the supply air compartment and is
set to open at the temperature indicated in the Gas Heat Limit
Control Settings Table 25. It resets manually. The limit switch
operates when a high temperature condition, caused by
inadequate supply air flow occurs, thus shutting down the
heater and energizing the blower.
The auxiliary limit switch is wired in series with the limit switch.
As such, the UCB cannot distinguish the auxiliary limit and the
gas heat limit switch operation except the auxiliary is manual
reset. Consequently, the control will respond in the same
manner as outlined above under “Limit Switch”.
Table 25: Gas Heat Limit Control Settings1
Unit
Size
ZS-06
ZS-07
The UCB and ICB continuously monitor the GV.
ZS-08
If the ICB senses voltage at the GV when not requested, the
ICB will energize the draft motor. The ICB will not operate the
furnace until voltage is no longer sensed at the GV. The draft
motor is stopped when voltage is not sensed at the GV.
Any time the UCB senses voltage at the GV without a call for
heat for a continuous five-minute period, the UCB will lock-on
Johnson Controls Unitary Products
ZS-10
ZS-12
Opt.
12
18
12
18
12
18
18
24
18
24
Main Limit Setting
°F
165
165
165
165
215
195
195
160
195
160
1. Rollout = 300°F, Auxiliary Limit = 200°F.
55
518676-BIM-E-1210
The ICB monitors the Pressure and Rollout switches of gas
heat units.
The control circuit includes the following safety controls:
Start-Up (Cooling)
Prestart Check List
After installation has been completed:
Pressure Switch (PS)
Once the draft motor has reached full speed and closes the
pressure switch during a normal ignition sequence, if the
pressure sw opens for 2 seconds, the GV will be de-energized,
the ignition cycle is aborted, and the ICB flashes the
appropriate code. See Table 31 Ignition Control Flash Codes.
The draft motor is energized until the pressure switch closes or
“W1” is lost.
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.
Rollout Switch (ROS)
The rollout switch is wired in series with the pressure switch. As
such, the ICB cannot distinguish the rollout switch operation
from that of the pressure switch.
Consequently, the control will only respond in the same manner
as outlined above under “Pressure Switch”. An open rollout will
inhibit the gas valve from actuating.
Operating Instructions
Internal Microprocessor Failure
If the ICB detects an internal failure, it will cease all outputs,
ignore inputs, and display the proper flash code for control
replacement. The ICB remains in this condition until replaced.
Flash Codes
The ICB will initiate a flash code associated with errors within
the system. Refer to IGNITION CONTROL FLASH CODES
Table 31.
Resets
Remove the call for heating by lowering the thermostat setting
lower than the conditioned space temperature. This resets any
flash codes.
Gas Heat Anticipator Setpoints
It is important that the anticipator setpoint be correct. Too high
of a setting will result in longer heat cycles and a greater
temperature swing in the conditioned space. Reducing the
value below the correct setpoint will give shorter “ON cycles
and may result in the lowering of the temperature within the
conditioned space. Refer to Table 26 for the required gas heat
anticipator setting.
Table 26: Gas Heat Anticipator Setpoints
W1
W2
0.65
0.1
Turn unit electrical power on.
NOTE: Prior to each cooling season, the crankcase heaters
must be energized at least 10 hours before the system
is put into operation.
2.
Set the room thermostat setting to lower than the room
temperature.
3.
First stage compressors will energize after the built-in time
delay (five minutes).
4.
The second stage of the thermostat will energize second
stage compressor if needed.
Post Start Check List
1.
Verify proper system pressures for both circuits.
2.
Measure the temperature drop across the evaporator coil.
Start-Up (Gas Heat)
Pre-Start Check List
Complete the following checks before starting the unit.
1. Check the type of gas being supplied. Be sure that it is the
same as listed on the unit nameplate.
2.
SETTING, AMPS
56
1.
Make sure that the vent outlet and combustion air inlet are
free of any debris or obstruction.
Johnson Controls Unitary Products
518676-BIM-E-1210
Operating Instructions
3.
Open gas heat access panel.
4.
Turn gas valve clockwise to “OFF” position (See Figure 35).
Checking Gas Heat Input
This furnace is equipped with an automatic re-ignition
system. DO NOT attempt to manually light the pilot.
1.
Turn “OFF” electric power to unit.
This unit has two stages of gas heat. The first stage is 60% of
the full fire input and is considered the minimum input for the
furnace. The intended input for each furnace is shown in
Table 28. The table applies to units operating on 60 Hz power
only.
2.
Turn room thermostat to lowest setting.
To determine the rate of gas flow (Second Stage).
3.
Turn gas valve counter-clockwise to “ON” position (See
Figure 35).
1.
Turn off all other gas appliances connected to the gas
meter.
4.
Turn “ON” electric power to unit.
2.
5.
If thermostat set temperature is above room temperature,
the main burners will ignite. If a second stage of heat is
called for, the main burners for second stage heat will
ignite for the second stage heat.
Turn on the furnace and make sure the thermostat is
calling for Second stage (100% input) heat.
3.
Measure the time needed for one revolution of the hand on
the smallest dial on the meter. A typical gas meter has a 1/
2 or a 1 cubic foot test dial.
Post Start Checklist
4.
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.
Using the number of seconds it takes for one revolution of
the dial, calculate the cubic feet of gas consumed per hour.
(See example below).
5.
If necessary, adjust the high pressure regulator as
discussed in the section “Manifold Gas Pressure
Adjustment”. Be sure not to over-fire the furnace on
Second stage. If in doubt, it is better to leave the Second
stage of the furnace slightly under-fired. Repeat Steps 1-5.
Lighting The Main Burners
To determine the rate of gas flow (First Stage)
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
2.
Check for correct manifold gas pressures. (See CHECKING
GAS INPUT.)
3.
Check the supply gas pressure. It must be within the limits
shown on the rating nameplate. Supply pressure should be
checked with all gas appliances in the building at full fire. At
no time should the standby gas pressure exceed 10.5 in. or
the operating pressure drop below 4.5 in for natural gas
units. If gas pressure is outside these limits, contact the
local gas utility or propane supplier for corrective action.
Shut Down
1.
Set the thermostat to the lowest temperature setting.
2.
Turn “OFF” all electric power to unit.
Johnson Controls Unitary Products
1.
Turn off all other gas appliances connected to the gas
meter.
2.
Turn on the furnace and make sure the thermostat is
calling for first stage (60% input) heat.
3.
Even when the thermostat is calling for first stage heat, the
unit will light on second stage and will run on Second stage
for 1 minute. Allow this one-minute time period to expire
and be certain the unit is running on first stage.
4.
Measure the time needed for one revolution of the hand on
the smallest dial on the meter. A typical gas meter has a 1/
2 or a 1 cubic foot test dial.
5.
Using the number of seconds it takes for one revolution of
the dial, calculate the cubic feet of gas consumed per hour
(See example below).
6.
If necessary, adjust the low pressure regulator as
discussed in the section “Manifold Gas Pressure
Adjustment”. Be sure not to under-fire the furnace on first
stage. If in doubt, it is better to leave the first stage of the
furnace slightly over-fired (greater than 60% input). Repeat
Steps 1-6.
57
518676-BIM-E-1210
Table 27: Gas Rate Cubic Feet Per Hour
Seconds for
One Rev.
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
180
360
150
300
129
257
113
225
100
200
90
180
82
164
75
150
69
138
64
129
60
120
56
113
53
106
50
100
47
95
45
90
43
86
41
82
39
78
37
75
36
72
35
69
34
67
32
64
31
62
30
60
Manifold Gas Pressure Adjustment
This gas furnace has two heat stages. Therefore, the gas valve
has two adjustment screws located under a plastic protective
cover. The second stage (100% input) adjustment screw is
adjacent to the “HI” marking on the valve and the first stage
(60% input) adjustment screw is located adjacent to the “LO”
marking on the valve (See Figure 35).
Manifold pressure adjustment procedure.
Adjust second stage (100% input) pressure first, then adjust
first stage (60% input) pressure.
1.
Turn off all power to the unit.
2.
Using the outlet pressure port on the gas valve, connect a
manometer to monitor the manifold pressure.
3.
Remove plastic cap covering HI and LO pressure
adjustment screws.
4.
Turn on power to the unit.
5.
Set thermostat to call for second stage heat and start
furnace.
6.
If necessary, using a screwdriver, turn the second stage
adjustment screw (adjacent to the “HI” marking on the
valve) clockwise to increase manifold pressure or
counterclockwise to decrease manifold pressure. Be sure
not to over-fire the unit on second stage.
7.
After the high manifold pressure has been checked, adjust
the thermostat to call for first stage heat.
8.
If necessary, using a screwdriver, turn the first stage
adjustment screw (adjacent to the “LO” marking on the
valve) clockwise to increase manifold pressure or
counterclockwise to decrease manifold pressure. Be sure
not to under-fire the unit on first stage.
EXAMPLE
9.
Once pressure has been checked, replace the plastic cap
covering the HI and LO pressure adjustment screws.
By actual measurement, it takes 19 seconds for the hand on a 1
cubic foot dial to make a revolution with a 192,000 Btuh furnace
running. To determine rotations per minute, divide 60 by 19 =
3.16. To calculate rotations per hour, multiply 3.16  60 = 189.6.
Multiply 189.6  1 (0.5 if using a 1/2 cubic foot dial) = 189.6.
Multiply 189.6  (the Btu rating of the gas). For this example,
assume the gas has a Btu rating of 1050 Btu/ft.3. The result of
199,000 Btuh is within 5% of the 192,000 Btuh rating of the
furnace.
NOTE: When using natural gas, the manifold pressure for
second stage (100% input) should be 3.5 IWG ± 0.3.
The manifold pressure for first stage (60% input) when
using natural gas should be 1.5 IWG ± 0.3.
NOTE: To find the Btu input, multiply the number of cubic feet
of gas consumed per hour by the Btu content of the gas
in your particular locality (contact your gas company for
this information as it varies widely from area to area).
58
Table 28: Gas Heat Stages
# of Burner Tubes
4
6
8
2nd Stage Input
(100% Btuh)
120,000
180,000
240,000
1st Stage Input
(60% Btuh)
72,000
108,000
144,000
Johnson Controls Unitary Products
518676-BIM-E-1210
Adjustment Of Temperature Rise
HIGH & LOW GAS ADJUSTMENT
The temperature rise (the difference of temperature between the
return air and the heated air from the furnace) must lie within the
range shown on the CSA rating plate and the data in Table 9.
LO
After the temperature rise has been determined, the CFM can
be calculated as follows:
HI
ON
INLET
PRESSURE
TAP
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).
OFF
OUTLET
MATE-N-LOCK
PRESSURE
CONNECTORS
TAP
MV
C
HI
NOTE: Each gas heat exchanger size has a minimum
allowable CFM. Below this CFM, the limit will open.
Burners/Orifices Inspection/Servicing
Before checking or changing burners, pilot or orifices, CLOSE
MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL
POWER TO THE UNIT.
Figure 35: Typical Gas Valve
1.
Open the union fitting just upstream of the unit gas valve
and downstream from the main manual shut-off valve in
the gas supply line.
All ZS units use Thermal Expansion Devices. Charge the unit to
nameplate charge or 10° subcooling.
2.
Remove the screws holding each end of the manifold to the
manifold supports.
Troubleshooting
3.
Disconnect wiring to the gas valves and spark igniter(s).
Remove the manifold & gas valve assembly. Orifices can
now be inspected and/or replaced.
To service burners, complete step 4.
4.
Remove the heat shield on top of the manifold supports.
Burners are now accessible for inspection and/or
replacement.
NOTE: Reverse the above procedure to replace the
assemblies.
Make sure that burners are level and seat at the rear of the gas
orifice.
HEAT EXCHANGER TUBE
GAS
SUPPLY
PIPE
BURNER
BURNER BRACKET
IGNITOR
Figure 34: Typical Flame
Johnson Controls Unitary Products
BURNER FLAME
(BLUE ONLY)
Charging The Unit
Troubleshooting of components may require opening
the electrical control box with the power connected to
the unit. Use extreme care when working with live
circuits! Check the unit nameplate for the correct line
voltage and set the voltmeter to the correct range before
making any connections with line terminals.
For troubleshooting of optional VFD, disconnect all
power to the drive. Be aware that high voltages are
present in the drive even after power has been
disconnected. Capacitors within the drive must be
allowed to discharge before beginning service.
When not necessary, shut off all electric power to the
unit prior to any of the following maintenance
procedures so as to prevent personal injury.
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.
59
518676-BIM-E-1210
ZS Flash Codes
Various flash codes are utilized by the unit control board (UCB)
to aid in troubleshooting. Flash codes are distinguished by the
short on and off cycle used (approximately 200ms on and
200ms off). To show normal operation, the control board
flashes a 1 second on, 1 second off "heartbeat" during normal
operation. This is to verify that the UCB is functioning correctly.
Do not confuse this with an error flash code. To prevent
confusion, a 1-flash, flash code is not used.
Alarm condition codes are flashed on the UCB lower left Red
LED, See Figure 36. While the alarm code is being flashed, it
will also be shown by the other LEDs: lit continuously while the
alarm is being flashed. The total of the continuously lit LEDs
equates to the number of flashes, and is shown in the table.
Pressing and releasing the LAST ERROR button on the UCB
can check the alarm history. The UCB will cycle through the last
five (5) alarms, most recent to oldest, separating each alarm
flash code by approximately 2 seconds. In all cases, a flashing
Green LED will be used to indicate non-alarm condition.
In some cases, it may be necessary to "zero" the ASCD for the
compressors in order to perform troubleshooting. To reset all
ASCDs for one cycle, press and release the UCB TEST/
RESET button once.
Flash codes that do and do not represent alarms are listed in
Table 29.
Table 29: Unit Control Board Flash Codes
Flash Code
On Steady
1 Flash
Description
Green
LED
16
Red
LED
8
Red
LED
4
Red
LED
2
Red
LED
1
This is a Control Failure
-
-
-
-
-
Not Applicable
-
-
-
-
-
2 Flashes
Control waiting ASCD1
Flashing
Off
Off
On
Off
3 Flashes
HPS1 Compressor Lockout
Off
Off
Off
On
On
4 Flashes
HPS2 Compressor Lockout
Off
Off
On
Off
Off
5 Flashes
LPS1 Compressor Lockout
Off
Off
On
Off
On
6 Flashes
LPS2 Compressor Lockout
Off
Off
On
On
Off
7 Flashes
FS1 Compressor Lockout
Off
Off
On
On
On
8 Flashes
FS2 Compressor Lockout
Off
On
Off
Off
Off
9 Flashes
Ignition Control Locked Out / Ignition Control Failure
Off
On
Off
Off
On
10 Flashes
Compressors Locked Out on Low Outdoor Air Temperature1
Flashing
On
Off
On
Off
11 Flashes
Compressors locked out because the Economizer is using free
Cooling1
Flashing
On
Off
On
On
12 Flashes
Unit Locked Out due to Fan Overload Switch Failure
13 Flashes
Compressor Held Off due to Low Voltage1
14 Flashes
OFF
Off
On
On
Off
Off
Flashing
On
On
Off
On
EEPROM Storage Failure
Off
On
On
On
Off
No Power or Control Failure
Off
Off
Off
Off
Off
1. Non-alarm condition.
60
Johnson Controls Unitary Products
518676-BIM-E-1210
Check
Alarm
History
Reset All
ASCDs for
One Cycle
Non Alarm
Condition Green
LED Flashing
Current Alarm
Flashed
Red LED
Figure 36: Unit Control Board
Unit Control Board Option Setup
Option Byte Setup
• Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2
seconds.
• The green status LED (Option Byte) will be turned on and
the red status LED (Heat Delay) is turned off.
• The 8, 4, 2 and 1 LEDs will then show the status of the 4
labeled options ((8) Fan Off at Heat Start, (4) Low
Ambient Lockout, (2) Free Cooling Lockout, and (1)
Lead / Lag).
• Press the UP or Down button to change the LED status to
correspond to the desired Option Setup.
• To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2 seconds.
When the value is saved, the green LED will flash a few
times and then normal display will resume.
NOTE: While in either Setup mode, if no buttons are pushed for
60 seconds, the display will revert to its normal display,
exiting the Option Setup mode. When saving, the
control board only saves the parameters for the
currently displayed mode (Option Byte or Heat
Delay).
Johnson Controls Unitary Products
Heat Delay Setup
• Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2
seconds.
• The green status LED (Option Byte) will be turned on and
the red status LED (Heat Delay) is turned off.
• Press the COMM SETUP / SELECT button to toggle into
the Heat Delay Setup, the green LED will turn off and the
red LED for Heat Delay will turn on.
• The 8, 4, 2 and 1 LEDs will then show the status of the
Heat Delay, (See Table 30). Press the UP or Down button
to change the LED status to correspond to the desired
Heat Delay Value.
• To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2 seconds.
When the value is saved, the red LED will flash a few
times and then normal display will resume.
NOTE: While in either Setup mode, if no buttons are pushed for
60 seconds, the display will revert to its normal display,
exiting the Option Setup mode. When saving, the
control board only saves the parameters for the
currently displayed mode (Option Byte or Heat
Delay).
61
518676-BIM-E-1210
Table 30: 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
Table 32: VAV Control Board Flash Codes
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
Table 31: Ignition Control Flash Codes
Flashes
Fault Conditions
STEADY ON
Control Failure
HEARTBEAT
Normal Operation
Not Applicable
2
Pressure Switch
Stuck Closed
Pressure Switch
3
Pressure Switch Failed
To Close
Venter Pressure Switch
Vent Blocked
4
Limit Switch Open
Main Limit
AUX Limit
5
Flame Present With Gas
Off First Stage Gas Valve
Energized With W1 Off
Second Stage Gas Valve
Energized With First
Stage
Gas Valve Off
Gas Valve
Ignition Lockout
Gas Flow
Gas Pressure
Gas Valve
Flame Sensor
No Power Or Control
Failure
24VAC or Control
STEADY OFF
Description
This is a Control Failure
Not Applicable
Loss of Communications with UCB
Space Sensor Failed
SAT Sensor Failed
RAT Sensor Failed
OAT Sensor Failed
OAH Sensor Failed
RAH Sensor Failed
IAQ Sensor Failed
OAQ Sensor Failed
APS Switch Failed
Limit 2 Switch Open
Purge
VFD Input Failure
Dirty Filter Switch
Econ Minimum Position Alarm
Space Temp/Time Alarm
Water Coil Freeze Stat Alarm
SAT Alarm for Cooling
SAT Alarm for Heating
Control
1
6
62
Check
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
Johnson Controls Unitary Products
518676-BIM-E-1210
Monitored
Systems
Problem?
No
Programming?
No
Call for
Heating?
Yes
Yes
Yes
Program
Unit
Control
Board
Trip/Failure
Loss of
Call for
Heating?
No
Yes
Heat Off
No
Call for 2nd
Stage
Cooling
Call for
Heat
No
Energize ID
Blower Motor
Monitor
Call for
Cooling?
Yes
First
Stage?
Yes
No
Yes
No
Turn off ID
Blower Motor
Yes
No
Fan on
>30 secs?
Yes
Yes
No
Call for 1st
Stage
Cooling
Fan off
>10 secs?
No
Lossof Call
for ID Blower?
Call for
ID Blower?
No
Loss of Call
for Cooling?
Yes
Cool Off
Figure 37: Basic Troubleshooting Flowchart
Power to
Unit
Call for
heat?
No
Initialize ASCD
Yes
Voltage @
Gas Valve?
Yes
No
Energize ID
Blower
Montior
Figure 38: Power On Flow Chart
Johnson Controls Unitary Products
63
518676-BIM-E-1210
Figure 39: Trip Failure Flow Chart
64
Johnson Controls Unitary Products
518676-BIM-E-1210
Cooling Troubleshooting Guide
NOTE: For units with optional VFD without manual bypass, the
M3 contactor has been replaced with an "ice cube"
relay (designated 'VFDR') located in the control box.
The relay is energized by "FAN" output from the UCB.
Normally-open relay contacts provide a run-permit
signal to the VFD.
On calls for cooling, the supply air blower motor is operating but
compressor #1 is not (the room thermostat fan switch is in the
“AUTO” position):
1.
If installed, check the position of the economizer blades. If
the blades are open, the economizer is providing free
cooling and the compressors will not immediately operate.
If both stages of cooling are requested simultaneously and
the economizer provides free cooling, following a short
delay compressor #1 will be energized unless it is locked
out. If compressor #1 is locked out, compressor #2 is
energized. Compressor #2 is always energized in place of
compressor #1 when compressor #1 is requested but
locked out.
2.
If no economizer is installed or the economizer is not
opening to provide free cooling and compressor #1 does
not energize on a call for cooling, check for line voltage at
the compressor contactor, M1, and that the contactor is
pulled in. Check for loose wiring between the contactor and
the compressor.
3.
If M1 is pulled in and voltage is supplied at M1, lightly touch
the compressor housing. If it is hot, the compressor may be
off on inherent protection. Cancel any calls for cooling and
wait for the internal overload to reset. Test again when
cool.
4.
If M1 is not pulled in, check for 24 volts at the M1 coil. If 24
volts are present and M1 is not pulled in, replace the
contactor.
5.
Failing the above, if voltage is supplied at M1, M1 is pulled
in, and the compressor still does not operate, replace the
compressor.
6.
If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose
wiring between C1 and the compressor contactor.
7.
If 24 volts is not present at the C1 terminal, check for 24
volts from the room thermostat at the UCB Y1 terminal. If
24 volts is not present from the room thermostat, check for
the following:
a. 24 volts at the thermostat Y1 terminal
b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and
c. Loose wiring from the room thermostat to the UCB
8.
If 24 volts is present at the UCB Y1 terminal, the
compressor may be out due to an open high-pressure
switch, low-pressure switch, or freezestat. Check for 24
volts at the HPS1, LPS1, and FS1 terminals of the UCB. If
a switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS1 has opened, there
will be a 24-volt potential between the LPS1 terminals.
9.
If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing an alarm code. If not, press and release
the ALARMS button on the UCB. The UCB will flash the
last five alarms on the LED. If the compressor is locked
On calls for cooling, if the compressors are operating but the
supply air blower motor does not energize after a short delay
(the room thermostat fan switch is in the “AUTO” position):
1.
Turn the thermostat fan switch to the ON position. If the
supply air blower motor does not energize, go to Step 3.
2.
If the blower motor runs with the fan switch in the ON
position but will not run after the first compressor has
energized when the fan switch is in the AUTO position,
check the room thermostat for contact between R and G in
the AUTO position during calls for cooling.
3.
If the supply air blower motor does not energize when the
fan switch is set to ON, check that line voltage is being
supplied to the contacts of the M3, contactor, and that the
contactor is pulled in. Check for loose wiring between the
contactor and the supply air blower motor.
4.
If M3 is pulled in and voltage is supplied to M3, lightly touch
the supply air blower motor housing. If it is hot, the motor
may be off on internal protection. Cancel any thermostat
calls and set the fan switch to AUTO. Wait for the internal
overload to reset. Test again when cool.
5.
If M3 is not pulled in, check for 24 volts at the M3 coil. If 24
volts are present at M3 but M3 is not pulled in, replace the
contactor.
6.
Failing the above, if there is line voltage supplied at M3, M3
is pulled in, and the supply air blower motor still does not
operate, replace the motor.
7.
If 24 volts is not present at M3, check that 24 volts is
present at the UCB supply air blower motor terminal,
“FAN”. If 24 volts is present at the FAN, check for loose
wiring between the UCB and M3.
8.
If 24 volts is not present at the “FAN” terminal, check for 24
volts from the room thermostat. If 24 volts are not present
from the room thermostat, check for the following:
a. Proper operation of the room thermostat (contact
between R and G with the fan switch in the ON position
and in the AUTO position during operation calls).
b. Proper wiring between the room thermostat and the
UCB, and
c. Loose wiring from the room thermostat to the UCB
9.
If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat and
the UCB, i.e. that the thermostat G terminal is connected to
the G terminal of the UCB, and for loose wiring.
10. If the thermostat and UCB are properly wired, replace the
UCB.
Johnson Controls Unitary Products
65
518676-BIM-E-1210
out, cancel any call for cooling. This will reset any
compressor lock outs.
NOTE: While the above step will reset any lockouts,
compressor #1 may be held off for the ASCD. See the
next step.
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.
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.
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.
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.
3.
If M2 is pulled in and voltage is supplied at M2, lightly touch
the compressor housing. If it is hot, the compressor may be
off on inherent protection. Cancel any calls for cooling and
wait for the internal overload to reset. Test again when cool.
4.
If M2 is not pulled in, check for 24 volts at the M2 coil. If 24
volts is present and M2 is not pulled in, replace the
contactor.
5.
Failing the above, if voltage is supplied at M2, M2 is pulled
in, and the compressor still does not operate, replace the
compressor.
6.
If 24 volts is not present at M2, check for 24 volts at the
UCB terminal, C2. If 24 volts are present, check for loose
wiring between C2 and the compressor contactor.
7.
If 24 volts is not present at the C2 terminal, check for 24
volts from the room thermostat at the UCB Y2 terminal. If
24 volts is not present from the room thermostat, check for
the following:
a. 24 volts at the thermostat Y2 terminal
b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and
c. Loose wiring from the room thermostat to the UCB
8.
If 24 volts is present at the UCB Y2 terminal, the
compressor may be out due to an open high-pressure
switch, low-pressure switch, or freezestat. Check for 24
volts at the HPS2, LPS2, and FS2 terminals of the UCB. If
a switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS2 has opened, there
will be 24 volts of potential between the LPS2 terminals.
9.
If 24 volts is present at the UCB Y2 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last
five alarms on the LED. If the compressor is locked out,
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.
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
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.
66
Johnson Controls Unitary Products
518676-BIM-E-1210
remove any call for cooling at the thermostat or by
disconnecting the thermostat wiring at the Y2 UCB
terminal. This will reset any compressor lock outs.
7.
If 24 volts is not present at the C1 terminal, check for 24
volts from the room thermostat at the UCB Y1 terminal. If
24 volts are not present at the UCB Y1 terminal, the UCB
may have faulted. Check for 24 volts at the Y1 ECON
terminal. If 24 volts is not present at Y1 “ECON”, the UCB
has faulted. The UCB should de-energize all compressors
on a loss of call for the first stage of cooling, i.e. a loss if 24
volts at the Y1 terminal.
8.
If 24 volts are present at the UCB Y1 terminal, the
compressor may be out due to an open high-pressure
switch, low-pressure switch, or freezestat. Check for 24
volts at the HPS1, LPS1, and FS1 terminals of the UCB. If
a switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS1 has opened, there
will be a 24-volt potential between the LPS1 terminals.
9.
If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last
five alarms on the LED. If the compressor is locked out,
remove any call for cooling. This will reset any compressor
lock outs.
NOTE: While the above step will reset any lock outs,
compressor #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.
Compressor #2 is energized in place of compressor #1
when compressor #1 is unavailable for cooling calls. Check
the UCB for alarms indicating that compressor #1 is locked
out. Press and release the ALARMS button if the LED is
not flashing an alarm.
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.
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.
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.
Johnson Controls Unitary Products
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”
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
67
518676-BIM-E-1210
economizer is not providing free cooling. To test the
economizer control, disconnect the Mate-N-Locks and
jumper between the WHITE and YELLOW wires of the
UCB’s Mate-N-Lock plug.
13. The UCB can be programmed to lock out compressor
operation during free cooling and in low ambient
conditions. These options are not enabled by default. They
can be checked by local distributors.
4.
If M3 is not pulled in, check for 24 volts at the M3 coil. If 24
volts is present at M3 but M3 is not pulled in, replace the
contactor.
5.
Failing the above, if there is line voltage supplied at M3, M3
is pulled in, and the supply air blower motor still does not
operate, replace the motor.
6.
If 24 volts is not present at M3, check that 24 volts is
present at the supply air blower motor terminal on the UCB.
If 24 volts is present at the UCB terminal, check for loose
wiring between the UCB and M3.
a. If 24 volts is not present at the UCB supply air blower
motor terminal, check for 24 volts from the room
thermostat. If 24 volts is not present from the room
thermostat, check for the following:
• Proper operation of the room thermostat (contact
between R and G with the fan switch in the “ON” position
and in the “AUTO” position during operation calls.)
• Proper wiring between the room thermostat and the
UCB, and
• Loose wiring from the room thermostat to the UCB
7.
If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat and
the UCB, i.e. that the thermostat G terminal is connected to
the G terminal of the UCB, and for loose wiring.
8.
If the thermostat and UCB are properly wired, replace the
UCB.
9.
If the blower motor runs with the fan switch in the “ON”
position but does not run shortly after the furnace has
ignited when the fan switch is in the “AUTO” position,
check the room thermostat for contact between R and G
during “W1” calls.
For units with factory installed economizers, the UCB is
programmed to lock out compressor operation when the
LAS set point is reached.
For units without factory installed or with field installed
economizers, the UCB allows compressor operation all the
time. This programming can be checked or changed by the
local distributor.
14. If none of the above corrected the error, test the integrity of
the UCB. Disconnect the C1 terminal wire and jumper it to
the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If
the compressor engages, the UCB has faulted.
15. If none of the above correct the error, replace the UCB.
Gas Heat Troubleshooting Guide
NOTE: For units with optional VFD without manual bypass, the
M3 contactor has been replaced with an "ice cube"
relay (designated 'VFDR') located in the control box.
The relay is energized by "FAN" output from the UCB.
Normally-open relay contacts provide a run-permit
signal to the VFD.
On calls for heating, the draft motor operates and the furnace
lights but the supply air blower motor does not energize after a
short delay (the room thermostat fan switch is in “AUTO”
position).
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.
1.
2.
3.
68
Place the thermostat fan switch in the “ON” position. If the
supply air blower motor energizes, go to Step 9.
If the supply air blower motor does not energize when the
fan switch is set to “ON,” check that line voltage is being
supplied to the contacts of the M3 contactor, and that the
contactor is pulled in. Check for loose wiring between the
contactor and the supply air blower motor.
If M3 is pulled in and voltage is supplied at M3, lightly touch
the supply air blower motor housing. If it is hot, the motor
may be off on inherent protection. Cancel any thermostat
calls and set the fan switch to “AUTO”, wait for the internal
overload to reset. Test again when cool.
On calls for heating, the supply air blower operates but the draft
motor does not (the room thermostat fan switch is in the
“AUTO” position).
1.
The draft motor has inherent protection. If the motor shell is
hot to the touch, wait for the internal overload to reset.
2.
If the motor shell is cold with the room thermostat calling
for heat, check for line voltage at the motor leads. If line
voltage is present, replace the draft motor.
3.
If line voltage is not present, check for line voltage on the
ignition control at the “inducer” terminal draft motor relay
(DMR or DMC) contacts in the main control box and check
to see if the (DMR or DMC) is pulled in.
The draft motor runs but the furnace does not light and the
spark ignitor does not spark.
1.
Check for 24 volts at the spark ignitor from the ignition
control board (ICB). Check the 24-volt wiring from the ICB
to the spark ignitor. Check for 24 volts at the ICB spark
ignitor terminal.
2.
Check the ground wiring for the ICB and the gas valve is
intact and making good electrical connection. Check the
ceramic insulator on the spark ignitor for breaks or cracks.
Replace the spark ignitor if damaged.
Johnson Controls Unitary Products
518676-BIM-E-1210
3.
With the draft motor running, check for 24 volts at the
pressure switch terminal on the ICB. If not present, check
for 24 volts on the terminal from the pressure switch. If
present, go to step 4. If 24 volts is not present, the either
pressure or rollout switch is not closed. Or the draft motor
is not sufficiently evacuating the heat exchanger tubes or
the pressure switch has failed. Check the operation of the
pressure switch. Check the line voltage to the unit; if line
voltage is low, call the local power company. If the problem
persists, the draft motor may need replacement.
4.
If the furnace is hot, it may be out on a high temperature
limit open; wait for limit reset.
5.
If all are intact replace the ICB.
The draft motor runs and the spark ignitor sparks at the burner,
but the burner does not ignite and a gas odor is not detected at
the draft motor outlet.
Johnson Controls Unitary Products
1.
Check to ensure gas is being supplied to the unit. Confirm
that the gas pressure to the unit is within the proper limits
as described in the “POST START CHECKLIST”.
2.
Check the voltage at the gas valve and at the gas valve
terminals on the ICB. Check all wiring between the ICB and
the gas valve. Check to make sure the ground connections
are intact.
3.
If 24 volts is present, remove the pilot burner and the
orifice. The removal procedure is described in “BURNER/
ORIFICE INSPECTION/SERVICING.” Inspect the orifice
for obstruction. If it is clear, replace the gas valve.
Main burners light but exhibit erratic flame characteristics.
1.
Check the main burner orifices for obstruction and
alignment. The removal procedure is described in
“BURNER/ORIFICE INSPECTION/SERVICING”. Clean or
replace burner orifices and burners as needed.
69
Subject to change without notice. Printed in U.S.A.
Copyright © 2011 by Johnson Controls, Inc. All rights reserved.
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
518676-BIM-E-1210
Supersedes: 518676-BIM-D-0810
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