Johnson Controls TempMaster ZD Series Installation Manual

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Page 1

R-410A ZD SERIES

3 - 6 Ton

60 Hertz

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . 15

Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Typical Cool/Heat Control Wiring (Smart Equipment™ ZDT03

through TA6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34

Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . .35

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 50

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 51

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 52

Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 56

Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 57

Smart Equipment™ Control Board Navigation Components . . . . 65

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

LIST OF TABLES

1 ZDT03 through TA6 Unit Limitations . . . . . . . . . . . . . . . . . . . . 6

2 ZDT03 through TA6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZDT03 through TA6 Unit Accessory Weights . . . . . . . . . . . . . 8

4 ZDT03 through TA6 Unit Clearances . . . . . . . . . . . . . . . . . . 10

5 ZDT03 through TA6 Utilities Entry . . . . . . . . . . . . . . . . . . . . . 11

6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

8 Electrical data: single-phase gas heat, belt drive . . . . . . . . . 28

9 ZDT03 through TA6 Physical Data . . . . . . . . . . . . . . . . . . . . 29

10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31

11 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31

12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32

13 Smart Equipment™ Economizer Board Details . . . . . . . . . . 37

14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 41

15 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 44

16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 45

17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 47

LIST OF FIGURES

1 ZDT03 through TA6 Component Location . . . . . . . . . . . . . . . 6

2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 ZDT03 through TA6 Cooling Only/Electric Heat Front View

Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 ZDT03 through TA6 Cooling Only/Gas Heat Front View

Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 ZDT03 through TA6 Fixed Outdoor Air Motorized Damper Rain

Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8 ZDT03 through TA6 Disconnect Location . . . . . . . . . . . . . . 10

9 ZDT03 through TA6 Unit Side Duct Openings . . . . . . . . . . . 11

10 ZDT03 through TA6 Roof Curb . . . . . . . . . . . . . . . . . . . . . . 11

11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13

13 Typical Smart Equipment™ Control Wiring . . . . . . . . . . . . . 15

19 Power Exhaust Specifications. . . . . . . . . . . . . . . . . . . . . . . . 47

20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 48

21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 51

23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 53

24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 53

25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 53

26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56

27 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

28 ZDT03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59

29 ZDT04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 59

30 ZDT05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60

31 ZDTA6 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60

32 Simplicity Lite Unit Control Board Flash Codes . . . . . . . . . . 65

33 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 65

34 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 66

35 Cable for FC Buses and SA Buses in Order of Preference . 71

14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 34

17 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . 34

18 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 37

19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

20 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42

21 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 48

22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

23 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 54

24 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 54

25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 55

26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 55

27 Simplicity Lite Control Board . . . . . . . . . . . . . . . . . . . . . . . . 65

28 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 66

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General

TempMaster® Model ZD units are either single package cooling units equipped with optional factory installed electric heaters, or single package gas-fired central heating furnaces with cooling unit. Both are designed for outdoor installation on a rooftop or slab.

The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested. The units require electric power, gas connection, duct connections, installation of the weatherproof convenience outlet cover, combustion air inlet hood, flue gas outlet hoods and fixed outdoor air intake damper (units without economizer or motorized damper option only) at the point of installation.

The supplemental electric heaters have nickel-chrome elements and utilize single point power connection.

The gas-fired heaters have aluminized-steel (or optional stainless steel) tubular heat exchangers. The units have spark ignition with proven pilot. All gas heaters are shipped from the factory equipped for natural gas use, but can be field converted to L.P./ Propane with Kit Model #1NP0440 for single stage and Kit Model #1NP0485 for 2 stage.

Safety Considerations

This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.

Understand and pay particular attention the signal words

DANGER, WARNING or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury

This product must be installed in strict compliance with the installation instructions and any applicable local, state and national codes including, but not limited to building, electrical, and mechanical codes.

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.

This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. Gage sets, hoses, refrigerant containers and recovery systems must be designed to handle R-410A. If you are unsure, consult the equipment manufacturer. Failure to use R-410A compatible servicing equipment may result in property damage or injury.

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 used to alert against unsafe practices and hazards involving only property damage.

Improper installation may create a condition where the operation of the product could cause personal injury or property damage. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual for assistance or for additional information, consult a qualified contractor, installer or service agency.

2 Johnson Controls Ducted Systems

. It is also

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

a. Do not try to light any appliance.

b. Do not touch any electrical switch; do not use any

phone in your building.

c. Immediately call your gas supplier from a neighbor’s

phone. Follow the gas supplier’s instructions.

d. If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

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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.

Wear safety glasses and work gloves. Use quenching cloth and have a fire extinguisher available during brazing operations.

Inspection

As soon as a unit is received, it should be inspected for possible damage during transit. If damage is evident, the extent of the damage should be noted on the carrier’s freight bill. A separate request for inspection by the carrier’s agent should be made in writing.

This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state and national codes including, but not limited to, building, electrical, and mechanical codes.

The furnace and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing at pressures in excess of 1/2 PSIG.

Pressures greater than 1/2 PSIG will cause gas valve damage resulting in a hazardous condition. If it is subjected to a pressure greater than 1/2 PSIG, the gas valve must be replaced.

The furnace must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG.

Reference

Additional information is available in the following reference forms:

• Technical Guide - ZDT03 through TA6, 5123270

• General Installation - ZDT03 through TA6, 5506653

Renewal Parts

Contact your local Ducted Systems

parts distribution center for

authorized replacement parts.

Approvals

Design certified by CSA as follows:

1. For use as a cooling only unit, cooling unit with supplemental electric heat or a forced air furnace.

2. For outdoor installation only.

3. For installation on combustible material.

4. For use with natural gas (convertible to LP with kit).

This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state, and national codes including, but not limited to, building, electrical, and mechanical codes.

Improper installation may create a condition where the operation of the product could cause personal injury or property damage.

This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system.

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Z D T04 N 07 A 2 A A 1 1 B A 4

Z = Package A/C

Product Category

A = Direct Drive

B = Direct Drive/Single Input Low Leak Econo

D = Direct Drive/Motorized Damper

E = Direct Drive/BAS Ready Low Leak Economizer

N = Belt Drive P = Belt Drive/Single Input Low Leak Econo R = Belt Drive/Motorized Damper S = Belt Drive/BAS Ready Low Leak Economizer T = Belt Drive High Static U = Belt Drive High Static/Single Input Low Leak Economizer V = Belt Drive High Static/Motorized Damper W = Belt Drive High Static/BAS Ready Low Leak Economizer

Product Generation

4 = Fourth Generation

5 = Fifth Generation

T03 = 3.0 Ton

Nominal Cooling Capacity

T04 = 4.0 Ton T05 = 5.0 Ton TA6 = 6.0 Ton

Product Identifier

Voltage

1 = 208/230-1-60

2 = 208/230-3-60 4 = 460-3-60 5 = 575-3-60

Coated Coils

A = Un-Coated B = E-Coat Cond & Evap Coils C = E-Coat Condenser Coil D = E-Coat Evaporator Coil

A = No Options Installed

Installation Options

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

1 = Disconnect 2 = Non-Pwr'd Conv. Outlet 3 = Smoke Detector S.A. 4 = Smoke Detector R.A. 5 = Pwr'd Conv. Outlet

Options

1 = None 2 = SS Drain Pan

Configuration Options

A = Stand Alone Smart Equipment™ C = BACnet MSTP,Modbus,N2 COM Card F = FDD H = Hnywll Excel 10 Ctrl, DFS, APS N = Novar UCM Ctrl, DFS, APS P = CPC Control, DFS, APS M = Verasys Single Zone N = Verasys Change Over Bypass

Control Options

1 = 2" Throwaway Filters 2 = 2” Pleated Filters (Merv 8)

Additional Options

A=No Options B= Phase Monitor (PM) C = Coil Guard (CG) D = Dirty Filter Switch (DFS) E = PM & CG F = PM & DFS G = CG & DFS H = PM, CG, & DFS J = Hinged Filter Door & Toolless Access Panels K = Phase Monitor, Hinged Filter Door & Toolless Access Panels L = Coil Guard, Hinged Filter Door & Toolless Access Panels M = Dirty Filter Switch, Hinged Filter Door & Toolless Access Panels N = Phase Monitor & Coil Guard, Hinged Filter Door & Toolless Access Panels P = Phase Monitor & Dirty Filter Switch, Hinged Filter Door & Toolless Access Panels Q = Coil Guard & Dirty Filter Switch, Hinged Filter Door & Toolless Access Panels R = Phase Monitor, Coil Guard, & Dirty Filter Switch, Hinged Filter Door & Toolless Access Panels

D =

Standard Efficiency

00 = Cooling Only. Suitable for Field

Installed Electric Heat

Heat Type and Nominal Heat Capacity

05 = 50 MBH Input (T03) Single Stage Only 07 = 75 MBH Input (T04) Single and Two Stage 07 = 75 MBH Input (T03, T05, TA6) Two Stage Only 11 = 100 MBH Input (T03, T05, TA6) Single Stage Only 12 = 115 MBH Input (T03) Two Stage Only 13 = 125 MBH Input (T04, T05, TA6) Single & Two Stage

05 = 5 KW 07 = 7 KW 10 = 10 KW 15 = 15 KW 20 = 20 KW 30 = 30 KW

Gas Heat Options

Electric Heat Options

Heat Type

C = Cooling Only, No Heat Installed E = Electric Heat N = Alum Steel, Single Stage S = Stainless Steel Single Stage D = Alum Steel, Two Stage T = Stainless Steel Two Stage

Filter Options

1. Only available on 208/230 Units

A = None B = Low NOx

Low NOx Option

2. 3 - 5 ton only

Product Nomenclature

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Installation

Installation Safety Information

Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are made available to the consumer and with instructions to retain them for future reference.

1. Refer to the unit rating plate for the approved type of gas for this product.

2. Install this unit only in a location and position as specified on Page 7 of these instructions.

3. Never test for gas leaks with an open flame. Use commercially available soap solution made specifically for the detection of leaks when checking all connections, as specified on Pages 5, 33 and 54 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 31 of these instructions.

5. This equipment is not to be used for temporary heating of buildings or structures under construction.

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.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could result in serious injury, death or property damage.

Never test for gas leaks with an open flame. use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

6. If a factory option convenience outlet is installed, the weatherproof outlet cover must be field installed. The cover shall be located behind the blower access panel. To install the cover, remove the shipping label covering the convenience outlet 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.

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 Smart Equipment™ control boards 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, switch gear, etc.), please call the applications department for Ducted Systems @ 1-877-874-SERV for guidance. Additional accessories may be needed for stable operation at temperatures below 30° F.

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Smoke Detector

3/4” PVC Female Condensate Drain

GFCI

Convenience Outlet

Knockout For Side Control Entry

Smart Equipment™

Control Board

Knockout For Side Gas Supply Entry

Full Perimeter Baserails

With Forklift Slots And

Lifting Holes

Highly Efficient Enhanced Copper Tube/Enhanced Aluminum Fin Or Micro-Channel Aluminum Tube/Aluminum Fin Condenser

Compressor

Power Ventor Motor With

Post Purge Cycle

20 Gauge Aluminized

Steel Tubular Heat Exchanger

Belt Drive Or

Direct Drive

Blower

HACR Breaker

Economizer

Hood

Knockout For Side Power Entry

Slide-In Economizer

Figure 1: ZDT03 through TA6 Component Location

Table 1: ZDT03 through TA6 Unit Limitations

Size

(Tons)

ZDT03

(3.0)

ZDT04

(4.0)

ZDT05

(5.0)

ZDTA6

(6.0)

Unit Voltage SCCR (kVA)

208/230-1-60 5 187 252 125

208/230-3-60 5 187 252 125

460-3-60 5 432 504 125

575-3-60 5 540 630 125

208/230-1-60 5 187 252 125

208/230-3-60 5 187 252 125

460-3-60 5 432 504 125

575-3-60 5 540 630 125

208/230-1-60 5 187 252 125

208/230-3-60 5 187 252 125

460-3-60 5 432 504 125

575-3-60 5 540 630 125

208/230-3-60 5 187 252 125

460-3-60 5 432 504 125

575-3-60 5 540 630 125

Unit Limitations

Applied Voltage Outdoor DB Temp

Min Max Max (°F)

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Location

Use the following guidelines to select a suitable location for these units:

1. Unit is designed for outdoor installation only.

2. Condenser coils must have an unlimited supply of air. Where a choice of location is possible, position the unit on either north or east side of building.

3. Suitable for mounting on roof curb.

4. For ground level installation, use a level concrete slab with a minimum thickness of 4 inches. The length and width should be at least 6 inches greater than the unit base rails. Do not tie slab to the building foundation.

5. Roof structures must be able to support the weight of the unit and its options/accessories. Unit must be installed on a solid, level roof curb or appropriate angle iron frame.

6. Maintain level tolerance to 1/2” across the entire width and length of unit.

Excessive exposure of this furnace to contaminated combustion air may result in equipment damage or personal injury. Typical contaminates include: permanent wave solution, chlorinated waxes and cleaners, chlorine based swimming pool chemicals, water softening chemicals, carbon tetrachloride, Halogen type refrigerants, cleaning solvents (e.g. perchloroethylene), printing inks, paint removers, varnishes, hydrochloric acid, cements and glues, anti static fabric softeners for clothes dryers, masonry acid washing materials.

codes. Refer to Table 4 for clearances required for combustible construction, servicing, and proper unit operation.

Do not permit overhanging structures or shrubs to obstruct condenser air discharge outlet, combustion air inlet or vent outlets.

Rigging And Handling

Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreader bars, whose length exceeds the largest dimension across the unit, MUST be used across the top of the unit.

If a unit is to be installed on a roof curb other than a Ducted Systems roof curb, gasketing must be applied to all surfaces that come in contact with the unit underside.

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.

Clearances

All units require particular clearances for proper operation and service. Installer must make provisions for adequate combustion and ventilation air in accordance with section 5.3 of Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2,

7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) -

Latest Edition, and/or applicable provisions of the local building

Johnson Controls Ducted Systems 7

LENGTH OF FORKS MUST BE A MINIMUM OF 42 INCHES.

All panels must be secured in place when the unit is lifted.

The condenser coils should be protected from rigging cable damage with plywood or other suitable material.

Page 8

5742640-TIM-A-0419

Front

LEFT

FRONT

Figure 2: Unit 4 Point Load Weight Figure 3: Unit 6 Point Load Weight

Figure 4: Center of Gravity

Table 2: ZDT03 through TA6

Size

(Tons)

T03

(3)

T04

(4)

T05

(5)

TA6

(6)

Weight (lbs.)

Shipping Operating X Y A B C D A B C D E F

475 470 34.5 18.25 111 80 117 162 78 62 51 74 91 114

603 598 36 18.5 139 108 154 198 96 81 69 98 116 137

637 632 37.5 18.2 139 117 171 204 96 85 76 111 124 140

670 665 35.5 17.75 150 114 173 228 104 86 72 111 132 160

Center of

4 point Load Location (lbs.) 6 point Load Location (lbs.)

Table 3: ZDT03 through TA6 Unit Accessory Weights

Unit Accessory

Economizer 55 50

Power Exhaust 55 50

Electric Heat

Gas Heat

1. Weight given is for the maximum heater size available (30KW).

2. Weight given is for the maximum number of tube heat exchangers available (5 tube).

Shipping Operating

Weight (lbs.)

28 28 70 70

8 Johnson Controls Ducted Systems

Page 9

5742640-TIM-A-0419

Figure 5: ZDT03 through TA6 Cooling Only/Electric Heat Front View Physical Dimensions

Figure 6: ZDT03 through TA6 Cooling Only/Gas Heat Front View Physical Dimensions

Johnson Controls Ducted Systems 9

Page 10

5742640-TIM-A-0419

Detail “A”

27-1/2

1-5/8

19-1/2 44-7/8

19-3/4

Rear View

Detail “B”

Dimension “A”

Fixed

Outdoor

Air Damper

16-1/2

Motorized

Damper

LH End View

27-1/2

7-1/4

“A” 44-7/8

4-3/8

8-1/4

3-1/2

10-1/4

19-1/8

Disconnect Switch Location and Motor Access Panel for Unit with “Belt-Drive” Option

Control Box Access

A,B Wiring Entry (See Detail “B”)

Mounting Bracket for Disconnect Switch (Field Supplied)

Field -Supplied Disconnect Switch Location

Blower Motor Access

Filter Access

Dot Plugs

Figure 7: ZDT03 through TA6 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions

Table 4: ZDT03 through TA6 Unit Clearances

Left Side (Filter Access)

Right Side (Cond. Coil) 24”

1. Units may be installed on combustible floors made from

2. Units must be installed outdoors. Overhanging structures

10 Johnson Controls Ducted Systems

Location Clearance

Front

24” (Cooling/Electric Heat)

32” (Gas Heat)

12” (Less Economizer)

Rear

36” (With Economizer or Fixed

Air/Motorized Damper) 24” (Less Economizer)

36” (With Economizer)

Below Unit

Above Unit

wood or class A, B, or C roof covering material.

Condenser Air Discharge)

0”

72” (For

or shrubs should not obstruct condenser air discharge outlet.

Figure 8: ZDT03 through TA6 Disconnect Location

Page 11

Figure 9: ZDT03 through TA6 Unit Side Duct Openings

Table 5: ZDT03 through TA6 Utilities Entry

Hole Opening Size (Dia.) Used For

A7/8” KO

B2” KO

C 1-5/8” KO Gas Piping (Front) D 1-1/2” KO Gas Piping (Bottom)

1. Opening in the bottom to the unit can be located by the slice in the insulation.

2. Do not remove the 2” knockout ring.

Control Wiring

Power Wiring

5742640-TIM-A-0419

Side

Bottom

Side

Bottom

Figure 10: ZDT03 through TA6 Roof Curb

Johnson Controls Ducted Systems 11

Page 12

5742640-TIM-A-0419

Ductwork

Ductwork should be designed and sized according to the methods in Manual D of the Air Conditioning Contractors of America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA.

A closed return duct system should be used. This will not preclude use of economizers or outdoor fresh air intake. The supply and return air duct connections at the unit should be made with flexible joints to minimize noise.

The supply and return air duct systems should be designed for the CFM and static pressure requirements of the job. They should NOT be sized to match the dimensions of the duct connections on the unit.

Refer to Figures 5 and 6 for bottom air duct openings. Refer to Figure 9 for side air duct openings.

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.

NOTE: It is recommended that, in Canada, the outlet duct be

provided with a removable access panel. It is recommended that this opening be accessible when the unit is installed in service, and of a size such that smoke or reflected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover should be attached in a manner adequate to prevent leakage.

Compressors

The scroll compressor used in this product is specifically designed to operate with R-410A Refrigerant and cannot be interchanged.

This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system.

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.

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.

Condensate Drain

Plumbing must conform to local codes. Use a sealing compound on male pipe threads. Install a condensate drain line from the 3/4” NPT female connection on the unit to an open drain.

NOTE: The condensate drain operates in a negative pressure

in the cabinet. The condensate drain line MUST be trapped to provide proper drainage. See Figure 11.

Figure 11: Condensate Drain

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.

Units with scroll compressors have a shipping bracket which must be removed after the unit is set in place. See Figure 12.

12 Johnson Controls Ducted Systems

Page 13

Figure 12: Compressor Restraining Bracket

Wire tie

(cut and remove)

Mounting bracket

top (remove)

Mounting bracket

base

Remove these

screws (2)

Compressor

Do not loosen compressor mounting bolts.

5742640-TIM-A-0419

Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 1.

208/230-3-60 and 380/415-3-50 units control transformers are factory wired for 230v and 415v power supply respectively. Change tap on transformer for 2083-60 or 380-3-50 operation. See unit wiring diagram.

The internal wiring harnesses furnished with this unit are an integral part of the design certified unit. Field alteration to comply with electrical codes should not be required. If any of the wire supplied with the unit must be replaced, replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire.

A disconnect must be utilized for these units. Factory installed disconnects are available.

Filters

One or two-inch filters can be 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.

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 13 and 14 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.

Johnson Controls Ducted Systems 13

Page 14

5742640-TIM-A-0419

When installing equipment in a facility with a 3 phase high-leg delta power supply, care must be taken to ensure that the high-leg conductor is not attached to either of the two legs of the (single phase, direct drive) X13 or ECM motors. Failure to do so can result in the motor acting erratically or not running at all.

Check for the high leg conductor by checking voltage of each phase to ground.

Example: A or L1 phase to ground, voltage reading is 120V. B or L2 phase to ground, voltage reading is 195 to 208V. C or L3 phase to ground, voltage reading is 120V. Therefore B or L2 phase is the high Leg. The high should always be wired to the center or B or L2 tap.

Note: Check all three phase motors and compressors for proper rotation after making a change. If it is necessary to change 3 phase motor rotation, swap A or L1 and C or L3 only.

Convenience Outlet

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 convenience outlet shipping label located in the lower section of the control panel, and attach the cover to the unit using the (4) screws provided.

Power Wiring Detail

Units are factory wired for the voltage shown on the unit nameplate. Refer to Electrical Data Table 7 to size power wiring, fuses, and disconnect switch.

Power wiring is brought into the unit through the side of the unit or the basepan inside the curb.

Thermostat Wiring

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. Eight (8) color-coded, insulated wires should be used to connect the thermostat to the unit. Refer to Table 6 for control wire sizing and maximum length.

Table 6: Control Wire Sizes

Wire Size Maximum Length

18 AWG 150 Feet

1. From the unit to the thermostat and back to the unit.

14 Johnson Controls Ducted Systems

Page 15

Typical Field Power and Control Wiring

REFER TO THE ELECTRICAL DATA TABLES TO SIZE THE DISCONNECT SWITCH, OVERCURRENT PROTECTION AND WIRING.

OCC

THERMOSTAT

TERMINALS

CONTROL

TERMINAL

BLOCK

TERMINALS ON A LIMITED NUMBER OF THERMOSTATS

Second stageŚĞĂƟŶŐŶot required on single stage heĂƟŶg units.

Jumper is required if there is no Smoke Detector circuit.

Jumper is required for any coŵďŝŶĂƟŽŶ of R, RC, or RH.

OCC is an output from the thermostat to indicate the Occupied ĐŽŶĚŝƟon.

X is an input to the thermostat to display Error Status condiƟons.

OCC

SD-24

24V

24 VAC

Class 2

SD-24

Jumper Located on Harness

Smoke

Detector

SD-R

24V Output

(If No Smoke Detector)

(If Smoke Detector Is Used)

R~Occ Jumper: Smart Equipment Control boards come from the factory with a jumper wire between R and OCC terminals on the thermostat terminal strip. Failure to remove this jumper will place the unit into the Occupied mode no matter what the occupancy demand is from the thermostat or EMS system. To allow Thermostat or EMS control of the Occupied mode for the unit, this jumper must be removed during commissioning.

Typical Power Wiring

Typical Cool/Heat Control Wiring (Smart Equipment™ ZDT03 through TA6)

5742640-TIM-A-0419

Figure 13: Typical Smart Equipment™ Control Wiring

Johnson Controls Ducted Systems 15

Page 16

5742640-TIM-A-0419

Table 7: Electrical Data ZDT03 through TA6 - Without Powered Convenience Outlet (Belt Drive)

Size

(Tons)

T03

(3.0)

T04

(4.0)

OD Fan

Motors

(each)

Volt

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

208-1-60

230-1-60

15.4 83.9 24 2.3 6.7 0

208-3-60 10.4 73 16.3 2.3 4.3 0

230-3-60 10.4 73 16.3 2.3 4.3 0

460-3-60 5.8 38 9 1.3 2.1 0

575-3-60 4.2 36.5 5.9 1.3 1.9 0

208-1-60

230-1-60

19.6 130 30.5 2.3 6.7 0

208-3-60 13.7 83.1 21.4 2.3 4.3 0

230-3-60 13.7 83.1 21.4 2.3 4.3 0

460-3-60 6.2 41 9.7 1.3 2.1 0

575-3-60 4.8 33 7.5 1.3 1.9 0

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 28.3 35

E05 4 1 19.2 32.4 40 E07 5.6 1 26.9 42 45 E10 8 1 38.5 56.5 60 E15 11.9 2 57.2 79.9 80 E20 15.9 2 76.4 103.9 110

NONE - - - 28.3 35

E05 5.3 1 22.1 36 40 E07 7.5 1 31.2 47.4 50 E10 10.6 1 44.2 63.6 70 E15 15.9 2 66.2 91.2 100 E20 21.2 2 88.3 118.8 125

NONE - - - 19.6 25

E05 4 1 11.1 19.6 25 E07 5.6 1 15.5 24.8 30 E10 8 1 22.2 33.1 35 E15 11.9 2 33 46.7 50 E20 15.9 2 44.1 60.5 70

NONE - - - 19.6 25

E05 5.3 1 12.7 21.3 30 E07 7.5 1 18 27.9 30 E10 10.6 1 25.5 37.2 40 E15 15.9 2 38.2 53.2 60 E20 21.2 2 51 69.1 70

NONE - - - 10.6 15

E07 6.8 1 8.2 12.8 15 E10 10.1 1 12.1 17.8 20 E15 13.6 2 16.4 23.1 25 E20 19.5 2 23.5 31.9 35

NONE - - - 8.2 15

E10 10.6 1 10.2 15.1 20 E15 15.9 2 15.3 21.5 25 E20 21.2 2 20.4 27.9 30

NONE - - - 33.5 45

E05 4 1 19.2 33.5 45 E07 5.6 1 26.9 42 50 E10 8 1 38.5 56.5 60 E15 11.9 2 57.2 79.9 80 E20 15.9 2 76.4 103.9 110

NONE - - - 33.5 45

E05 5.3 1 22.1 36 45 E07 7.5 1 31.2 47.4 50 E10 10.6 1 44.2 63.6 70 E15 15.9 2 66.2 91.2 100 E20 21.2 2 88.3 118.8 125

NONE - - - 23.7 30

E05 4 1 11.1 23.7 30 E07 5.6 1 15.5 24.8 30 E10 8 1 22.2 33.1 35 E15 11.9 2 33 46.7 50 E20 15.9 2 44.1 60.5 70

NONE - - - 23.7 30

E05 5.3 1 12.7 23.7 30 E07 7.5 1 18 27.9 35 E10 10.6 1 25.5 37.2 40 E15 15.9 2 38.2 53.2 60 E20 21.2 2 51 69.1 70

NONE - - - 11.1 15

E07 6.8 1 8.2 12.8 15 E10 10.1 1 12.1 17.8 20 E15 13.6 2 16.4 23.1 25 E20 19.5 2 23.5 31.9 35

NONE - - - 8.9 15

E10 10.6 1 10.2 15.1 20 E15 15.9 2 15.3 21.5 25 E20 21.2 2 20.4 27.9 30

MCA

(Amps)

Max

Fuse

Breaker

Size

(Amps)

16 Johnson Controls Ducted Systems

Page 17

ZDT03 through TA6 - Without Powered Convenience Outlet (Belt Drive) (Continued)

OD Fan

Motors

(each)

Size

(Tons)

T05

(5.0)

TA6 (6.0)

Compressors

Volt

208-1-60

230-1-60

208-3-60 16 110 24.9 4.4 4.3 0

230-3-60 16 110 24.9 4.4 4.3 0

460-3-60 7.8 52 12.1 4.4 2.1 0

575-3-60 5.7 38.9 8.9 4.4 1.9 0

208-3-60 19.6 136 27 4.4 4.3

230-3-60 19.6 136 27 4.4 4.3

460-3-60 9.4 66.1 13 2.4 2.1

575-3-60 7.1 55.3 10 4.4 1.9

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

24.4 144.2 38 4.4 6.7 0

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

4. Electrical data for single phase gas heating units with belt drive is at the end of the electrical data section.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 41.6 50

E05 4 1 19.2 41.6 50 E07 5.6 1 26.9 42 60 E10 8 1 38.5 56.5 60 E15 11.9 2 57.2 79.9 80 E20 15.9 2 76.4 103.9 110 E30 22.2 2 106.7 141.8 150

NONE - - - 41.6 50

E05 5.3 1 22.1 41.6 50 E07 7.5 1 31.2 47.4 60 E10 10.6 1 44.2 63.6 70 E15 15.9 2 66.2 91.2 100 E20 21.2 2 88.3 118.8 125 E30 29.6 2 123.3 162.5 175

NONE - - - 28.7 35

E05 4 1 11.1 28.7 35 E07 5.6 1 15.5 28.7 35 E10 8 1 22.2 33.1 40 E15 11.9 2 33 46.7 50 E20 15.9 2 44.1 60.5 70 E30 22.2 2 61.6 82.4 90

NONE - - - 28.7 35

E05 5.3 1 12.7 28.7 35 E07 7.5 1 18 28.7 35 E10 10.6 1 25.5 37.2 40 E15 15.9 2 38.2 53.2 60 E20 21.2 2 51 69.1 70 E30 29.6 2 71.2 94.4 100

NONE - - - 14.1 20

E07 6.8 1 8.2 14.1 20 E10 10.1 1 12.1 17.8 20 E15 13.6 2 16.4 23.1 25 E20 19.5 2 23.5 31.9 35 E30 28.8 2 34.6 45.9 50

NONE - - - 10.8 15

E10 10.6 1 10.2 15.1 20 E15 15.9 2 15.3 21.5 25 E20 21.2 2 20.4 27.9 30 E30 30.4 2 29.3 38.9 40

None - - - 33.2 45

E05 4 1 11.1 33.2 45 E07 5.6 1 15.5 33.2 45 E10 8 1 22.2 33.2 45 E15 11.9 1 33 46.6 50 E20 15.9 2 44.1 60.5 70 E30 22.2 2 61.6 82.4 90

None - - - 33.2 45

E05 5.3 1 12.7 33.2 45 E07 7.5 1 18 33.2 45 E10 10.6 1 25.5 37.3 50 E15 15.9 1 38.2 53.1 60 E20 21.2 2 51 69.1 70 E30 29.6 2 71.2 94.4 100

None - - - 16.3 25

E07 6.8 1 8.2 16.3 25 E10 10.1 1 12.1 17.8 25 E15 13.6 1 16.4 23.1 25 E20 19.5 2 23.5 32 35 E30 28.8 2 34.6 45.9 50

None - - - 12.6 15

E10 10.6 1 10.2 15.1 20 E15 15.9 1 15.3 21.5 25 E20 21.2 2 20.4 27.9 30 E30 30.4 2 29.3 39 40

MCA

(Amps)

5742640-TIM-A-0419

Max

Fuse

Breaker

Size

(Amps)

Johnson Controls Ducted Systems 17

Page 18

5742640-TIM-A-0419

ZDT03 through TA6 - Without Powered Convenience Outlet (Belt Drive High Static)

Size

(Tons)

T03

(3.0)

T04

(4.0)

OD Fan

Motors

(each)

Volt

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

208-1-60

230-1-60

15.4 83.9 24 2.3 6.7 0

208-3-60 10.4 73 16.3 2.3 4.3 0

230-3-60 10.4 73 16.3 2.3 4.3 0

460-3-60 5.8 38 9 1.3 2.1 0

575-3-60 4.2 36.5 5.9 1.3 1.9 0

208-1-60

230-1-60

19.6 130 30.5 2.3 6.7 0

208-3-60 13.7 83.1 21.4 2.3 4.3 0

230-3-60 13.7 83.1 21.4 2.3 4.3 0

460-3-60 6.2 41 9.7 1.3 2.1 0

575-3-60 4.8 33 7.5 1.3 1.9 0

Supply Blower

Motor

Pwr

Conv

Electric Heat Option

Outlet

NONE - - - 28.3 35

E05 4 1 19.2 32.4 40 E07 5.6 1 26.9 42 45 E10 8 1 38.5 56.5 60 E15 11.9 2 57.2 79.9 80 E20 15.9 2 76.4 103.9 110

NONE - - - 28.3 35

E05 5.3 1 22.1 36 40 E07 7.5 1 31.2 47.4 50 E10 10.6 1 44.2 63.6 70 E15 15.9 2 66.2 91.2 100 E20 21.2 2 88.3 118.8 125

NONE - - - 19.6 25

E05 4 1 11.1 19.6 25 E07 5.6 1 15.5 24.8 30 E10 8 1 22.2 33.1 35 E15 11.9 2 33 46.7 50 E20 15.9 2 44.1 60.5 70

NONE - - - 19.6 25

E05 5.3 1 12.7 21.3 30 E07 7.5 1 18 27.9 30 E10 10.6 1 25.5 37.2 40 E15 15.9 2 38.2 53.2 60 E20 21.2 2 51 69.1 70

NONE - - - 10.6 15

E07 6.8 1 8.2 12.8 15 E10 10.1 1 12.1 17.8 20 E15 13.6 2 16.4 23.1 25 E20 19.5 2 23.5 31.9 35

NONE - - - 8.2 15

E10 10.6 1 10.2 15.1 20 E15 15.9 2 15.3 21.5 25 E20 21.2 2 20.4 27.9 30

NONE - - - 33.5 45

E05 4 1 19.2 33.5 45 E07 5.6 1 26.9 42 50 E10 8 1 38.5 56.5 60 E15 11.9 2 57.2 79.9 80 E20 15.9 2 76.4 103.9 110

NONE - - - 33.5 45

E05 5.3 1 22.1 36 45 E07 7.5 1 31.2 47.4 50 E10 10.6 1 44.2 63.6 70 E15 15.9 2 66.2 91.2 100 E20 21.2 2 88.3 118.8 125

NONE - - - 23.7 30

E05 4 1 11.1 23.7 30 E07 5.6 1 15.5 24.8 30 E10 8 1 22.2 33.1 35 E15 11.9 2 33 46.7 50 E20 15.9 2 44.1 60.5 70

NONE - - - 23.7 30

E05 5.3 1 12.7 23.7 30 E07 7.5 1 18 27.9 35 E10 10.6 1 25.5 37.2 40 E15 15.9 2 38.2 53.2 60 E20 21.2 2 51 69.1 70

NONE - - - 11.1 15

E07 6.8 1 8.2 12.8 15 E10 10.1 1 12.1 17.8 20 E15 13.6 2 16.4 23.1 25 E20 19.5 2 23.5 31.9 35

NONE - - - 8.9 15

E10 10.6 1 10.2 15.1 20 E15 15.9 2 15.3 21.5 25 E20 21.2 2 20.4 27.9 30

MCA

(Amps)

Max

Fuse

Breaker

Size

(Amps)

18 Johnson Controls Ducted Systems

Page 19

ZDT03 through TA6 - Without Powered Convenience Outlet (Belt Drive High Static) (Continued)

OD Fan

Motors

(each)

Size

(Tons)

T05

(5.0)

TA6 (6.0)

Compressors

Volt

208-3-60 16 110 24.9 4.4 6.8 0

230-3-60 16 110 24.9 4.4 6.8 0

460-3-60 7.8 52 12.1 4.4 3.15 0

575-3-60 5.7 38.9 8.9 4.4 2.2 0

208-3-60 19.6 136 27 4.4 8.3

230-3-60 19.6 136 27 4.4 8.3

460-3-60 9.4 66.1 13 2.4 4.1

575-3-60 7.1 55.3 10 4.4 3.2

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

4. Single phase, high static belt drive motors not available on gas heating units.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 31.2 40

E05 4 1 11.1 31.2 40 E07 5.6 1 15.5 31.2 40 E10 8 1 22.2 36.3 45 E15 11.9 2 33 49.8 50 E20 15.9 2 44.1 63.7 70 E30 22.2 2 61.6 85.5 90

NONE - - - 31.2 40

E05 5.3 1 12.7 31.2 40 E07 7.5 1 18 31.2 40 E10 10.6 1 25.5 40.4 45 E15 15.9 2 38.2 56.3 60 E20 21.2 2 51 72.2 80 E30 29.6 2 71.2 97.5 100

NONE - - - 15.1 20

E07 6.8 1 8.2 15.1 20 E10 10.1 1 12.1 19.1 20 E15 13.6 2 16.4 24.4 25 E20 19.5 2 23.5 33.3 35 E30 28.8 2 34.6 47.2 50

NONE - - - 11.1 15

E10 10.6 1 10.2 15.5 20 E15 15.9 2 15.3 21.9 25 E20 21.2 2 20.4 28.2 30 E30 30.4 2 29.3 39.3 40

None - - - 37.2 50

E05 4 1 11.1 37.2 50 E07 5.6 1 15.5 37.2 50 E10 8 1 22.2 38.1 50 E15 11.9 1 33 51.6 60 E20 15.9 2 44.1 65.5 70 E30 22.2 2 61.6 87.4 90

None - - - 37.2 50

E05 5.3 1 12.7 37.2 50 E07 7.5 1 18 37.2 50 E10 10.6 1 25.5 42.3 50 E15 15.9 1 38.2 58.1 60 E20 21.2 2 51 74.1 80 E30 29.6 2 71.2 99.4 100

None - - - 18.3 25

E07 6.8 1 8.2 18.3 25 E10 10.1 1 12.1 20.3 25 E15 13.6 1 16.4 25.6 30 E20 19.5 2 23.5 34.5 35 E30 28.8 2 34.6 48.4 50

None - - - 13.9 20

E10 10.6 1 10.2 16.8 20 E15 15.9 1 15.3 23.1 25 E20 21.2 2 20.4 29.5 30 E30 30.4 2 29.3 40.6 45

MCA

(Amps)

Max

Fuse

Breaker

Size

(Amps)

5742640-TIM-A-0419

Johnson Controls Ducted Systems 19

Page 20

5742640-TIM-A-0419

ZDT03 through T05 - Without Powered Convenience Outlet (Direct Drive)

Size

(Tons)

(3.0)

(4.0)

Volt

208-1-60 15.4 83.9 24 2.3 6 0

230-1-60 15.4 83.9 24 2.3 6 0

T03

208-3-60 10.4 73 16.3 2.3 6 0

230-3-60 10.4 73 16.3 2.3 6 0

208-1-60 19.6 130 30.5 2.3 7.6 0

230-1-60 19.6 130 30.5 2.3 7.6 0

T04

208-3-60 13.7 83.1 21.4 2.3 7.6 0

230-3-60 13.7 83.1 21.4 2.3 7.6 0

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 27.5 35

E05 4 1 19.2 31.5 40 E07 5.6 1 26.9 41.2 45 E10 8 1 38.5 55.6 60 E15 11.9 2 57.2 79 80 E20 15.9 2 76.4 103.1 110

NONE - - - 27.5 35

E05 5.3 1 22.1 35.1 40 E07 7.5 1 31.2 46.6 50 E10 10.6 1 44.2 62.7 70 E15 15.9 2 66.2 90.3 100 E20 21.2 2 88.3 117.9 125

NONE - - - 21.3 30

E05 4 1 11.1 21.4 30 E07 5.6 1 15.5 26.9 30 E10 8 1 22.2 35.3 40 E15 11.9 2 33 48.8 50 E20 15.9 2 44.1 62.7 70

NONE - - - 21.3 30

E05 5.3 1 12.7 23.4 30 E07 7.5 1 18 30.1 35 E10 10.6 1 25.5 39.4 40 E15 15.9 2 38.2 55.3 60 E20 21.2 2 51 71.2 80

NONE - - - 34.4 45

E05 4 1 19.2 34.4 45 E07 5.6 1 26.9 43.2 50 E10 8 1 38.5 57.6 60 E15 11.9 2 57.2 81 90 E20 15.9 2 76.4 105.1 110

NONE - - - 34.4 45

E05 5.3 1 22.1 37.1 45 E07 7.5 1 31.2 48.6 50 E10 10.6 1 44.2 64.7 70 E15 15.9 2 66.2 92.3 100 E20 21.2 2 88.3 119.9 125

NONE - - - 27 35

E05 4 1 11.1 27 35 E07 5.6 1 15.5 28.9 35 E10 8 1 22.2 37.3 40 E15 11.9 2 33 50.8 60 E20 15.9 2 44.1 64.7 70

NONE - - - 27 35

E05 5.3 1 12.7 27 35 E07 7.5 1 18 32.1 40 E10 10.6 1 25.5 41.4 45 E15 15.9 2 38.2 57.3 60 E20 21.2 2 51 73.2 80

MCA

(Amps)

Max

Fuse

Breaker

Size

(Amps)

20 Johnson Controls Ducted Systems

Page 21

ZDT03 through T05 - Without Powered Convenience Outlet (Direct Drive) (Continued)

Size

(Tons)

(5.0)

Volt

208-1-60 24.4 144.2 38 4.4 7.6 0

230-1-60 24.4 144.2 38 4.4 7.6 0

T05

208-3-60 16 110 24.9 4.4 7.6 0

230-3-60 16 110 24.9 4.4 7.6 0

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 42.5 60

E05 4 1 19.2 42.5 60 E07 5.6 1 26.9 43.2 60 E10 8 1 38.5 57.6 60 E15 11.9 2 57.2 81 90 E20 15.9 2 76.4 105.1 110 E30 22.2 2 106.7 142.9 150

NONE - - - 42.5 60

E05 5.3 1 22.1 42.5 60 E07 7.5 1 31.2 48.6 60 E10 10.6 1 44.2 64.7 70 E15 15.9 2 66.2 92.3 100 E20 21.2 2 88.3 119.9 125 E30 29.6 2 123.3 163.7 175

NONE - - - 32 40

E05 4 1 11.1 32 40 E07 5.6 1 15.5 32 40 E10 8 1 22.2 37.3 45 E15 11.9 2 33 50.8 60 E20 15.9 2 44.1 64.7 70 E30 22.2 2 61.6 86.5 90

NONE - - - 32 40

E05 5.3 1 12.7 32 40 E07 7.5 1 18 32.1 40 E10 10.6 1 25.5 41.4 45 E15 15.9 2 38.2 57.3 60 E20 21.2 2 51 73.2 80 E30 29.6 2 71.2 98.5 100

MCA

(Amps)

Max

Fuse

Breaker

Size

(Amps)

5742640-TIM-A-0419

Johnson Controls Ducted Systems 21

Page 22

5742640-TIM-A-0419

ZDT03 through TA6 - With Powered Convenience Outlet (Belt Drive)

Size

(Tons)

T03

(3.0)

T04

(4.0)

Supply Blower

Motor

Volt

Compressors

(each)

OD Fan

Motors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

208-1-60

230-1-60

15.4 83.9 24 2.3 6.7 10

208-3-60 10.4 73 16.3 2.3 4.3 10

230-3-60 10.4 73 16.3 2.3 4.3 10

460-3-60 5.8 38 9 1.3 2.1 5

575-3-60 4.2 36.5 5.9 1.3 1.9 4

208-1-60

230-1-60

19.6 130 30.5 2.3 6.7 10

208-3-60 13.7 83.1 21.4 2.3 4.3 10

230-3-60 13.7 83.1 21.4 2.3 4.3 10

460-3-60 6.2 41 9.7 1.3 2.1 5

575-3-60 4.8 33 7.5 1.3 1.9 4

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 38.3 50

E05 4 1 19.2 44.9 50 E07 5.6 1 26.9 54.5 60 E10 8 1 38.5 69 70 E15 11.9 2 57.2 92.4 100 E20 15.9 2 76.4 116.4 125

NONE - - - 38.3 50

E05 5.3 1 22.1 48.5 50 E07 7.5 1 31.2 59.9 60 E10 10.6 1 44.2 76.1 80 E15 15.9 2 66.2 103.7 110 E20 21.2 2 88.3 131.3 150

NONE - - - 29.6 40

E05 4 1 11.1 31.8 40 E07 5.6 1 15.5 37.3 40 E10 8 1 22.2 45.6 50 E15 11.9 2 33 59.2 60 E20 15.9 2 44.1 73 80

NONE - - - 29.6 40

E05 5.3 1 12.7 33.8 40 E07 7.5 1 18 40.4 45 E10 10.6 1 25.5 49.7 50 E15 15.9 2 38.2 65.7 70 E20 21.2 2 51 81.6 90

NONE - - - 15.6 20

E07 6.8 1 8.2 19.1 20 E10 10.1 1 12.1 24.1 25 E15 13.6 2 16.4 29.3 30 E20 19.5 2 23.5 38.2 40

NONE - - - 12.2 15

E10 10.6 1 10.2 20.1 25 E15 15.9 2 15.3 26.5 30 E20 21.2 2 20.4 32.9 35

NONE - - - 43.5 60

E05 4 1 19.2 44.9 60 E07 5.6 1 26.9 54.5 60 E10 8 1 38.5 69 70 E15 11.9 2 57.2 92.4 100 E20 15.9 2 76.4 116.4 125

NONE - - - 43.5 60

E05 5.3 1 22.1 48.5 60 E07 7.5 1 31.2 59.9 60 E10 10.6 1 44.2 76.1 80 E15 15.9 2 66.2 103.7 110 E20 21.2 2 88.3 131.3 150

NONE - - - 33.7 45

E05 4 1 11.1 33.7 45 E07 5.6 1 15.5 37.3 45 E10 8 1 22.2 45.6 50 E15 11.9 2 33 59.2 60 E20 15.9 2 44.1 73 80

NONE - - - 33.7 45

E05 5.3 1 12.7 33.8 45 E07 7.5 1 18 40.4 45 E10 10.6 1 25.5 49.7 50 E15 15.9 2 38.2 65.7 70 E20 21.2 2 51 81.6 90

NONE - - - 16.1 20

E07 6.8 1 8.2 19.1 20 E10 10.1 1 12.1 24.1 25 E15 13.6 2 16.4 29.3 30 E20 19.5 2 23.5 38.2 40

NONE - - - 12.9 15

E10 10.6 1 10.2 20.1 25 E15 15.9 2 15.3 26.5 30 E20 21.2 2 20.4 32.9 35

MCA

(Amps)

Max Fuse

Breaker

Size

(Amps)

22 Johnson Controls Ducted Systems

Page 23

ZDT03 through TA6 - With Powered Convenience Outlet (Belt Drive) (Continued)

Size

(Tons)

T05

(5.0)

TA6 (6.0)

Compressors

Volt

208-1-60

230-1-60

208-3-60 16 110 24.9 4.4 4.3 10

230-3-60 16 110 24.9 4.4 4.3 10

460-3-60 7.8 52 12.1 4.4 2.1 5

575-3-60 5.7 38.9 8.9 4.4 1.9 4

208-3-60 19.6 136 27 4.4 4.3 20

230-3-60 19.6 136 27 4.4 4.3 20

460-3-60 9.4 66.1 13 2.4 2.1 20

575-3-60 7.1 55.3 10 4.4 1.9 20

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

24.4 144.2 38 4.4 6.7 10

OD Fan

Motors

(each)

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

4. Electrical data for single phase gas heating units with belt drive is at the end of the electrical data section.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 51.6 70

E05 4 1 19.2 51.6 70 E07 5.6 1 26.9 54.5 70 E10 8 1 38.5 69 70 E15 11.9 2 57.2 92.4 100 E20 15.9 2 76.4 116.4 125 E30 22.2 2 106.7 154.3 175

NONE - - - 51.6 70

E05 5.3 1 22.1 51.6 70 E07 7.5 1 31.2 59.9 70 E10 10.6 1 44.2 76.1 80 E15 15.9 2 66.2 103.7 110 E20 21.2 2 88.3 131.3 150 E30 29.6 2 123.3 175 200

NONE - - - 38.7 50

E05 4 1 11.1 38.7 50 E07 5.6 1 15.5 38.7 50 E10 8 1 22.2 45.6 50 E15 11.9 2 33 59.2 60 E20 15.9 2 44.1 73 80 E30 22.2 2 61.6 94.9 100

NONE - - - 38.7 50

E05 5.3 1 12.7 38.7 50 E07 7.5 1 18 40.4 50 E10 10.6 1 25.5 49.7 50 E15 15.9 2 38.2 65.7 70 E20 21.2 2 51 81.6 90 E30 29.6 2 71.2 106.9 110

NONE - - - 19 25

E07 6.8 1 8.2 19.1 25 E10 10.1 1 12.1 24.1 25 E15 13.6 2 16.4 29.3 30 E20 19.5 2 23.5 38.2 40 E30 28.8 2 34.6 52.2 60

NONE - - - 14.8 15

E10 10.6 1 10.2 20.1 25 E15 15.9 2 15.3 26.5 30 E20 21.2 2 20.4 32.9 35 E30 30.4 2 29.3 43.9 45

None - - - 43.2 60

E05 4 1 11.1 43.2 60 E07 5.6 1 15.5 43.2 60 E10 8 1 22.2 45.6 60 E15 11.9 1 33 59.1 60 E20 15.9 2 44.1 73 80 E30 22.2 2 61.6 94.9 100

None - - - 43.2 60

E05 5.3 1 12.7 43.2 60 E07 7.5 1 18 43.2 60 E10 10.6 1 25.5 49.8 60 E15 15.9 1 38.2 65.6 70 E20 21.2 2 51 81.6 90 E30 29.6 2 71.2 106.9 110

None - - - 21.3 30

E07 6.8 1 8.2 21.3 30 E10 10.1 1 12.1 24 30 E15 13.6 1 16.4 29.4 30 E20 19.5 2 23.5 38.3 40 E30 28.8 2 34.6 52.1 60

None - - - 16.6 20

E10 10.6 1 10.2 20.1 25 E15 15.9 1 15.3 26.5 30 E20 21.2 2 20.4 32.9 35 E30 30.4 2 29.3 44 45

MCA

(Amps)

Max Fuse

Breaker

Size

(Amps)

5742640-TIM-A-0419

Johnson Controls Ducted Systems 23

Page 24

5742640-TIM-A-0419

ZDT03 through TA6 - With Powered Convenience Outlet (Belt Drive High Static)

Size

(Tons)

T03

(3.0)

T04

(4.0)

OD Fan

Motors

(each)

Volt

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

208-1-60

230-1-60

15.4 83.9 24 2.3 6.7 10

208-3-60 10.4 73 16.3 2.3 4.3 10

230-3-60 10.4 73 16.3 2.3 4.3 10

460-3-60 5.8 38 9 1.3 2.1 5

575-3-60 4.2 36.5 5.9 1.3 1.9 4

208-1-60

230-1-60

19.6 130 30.5 2.3 6.7 10

208-3-60 13.7 83.1 21.4 2.3 4.3 10

230-3-60 13.7 83.1 21.4 2.3 4.3 10

460-3-60 6.2 41 9.7 1.3 2.1 5

575-3-60 4.8 33 7.5 1.3 1.9 4

Supply Blower

Motor

Pwr

Conv

Electric Heat Option

Outlet

NONE - - - 38.3 50

E05 4 1 19.2 44.9 50 E07 5.6 1 26.9 54.5 60 E10 8 1 38.5 69 70 E15 11.9 2 57.2 92.4 100 E20 15.9 2 76.4 116.4 125

NONE - - - 38.3 50

E05 5.3 1 22.1 48.5 50 E07 7.5 1 31.2 59.9 60 E10 10.6 1 44.2 76.1 80 E15 15.9 2 66.2 103.7 110 E20 21.2 2 88.3 131.3 150

NONE - - - 29.6 40

E05 4 1 11.1 31.8 40 E07 5.6 1 15.5 37.3 40 E10 8 1 22.2 45.6 50 E15 11.9 2 33 59.2 60 E20 15.9 2 44.1 73 80

NONE - - - 29.6 40

E05 5.3 1 12.7 33.8 40 E07 7.5 1 18 40.4 45 E10 10.6 1 25.5 49.7 50 E15 15.9 2 38.2 65.7 70 E20 21.2 2 51 81.6 90

NONE - - - 15.6 20

E07 6.8 1 8.2 19.1 20 E10 10.1 1 12.1 24.1 25 E15 13.6 2 16.4 29.3 30 E20 19.5 2 23.5 38.2 40

NONE - - - 12.2 15

E10 10.6 1 10.2 20.1 25 E15 15.9 2 15.3 26.5 30 E20 21.2 2 20.4 32.9 35

NONE - - - 43.5 60

E05 4 1 19.2 44.9 60 E07 5.6 1 26.9 54.5 60 E10 8 1 38.5 69 70 E15 11.9 2 57.2 92.4 100 E20 15.9 2 76.4 116.4 125

NONE - - - 43.5 60

E05 5.3 1 22.1 48.5 60 E07 7.5 1 31.2 59.9 60 E10 10.6 1 44.2 76.1 80 E15 15.9 2 66.2 103.7 110 E20 21.2 2 88.3 131.3 150

NONE - - - 33.7 45

E05 4 1 11.1 33.7 45 E07 5.6 1 15.5 37.3 45 E10 8 1 22.2 45.6 50 E15 11.9 2 33 59.2 60 E20 15.9 2 44.1 73 80

NONE - - - 33.7 45

E05 5.3 1 12.7 33.8 45 E07 7.5 1 18 40.4 45 E10 10.6 1 25.5 49.7 50 E15 15.9 2 38.2 65.7 70 E20 21.2 2 51 81.6 90

NONE - - - 16.1 20

E07 6.8 1 8.2 19.1 20 E10 10.1 1 12.1 24.1 25 E15 13.6 2 16.4 29.3 30 E20 19.5 2 23.5 38.2 40

NONE - - - 12.9 15

E10 10.6 1 10.2 20.1 25 E15 15.9 2 15.3 26.5 30 E20 21.2 2 20.4 32.9 35

MCA

(Amps)

Max Fuse

Breaker

Size

(Amps)

24 Johnson Controls Ducted Systems

Page 25

ZDT03 through TA6 - With Powered Convenience Outlet (Belt Drive High Static) (Continued)

Size

(Tons)

T05

(5.0)

TA6 (6.0)

Compressors

Volt

208-3-60 16 110 24.9 4.4 6.8 10

230-3-60 16 110 24.9 4.4 6.8 10

460-3-60 7.8 52 12.1 4.4 3.15 5

575-3-60 5.7 38.9 8.9 4.4 2.2 4

208-3-60 19.6 136 27 4.4 8.3 20

230-3-60 19.6 136 27 4.4 8.3 20

460-3-60 9.4 66.1 13 2.4 4.1 20

575-3-60 7.1 55.3 10 4.4 3.2 20

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

4. Single phase, high static belt drive motors not available on gas heating units.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 41.2 50

E05 4 1 11.1 41.2 50 E07 5.6 1 15.5 41.2 50 E10 8 1 22.2 48.8 50 E15 11.9 2 33 62.3 70 E20 15.9 2 44.1 76.2 80 E30 22.2 2 61.6 98 100

NONE - - - 41.2 50

E05 5.3 1 12.7 41.2 50 E07 7.5 1 18 43.6 50 E10 10.6 1 25.5 52.9 60 E15 15.9 2 38.2 68.8 70 E20 21.2 2 51 84.7 90 E30 29.6 2 71.2 110 125

NONE - - - 20.1 25

E07 6.8 1 8.2 20.4 25 E10 10.1 1 12.1 25.4 30 E15 13.6 2 16.4 30.6 35 E20 19.5 2 23.5 39.5 40 E30 28.8 2 34.6 53.5 60

NONE - - - 15.1 20

E10 10.6 1 10.2 20.5 25 E15 15.9 2 15.3 26.9 30 E20 21.2 2 20.4 33.2 35 E30 30.4 2 29.3 44.3 45

None - - - 47.2 60

E05 4 1 11.1 47.2 60 E07 5.6 1 15.5 47.2 60 E10 8 1 22.2 50.6 60 E15 11.9 1 33 64.1 70 E20 15.9 2 44.1 78 80 E30 22.2 2 61.6 99.9 100

None - - - 47.2 60

E05 5.3 1 12.7 47.2 60 E07 7.5 1 18 47.2 60 E10 10.6 1 25.5 54.8 60 E15 15.9 1 38.2 70.6 80 E20 21.2 2 51 86.6 90 E30 29.6 2 71.2 111.9 125

None - - - 23.3 30

E07 6.8 1 8.2 23.3 30 E10 10.1 1 12.1 26.5 30 E15 13.6 1 16.4 31.9 35 E20 19.5 2 23.5 40.8 45 E30 28.8 2 34.6 54.6 60

None - - - 17.9 25

E10 10.6 1 10.2 21.8 25 E15 15.9 1 15.3 28.1 30 E20 21.2 2 20.4 34.5 35 E30 30.4 2 29.3 45.6 50

MCA

(Amps)

Max Fuse

Breaker

Size

(Amps)

5742640-TIM-A-0419

Johnson Controls Ducted Systems 25

Page 26

5742640-TIM-A-0419

ZDT03 through T05 - With Powered Convenience Outlet (Direct Drive)

Size

(Tons)

(3.0)

(4.0)

Volt

208-1-60 15.4 83.9 24 2.3 6 10

230-1-60 15.4 83.9 24 2.3 6 10

T03

208-3-60 10.4 73 16.3 2.3 6 10

230-3-60 10.4 73 16.3 2.3 6 10

208-1-60 19.6 130 30.5 2.3 7.6 10

230-1-60 19.6 130 30.5 2.3 7.6 10

T04

208-3-60 13.7 83.1 21.4 2.3 7.6 10

230-3-60 13.7 83.1 21.4 2.3 7.6 10

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 37.5 50

E05 4 1 19.2 44 50 E07 5.6 1 26.9 53.7 60 E10 8 1 38.5 68.1 70 E15 11.9 2 57.2 91.5 100 E20 15.9 2 76.4 115.6 125

NONE - - - 37.5 50

E05 5.3 1 22.1 47.6 50 E07 7.5 1 31.2 59.1 60 E10 10.6 1 44.2 75.2 80 E15 15.9 2 66.2 102.8 110 E20 21.2 2 88.3 130.4 150

NONE - - - 31.3 40

E05 4 1 11.1 33.9 40 E07 5.6 1 15.5 39.4 40 E10 8 1 22.2 47.8 50 E15 11.9 2 33 61.3 70 E20 15.9 2 44.1 75.2 80

NONE - - - 31.3 40

E05 5.3 1 12.7 35.9 40 E07 7.5 1 18 42.6 45 E10 10.6 1 25.5 51.9 60 E15 15.9 2 38.2 67.8 70 E20 21.2 2 51 83.7 90

NONE - - - 44.4 60

E05 4 1 19.2 46 60 E07 5.6 1 26.9 55.7 60 E10 8 1 38.5 70.1 80 E15 11.9 2 57.2 93.5 100 E20 15.9 2 76.4 117.6 125

NONE - - - 44.4 60

E05 5.3 1 22.1 49.6 60 E07 7.5 1 31.2 61.1 70 E10 10.6 1 44.2 77.2 80 E15 15.9 2 66.2 104.8 110 E20 21.2 2 88.3 132.4 150

NONE - - - 37 45

E05 4 1 11.1 37 45 E07 5.6 1 15.5 41.4 50 E10 8 1 22.2 49.8 50 E15 11.9 2 33 63.3 70 E20 15.9 2 44.1 77.2 80

NONE - - - 37 45

E05 5.3 1 12.7 37.9 50 E07 7.5 1 18 44.6 50 E10 10.6 1 25.5 53.9 60 E15 15.9 2 38.2 69.8 70 E20 21.2 2 51 85.7 90

MCA

(Amps)

Max Fuse

Breaker

Size

(Amps)

26 Johnson Controls Ducted Systems

Page 27

ZDT03 through T05 - With Powered Convenience Outlet (Direct Drive) (Continued)

Size

(Tons)

(5.0)

Volt

208-1-60 24.4 144.2 38 4.4 7.6 10

230-1-60 24.4 144.2 38 4.4 7.6 10

T05

208-3-60 16 110 24.9 4.4 7.6 10

230-3-60 16 110 24.9 4.4 7.6 10

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

NONE - - - 52.5 70

E05 4 1 19.2 52.5 70 E07 5.6 1 26.9 55.7 70 E10 8 1 38.5 70.1 80 E15 11.9 2 57.2 93.5 100 E20 15.9 2 76.4 117.6 125 E30 22.2 2 106.7 155.4 175

NONE - - - 52.5 70

E05 5.3 1 22.1 52.5 70 E07 7.5 1 31.2 61.1 70 E10 10.6 1 44.2 77.2 80 E15 15.9 2 66.2 104.8 110 E20 21.2 2 88.3 132.4 150 E30 29.6 2 123.3 176.2 200

NONE - - - 42 50

E05 4 1 11.1 42 50 E07 5.6 1 15.5 42 50 E10 8 1 22.2 49.8 50 E15 11.9 2 33 63.3 70 E20 15.9 2 44.1 77.2 80 E30 22.2 2 61.6 99 100

NONE - - - 42 50

E05 5.3 1 12.7 42 50 E07 7.5 1 18 44.6 50 E10 10.6 1 25.5 53.9 60 E15 15.9 2 38.2 69.8 70 E20 21.2 2 51 85.7 90 E30 29.6 2 71.2 111 125

MCA

(Amps)

Max Fuse

Breaker

Size

(Amps)

5742640-TIM-A-0419

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Table 8: Electrical data: single-phase gas heat, belt drive

ZDT03 through T05 - Without Powered Convenience Outlet (Belt Drive Single Phase Gas Heat)

Compressors

Size

(Tons)

Volt

208-1-60 15.4 83.9 24 2.3 17.4 None - - - 39.5 50

T03

(3)

230-1-60 15.4 83.9 24 2.3 17.4 None - - - 39.5 50

208-1-60 19.6 130 31 2.3 17.4 None - - - 44.2 60

T04

(4)

230-1-60 19.6 130 31 2.3 17.4 None - - - 44.2 60

208-1-60 24.4 144.2 38 4.4 17.4 None - - - 52.3 70

T05

(5)

230-1-60 24.4 144.2 38 4.4 17.4 None - - - 52.3 70

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

MCA

(Amps)

ZDT03 through T05 - With Powered Convenience Outlet (Belt Drive Single Phase Gas Heat)

Size

(Tons)

Volt

208-1-60 15.4 83.9 24 2.3 17.4 20 None - - - 49.5 60

T03

(3)

230-1-60 15.4 83.9 24 2.3 17.4 20 None - - - 49.5 60

208-1-60 19.6 130 31 2.3 17.4 20 None - - - 54.2 70

T04

(4)

230-1-60 19.6 130 31 2.3 17.4 20 None - - - 54.2 70

208-1-60 24.4 144.2 38 4.4 17.4 20 None - - - 62.3 80

T05

(5)

230-1-60 24.4 144.2 38 4.4 17.4 20 None - - - 62.3 80

Compressors

(each)

RLA LRA MCC FLA FLA FLA Model kW Stages Amps

OD Fan

Motors

(each)

1. Minimum Circuit Ampacity.

2. Dual Element, Time Delay Type.

3. HACR type per NEC.

Supply Blower

Motor

Pwr

Conv

Outlet

Electric Heat Option

MCA

(Amps)

Max Fuse

Breaker

(Amps)

Max

Fuse

Breaker

Size

(Amps)

Size

28 Johnson Controls Ducted Systems

Page 29

Table 9: ZDT03 through TA6 Physical Data

ZDT03 through TA6 Physical Data

5742640-TIM-A-0419

Component

ZDT03 ZDT04 ZDT05 ZDTA6

Models

Nominal Tonnage 3 4 5 6

ARI COOLING PERFORMANCE

Gross Capacity @ AHRI A point (Btu) 36600 49100 59000 68000

AHRI net capacity (Btu) 35500 47500 57000 66000

EER 12.0 12.0 11.8 11.20

/11.00

SEER 14.0 14.0 14.0 -

IEER -

IEER IntelliSpeed 14.2

CFM 1200 1450 1680 2057

System power (KW) 2.96 3.96 4.83 5.9

Refrigerant type R-410A R-410A R-410A R-410A

Refrigerant charge (lb-oz)

System 1 4-4 5-6 6-6 6.33

AHRI HEATING PERFORMANCE

Heating model

(N,S)05(N,S)11(D,T)07(D,T)12(N,S)07(N,S)13(D,T)07(D,T)13(N,S)11(N,S)13(D,T)07(D,T)

H10 H12 N07 N12

Heat input (K Btu) 50 100 75 115 75 125 75 125 100 125 75 125 100 125 75 125

Heat output (K Btu) 40 80 60.8 92 60 100 60.8 100.6 80 100 60.8 100.6 80 100 61 100.6

AFUE% (Single Phase Only) 81 81 - - 81 81 - - 81 81 - - - - - -

FER Compliant Direct Drive (Single Phase Gas Heat Only)

FER Compliant Belt Drive (Single Phase Gas Heat Only)

YesYes--YesYes--YesYes----

Yes Yes - - Yes Yes - - No Yes - - - -

Steady state efficiency (%) (3 Phase Only) 80 80 81.1 80.2 80 80 81.1 80.5 80 80 81.1 80.5 80.0 80.0 81.1 80.5

No. burners 2435353545354535

No. stages 1 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2

Temperature Rise Range (ºF) 15-45 45-75 35-70 55-90 25-70 45-75 25-70 45-75 25-55 35-75 20-55 35-75 25-55 30-75 15-45 30-75

Gas Limit Setting (ºF) - Direct Drive 240 170 210 200 210 165 210 165 170 165 210 165 - - - -

Gas Limit Setting (ºF) - Belt Drive 240 210 240 200 240 210 240 210 210 210 210 210 210 210 210 210

Gas piping connection (in.) 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2

DIMENSIONS (inches)

Length 82 1/4 82 1/4 82 1/4 82 1/4

Width 44 7/8 44 7/8 44 7/8 44 7/8

Height 32 5/8 32 5/8 32 5/8 32 5/8

OPERATING WT. (lbs.) 470 598 632 665

COMPRESSORS

Type Scroll Scroll Scroll 2-stage scroll

Quantity 1 1 1 1

Unit Capacity Steps (%) 100 100 100 67/100

CONDENSER COIL DATA

Face area (Sq. Ft.) 16.3 16.3 16.3 16.3

Rows 1111

Fins per inch 23 23 23 23

Tube diameter (in.) 0.71 / 18 0.71 / 18 1.00 / 25.4 1.00 / 25.4

Circuitry Type 2-pass Microchannel 2-pass Microchannel 2-pass Microchannel 2-pass Microchannel

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ZDT03 through TA6 Physical Data (Continued)

Component

ZDT03 ZDT04 ZDT05 ZDTA6

Models

Nominal Tonnage 3 4 5 6

EVAPORATOR COIL DATA

Face area (Sq. Ft.) 5.06 5.06 5.06 5.01

Rows 3444

Fins per inch 13 13 13 13

Tube diameter 0.375 0.375 0.375 0.375

Circuitry Type Intertwined Intertwined Intertwined Intertwined

Refrigerant control Orifice Orifice TXV TXV

CONDENSER FAN DATA

Quantity of fans 1 1 1 1

Fan diameter (Inch) 24 24 24 24

Type Prop Prop Prop Prop

Drive type Direct Direct Direct Direct

Quantity of motors 1 1 1 1

Motor HP each 1/2 1/2 1/2

1/2

No. speeds 1 1 1 2

RPM 1090 1090 1100 900 / 1150

CFM 4000 4000 4200 3300 / 4200

BELT DRIVE EVAP FAN DATA

Quantity 1 1 1 1

Fan Size (Inch) 11 x 10 11 x 10 11 x 10 11 x 10

Type Centrifugal Centrifugal Centrifugal Centrifugal

Motor Sheave 1VL44 1VP56 1VL44 1VP56 1VL44 1VP56 VL44 1VP56

Blower Sheave AK64 AK66 AK56 AK61 AK56 AK56 AK56 AK56

Belt A37 A39 A36 A38 A36 A38 A36 A38

Motor HP each 1-1/2 1-1/2 1-1/2 1-1/2 1-1/2 2 1-1/2 3

RPM 1740 1740 1740 1740

Frame size 56 56 56 56

DIRECT DRIVE EVAP FAN DATA

Quantity 1 1 1 -

Fan Size (Inch) 11 x 10 11 x 10 11 x 10 -

Type Centrifugal Centrifugal Centrifugal -

Motor HP each 3/4 1 1 -

RPM 1050 1050 1050 -

FILTERS

15" x 20" x 1" or 2" 2 2 2 2

14" x 25" x 1" or 2" 1 1 1 1

NOTE: All 2 Stage Gas Heat, 60% Capacity 1

Stage, 40% 2nd Stage

1. Cooling Only Unit or cooling Unit with Electric Heat

2. Cooling Unit with Gas Heat

3. FER or Fan Energy Rating is a Department of Energy (DOE) requirement for single phase gas/electric product rated 65K or less of cooling capacity. DOE ruling effective 7/2019.

4. ECM O.D. Fan Motor

5. Only available on 208/230 Volt Models

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Optional Electric Heat

The factory or field installed heaters are wired for single point power supply. Power supply need only be brought into the single point terminal block, and thermostat wiring to the low voltage terminal strip located in the upper portion of the unit control box.

Table 10: Electric Heat Minimum Supply Air

Size

(Tons)

T03

(3.0)

T04

(4.0)

T05

(5.0)

TA6

(6.0)

Voltage

5 7 10 15 20 30

208/230-1-60 900 900 900 900 900 208/230-3-60 900 900 900 900 900 -

460-3-60 - 900 900 900 900 -

600-3-60 - - 900 900 900 208/230-1-60 1200 1200 1200 1200 1200 208/230-3-60 1200 1200 1200 1200 1200 -

460-3-60 - 1200 1200 1200 1200 -

600-3-60 - - 1200 1200 1200 208/230-1-60 1500 1500 1500 1500 1500 1500 208/230-3-60 1500 1500 1500 1500 1500 1500

460-3-60 - 1500 1500 1500 1500 1500

600-3-60 - - 1500 1500 1500 1500 208/230-3-60 1500 1500 1500 1500 1500 1500

460-3-60 - 1500 1500 1500 1500 1500

600-3-60 - - 1500 1500 1500 1500

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 9 for minimum CFM limitations and to Table 7 for electrical data.

Minimum Supply Air (CFM)

Heater kW

Optional Gas Heat

These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition with proven pilot.

All gas heaters are shipped from the factory equipped for natural gas use. See Gas Heat Application Data Table.

For natural gas heating installations in locations requiring low Nox emissions, Accessory model 1LN0406 must be used.

Table 11: Gas Heat Application Data

Output

Capacity

(MBH)

Available

On Models

Gas Rate

(Ft3/hr)

Temperature Rise °F At Full Input

Min. Max.

Gas Heat

Option

(N,S)05 50 40 3 TON 47 15 45 (N,S)07 75 60 4 TON 70 25 70 (N,S)11 100 80 3/5 TON 93 45/25 75/55 (N,S)12 125 100 4/5 TON 116 45/35 75/75

(D,T)07 75 61 3/4/5 TON 70 35/25/20 70/70/55 (D,T)12 115 92 3 TON 107 55 90 (D,T)13 125 101 4/5TON 116 45/35 75/75

NOTE: Gas Heaters are shipped available for natural gas, but can be converted to L.P. with Kit Model No. 1NP0440 or 1NP0485 (2 Stage).

1. Based on 1075 Btu/Ft.

2. The air flow must be adjusted to obtain a temperature rise within the range shown.

Input

Capacity

(MBH)

All furnaces meet the latest California seasonal efficiency requirements.

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Gas Piping

Proper sizing of gas piping depends on the cubic feet per hour of gas flow required, specific gravity of the gas and the length of run. “National Fuel Gas Code” Z223.1 (in U.S.A.) or the current Gas Installation Codes CSA-B149.1 (in Canada) should be followed in all cases unless superseded by local codes or gas utility requirements. Refer to the Pipe Sizing Table 12. The heating value of the gas may differ with locality. The value should be checked with the local gas utility.

Figure 14: Side Entry Gas Piping

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 1/2 inch pipe connection at the entrance fitting. Line should not be sized smaller than the entrance fitting size.

Gas Connection

The gas supply line can be routed within the space and roof curb, exiting through the unit’s basepan. Refer to Figure 6 for the gas piping inlet locations. Typical supply piping arrangements are shown in Figures 14 and 15. All pipe nipples, fittings, and the gas cock are field supplied or may be purchased in Ducted Systems accessory kit #1GP0401.

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.

Figure 15: Bottom Entry Gas Piping

Table 12: Gas Pipe Sizing - Capacity of Pipe

Length of

Pipe (ft.)

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

3/4 in. 1 in. 1-1/4 in.

Nominal Iron Pipe Size

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 Johnson Controls Ducted Systems

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FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could result in serious injury, death or property damage.

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.

Threaded joints should be coated with a sealing compound that is resistant to the action of liquefied petroleum gases. Do not use Teflon tape.

5742640-TIM-A-0419

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.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could result in serious injury, death or property damage.

Vent And Combustion Air Hoods

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 1NP0440 or 1NP0485 (2 Stage).

All LP gas equipment must conform to the safety standards of the National Fire Protection Association.

For satisfactory operation, adequate LP gas pressure must be provided at the unit manifold 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).

Johnson Controls Ducted Systems 33

The vent hood and combustion air hood (with screens) are shipped attached to the blower housing in the blower compartment. These hoods must be installed to assure proper unit function. All hoods must be fastened to the outside of the gas heat access panel with the screws provided in the bag also attached to the blower housing.

The screen for the combustion air intake hood is secured to the inside of the access panel opening with three fasteners and the screws used for mounting the hood to the panel. The top flange of this hood slips in under the top of the access panel opening when installing. Refer to Vent and Combustion Air Hood Figure 16.

The vent hood is installed by inserting the top flange of the hood into the slotted opening in the access panel and securing in place.

The products of combustion are discharged horizontally through this screened, hooded vent opening on the gas heat access panel.

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Figure 16: Vent And Combustion Air Hood

An adhesive backed label is provided over the outside of the combustion air inlet opening to prevent moisture from entering the unit, which could cause damage to electrical components. Allow this closure label to remain in place until the combustion air hood is to be installed.

Options/Accessories

• Keypad and menu navigation

• Settings and parameter changes

• Menu structure and selection

User Interface

The user interface consists of an LCD display and a 4-button keypad on the front of the economizer module.

Electric Heat

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

Economizer/Motorized Damper and Rain Hood

The instructions for the optional economizer/motorized damper rain hood can be found in forms 828640 (Simplicity Lite) or 5004617 (Smart Equipment). Use these instructions when field assembling an economizer rain hood onto a unit. The outdoor and return air dampers, the damper actuator, the damper linkage, the outdoor and return air divider baffles, and all the control sensors are factory mounted as part of the “Factory installed” economizer/motorized damper options.

Power Exhaust/barometric Relief Damper and Rain Hood

The instructions for the power exhaust/barometric relief damper and rain hood can be found in form 1200060.

All of the components, including the dampers, hardware, and mounting instructions are shipped in a single package external from the unit and must be field assembled and installed.

Power exhaust is only available as a field installed accessory.

RRS Economizer Interface Overview

Units with Simplicity Lite Controls will have a field installed (RRS) Economizer Kit Offered.

This section describes how to use the Economizer’s user interface for:

Figure 17: RRS Economizer LCD and Keypad Layout.

Keypad

The 4 navigation buttons illustrated in Figure 17 are used to scroll through the menus and menu items, select menu items, and to change parameter and configuration settings.

Using the Keypad with Menus

To use the keypad when working with menus:

• Press the  (enter) button navigates to the next level.

• Each press of the ^ (scroll up) and v (scroll down) buttons move the > cursor.

• Each press of the esc (cancel) button navigates to the previous level.

Level 0 of the parameter menu, where either a blank screen is shown or active Alarm(s) are shown in 20-second intervals, is displayed following:

• The boot-up sequence

• 45 minutes of menu navigation inactivity

• Multiple presses of the esc (cancel) button

From Level 0 of the parameter menu, navigation to Level 1 of the menu is done with a press of the ^ (scroll up), v (scroll down) or  (enter) button.

The LEDs at the center-left of the RRS Economizer Controller indicate:

• POWER (green)

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• Lit whenever 24 volts AC power is present to the RRS Economizer Controller C and R pins

• FAULT (red)

• Lit, then flashes during the boot-up sequence of the RRS Economizer Controller

• Not lit when there are no Alarms active

• Double-flash/pause continuously when Alarms are active

• SA BUS (green)

• Will not be lit

Menu Structure

The top level menus are:

•STATUS

•ALARMS

•SUMMARY ECONOMIZER, POWER EXHAUST, COMPRESSOR

• COMMISSION

• CONTROLLER SETTINGS

• UPDATE

• DETAILS

• SELF TEST

• VIEW RESULTS

NOTE: Your menu parameters will be different depending on

your configuration. Refer to the RRS Economizer Control Quick Start Guide P/N 5292230-USG available from your equipment dealer or distributor.

Free Cooling

Four types of free cooling options are available: dry bulb changeover, single enthalpy, dual enthalpy changeover, and Auto.

Dry Bulb Changeover

For dry bulb economizer operation, the outside air is suitable for free cooling if the outside air temperature is 1°F below the Economizer OAT Enable Setpoint and 1°F below the Return Air Temperature.

Free cooling is no longer available if the outside air temperature rises above either the Economizer OAT Enable setpoint or the return air temperature.

Single Enthalpy Changeover

For single enthalpy economizer operation, the outside air is suitable for free cooling if the outside air enthalpy is at least 1 BTU/lb below the Economizer Outside Air Enthalpy Setpoint and the outside air temperature is no greater than the RAT plus 9°F.

If the outside air temperature rises above the RAT plus 10°F, free cooling is no longer available. The outside air temperature must drop to no greater than RAT plus 9°F to enter free cooling again.

Free cooling is no longer available if the outside air enthalpy rises above the Economizer Outside Air Enthalpy Setpoint.

RRS Economizer Controller Parameter Menu Functions

There are several "conditional" parameters within the menu. Parameters for temperature, humidity and CO shown in the menu once sensor presence has been detected. Parameters associated with a function are only shown in the menu when that function is enabled.

inputs are only

Smart Equipment™ Economizer Sequences

Units with the Smart Equipment™ Control will have a factory option or field kit with Johnson Controls Economizer.

Several functions can drive the economizer, including: minimum position, free cooling, economizer loading, and minimum outdoor air supply.

Economizer Minimum Position

The economizer minimum position is set during occupied mode when outside air is not suitable for free cooling. The position of the damper is set proportionally between the "Economizer Minimum Position and the Economizer Minimum Position Low Speed Fan" set points, in relationship to the VFD output percentage. On a constant volume single speed supply fan system both set-points should be set to the same value.

Dual Enthalpy Changeover

For dual enthalpy economizer operation, the outside air enthalpy must be lower than the return air enthalpy by 1 btu/lb AND the outside air temperature is no greater than the RAT plus 9°F.

Auto

The control determines the type of free cooling changeover based on which sensors are present and reliable. Conditions include:

• Return and outside air dry bulb = dry bulb changeover

• Return and outside air dry bulb and outside air humidity = single enthalpy

• Return and outside air dry bulb and return and outside air humidity = dual enthalpy

• If either the return or outside air dry bulb sensors are unreliable, free cooling is not available

Free Cooling Operation

When the control determines that the outside air is suitable, the first stage of cooling will always be free cooling.

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Thermostat

In free cooling, with a thermostat input to Y1, the dampers modulate to control the supply air temperature to the Economizer Setpoint +/- 1°F (default 55°F).

If the thermostat provides an input to Y2 and the parameter Compressors Off in Free Cooling is turned OFF a compressor output energizes. The economizer dampers continue to modulate to control the supply air temperature to the Economizer Setpoint.

If the supply air temperature cannot be maintained within 5°F of the economizer setpoint, the first stage compressor (C1) will be turned on. Second stage compressor (C2) will be added as needed to keep the supply air temperature within the 5°F of the economizer setpoint.

Sensor

In free cooling, with a demand from the zone/return sensor for the first stage of cooling, the dampers modulate to control the supply air temperature to the Economizer Setpoint +/- 1°F.

If the economizer output is at 100% and the SAT is greater than the Economizer setpoint + 1°F, the control starts a 12-minute timer to energize a compressor output.

If at any time the economizer output drops below 100% the timer stops and resets when the economizer output returns to 100%.

Once a compressor output is turned ON, the economizer dampers continue to modulate to control the supply air temperature to the Economizer Setpoint.

At no time will a compressor output be turned ON if the economizer output is less than 100%, even if the differential between zone (or return) temperature and the current cooling setpoint is great enough to demand more than one stage of cooling.

If the economizer output goes to minimum position and the SAT is less than Economizer Setpoint -1°F, the control starts a 12minute timer to de-energize a compressor output.

If at any time the economizer output goes above the minimum position the timer stops and resets when the economizer output returns to minimum position.

If the demand for cooling from the space/return is satisfied, the economizer output will modulate to minimum position and the compressor outputs will be de-energized as long as their minimum run timers have expired.

Power Exhaust

Setpoints

a. Economizer Enable ON

b. Power Exhaust Enable ON

c. Modulating Power Exhaust OFF

d. Exhaust VFD Installed OFF

e. Building Pressure Sensor Enabled OFF

f. Econo Damper Position For Exh Fan ON Percent

g. Econo Damper Position For Exh Fan OFF Percent

Inputs

No inputs are present for non-modulating power exhaust.

Outputs

a. 2-10 VDC from ECON on Economizer Expansion module

b. 24 VAC from EX-FAN to energize exhaust fan on

Economizer Expansion module

Operation

Operation details include:

a. Compares economizer output to the Economizer Damper

Position For Exhaust Fan On and OFF.

b. Energizes exhaust fan when economizer output is above

Economizer Damper Position For Exhaust Fan On.

c. De-energizes exhaust fan when economizer output is

below the Economizer Damper Position for Exhaust Fan OFF

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Figure 18: SE-ECO1001-0 Economizer Controller

Table 13: Smart Equipment™ Economizer Board Details

Board

Label

IN2

IN1

POWER

FAULT

SA BUS

Cover

Label

COM

ECOFB

24V~

COM

MAT

POWER Green UCB power indicator Lit indicates 24 VAC is present at 24V~ IN COM and HOT pins

FAULT

SA BUS

24 VAC common/0-10 VDC negative for economizer actuator position feedback

0-10 VDC positive input from Economizer actuator position Feedback

24 VAC hot supplied for economizer actuator position feedback

Mixed Air Temperature sensor input from 10KΩ @ 77°F, Type III negative temperature coefficient thermistor

Red networking error and firmware error indicator

Green UCB SA bus communication transmission indicator

Description Function & Comments

Directional orientation: viewed with the center text of the cover label upright

ANALOG INPUTS Terminal at left on upper edge of economizer board

LEDs at left on upper edge of economizer board

Connects through circuit trace to 24V~ IN pin COM

EconDampPos parameter reports input status (0-100%). Used to meet Cali. Title 24 requirements for economizer actuator position feedback

Connects through circuit trace to 24V~ IN pin HOT

MAT parameter reports input status (°F/°C), 3.65 VDC reading MAT (+) to COM (−) with open circuit. Read-only use in current control revision.

1/10th second on/off flashing indicates a networking error (polarity, addressing, etc.) or a firmware error (likely correctable with re-loading from USB flash drive)

Lit/flickering indicates UCB-to-economizer board SA bus communication is currently active, off indicates the economizer board is awaiting SA bus communication

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Table 13: Smart Equipment™ Economizer Board Details (Continued)

Board

Label

–

Cover

Label

COM

Common for SA BUS power and communication circuits

– Communication for SA BUS devices

+ Communication for SA BUS devices

Description Function & Comments

SA BUS1 Pin connections at left on upper edge of economizer board

ANALOG OUTPUTS Pin at center on upper edge of economizer board

EconCtrlr parameter reports UCB-to-economizer board SA bus communication status. Negative of the SA BUS communication circuit to the UCB. Through the unit wiring harness, may continue on to the 4-stage board and/or fault detection & diagnostics board

EconCtrlr parameter reports UCB-to-economizer board SA BUS communication status. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts lower than +) SA BUS communication circuit to the UCB. Through the unit wiring harness, may continue on to the 4-stage board and/or fault detection & diagnostics board

EconCtrlr parameter reports UCB-to-economizer board SA BUS communication status. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts higher than –) SA BUS communication circuit to the UCB. Through the unit wiring harness, may continue on to the 4-stage board and/or fault detection & diagnostics board

2-10 VDC positive output for the modulating

EX VFD

COM

24V~

ECON 2-10 VDC output for the Economizer actuator

COM

24V~

ACT-A

ACT-B 24 VAC return Unused in current control revision

COM

EX-FAN

COM

power Exhaust fan Variable Frequency Drive/ discharge damper modulating power exhaust actuator

24 VAC common/0-10 VDC negative for the power exhaust variable frequency drive/ discharge damper modulating power exhaust actuator

24 VAC hot supplied for the discharge damper modulating power exhaust actuator and economizer actuator

24 VAC common/0-10 VDC negative for economizer actuator

BINARY OUTPUTS Pin at right on upper edge of economizer board

24 VAC hot supplied for an incremental (floating control) economizer actuator

24 VAC hot outputs to position an incremental (floating control) economizer actuator

24 VAC common for an incremental (floating control) economizer actuator

24 VAC hot output to energize power exhaust fan contactor coil/VFD enable relay coil

24 VAC common/0-10 VDC negative for economizer actuator

ExFanVFD parameter reports output status (0-100%) when ExFType selection is Variable Frequency Fan; EAD-O parameter reports output status (0-100%) when ExFType selection is Modulating Damper. Used to ramp the power exhaust fan VFD/ position the discharge damper actuator.

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

Econ parameter reports output status (0-100%). Used to position the economizer actuator for minimum position, free cooling, demand ventilation, cooling economizer loading and purge functions

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

Unused in current control revision

Connects through circuit trace to 24V~ IN pin COM

ExFan parameter reports output status (Off-On) when ExFType selection is Non-Modulating, Modulating Damper or Variable Frequency Fan. Used to turn on/enable the power exhaust fan motor.

Connects through circuit trace to 24V~ IN pin COM

38 Johnson Controls Ducted Systems

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Table 13: Smart Equipment™ Economizer Board Details (Continued)

Board

Label

IN3

IN4

Cover

Label

COM

HOT 24 VAC transformer HOT

24V~

OAH

COM

24V~

SAH

COM

24V~

24 VAC transformer Common referenced to cabinet ground

24 VAC hot supplied for the outdoor air humidity sensor

0-10 VDC positive input from the Outdoor Air Humidity sensor

24 VAC common/0-10 VDC negative for the outdoor air humidity sensor

24 VAC hot supplied for the supply air humidity sensor

0-10 VDC positive input from the Supply Air Humidity sensor

24 VAC common/0-10 VDC negative for the supply air humidity sensor

24 VAC hot supplied for the indoor air quality sensor

Description Function & Comments

24V~ IN Pin connections at right on upper edge of economizer board

ANALOG INPUTS Terminal on lower edge of economizer board

5742640-TIM-A-0419

24 VAC common connection to power the economizer board. Connects through circuit traces to C/COM terminals and pins distributed on the economizer board.

24 VAC hot connection to power the economizer board. Connects through circuit traces to R/24V~ terminals and pins distributed on the economizer board.

Connects through circuit trace to 24V~ IN pin HOT

OAH parameter reports input status (0-100%H). Used in outdoor air enthalpy calculation for dual enthalpy economizer free cooling changeover.

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

SAH parameter reports input status (0-100%H). Unused in current control revision.

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

IN5

IN6

IN7

IAQ

COM

24V~

OAQ

COM

24V~

FR AIR

COM

24V~

0-10 VDC positive input from the Indoor Air Quality sensor

24 VAC common/0-10 VDC negative for the indoor air quality sensor

24 VAC hot supplied for the outdoor air quality sensor

0-10 VDC positive input from the Outdoor Air Quality sensor

24 VAC common/0-10 VDC negative for the outdoor air quality sensor

24 VAC hot supplied for the air monitoring station sensor

0-10 VDC positive input from the air monitoring station sensor

24 VAC common/0-10 VDC negative for the air monitoring station sensor

24 VAC hot supplied for the building pressure sensor

IAQRange parameter sets the CO2 parts per million measured by the indoor air quality sensor when it outputs 10 VDC; IAQ parameter reports input status (0-5000ppm). Used for demand ventilation functions if the NetIAQ parameter indicates ?Unrel.

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

OAQRange parameter sets the CO2 parts per million measured by the outdoor air quality sensor when it outputs 10 VDC; OAQ parameter reports input status (0-5000ppm). Used for demand ventilation function when DVent-Mode selection is Diff between IAQ and OAQ and the NetOAQ parameter indicates ?Unrel.

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

MOA-Range parameter sets the cubic feet per minute/liters per second measured by the air monitoring station sensor when it outputs 10 VDC; Fr Air parameter reports input status (050000CFM/23595lps). Used for economizer minimum position reset in speed-controlled indoor blower applications.

Connects through circuit trace to 24V~ IN pin COM

Connects through circuit trace to 24V~ IN pin HOT

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Table 13: Smart Equipment™ Economizer Board Details (Continued)

Board

Label

IN8

IN9

IN10

1. When wiring unit and other devices using the SA Bus and FC Bus, see Table 31.

Cover

Label

BLDG PRES

COM

PURGE 24 VAC hot input from the PURGE dry contact

24V~ 24 VAC hot supplied for the purge dry contact Connects through circuit trace to 24V~ IN pin HOT

EX VFD FLT

24V~

0-5 VDC positive input from the Building Pressure sensor

24 VAC common/0-5 VDC negative for the building pressure sensor

24 VAC hot input from the power Exhaust Variable Frequency Drive Fault contact

24 VAC hot supplied for the power exhaust variable frequency drive fault contact

Description Function & Comments

BINARY INPUTS at right on lower edge of economizer board

BldgPres parameter reports input status (-.250-.250”/w/-.062.062kPa). Used for modulating power exhaust functions when ExFType selection is Modulating Damper or Variable Frequency Fan.

Connects through circuit trace to 24V~ IN pin COM

Purge parameter reports input status (False with 0 VAC inputTrue with 24 VAC input). When Purge status is True, heating and cooling operation is prevented, the indoor blower and power exhaust fan operate, the economizer actuator is positioned to 100%.

ExFanVFDFlt parameter reports input status (Normal with 0 VAC input-Alarm with 24 VAC input) when ExFType selection is Variable Frequency Fan. When ExFanVFDFlt status is Alarm, EX-FAN fan output is prevented.

Connects through circuit trace to 24V~ IN pin HOT

Indoor Air Quality - IAQ

Indoor Air Quality (indoor sensor input): The Indoor Air Quality sensor is connected to the economizer board through the IAQ analog input terminal and the associated COM and 24V~ inputs on the economizer board. Terminal IAQ accepts a 0 to +10 Vdc signal with respect to the (IAQ) terminal. When the signal is below its set point, the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs. When the IAQ signal exceeds its set point setting, and there is no call for free cooling, the actuator is proportionately modulated from the 0 to 10 Vdc signal, with 0 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 its 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 IAQ voltage input.

• Optional CO2 Space Sensor Kit Part #2AQ04700524

• Optional CO2 Sensor Kit Part #2AQ04700624

Phasing

ZE units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the phasing of the Field Line Connection at the factory or field supplied disconnect to obtain proper rotation. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar

suction and discharge pressures, or producing a high noise level, the scroll is misphased.)

Scroll compressors require proper rotation to operate correctly. Units are properly phased at the factory. Do not change the internal wiring to make the blower condenser fans, or compressor rotate correctly.

Check for the high leg conductor by checking voltage of each phase to ground.

Note: Check all three phase motors and compressors for proper rotation after making a change. If it is necessary to change 3 phase motor rotation, swap A or L1 and C or L3 only.

40 Johnson Controls Ducted Systems

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Blower Rotation

*Never Loosen

(A)

(C)*

(B)

Span Length

Defl Force

Check for proper supply air blower rotation. If the blower is rotating backwards, the line voltage at the unit point of power connection is misphased (See ‘PHASING’).

Belt Tension

The tension on the belt should be adjusted as shown in Figure 20.

Figure 19: Belt Adjustment

5742640-TIM-A-0419

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 re-tighten nuts (A).

CFM Static Pressure and Power-Altitude and Temperature Corrections

The information below should be used to assist in application of product when being applied at altitudes at or exceeding 1000 feet above sea level.

The air flow rates listed in the standard blower performance tables are based on standard air at sea level. As the altitude or temperature increases, the density of air decreases. In order to use the indoor blower tables for high altitude applications, certain corrections are necessary.

A centrifugal fan is a “constant volume” device. This means that, if the rpm remains constant, the CFM delivered is the same regardless of the density of the air. However, since the air at high altitude is less dense, less static pressure will be generated and less power will be required than a similar application at sea level. Air density correction factors are shown in Table 14 and Figure 20.

Table 14: Altitude/Temperature Correction Factors

Air

Temp.

40 1.060 1.022 0.986 0.950 0.916 0.882 0.849 0.818 0.788 0.758 0.729 50 1.039 1.002 0.966 0.931 0.898 0.864 0.832 0.802 0.772 0.743 0.715 60 1.019 0.982 0.948 0.913 0.880 0.848 0.816 0.787 0.757 0.729 0.701 70 1.000 0.964 0.930 0.896 0.864 0.832 0.801 0.772 0.743 0.715 0.688 80 0.982 0.947 0.913 0.880 0.848 0.817 0.787 0.758 0.730 0.702 0.676 90 0.964 0.929 0.897 0.864 0.833 0.802 0.772 0.744 0.716 0.689 0.663

100 0.946 0.912 0.880 0.848 0.817 0.787 0.758 0.730 0.703 0.676 0.651

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Altitude (Ft.)

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0.600

0.650

0.700

0.750

0.800

0.850

0.900

0.950

1.000

1.050

1.100

40 50 60 70 80 90 100

Air Temperature (ºF)

Correction Factor

Sea Level

1000 ft

2000 ft

3000 ft

4000 ft

6000 ft

7000 ft

8000 ft

9000 ft

10000 ft

5000 ft

Figure 20: Altitude/Temperature Correction Factors

The examples below will assist in determining the airflow performance of the product at altitude.

Example 1: What are the corrected CFM, static pressure, and BHP at an elevation of 5,000 ft. if the blower performance data is 1,400 CFM, 0.6 IWC and 0.67 BHP?

Solution: At an elevation of 5,000 ft. the indoor blower will still deliver 1,400 CFM if the rpm is unchanged. However, Table 15 must be used to determine the static pressure and BHP. Since no temperature data is given, we will assume an air temperature of 70°F. Table 14 shows the correction factor to be 0.832.

Corrected static pressure = 0.6 x 0.832 = 0.499 IWC

Corrected BHP = 0.67 x 0.832 = 0.56

Example 2: A system, located at 5,000 feet of elevation, is to deliver 1,400 CFM at a static pressure of 1.5". Use the unit

blower tables to select the blower speed and the BHP requirement.

Solution: As in the example above, no temperature information is given so 70°F is assumed.

The 1.5" static pressure given is at an elevation of 5,000 ft. The first step is to convert this static pressure to equivalent sea level conditions.

Sea level static pressure = 0.6 / .832 = 0.72"

Enter the blower table at 1,400 sCFM and static pressure of

0.72". The rpm listed will be the same rpm needed at 5,000 ft.

Suppose that the corresponding BHP listed in the table is 0.7. This value must be corrected for elevation.

BHP at 5,000 ft. = 0.7 x .832 = 0.58

42 Johnson Controls Ducted Systems

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5742640-TIM-A-0419

Drive Selection

1. Determine side or bottom supply air 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. 2200 CFM

2. 1.6 iwg

3. Using the supply air blower performance table below, the following data point was located: 1478 RPM & 1.82 BHP.

4. Using the RPM selection table below, Size X and Model Y is found.

5. 1.82 BHP exceeds the maximum continuous BHP rating of the 1.5 HP motor. The 2 HP motor is required.

6. 1478 RPM is within the range of the 2 HP drive.

7. Using the 2 HP motor and drive, 2.5 turns open will achieve 1478 RPM.

Example Supply Air Blower Performance

Air Flow

(CFM)

2000 907 1.00 990 1.07 1070 1.15 1146 1.23 1220 1.31 1291 1.40 1359 1.49 1425 1.58 1488 1.68 1550 1.77 2200 960 1.24 1043 1.31 1123 1.39 1199 1.47 1273 1.55 1344 1.64 1412 1.73 1478 1.82 1541 1.92 1602 2.01 2400 1015 1.51 1099 1.59 1178 1.66 1255 1.74 1329 1.83 1400 1.92 1468 2.01 1534 2.10 1597 2.19 1658 2.29 2600 1074 1.83 1157 1.90 1237 1.98 1314 2.06 1387 2.14 1458 2.23 - - - - - - - -

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

Standard Drive Option HIgh Static Drive Option

Available External Static Pressure - IWG

Table X: RPM Selection

Size

(Tons)

Model HP

Max

BHP

1.5 1.73 1VL44 AK56 930 995 1060 1130 1195 1260 2 2.3 1VP56 AK56 1325 1395 1460 1525 1590 1660

Motor

Sheave

Blower Sheave

5 Turns

Open

4 Turns

Open

3 Turns

Open

2 Turns

Open

1 Turn

Open

Fully

Closed

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5742640-TIM-A-0419

Table 15: ZD Blower Performance Side Duct

ZDT03 (3 Ton Belt Drive) Side Duct

Air Flow

(CFM)

800 634 0.28 735 0.34 828 0.40 914 0.47 995 0.55 1070 0.63 1140 0.72 1207 0.81 1270 0.90 1332 0.98 1000 659 0.34 760 0.40 853 0.46 939 0.53 1019 0.61 1094 0.69 1165 0.77 1232 0.87 1295 0.95 1356 1.05 1200 685 0.42 786 0.47 879 0.54 965 0.61 1045 0.69 1120 0.77 1191 0.86 1258 0.94 1321 1.04 1382 1.12 1400 716 0.53 816 0.58 909 0.65 995 0.72 1076 0.79 1151 0.88 1221 0.96 1288 1.05 1352 1.15 1413 1.23 1600 752 0.66 852 0.72 945 0.78 1032 0.86 1112 0.93 1187 1.02 1258 1.10 1324 1.19 1388 1.27 1449 1.37

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications.

2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.

3. kW = BHP x 0.932.

4. Field Supplied Drive.

ZDT04 (4 Ton Belt Drive) Side Duct

Air Flow

(CFM)

1000 703 0.27 786 0.42 866 0.49 942 0.58 1016 0.67 1087 0.76 1155 0.85 1221 0.96 1284 1.05 1345 1.16 1200 733 0.33 817 0.47 896 0.56 973 0.64 1047 0.73 1118 0.82 1186 0.92 1252 1.01 1315 1.11 1376 1.21 1400 770 0.42 853 0.56 933 0.63 1010 0.73 1083 0.81 1154 0.90 1222 1.00 1288 1.10 1352 1.19 1413 1.30 1600 811 0.55 895 0.67 974 0.76 1051 0.84 1125 0.94 1196 1.02 1264 1.12 1330 1.22 1393 1.32 1454 1.42 1800 857 0.73 940 0.84 1020 0.93 1097 1.01 1171 1.10 1242 1.19 1310 1.29 1375 1.38 1439 1.49 1500 1.59 2000 907 0.95 990 1.05 1070 1.14 1146 1.22 1220 1.31 1291 1.40 1359 1.50 1425 1.59 1488 1.70 1550 1.79

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications.

2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.

3. kW = BHP x 0.932.

4. Field Supplied Drive.

FS4

ZDT05 (5 Ton Belt Drive) Side Duct

Air Flow

(CFM)

1200 733 0.39 817 0.47 896 0.56 973 0.64 1047 0.73 1118 0.82 1186 0.92 1252 1.01 1315 1.11 1376 1.21 1400 770 0.47 853 0.56 933 0.63 1010 0.73 1083 0.81 1154 0.91 1222 1.00 1288 1.10 1352 1.19 1413 1.30 1600 811 0.60 895 0.67 974 0.76 1051 0.84 1125 0.94 1196 1.02 1264 1.12 1330 1.22 1393 1.32 1454 1.43 1800 857 0.77 940 0.84 1020 0.93 1097 1.01 1171 1.10 1242 1.19 1310 1.29 1375 1.38 1439 1.49 1500 1.60 2000 907 0.98 990 1.05 1070 1.14 1146 1.22 1220 1.31 1291 1.40 1359 1.50 1425 1.60 1488 1.70 1550 1.80 2200 960 1.23 1043 1.31 1123 1.39 1199 1.48 1273 1.56 1344 1.66 1412 1.75 1478 1.85 1541 1.96 1602 2.05 2400 1015 1.52 1099 1.61 1178 1.68 1255 1.76 1329 1.86 1400 1.96 1468 2.05 1534 2.15 1597 2.24 1658 2.35 2600 1074 1.86 1157 1.93 1237 2.02 1314 2.10 1387 2.19 1458 2.28 - - - - - - - -

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications.

2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.

3. kW = BHP x 0.932.

4. Field Supplied Drive.

44 Johnson Controls Ducted Systems

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5742640-TIM-A-0419

ZDTA6 (6 Ton Belt Drive) Side Duct

Air Flow

(CFM)

1600 917 0.28 975 0.48 1027 0.63 1075 0.75 1120 0.84 1166 0.93 1213 1.02 1265 1.13 1323 1.26 1390 1.44 1800 945 0.44 1004 0.64 1056 0.79 1104 0.91 1149 1.00 1194 1.09 1242 1.18 1294 1.29 1352 1.43 1418 1.60 2000 981 0.65 1039 0.84 1091 0.99 1139 1.11 1184 1.21 1230 1.30 1277 1.39 1329 1.50 1387 1.63 1454 1.80 2200 1023 0.90 1081 1.09 1133 1.24 1181 1.36 1226 1.46 1272 1.55 1319 1.64 1371 1.75 1429 1.88 1496 2.06 2400 1072 1.19 1130 1.39 1182 1.54 1230 1.66 1276 1.75 1321 1.84 1369 1.93 1420 2.04 1478 2.17 1545 2.35 2600 1128 1.53 1186 1.73 1238 1.88 1286 1.99 1332 2.09 1377 2.18 1425 2.27 1476 2.38 1534 2.51 1601 2.69 2800 1191 1.91 1249 2.10 1301 2.25 1349 2.37 1394 2.47 1440 2.55 1487 2.65 1539 2.75 1597 2.89 1664 3.06 3000 1260 2.32 1318 2.52 1370 2.67 1418 2.79 1463 2.88 1509 2.97 1556 3.06 1608 3.17 1666 3.30 ---- ----

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

FSD

Available External Static Pressure - IWG

Standard Static Drive Option High Static Drive Option

1. Blower performance includes gas heat exchangers and 1” filters. See STATIC RESISTANCE table for additional applications.

2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP.

3. kW = BHP x 0.932.

4. Field Supplied Drive.

ZDT03 through TA6 (3-6 Ton Direct Drive) Side Duct

WATTS

CFM

WATTS

CFM

WATTS

AVAILABLE EXTERNAL STATIC PRESSURE - IWG

UNIT

TONNAGE

MOTOR

SPEED

5 (HI) 1574 320 1530 335 1488 349 1451 363 1411 376 1374 390 1331 403 1292 417 1249 430

4 (MED/HI) 1480 263 1433 276 1389 290 1347 303 1303 316 1257 329 1208 343 1153 358 1080 374

3 (MED) 1332 208 1286 221 1241 234 1195 246 1146 258 1097 272 1031 288 962 303 919 313

2 (MED/LOW) 1227 171 1178 183 1129 195 1076 207 1021 220 953 235 891 248 - - - -

1 (LOW) 1075 130 992 134 930 145 858 158 - - - - - - - - - -

5 (HI) - - 2067 696 2027 714 1991 734 1953 749 1910 764 1860 769 1770 743 1621 685

4 (MED/HI) 1913 539 1877 557 1839 571 1798 585 1764 602 1721 619 1677 638 1621 653 1545 639

3 (MED) 1722 408 1682 426 1634 438 1597 455 1554 472 1506 490 1450 505 1404 521 1370 536

2 (MED/LOW) 1475 321 1435 335 1388 352 1359 362 1319 376 1271 393 1220 411 1186 422 1142 437

1 (LOW) 1332 223 1290 237 1232 247 - - - - - - - - - - - -

5 (HI) 2245 883 2247 931 2236 950 2211 964 2171 979 2114 971 2034 940 1948 898 1855 854

4 (MED/HI) 2135 771 2116 784 2108 808 2078 826 2041 844 2004 859 1955 861 1886 843 1792 806

3 (MED) 2010 637 1989 656 1975 675 1938 696 1900 715 1867 730 1822 740 1784 756 1716 748

2 (MED/LOW) 1672 408 1633 426 1586 438 1550 455 1509 472 1462 490 1408 505 1363 521 1330 536

1 (LOW) 1562 327 1529 339 1491 356 - - - - - - - - - - - -

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

CFM

WATTS

CFM

WATTS

CFM

WATTS

CFM

WATTS

CFM

WATTS

CFM

1. Factory set on medium speed tap.

2. Includes allowances for a wet evaporator coil, 1” filters, and the heat exchangers. Refer to STATIC RESISTANCES Table for resistance values.

3. Side Duct application (230 Volts)

CFM

WATTS

Table 16: ZD Blower Performance Bottom Duct

ZDT03 (3 Ton Belt Drive) Bottom Duct

Air Flow

(CFM)

800 613 0.29 724 0.34 826 0.41 920 0.48 1007 0.56 1089 0.63 1165 0.71 1237 0.80 1306 0.88 1372 0.98 1000 640 0.34 751 0.41 853 0.47 947 0.53 1034 0.61 1116 0.69 1192 0.77 1264 0.86 1333 0.95 1399 1.03 1200 669 0.43 779 0.48 881 0.55 975 0.61 1063 0.69 1144 0.77 1220 0.85 1293 0.94 1361 1.02 1427 1.12 1400 702 0.52 812 0.59 914 0.65 1009 0.71 1096 0.79 1177 0.87 1254 0.96 1326 1.04 1394 1.13 1460 1.21 1600 741 0.66 852 0.71 954 0.78 1048 0.85 1135 0.93 1217 1.00 1293 1.08 1365 1.17 1434 1.25 1500 1.35

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” 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.

FS4

Johnson Controls Ducted Systems 45

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5742640-TIM-A-0419

ZDT04 (4 Ton Belt Drive) Bottom Duct

`Air Flow

(CFM)

1000 688 0.34 779 0.42 866 0.50 949 0.59 1029 0.67 1107 0.77 1181 0.85 1253 0.95 1322 1.05 1388 1.15 1200 722 0.40 812 0.48 899 0.56 983 0.64 1063 0.73 1140 0.82 1215 0.90 1286 1.01 1355 1.11 1422 1.20 1400 761 0.48 852 0.56 939 0.64 1022 0.73 1103 0.81 1180 0.89 1254 0.99 1326 1.08 1395 1.19 1462 1.29 1600 807 0.61 897 0.68 984 0.76 1068 0.84 1148 0.93 1225 1.02 1300 1.12 1371 1.21 1440 1.31 1507 1.40 1800 856 0.77 947 0.84 1034 0.93 1118 1.00 1198 1.10 1275 1.18 1349 1.28 1421 1.37 1490 1.47 1557 1.57 2000 910 0.97 1001 1.04 1088 1.13 1172 1.21 1252 1.30 1329 1.39 1403 1.48 1475 1.57 1544 1.68 1611 1.77

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” 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.

FS4

ZDT05 (5 Ton Belt Drive) Bottom Duct

Air Flow

(CFM)

1200 722 0.40 812 0.48 899 0.56 983 0.64 1063 0.73 1140 0.82 1215 0.90 1286 1.01 1355 1.11 1422 1.20 1400 761 0.48 852 0.56 939 0.64 1022 0.73 1103 0.81 1180 0.89 1254 0.99 1326 1.08 1395 1.19 1462 1.29 1600 807 0.61 897 0.68 984 0.76 1068 0.84 1148 0.93 1225 1.02 1300 1.12 1371 1.21 1440 1.31 1507 1.40 1800 856 0.77 947 0.84 1034 0.93 1118 1.00 1198 1.10 1275 1.18 1349 1.28 1421 1.37 1490 1.47 1557 1.57 2000 910 0.97 1001 1.04 1088 1.13 1172 1.21 1252 1.30 1329 1.39 1403 1.48 1475 1.57 1544 1.68 1611 1.77 2200 968 1.22 1059 1.30 1146 1.37 1229 1.46 1309 1.54 1387 1.64 1461 1.73 1533 1.83 1602 1.92 1668 2.03 2400 1029 1.51 1119 1.58 1206 1.67 1290 1.74 1370 1.84 1448 1.92 1522 2.02 15932.1116632.211729 2.31 2600 1093 1.84 1183 1.91 1270 1.98 1354 2.07 1434 2.15 1511 2.25 1586 2.34 - - - -- -

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” 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.

FS4

ZDTA6 (6 Ton Belt Drive) Bottom Duct

Air Flow

(CFM)

1600 829 0.46 914 0.52 988 0.61 1055 0.71 1115 0.83 1170 0.95 1222 1.09 1273 1.23 1324 1.36 1377 1.50 1800 858 0.63 943 0.70 1017 0.78 1084 0.89 1144 1.00 1199 1.13 1251 1.26 1302 1.40 1353 1.54 1406 1.67 2000 898 0.84 983 0.90 1057 0.99 1124 1.09 1184 1.21 1239 1.34 1291 1.47 1342 1.61 1393 1.75 1446 1.88 2200 945 1.08 1030 1.15 1104 1.23 1171 1.34 1231 1.45 1286 1.58 1338 1.72 1389 1.85 1440 1.99 1493 2.13 2400 997 1.37 1081 1.44 1156 1.52 1222 1.62 1282 1.74 1338 1.87 1390 2.00 1441 2.14 1491 2.28 1544 2.41 2600 1052 1.70 1136 1.77 1211 1.85 1277 1.96 1337 2.07 1392 2.20 1445 2.33 14952.4715462.611599 2.74 2800 1108 2.08 1192 2.14 1267 2.23 1334 2.33 1394 2.45 1449 2.58 1501 2.71 15522.8516032.991656 3.12 3000 1166 2.50 1250 2.57 1325 2.65 1391 2.75 1451 2.87 1506 3.00 1558 3.13 1609 3.27 ---- ---- ---- ----

0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP

Field Supplied Drive Standard Static Drive Option High Static Drive Option

Available External Static Pressure - IWG

1. Blower performance includes gas heat exchangers and 1” 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. 1kW = BHP x 0.862.

46 Johnson Controls Ducted Systems

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5742640-TIM-A-0419

ZDT03 through TA6 (3-6 Ton Direct Drive) Bottom Duct

WATTS

CFM

WATTS

CFM

WATTS

AVAILABLE EXTERNAL STATIC PRESSURE - IWG

UNIT

TONNAGE

MOTOR

SPEED

5 (HI) 1520 320 1478 335 1438 349 1401 363 1363 376 1327 390 1286 403 1248 417 1207 430

4 (MED/HI) 1430 263 1384 276 1342 290 1302 303 1259 316 1215 329 1168 343 1114 358 1044 374

3 (MED) 1287 208 1242 221 1199 234 1155 246 1108 258 1060 272 997 288 930 303 889 313

2 (MED/LOW) 1185 171 1138 183 1091 195 1041 207 987 220 921 235 862 248 - - - -

1 (LOW) 1040 130 959 134 900 145 - - - - - - - - - - - -

5 (HI) - - 1995 696 1957 714 1922 734 1885 749 1844 764 1795 769 1709 743 1566 685

4 (MED/HI) 1846 539 1812 557 1776 571 1736 585 1704 602 1662 619 1619 638 1566 653 1492 639

3 (MED) 1662 408 1624 426 1577 438 1542 455 1501 472 1454 490 1400 505 1356 521 1323 536

2 (MED/LOW) 1566 362 1526 380 1480 391 1450 406 1411 423 1363 440 1312 455 1279 469 1235 485

1 (LOW) 1287 223 1246 237 1190 247 - - - - - - - - - - - -

5 (HI) 2166 883 2169 931 2158 950 2134 964 2095 979 2040 971 1963 940 1881 898 1791 854

4 (MED/HI) 2060 771 2042 784 2035 808 2006 826 1970 844 1934 859 1888 861 1821 843 1730 806

3 (MED) 1940 637 1920 656 1907 675 1870 696 1834 715 1802 730 1759 740 1722 756 1657 748

2 (MED/LOW) 1688 413 1645 432 1611 451 1575 468 1534 479 1498 497 1461 513 - - - -

1 (LOW) 1509 327 1477 339 - - - - - - - - - - - - - -

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

CFM

WATTS

CFM

WATTS

CFM

WATTS

CFM

WATTS

CFM

WATTS

CFM

1. Factory set on medium speed tap.

2. Includes allowances for a wet evaporator coil, 1” filters, and the heat exchangers. Refer to STATIC RESISTANCES Table for resistance values.

3. Bottom Duct application (230 Volts)

CFM

WATTS

Table 17: Belt Drive RPM Selection

Size

(Tons)

T03

(3)

T04

(4)

T05

(5)

TA6

(6)

Model HP

* Field Option Sheave.

Max

BHP

1.5 1.73 1VL44 AK64 805 865 920 980 1035 1095

1.5 1.73 1VP56 AK66 1115 1170 1225 1280 1335 1390

1.5 1.73 1VL44 AK56 930 995 1060 1130 1195 1260

1.5 1.73 1VP56 AK61 1210 1270 1330 1390 1455 1515

1.5 1.73 1VL44 AK56 930 995 1060 1130 1195 1260 2 2.3 1VP56 AK56 1325 1395 1460 1525 1590 1660

1.5 1.73 1VL44 AK56 930 995 1060 1130 1195 1260 3 3.45 1VP56 AK56 1325 1395 1460 1525 1590 1660

Motor

Sheave

Blower

Sheave

5 Turns

Open

4 Turns

Open

3 Turns

Open

2 Turns

Open

1 Turn

Open

Fully

Closed

Table 18: Indoor Blower Specifications (Belt Drive)

Size

(Tons)

T03

(3.0)

T04

(4.0)

T05

(5.0)

TA6

(6.0)

HP RPM Eff. SF Frame

1-1/2 1725 0.8 1.15 56 2.8 - 3.8 7/8 1VL44 6.0 1 AK64 A37 1-1/2 1725 0.8 1.15 56 4.0 - 5.0 7/8 1VP56 6.2 1 AK66 A39 1-1/2 1725 0.8 1.15 56 2.8 - 3.8 7/8 1VL44 5.2 1 AK56 A36 1-1/2 1725 0.8 1.15 56 4.0 - 5.0 7/8 1VP56 5.7 1 AK61 A38 1-1/2 1725 0.8 1.15 56 2.8 - 3.8 7/8 1VL44 5.2 1 AK56 A36

2 1725 0.8 1.15 56 4.0 - 5.0 7/8 1VP56 5.2 1 AK56 A38

1-1/2 1725 0.8 1.15 56 2.8 - 3.8 7/8 1VL44 5.2 1 AK56 A36

3 1725 0.8 1.15 56 4.0 - 5.0 7/8 1VP56 5.2 1 AK56 A38

Motor Motor Sheave Blower Sheave

Datum Dia.

(in.)

Bore (in.) Model

Datum Dia.

(in.)

Bore (in.) Model

Belt

Table 19: Power Exhaust Specifications

Model Voltage

HP RPM QTY LRA FLA MCA

2PE04703725 208/230-1-60 1/2 1725 2PE04703746 460-1-60 1/2 1725

Motor Motor

1 23.7 4.4 5.5 8 1350 1 4.1 1.7 2.1 5 1350

2PE04703758 575-3-60 1/2 1725 1 4.5 0.9 1.1 2 1350

1. Motors are multi-tapped and factory wired for high speed.

Fuse

Size

CFM @

0.1 ESP

Johnson Controls Ducted Systems 47

Page 48

5742640-TIM-A-0419

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

0 500 1000 1500 2000 2500 3000 3500

NOMINAL CFM

PRESSURE DROP (IWG)

T03

T04

T05 TA6

Checking Supply Air CFM

The RPM of the supply air blower will depend on the required CFM, the unit accessories or options and the static resistances of both the supply and the return air duct systems. With this information, the motor speed tap (direct drive) or the motor pulley number of turns open (belt drive) can be determined from the Blower Performance Data Tables.

Note the following:

1. The supply air CFM must be within the limitations shown in the Unit Physical Data Table .

2. Pulleys can be adjusted in half turn increments.

3. The tension on the belt should be adjusted as shown in the Belt Adjustment Figure 19.

4. Tighten blower pulley and motor sheave set screws after any adjustments. Re-check set screws after 10-12 hrs run time is recommended.

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.

To check the supply air CFM after the initial balancing has been completed:

1. Remove the two 5/16” dot plugs from the blower motor and the filter access panels shown in Figure 8.

2. Insert at least 8" of 1/4 inch tubing into each of these holes for sufficient penetration into the air flow on both sides of the indoor coil.

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.

drop across a wet coil under field conditions would be inaccurate. To assure a dry coil, the compressors should be deactivated while the test is being run.

4. Knowing the pressure drop across a dry coil, the actual CFM through the unit can be determined from the curve in Pressure Drop vs. Supply Air CFM (Figure 21).

Failure to properly adjust the total system air quantity and static pressure can result in extensive system damage.

After readings have been obtained, remove the tubes and reinstall the two 5/16” dot plugs that were removed in Step 1.

NOTE: De-energize the compressors before taking any test

measurements to assure a dry indoor coil.

3. Using an inclined manometer, determine the pressure drop across a dry evaporator coil. Since the moisture on an evaporator coil may vary greatly, measuring the pressure

Table 20: Additional Static Resistance

Size

(Tons)

T03 (3.0) T04 (4.0) T05 (5.0) TA6 (6.0)

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.

48 Johnson Controls Ducted Systems

CFM Cooling Only

1000 0.08 0.07 0.04 0.06 1200 0.10 0.08 0.05 0.07 1400 0.12 0.09 0.06 0.08 1600 0.14 0.11 0.07 0.09 1800 0.16 0.13 0.08 0.11 2000 0.18 0.15 0.10 0.13 2200 0.20 0.17 0.12 0.15 2400 0.23 0.20 0.14 0.17 2600 0.26 0.23 0.16 0.20 2800 0.29 0.26 0.19 0.23 3000 0.32 0.30 0.22 0.26

Figure 21: Pressure Drop Across Coil

Economizer

2 3

Electric Heat kW

7 - 15 20 - 30

Page 49

Sequence Of Operation

Cooling Sequence Of Operation

ZD units have Smart Equipment™ Control Board.

With a demand for first stage cooling either from a thermostat or space sensor, the low-voltage control circuit to "C1" and "G" is completed. For first stage cooling, the compressor is energized and the 1st stage operates (67% capacity). The UCB will energize the VFD equipped blower motor at low speed as set in the Smart Equipment™ control. When the thermostat calls for the second stage of cooling, the low-voltage control circuit to "C2" is completed. The control board energizes the 2nd stage of the compressor (100% capacity). If there is an initial call for both stages of cooling, the UCB will delay energizing the 2nd stage of the compressor by 30 seconds in order to avoid a power rush. Once the thermostat has been satisfied, it will deenergize C1 and C2. If the compressor has satisfied the minimum run time (3 min default), the compressors and condenser fans are de-energized. Otherwise, the unit operates until the minimum run has been completed. Upon the compressor de-energizing, the blower is stopped following the elapse of the fan off delay for 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.

If at any time a call for both heating and cooling are present, the heating operation will be performed. If operating, the cooling system is halted as with a completion of a call for cooling. Heating always takes priority.

Continuous Blower

By setting the room thermostat fan switch to "ON," the supply air blower will operate continuously.

Intermittent Blower

With the room thermostat fan switch set to "AUTO" and the system switch set to either the "AUTO" or "HEAT" settings, the blower is energized whenever a cooling or heating operation is requested. The blower is energized after any specified delay associated with the operation.

When energized, the indoor blower has a minimum run time of 30 seconds. Additionally, the indoor blower has a minimum off delay of 10 seconds.

No Outdoor Air Options

5742640-TIM-A-0419

To be available, a compressor must not be locked-out due to a high or low-pressure switch or Evaporator Low Limit sensor (EC1) detecting a temperature below 26° F Smart Equipment™ Control and the anti-short cycle delay (ASCD) must have elapsed.

Economizer With Dry Bulb Sensor (Smart Equipment™)

When the room thermostat calls for 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 Dry bulb temperature of the outdoor air is below the setpoint of the enthalpy or dry bulb 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 dry bulb temperature is above the setpoint, “Y1” energizes the compressor and condenser fan motor only.

Once the thermostat has been satisfied, it will de-energize “Y1”. If the compressor has satisfied its minimum run time, the compressor and condenser fan are de-energized. Otherwise, the unit operates the cooling system until the minimum run times for the compressor has been completed. After the compressor deenergizes, 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 continuous fan operation the economizer damper goes to the min. 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 (dry bulb single or dual enthalpy) and a power exhaust operates as specified above with one addition. The power exhaust motor is energized 45 seconds after the actuator position exceeds the exhaust fan set point on the economizer control. When the power exhaust is operating, the second stage of mechanical cooling will not operate. As always, the "R" to "G" connection provides minimum position but does not provide power exhaust operation.

When the thermostat calls for cooling, the low-voltage control circuit from “R” to “Y1” and “G” is completed. The compressor and condenser fan motor are energized. After completing the specified fan on delay for cooling, the UCB will energize the blower motor.

Once the thermostat has been satisfied, it will de-energize Y1. If the compressor has satisfied its minimum run time, the compressor and condenser fan de-energize. Otherwise, the unit operates the cooling system until the minimum run time for the compressor has been completed. After the compressor deenergizes, the blower is stopped following the elapse of the fan off delay for cooling.

Johnson Controls Ducted Systems 49

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.

Page 50

5742640-TIM-A-0419

High-Pressure Limit Switch

During cooling operation, if a high-pressure limit switch opens, the UCB will de-energize the compressor, initiate the ASCD (Anti-short cycle delay), and stop the condenser fan. If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the compressor.

Should a high-pressure switch open three times within two hours of operation, the UCB will lock-out the associated compressor and sent error message to the LCD Smart Equipment™ Control.

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

When operating in low ambient mode, an Evaporator Low Limit Sensor (EC1) temperature below 26ºF will de-energize the compressor. If the call for cooling is still present at the end of the ASCD and the evaporator temperature (EC1) is above 26ºF, the unit will resume operation.

Safety Controls

Low-Pressure Limit Switch

The low-pressure limit switch is not monitored during the initial 30 seconds of a cooling system's operation. For the following 30 seconds, the UCB will monitor the low-pressure switch to ensure it closes. If the low-pressure switch fails to close after the 30-second monitoring phase, the UCB will de-energize the compressor, initiate the ASCD, and stop the condenser fan.

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 compressor, initiate the ASCD, and stop the condenser fan.

If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the compressor.

Should a low-pressure switch open three times within one hour of operation, the UCB will lock-out the compressor sent error message to the LCD Smart Equipment™ Control.

Evaporator Low Limit

During cooling operation, if the Evaporator Low Limit Sensor (EC1) (Located on the Suction Line at the Evaporator Coil.)

detects a temperature below 26 Deg. F (default), the UCB will de-energize the compressor, initiate the ASCD, and stop the condenser fan. If the call for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the halted compressor.

Should the evaporator low limit sensor (EC1) detect a temperature below 26°F three times within two hours of operation, the UCB will lock-out the associated compressor and sends an error message to the control LCD.

The unit control board monitors the following inputs for each cooling system:

1. A evaporator low limit sensor (EC1) (Located on the Suction Line at the Evaporator Coil.) to protect against low evaporator temperatures due to a low airflow or a low return air temperature, set at 26°F.

2. A high-pressure switch to protect against excessive discharge pressures due to a blocked condenser coil or a condenser motor failure, (opens at 625 ± 25 psig).

3. A low-pressure switch to protect against loss of refrigerant charge, (opens at 50 ± 5 psig).

The above pressure switches are hard-soldered to the unit. The refrigeration systems are independently monitored and controlled. On any fault, only the associated system will be affected by any safety/preventive action.

The 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 compressor also has 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.

Low Ambient Cooling

To determine when to operate in low ambient mode, the UCB has an Outdoor Air Temperature Sensor (OAT) with a low ambient setpoint at 45ºF (default). When the OAT Sensor senses a temperature below the low ambient setpoint 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.

50 Johnson Controls Ducted Systems

Error Messages

The UCB will or sent error message to the LCD Smart Equipment™ Control associated with errors within the system.

Reset

Remove the call for cooling, by raising thermostat setting higher than the conditioned space temperature. This resets any pressure or freezestat lockouts.

Electric Heating Sequence Of Operations

The following sequence describes the operation of the electric heat section.

Page 51

5742640-TIM-A-0419

Single-stage heating (applies only to 5, 7 & 10 kW 230V heaters and to 7, 10, & 15 kW 460V and 575V heaters. All other heaters MUST use a two-stage thermostat):

a. Upon a call for heat by the thermostat, the heater

sequencer (1S) will be energized. After completing the specified fan on delay for heating, the UCB will energize the blower motor.

b The thermostat will cycle the electric heat to satisfy the

heating requirements of the conditioned space.

Two-stage heating (applies only to 15, 20 and 30 kW 230V heaters and 20 and 30 kW heater 460V and 575V heaters.):

a. Upon a call for first-stage heat by the thermostat, the

heater sequencer (1S) (15, 20, 30 kW 230 volt) and contactor (2M) (20, 30 kW 460 and 575 volt) 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 sequencer (2S) (12, 20, 30 kW 230 volt) or contactor (3M) (20, 30 kW 460 and 575 volt) 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

Table 21: Electric Heat Limit Setting

Voltage kW

10 1,2,3 140

208-1-60

230-3-60

460-3-60

575-3-60

15 2,4,6 140

30 1,2,3,4,5,6 150

10 1,2,3 150 15 2,4,6 140 20 1,2,3,4,5,6 150

10 2,4,6 140 15 2,4,6 140 20 3 160 30 3 150 10 2,4,6 140 15 2,4,6 140 20 5 160 30 5 150

Temperature Limit

Switch

5 1 140 7 1,3 140

1,2,3,4,5 140

6 150

5 1,2,3 140 7 1,2,3 140

1,3,5 160 2,4,6 150

7 2,4,6 140

Open Temperature

°F

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 send an error message to the LCD Smart Equipment™ Control.

Safety Controls

The UCB monitors the temperature limit switch of electric heat units.

The control circuit includes the following safety controls:

Temperature Limit Switch (TLS)

This control is located inside the heater compartment and is set to open at the temperature indicated in the Electric Heat Limit Setting Table 21. 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.

Error Messages

The UCB will initiate an error message to the LCD Smart Equipment™ Control.

Reset

Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature.This resets any flash codes.

Electric Heat Anticipator Setpoints

It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater temperature swing in the conditioned space. Reducing the value below the correct setpoint will give shorter “ON” cycles and may result in the lowering of the temperature within the conditioned space. Refer to Table 22 for the required electric heat anticipator setting.

Table 22: Electric Heat Anticipator Setpoints

Heater

70.3510 0.35 15 0.35 0.19 20 0.35 0.38 30 0.35 0.38

7 10 0.35 15 0.35 20 0.37 0.29 30 0.37 0.29

Voltage

230-3-60

460-3-60

Setting, Amps

TH1 TH2

0.35 -

Johnson Controls Ducted Systems 51

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5742640-TIM-A-0419

Gas Valve

Gas main

Main valve

To main burner

Redundant valve

To pilot burner

Table 22: Electric Heat Anticipator Setpoints

Heater

10 15 0.35 20 0.37 0.29 30 0.37 0.29

Voltage

575-3-60

Setting, Amps

TH1 TH2

0.35 -

Gas Heating Sequence Of Operations

When there is a W1 call for heat, the heat relay (RW1) is energized by the unit control board (UCB). The RW1-1 contacts immediately close energizing the ignition control board (ICB). The ICB checks the state of the flame sense circuit, the roll out switch, the centrifugal switch and the primary / auxiliary temperature limit switch circuit. If they are in the expected state, then the ICB energizes the draft motor and verifies that the centrifugal switch located on the end of the draft motor closes. After the centrifugal switch closes, a 15 second heat exchanger purging period is completed. After this purging period, the ICB will simultaneously energize the pilot gas valve and the ignition coil. Once the flame sensor senses a pilot flame is present, the ignition coil is de-energized. The ICB checks for pilot flame stability and once the ICB is satisfied that the pilot flame is stable, the main gas valve is energized by the ICB. The UCB will energize the indoor blower after a 45 second delay from the call for heat. The ICB and UCB both monitor the furnace safety devices during the furnace operation. When the call for heat is satisfied, the ICB closes the pilot and main gas valves and performs a 30 second purging of the heat exchanger by continuing the operation of the draft motor. The UCB continues the operation of the indoor blower for a configurable amount of time after the call for heat is satisfied.

Figure 22: Gas Valve Piping

Two Stage Furnace Only

If a W1 only call for heat from a two stage thermostat is present, then a two stage furnace will start on high fire for 1 minute and then reduce to low fire until the call for heat is satisfied or a W2 call for heat is received. If a W2 call for heat is received while in low fire operation, then the ICB will immediately move to high fire operation. If a W1 and W2 call for heat is present, then the furnace will remain on high fire operation until the W2 call for heat is satisfied.

Automatic staging of a two stage furnace using a single stage thermostat is possible. To achieve automatic staging of a two stage furnace using a single stage thermostat, cut the 440/GY wire that runs from pin 2 of the S3 connector on the (UCB) unit control board to P2-4 on the ignition control board. Cut the wire 1/2" from the S3 mate-n-lock connector. Wire nut or tape off the

1/2" wire. Attach the other end of the 440/GY wire to the R terminal on the UCB, or to the TB1 power strip.

The unit will operate the same as a W1 only call for heat for 10 minutes. If the call for heat is not satisfied in the 10 minutes, then the ICB will move to high fire operation until the W1 call for heat has been satisfied.

Gas Heat Operation Errors

During furnace operation, the ICB monitors the flame sense circuit, the centrifugal switch, the primary limit switch and the roll out switch. If a signal from any of the inputs moves to a fault state, then the ICB immediately closes the pilot and main gas valves. The ICB will determine the device that is signaling a fault and flash a code for that device. A primary limit trip, centrifugal switch trip or flame sense fault triggers a temporary lock out. An auxiliary limit or a roll out switch trip requires intervention to reset the ICB. The UCB also monitors the primary limit and gas valve.

Temperature Limits

The primary limit is located such that the temperature sensitive switch can sense the temperature of the heat exchanger tubes. On single or two stage models the limit is mounted just above the inlet of the heat exchanger tubes on the right side. If a primary limit (LS) fault occurs (the primary limit opens due to excessive heat exchanger temperature), then the ICB will flash the appropriate code (Table 29) and monitor the primary limit. The UCB will energize the indoor blower and the ICB will energize the draft motor while the primary limit is open. When the primary limit closes and the call for heat still exists, the ICB will start the ignition sequence over and the UCB will de-energize the blower for 45 seconds. However, the auxiliary limit is in series with the primary limit and it takes first control. If the excessive heat has been high enough to cause the auxiliary limit (AUX) to open, then the ICB will flash the primary limit code but the furnace will not retry ignition during the same call for heat. The auxiliary limit is of the manual reset type and is mounted in the upper right hand corner of the panel between the burner manifold and the flue gas collector box just behind the draft motor. If the auxiliary switch has opened, then special attention should be paid to the primary limit as it may be faulty as well. However, the auxiliary switch is sized such that multiple trips of the primary limit due to complete blower failure will cause enough heat to build up and trip the auxiliary.

If the primary limit opens three times within one hour, then the UCB will lock on the indoor blower and send an error code on the LCD Smart Equipment™ Control.

Gas Valve

The UCB monitors the gas valve (GV). Any time the UCB senses voltage at the GV without a call for heat for a continuous fiveminute period, the UCB will lock on the indoor blower and send a error message to the LCD Smart Equipment™ Control. When the UCB no longer senses voltage at the GV the UCB will deenergize the indoor blower after the expiration of the indoor blower heating off delay.

52 Johnson Controls Ducted Systems

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If the voltage has been sensed at the GV for at least 15 seconds during the fan on delay for heating and the UCB no longer senses voltage at the GV (W1 call for heat removed or an ICB fault exists), then the UCB forces the indoor blower on for the indoor blower heating off delay.

The gas valve is of the redundant type. If for any reason the main gas valve fails in the open position, then the redundant valve ahead of the main gas valve will shut off the flow of gas to both the pilot and main gas valves.

Centrifugal Switch

The centrifugal switch is mounted on the end of the draft motor and it is an integral part of the motor assembly. On a call for heat, the ICB checks the centrifugal switch (CS) for open state before it energizes the draft motor. If it is closed, then the ICB will lock out the furnace and flash a code (Table 29). If open, then the ICB will energize the draft motor and verify that the switch closes before initiating the purging and ignition sequence. If at any time during furnace operation the centrifugal switch opens, then the ICB will de-energize the pilot and main gas valves and monitor the centrifugal switch. If the centrifugal switch closes and the call for heat still exists, then the ICB will retry the purging and ignition sequence.

Roll-out Switch

This temperature sensitive switch is located in the burner vestibule just above the right hand side of the burner assembly. In the event of the flame spilling out into the burner manifold area the roll-out switch will open, the ICB will close both the main and pilot gas valves and flash a code (Table 29). The ICB will not retry the ignition sequence during the same call for heat.

Flame Sense Circuit

The flame sensor is mounted on the left hand side of the burner assembly and is positioned such that the pilot flame surrounds the tip of the sensor. On a call for heat the ICB checks for the flame sense circuit to be open. If open, then the ICB initiates the purging and ignition sequence. Once the pilot flame is present, the ICB monitors the flame sense circuit for pilot flame stability. If the pilot flame is unstable or lost completely, then the ICB will immediately close both the pilot and main gas valves. The ICB will retry the purging and ignition sequence. If the flame is unstable or lost more than 16 times during the same call for heat, then the ICB will lock out furnace operation for 5 minutes.

Table 23: Single Stage Gas Heat Limit Control Setting

Unit

(Tons)

3 50 40 240 240 3 100 80 170 210 4 75 60 210 240 4 125 100 165 210 5 100 80 170 210 5 125 100 165 210 6 100 80 170 210 6 125 100 165 210

Capacity, MBH Limit Control Opens, °F

Input Output Direct Drive Belt Drive

Table 24: 2 Stage Gas Heat Limit Control Setting

1st Stage

Unit

(Tons)

3 45 36 75 61 210 240 3 69 55 115 92 200 200 4 45 36 75 61 210 240 4 75 60 125 101 165 210 5 45 36 75 61 210 210 5 75 60 125 101 165 210 645367561 210 210 6 75 60 125 101 165 210

Capacity

Input

(MBH)

Output

(MBH)

2nd Stage

Capacity

Input

(MBH)

Output

(MBH)

Limit Control Opens,

°F

Direct

Drive

Belt

Drive

Error Messages

The UCB will initiate an error message to the LCD Smart Equipment™ Control.

Resets

Remove the call for heating by lowering the thermostat setting lower than the conditioned space temperature. This resets any lock outs.

Heat Anticipator Setpoints

Table 25: Gas Heat Anticipator Setpoints

Gas Valve Anticipator Setpoints

Honeywell VR8204M 0.60 amp White-Rogers 36E36 0.54 amp

Start-up (Cooling)

Prestart Check List

After installation has been completed:

1. Check the electrical supply voltage being supplied. Be sure that it is the same as listed on the unit nameplate.

2. Set the room thermostat to the off position.

3. Turn unit electrical power on.

4. Set the room thermostat fan switch to on.

5. Check indoor blower rotation.

• If blower rotation is in the wrong direction. Refer to

Phasing Section in general information section.

• Check blower drive belt tension.

6. Check the unit supply air (CFM). See “CHECKING SUPPLY AIR CFM” on page 48.

7. Measure evaporator fan motor's amp draw.

8. Set the room thermostat fan switch to off.

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Pilot Adj.

(Under Screw)

“ON” - “OFF” Control

High Fire Adj.

(Under Screw)

Honeywell VR8204M

Regulator Adj. “HI”

(Under Screw)

Regulator Adj. “LO”

(Under Screw)

“ON” - “OFF” Control

Pilot Adj.

(Under Screw)

Honeywell VR820RQ

9. Turn unit electrical power off.

Operating Instructions

1. Turn unit electrical power on.

2. Set the room thermostat setting to lower than the room temperature.

3. Compressor will energize after the built-in time delay (five minutes).

Post Start Check List

1. Verify proper system pressures.

2. Measure the temperature drop across the evaporator coil.

3. Measure the system Amperage draw across all legs of 3 phase power wires.

4. Measure the condenser fan amp draw.

Shut Down

1. Set the thermostat to highest temperature setting.

2. Turn off the electrical power to the unit.

Start-up (Gas Heat)

Pre-start Check List

Complete the following checks before starting the unit.

1. Check the type of gas being supplied. Be sure that it is the same as listed on the unit nameplate.

2. Make sure that the vent and combustion air hoods have been properly installed.

Post-Start Check List (Gas)

After the entire control circuit has been energized and the heating section is operating, make the following checks:

1. Check for gas leaks in the unit piping as well as the supply piping.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warning exactly could result in serious injury, death or property damage.

2. Check for correct manifold gas pressures. See “Checking Gas Input” on page 55.

3. Check the supply gas pressure. It must be within the limits shown on rating nameplate. Supply pressure should be checked with all gas appliances in the building at full fire. At no time should the standby gas line pressure exceed 13", nor the operating pressure drop below 5.0" for natural gas units. If gas pressure is outside these limits, contact the local gas utility for corrective action.

Operating Instructions

This furnace is equipped with an intermittent pilot

Figure 23: Typical Single Stage Gas Valves

and automatic re-ignition system. DO NOT attempt to manually light the pilot.

To Light Pilot And Main Burners:

1. Turn “off” electric power to unit.

2. Turn room thermostat to lowest setting.

3. Turn gas valve knob or switch to “on” position.

4. Turn “on” electric power to unit.

5. Set room thermostat to desired temperature. (If thermostat “set” temperature is above room temperature, pilot burner ignition will occur and, after an interval to prove pilot flame, main burners will ignite).

To Shut Down:

1. Turn “off” electric power to unit.

2. Depress knob of gas valve while turning to “off” position or position the switch to the “off” position.

54 Johnson Controls Ducted Systems

Figure 24: Typical 2 Stage Gas Valves

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Burner assembly bracket

Flame sensor bulb

1/8” gap between carry-over

tube and flame sensor bulb

Carry-over tube

Gas Supply Pipe

Pilot Tube

Burner Flame

(Blue Only)

Heat Tube

Exchanger

Burner

Adjustable Shutter

Manifold Gas Pressure Adjustment

Adjustments to the high-fire and low-fire (2 stage) gas flow may be made by turning the pressure regulator adjusting screws on the automatic gas valve.

Adjust as follows:

1. Remove the adjustment screw cap(s) on the regulator.

2. To decrease the gas pressure, turn the adjusting screw counterclockwise.

3. To increase the gas pressure, turn the adjusting screw clockwise.

4. Replace adjustment screw caps.

NOTE: The factory set high-fire manifold pressure for these

furnaces is 3.50 IWG. The actual manifold pressure depends on the local fuel heating value.

2. Open the union fitting in the gas supply line just upstream of the unit gas valve and downstream from the main manual shut-off valve.

3. Remove the gas piping closure panel.

4. Disconnect wiring to the gas valves and spark ignitors. Remove the manifold-burner gas valve assembly by lifting up and pulling back.

Figure 26: Typical Flame Appearance

Burners are now accessible for service.

Reverse the above procedure to replace the assemblies. Make sure that burners are level and seat at the rear of the heat exchanger.

Burner Air Shutter Adjustment

Adjust burner shutters so no yellow flame is observed in the heat exchanger tubes.

Figure 25: Proper Flame Adjustment

Pilot Checkout

The pilot flame should envelope the end of the flame sensor. To adjust pilot flame, (1) remove pilot adjustment cover screw, (2) increase or decrease the clearance for air to the desired level, (3) be sure to replace cover screw after adjustment to prevent possible gas leakage.

Put the system into operation and observe through complete cycle to be sure all controls function properly.

Burner Instructions

To check or change burners, pilot or orifices, CLOSE MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF ALL ELECTRIC POWER TO THE UNIT.

1. Remove the screws holding either end of the manifold to the burner supports.

Checking Gas Input

Natural Gas

1. Turn off all other gas appliances connected to the gas meter.

2. With the furnace turned on, measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter usually has a 1/2 or a 1 cubic foot test dial.

3. Using the number of seconds for each revolution and the size of the test dial increment, find the cubic feet of gas consumed per hour from the Gas Rate - Cubic Feet Per Hour (Table 26).

If the actual input is not within 5% of the furnace rating (with allowance being made for the permissible range of the regulator setting), replace the orifice spuds with spuds of the proper size.

NOTE: To find the Btu input, multiply the number of cubic feet

of gas consumed per hour by the Btu content of the gas in your particular locality (contact your gas company for this information - it varies widely from city to city.)

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CFM

Btuh Input x 0.8

108..xFTempRise

Table 26: Gas Rate-Cubit Feet per Hour

Seconds for

One Rev.

10 180 360 12 150 300 14 129 257 16 113 225 18 100 200 20 90 180 22 82 164 24 75 150 26 69 138 28 64 129 30 60 120 32 56 113 34 53 106 36 50 100 38 47 95 40 45 90 42 43 86 44 41 82 46 39 78 48 37 75 50 36 72 52 35 69 54 34 67 56 32 64 58 31 62 60 30 60

1. By actual measurement, it takes 38 seconds for the hand on the 1-cubic foot dial to make a revolution with a 100,000 Btuh furnace running. Using this information, located 38 seconds in the first column in the table above. Read across to the column headed “1 Cubic Foot”, where you will see that 95 cubic feet of gas per hour are consumed by the furnace at that rate. Multiply 95 X 1050 (the Btu rating of the gas obtained from the local gas company). The result is 99,750 Btuh, which is close to the 100,000 Btuh rating of the furnace.

Size of Test Dial

1/2 cu. ft. 1 cu. ft.

Adjustment Of Temperature Rise

The temperature rise (or temperature difference between the return air and the heated air from the furnace) must lie within the range shown on the rating plate and the data in the Gas Heat Application Table 11.

After the temperature rise has been determined, the cfm can be calculated as follows:

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 six feet from the furnace) where they will not be affected by radiant heat. Increase cfm to decrease

the temperature rise; decrease the blower cfm

the blower

to increase the rise. Refer to the In Door Blower Specification Table 18.

Start Up For Units Equipped for FER

This section applies to single phase gas heat only.

Direct Drive

Direct drive FER units come from the factory with the following three leads that lead to the indoor motor.

• A yellow cooling lead

• A red heating lead

• A white, fan only lead

Each lead is put on a different tap on the motor and provides different speeds. The leads are set on default taps from the factory. See the wiring diagrams for details on factory default speeds. During installation, you may need to move the leads to different taps depending on the airflow and static requirements of the application.

NOTE: During installation, the tap chosen for the heating

speed must produce a temperature rise that lies within the rise range stated on the rating plate and the data in Table 11.

Belt Drive

Belt drive FER units come with a VFD that provides heating, cooling, and fan only speeds. The units are controlled by a 2-10 vdc output from the Smart Equipment™ control to the supply fan VFD.

You may need to adjust the speeds for specific applications as factory defaults may not always be suitable. To make airflow changes, adjust the variable pitch sheave pulley. If pulley adjustments fail to achieve the required airflow, you may need to adjust the factory default speed settings for the Smart

Equipment™ control, see Adjusting the fan speed percentages.

NOTE: During installation, the speed chosen for the heating

speed must produce a temperature rise that lies within the rise range stated on the rating plate and the data in Table 11.

Adjusting the fan speed percentages

1. On the unit control board, use the joystick to select Details, Fan, Setup and press ENTER.

From the Mobile Access Portal (MAP) Gateway, select the indoor fan section.

2. Make the required changes to the fan speed commands. The following table shows available fan speed commands.

Table 27: Fan setup commands

Command Adjustment Setting

Fan Only-% Cmd Adjust based on application (CV IS Fan Only)

1ClgStg-% Cmd Adjust based on application (CV IS 1 Stg Cool)

56 Johnson Controls Ducted Systems

(Occupied: One

1HtgStg-%Cmd Adjust based on application

Stage of Heat % Command)

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Troubleshooting (Simplicity Lite Only)

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.

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.

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 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 M2, contactor, and that the contactor is pulled in. Check for loose wiring between the contactor and the supply air blower motor.

4. If M2 is pulled in and voltage is supplied to M2, 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 M2 is not pulled in, check for 24 volts at the M2 coil. If 24 volts are present at M2 but M2 is not pulled in, replace the contactor.

6. Following the above, if there is line voltage supplied at M2, M2 is pulled in, and the supply air blower motor still does not operate, replace the motor.

7. If 24 volts is not present at M2, 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 M2.

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.

c. Loose wiring from the room thermostat to the UCB.

9. If 24 volts is present at the room thermostat but not at the UCB, check for proper wiring between the thermostat and the UCB, i.e. that the thermostat G terminal is connected to the G terminal of the UCB, and for loose wiring.

10. If the thermostat and UCB are properly wired, replace the UCB.

On a call for cooling, the supply air blower motor is operating but the compressor 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 the compressor will be energized unless it is locked out, unless this option has been disabled through computer communications.

2. If no economizer is installed or the economizer is not opening to provide free cooling and the compressor 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. Following 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

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.

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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 out, cancel any call for cooling. This will reset any compressor lock outs.

NOTE:

10. If 24 volts is present at the UCB Y1 terminal and none of

11. If 24 volts is present at the UCB Y1 terminal and the

12. For units without economizers: If 24 volts is present at the

While the above step will reset any lockouts, the compressor may be held off for the ASCD. See the next step.

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.

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.

Y1 OUT terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, the

jumper in the Mate-N-Lock plug, and in the wiring from the Mate-N-Lock plug to the Y1 “ECON” terminal.

13. For units with economizers: If 24 volts is present at the Y1

“OUT” terminal, check for 24 volts at the Y1 “ECON” terminal. If 24 volts is not present, check for loose wiring from the Y1 “OUT” terminal to the Mate-N-Lock plug, a poor connection between the UCB and economizer MateN-Lock plugs, loose wiring from the Mate-N-Lock plug to the economizer, back to the Mate-N-Lock plug, and from the Mate-N-Lock plug to the Y1 “ECON” terminal. If nothing is found, the economizer actuator 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 the compressor energizes, there is a fault in the economizer wiring or actuator.

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 correct the error, replace the UCB.

58 Johnson Controls Ducted Systems

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Normal Operating Pressures

Table 28: ZDT03 (3.0 Ton) Operating Pressures

5742640-TIM-A-0419

Air Flow

Indoor Db/Wb

300 Cfm/Ton 80/62

300 Cfm/Ton 80/67

300 Cfm/Ton 80/72

300 Cfm/Ton 75/63

400 Cfm/Ton 80/62

400 Cfm/Ton 80/67

400 Cfm/Ton 80/72

400 Cfm/Ton 75/63

Indoor

DB/WB

OutdoorDBSuction

Pressure

75 123 53 259 80 -30 80 50 8 85 128 48 305 92 -28 80 52 9 95 133 48 351 103 -27 80 53 11 75 131 61 262 77 -25 80 55 8 85 138 60 307 90 -24 80 56 9 95 143 55 357 101 -22 80 58 11 75 140 67 270 75 -20 80 60 8 85 147 66 316 87 -19 80 61 9 95 154 67 361 99 -17 80 63 11 75 124 52 261 79 -24 75 51 8 85 130 49 308 91 -23 75 52 9 95 135 49 351 102 -21 75 54 10 75 128 61 258 78 -27 80 53 8 85 134 57 301 90 -26 80 54 9 95 139 52 352 102 -24 80 56 10 75 137 68 261 74 -22 80 58 8 85 143 66 307 87 -21 80 59 9 95 149 62 357 99 -20 80 60 11 75 145 73 272 74 -17 80 63 8 85 153 72 314 85 -16 80 64 9 95 159 70 364 97 -15 80 65 11 75 130 60 256 76 -21 75 54 8 85 135 57 299 88 -20 75 55 9 95 140 52 348 100 -19 75 56 10

Table 29: ZDT04 (4.0 Ton) Operating Pressures

Suction

Temp.

Liquid

Pressure

Liquid Temp.

Delta TDbEntering

Evap Db

Leaving

Evap Db

Compressor

Amps

Air Flow

Indoor Db/Wb

300 Cfm/Ton 80/62

300 Cfm/Ton 80/67

300 Cfm/Ton 80/72

300 Cfm/Ton 75/63

400 Cfm/Ton 80/62

400 Cfm/Ton 80/67

400 Cfm/Ton 80/72

400 Cfm/Ton 75/63

Indoor

DB/WB

OutdoorDBSuction

Pressure

75 123 62 276 79 -30 80 50 11 85 127 55 324 91 -30 80 51 13 95 133 47 379 103 -28 80 52 15 75 133 69 283 76 -26 80 54 11 85 138 65 324 86 -25 80 55 13 95 142 60 380 100 -23 80 57 15 75 141 73 296 76 -20 80 60 12 85 148 72 343 88 -19 80 61 14 95 154 69 395 99 -18 80 62 16 75 124 60 280 79 -25 75 50 11 85 129 56 325 90 -24 75 51 13 95 134 47 380 103 -22 75 53 16 75 127 67 277 77 -28 80 52 11 85 134 63 328 90 -26 80 54 13 95 140 58 381 102 -25 80 55 15 75 136 72 286 75 -23 80 57 12 85 144 70 336 87 -21 80 59 13 95 150 65 390 100 -20 80 60 16 75 146 75 298 75 -17 80 63 12 85 153 75 348 87 -16 80 64 14 95 160 73 402 99 -15 80 65 16 75 130 65 286 77 -21 75 54 12 85 136 60 333 90 -20 75 55 13 95 140 53 388 102 -19 75 56 16

Suction

Temp.

Liquid

Pressure

Liquid Temp.

Delta TDbEntering

Evap Db

Leaving

Evap Db

Compressor

Amps

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Table 30: ZDT05 (5.0 Ton) Operating Pressures

Air Flow

Indoor Db/Wb

300 Cfm/Ton 80/62

300 Cfm/Ton 80/67

300 Cfm/Ton 80/72

300 Cfm/Ton 75/63

400 Cfm/Ton 80/62

400 Cfm/Ton 80/67

400 Cfm/Ton 80/72

400 Cfm/Ton 75/63

Indoor

DB/WB

OutdoorDBSuction

Pressure

75 123 52 283 77 -30 80 50 14 85 126 53 329 85 -29 80 51 16 95 130 55 381 94 -27 80 53 19 75 135 58 289 79 -24 80 56 14 85 138 58 335 86 -24 80 56 17 95 143 60 387 95 -22 80 58 19 75 147 64 294 80 -19 80 61 15 85 150 64 340 88 -19 80 61 17 95 153 66 392 95 -18 80 62 19 75 124 54 283 76 -24 75 51 14 85 128 55 329 84 -23 75 52 16 95 132 56 382 94 -22 75 53 19 75 130 56 285 78 -26 80 54 14 85 133 57 331 86 -25 80 55 16 95 139 59 382 95 -24 80 56 19 75 141 60 292 79 -21 80 59 15 85 144 61 339 87 -20 80 60 17 95 147 62 390 95 -20 80 60 19 75 152 67 297 80 -16 80 64 15 85 156 67 342 88 -16 80 64 17 95 160 67 396 96 -15 80 65 20 75 132 56 287 77 -20 75 55 14 85 134 57 334 85 -20 75 55 17 95 138 58 386 94 -19 75 56 19

Table 31: ZDTA6 (6.0 Ton) Operating Pressures

Suction

Temp.

Liquid

Pressure

Liquid Temp.

Delta TDbEntering

Evap Db

Leaving

Evap Db

Compressor

Amps

Air Flow

Indoor Db/Wb

300 Cfm/Ton 80/62

300 Cfm/Ton 80/67

300 Cfm/Ton 80/72

300 Cfm/Ton 75/62

400 Cfm/Ton 80/62

400 Cfm/Ton 80/67

400 Cfm/Ton 80/72

400 Cfm/Ton 75/62

Indoor

DB/WB

OutdoorDBSuction

Pressure

75 129 58 304 137 -24 80 85 128 54 352 148 -24 80 95 128 50 399 159 -25 80 75 128 60 304 137 -24 80 85 131 59 356 151 -23 80 95 133 58 408 164 -22 80 75 127 62 305 137 -24 80 85 132 64 361 153 -21 80 95 138 66 416 169 -19 80 75 123 56 302 137 -21 75 85 124 51 350 148 -21 75 95 125 47 399 158 -21 75 75 134 58 304 133 -21 80 85 135 57 353 146 -21 80 95 136 55 402 158 -21 80 75 135 59 305 134 -21 80 85 137 59 357 148 -20 80 95 139 59 408 161 -19 80 75 135 60 307 134 -21 80 85 138 62 360 149 -19 80 95 141 64 413 164 -18 80 75 128 55 302 134 -19 75 85 130 54 352 146 -18 75 95 132 52 402 159 -18 75

Suction

Temp.

Liquid

Pressure

Liquid Temp.

Delta TDbEntering

Evap Db

Leaving

Evap Db

56 56 55 56 57 58 56 59 61 54 54 54 59 59 59 59 60 61 59 61 62 56 57 57

Compressor

Amps

12.0

13.4

14.7

12.0

13.5

15.0

12.0

13.6

15.3

11. 9

13.3

14.8

11. 8

13.3

14.8

11. 9

13.4

14.9

11. 9

13.5

15.1

11. 8

13.3

14.8

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Gas Heat Troubleshooting Guide

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.

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.

Before beginning symptomatic troubleshooting activities read the flash code LEDs on the unit control board (UCB) and the ignition control board (ICB). Fault codes have a quick sequence of flashes indicating the flash code number followed by a pause with the LED off. The ICB flash codes are repeated until the fault is cleared. The ICB monitors itself, the centrifugal switch, lockout due to > 16 pilot flame losses, primary limit, roll-out and a flame present when the ICB expects no flame.

With power applied to the unit, if the LED on the ICB is flashing the heartbeat and the furnace will not operate, then proceed to the symptomatic troubleshooting section. If the ICB LED is not flashing, then perform the ICB troubleshooting procedures. If the ICB has a flash code other than the heartbeat, then determine the flash code and locate its troubleshooting procedures in the flash code troubleshooting section. Refer to Table 29 for flash code identification and component causing fault.

Flash Code Troubleshooting

Power to the unit should be interrupted during the troubleshooting of individual components unless otherwise

indicated. All troubleshooting procedures assume the unit is wired per the wiring diagram. If there is any indication the unit has been previously repaired, then the first priority is to verify that the furnace is wired per the wiring diagram. Miss-wired units will give false flash codes.

Ignition Control Board

The ICB controls the ignition of the pilot, the opening and closing of the gas valves and the operation of the draft (inducer) motor. It also monitors all the furnace safety components.

If the ICB LED is on steady, then verify the wiring of the unit to the wiring diagram and if OK, then replace the ICB. If the unit has power and the ICB LED is not flashing, then remove the 3 pin connector (single stage gas heat) or 4 pin connector (2 stage gas heat) from the ICB. Measure the control voltage between terminals 1 and 2 of the wiring harness connector. The control voltage must be between 18 and 30 volts. If control voltage is not present, then check the 3.2A circuit breaker to verify that the circuit breaker has control voltage on both input and output terminals. If control voltage is present on the input and not the output of the circuit breaker, then reset or replace the circuit breaker as necessary. If control voltage is present on both sides of the circuit breaker, then check the power and common wires between the unit control box and the ICB and repair as necessary. If the control voltage is present, then verify the cleanliness of the harness and the ICB connector, clean if necessary and reconnect the wiring harness to the ICB and observe ICB LED. If it now flashes the heartbeat, then the fault was a bad connection between the harness connector and the ICB connector or a broken wire exists in the harness. With the harness connected to the ICB, gently move the wires in the harness while observing the ICB LED. If heartbeat is steady, then verify proper operation of the furnace. If the ICB does not flash the heartbeat, then gently move the wires in the harness connector while observing the ICB LED. If you get any flashes of the ICB LED, then there is still a bad connection or a broken wire. If no flashes are seen while gently moving the wires with the harness connected to the ICB, then replace the ICB and verify proper operation of the furnace.

Centrifugal Switch

The centrifugal switch is an integral part of the draft motor. The centrifugal switch closes when the motor speed increases to ~2500 rpm and opens when the motor speed descends to ~2000 rpm.

If a flash code indicates the centrifugal switch is causing a fault, then

1. If the flash code indicates the switch is open with the draft (inducer) motor on (flash code 2), then

a. Disconnect power to the unit. Using a screw driver, spin

the draft motor blower wheel. If bound or dragging, then visually inspect the draft motor blower wheel area for debris. If debris is present, then clear debris and verify proper furnace operation. If clear, then replace the draft motor and verify proper furnace operation.

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b. Restore power to unit and induce a call for heat.

Measure the voltage across the two draft motor leads (white and red on single stage models and white and black on two stage models). If it is less than 177 volts, then check and repair the power circuit to the draft motor. If the voltage is greater than 176 volts and the draft motor is not turning, then disconnect power and draft motor power leads. Measure the resistance of the draft motor windings. If an open circuit exists in the motor, then replace the draft motor. If the voltage is greater than 176 volts and the motor is turning, then check the centrifugal switch wiring between the ICB and the draft motor. If OK, then disconnect power to the unit and place the gas valve in the off position. Prepare to temporarily jumper the wires connected to terminals 3 and 8 of the ICB 9 pin harness connector by disconnecting the draft motor leads from the 9 pin harness. Restore the power to the unit and induce a call for heat. Jumper wires 3 and 8. If the ignition sequence is started after 15 seconds (audible sparking of the igniter), then replace the draft motor reconnecting the centrifugal switch wiring per the wiring diagram. If not, then replace the ICB, remove the jumper and reconnect the centrifugal switch wiring per the wiring diagram. Place the gas valve in the on position and verify proper furnace operation.

2. If the flash code indicates the switch is closed with the draft (inducer) motor off (flash code 3), then disconnect the 9 pin connector from the ICB and measure the continuity of the centrifugal switch with a battery powered test light or an ohm meter between terminals 3 and 8 of the harness connector. If a closed circuit is indicated, then check the wiring between the ICB and the draft motor. If the wiring is not shorted together, then replace the draft motor. If an open circuit is indicated, then reconnect the 9 pin wiring harness to the ICB and remove power to the unit for at least 20 seconds. Restore power to the unit. If the ICB continues to flash a code 3, then replace the ICB.

Pilot Flame Lockout

The ICB counts the number of flame losses during the same call for heat. If more than 16 flame losses occur within the same call for heat, then the control temporarily locks out furnace operation for 5 minutes (flash code 5). If the call for heat remains after the 5 minutes, then the ICB will retry the ignition sequence. The flame losses can be due to low inlet pressure, debris around flame sensor, plugged pilot burner, soot on the surface of the flame sensor or misadjusted pilot pressure. Remove the power to the unit for 20 seconds and then restore power to the unit. Induce a call for heat and observe the pilot flame in the flame sensor area to determine the best course of action.

1. If the flame is strong and stable in the flame sensor area, then verify the position of the flame sensor per the start up procedures. If ok, then remove the flame sensor and check the cleanliness of the electrode. If clean, then replace the flame sensor and adjust pilot per the start up procedures. If not clean, then clean, reinstall and adjust pilot per the start up procedures.

2. If the flame is weak or unstable in the flame sensor area, then verify the gas inlet pressure. If gas inlet pressure is above the minimum inlet pressure stated on unit data label, then adjust the pilot pressure per the start up procedures. If the pilot cannot be adjusted to obtain a strong and stable flame in the flame sensor area, then remove the burner assembly and verify the pilot burner assembly is open internally and the holes in the burner are clean. Check the pilot orifice size to the unit data plate and the cleanliness of the pilot orifice. Verify that the flame sensor electrode is clean and is adjusted properly. After cleaning or replacement of the pilot assembly components, reinstall the burner assembly and adjust pilot per the start up procedure.

Primary or Aux Temperature Limit

The temperature limits limit the temperature in the furnace to a safe level. If a temperature higher than the preset limit is achieved due to low or no air flow through the furnace, then the temperature limits opens and the ICB closes the gas valve and flashes code 6. The primary limit is automatic reset type while the auxiliary limit is manual reset type. If either one opens, then the ICB removes power to the gas valve and the UCB energizes the indoor blower until the primary limit automatically resets or the auxiliary limit is manually reset. Verify adequate air flow through the furnace. If air flow is nonexistent or weak, then troubleshoot and repair the conditioned space air circulation system as necessary. Reset the auxiliary limit and verify proper operation of the furnace. If airflow is normal, then verify the gas input rate to the furnace following the start up procedures (auxiliary limit must be reset before the furnace will operate). If after verifying the circulating air system, the input rate to the furnace and that the air temperature rise through the furnace is within the rise range on the unit data plate the flash code still exists, then set the gas valve to the off position and temporarily apply control voltage (~24 volts) to pin 9 of the 9 pin ICB connector. With power applied to the unit, if the ICB LED continues to flash a code 6, then replace the ICB and return unit to operation (you must remove the temporary voltage to pin 9 before the gas valve is turned on). If the ICB LED flashes a heartbeat, then replace the limit that is opening, remove the temporary voltage applied to pin 9, turn on the gas valve, restart the furnace and verify proper operation of the furnace.

Roll-out Switch

The roll-out switch is installed to protect the furnace from damage due to excessive heat in the burner area. There are 4 main reasons the roll-out switch will open (flash code 7) due to excessive heat in the burner area. You must remove power to the unit for 20 seconds to reset the ICB.

1. A blocked flue outlet is the most common cause for the rollout switch to open. Check the flue outlet for debris and clear if necessary.

2. Loose blower wheel on draft motor. Verify that the blower wheel is securely fastened to the draft motor shaft.

3. Unit operating outside the air temperature rise range stated on the unit data plate. Either the air flow through the furnace is not sufficient or the gas input rate to the furnace

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exceeds the recommended rate. Verify both conditions are within the published ranges.

4. Cracked heat exchanger tube(s). If a heat exchanger tube or tubes is cracked, then the flow through the heat exchanger is restricted and the flame will either roll out of the tube inlet or heat will build to an abnormal level in the burner area. This can usually be determined by observing burner flame with and without indoor blower operation. If the flame changes when the blower is running compared to when it is not, then visually inspect the heat exchanger tubes.

If all of the above are found to be in good condition or within the operating ranges, then set the gas valve to the off position and temporarily apply control voltage (~24 volts) to pin 6 of the 9 pin ICB connector. With power applied to the unit, if the ICB LED continues to flash a code 7, then replace the ICB and return unit to operation (you must remove the temporary voltage to pin 6 before the gas valve is turned on). If the ICB LED flashes a heartbeat, then replace the roll-out switch, remove the temporary voltage applied to pin 6, turn on the gas valve, restart the furnace and verify proper operation of the furnace.

Unexpected Flame Presence

If a flame is present without a call for heat (flash code 8), then the ICB will continue operation of the draft motor and the UCB will call for indoor operation when either of the temperature limit opens. If the unit is correctly wired and there is not a call for heat, then check for control voltage to the gas valve. If control voltage exists at the gas valve, then replace the ICB. If voltage is not present at the gas valve, then replace the gas valve.

Gas Valve Stuck Off or On

If the pilot and/or the main valves are sensed to be off more than 1 second when commanded to be on, the control will shut off all outputs and enter a hard lockout (flash code 9). Likewise, if the pilot and/or the main valves are sensed to be on more than 1 second when commanded to be off, the control will shut off all outputs and enter a hard lockout (flash code 9). The control will not respond to thermostat demands during a hard lockout. The only way to recover from a hard lockout is to remove and reapply 24VAC power to the control.

Flame Sense Circuit Failure

If the control detects an internal hardware failure in the flame sense circuit, it shuts off all outputs and enters a hard lockout (flash code 10). The control will not respond to thermostat demands during a hard lockout. The only way to recover from a hard lockout is to remove and reapply 24VAC power to the control. If problem persists after removal and reapplication of 24VAC power, the board may need to be replaced.

1. Place the thermostat fan switch in the “ON” position. If the supply air blower motor energizes, go to Step 10.

2. If the supply air blower motor does not energize when the fan switch is set to “ON,” check that line voltage is being supplied to the contacts of the M2 contactor, and that the contactor is pulled in. Check for loose wiring between the contactor and the supply air blower motor.

3. If M2 is pulled in and voltage is supplied at M2, lightly touch the supply air blower motor housing. If it is hot, the motor may be off on inherent protection. Cancel any thermostat calls and set the fan switch to “AUTO”, wait for the internal overload to reset. Test again when cool.

4. If M2 is not pulled in, check for 24 volts at the M2 coil. If 24 volts is present at M2 but M2 is not pulled in, replace the contactor.

5. Failing the above, if there is line voltage supplied at M2, M2 is pulled in, and the supply air blower motor still does not operate, replace the motor.

6. If 24 volts is not present at M2, 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 M2.

7. 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:

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.

c. Loose wiring from the room thermostat to the UCB.

8. If 24 volts is present at the room thermostat but not at the UCB, check for proper wiring between the thermostat and the UCB, i.e. that the thermostat G terminal is connected to the G terminal of the UCB, and for loose wiring.

9. If the thermostat and UCB are properly wired, replace the UCB.

10. If the blower motor runs with the fan switch in the “ON” position but does not run shortly after the furnace has ignited when the fan switch is in the “AUTO” position, check the room thermostat for contact between R and G during “W1” calls.

On calls for heating, the supply air blower operates but the draft motor does not (the room thermostat fan switch is in the “AUTO” position).

Symptomatic Troubleshooting

On calls for heating, the draft motor operates and the furnace lights but the supply air blower motor does not energize after short delay (the room thermostat fan switch is in “AUTO” position).

Johnson Controls Ducted Systems 63

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 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 “W1”

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terminal is connected to the “W1” terminal of the UCB, and for loose wiring.

3. The draft motor is a 230 volt draft motor on all models regardless of unit supply voltage. If the ICB is flashing a code other than the heartbeat, then troubleshoot the device indicated by the fault code. If not, then remove power to the unit for more than 20 seconds. If upon restoring the power to the unit the draft motor does not start with a call for heat, then verify that terminal “L1” of the ICB has a minimum of 120 volts to ground on 230 and 460 volt models or a minimum of 18 volts to ground on 575 volt models. If terminal “L1” does not have the minimum voltage, then check the wiring between the unit control box and the ICB on all models and on 460 volt models, the transformer in the gas heat compartment and its wiring. If terminal “L1” does have the minimum voltage, then check for the minimum voltage on terminal “IND” of the ICB on single stage models and terminal “IND HIGH” of the ICB on two stage models. If voltage is not present at the terminal, then verify wiring between the control box and the ICB. If all wiring is intact, then ICB is at fault. If voltage is present at the terminal on 230 and 460 volt models, then the draft motor is at fault. On 575 volt models, if voltage is present at the terminal, then check the draft motor relay (DMR on single stage gas heat and DMR-2 on two stage gas heat) mounted above the ICB. First verify that the relay is pulled in by visual inspection. If not, then verify the minimum voltage is present between terminals “A” and “B” of the relay. If the minimum voltage is not present, then check the wiring. If it is present, then verify that a minimum of 150 volts is present at terminals “6” and “8” of the draft motor relay. If not present at terminal “8” of the draft motor relay, then troubleshoot the transformer in blower section and its wiring. If present at terminal “8” and not at terminal “6” of the draft motor relay, then the relay is at fault. If the minimum voltage is present at terminal 6 of the draft motor relay, then the draft motor is at fault.

The igniter sparks at the pilot burner but the pilot does not ignite and a gas odor is detected at the draft motor outlet.

1. Adjust the pilot adjust screw on the gas valve as described in “PILOT CHECKOUT” on page 55.

2. Check the supply pressure as described in “POST START CHECK LIST” on page 54. Make adjustments as necessary.

3. Check the pilot orifice and pilot burner for obstruction as described in paragraph above. Clean as needed but the problem should not be the gas valve.

The pilot burner ignites but the igniter continues to spark and the main burners do not ignite.

1. Make the same checks and adjustment as described in “PILOT CHECKOUT” on page 55.

2. Check the supply pressure as described in “POST START CHECK LIST” on page 54. Make adjustments as necessary.

3. Make sure that the pilot burner is not bent or damaged.

4. Make sure that the ground connections at the pilot burner, gas valve and ignition control are intact. Check the igniter wire for good electrical connection. If all are intact, replace the ignition control.

The pilot burner lights and the spark stops but the main burners do not light.

1. Check electrical connections between the ignition control and the gas valve. If intact, check for 24 volts across terminals “MV” and “GROUND” terminals. If no voltage detected, replace ignition control. If voltage is present, replace gas valve.

Main burners light but exhibit erratic flame characteristics.

1. Adjust air shutters as described in “BURNER AIR SHUTTER ADJUSTMENT” on page 55.

2. Check the main burner orifices for obstruction and alignment. Removal procedure is described in BURNER INSTRUCTIONS on page 55. Clean or replace burner orifices and burners as needed.

Simplicity Lite Unit Flash Codes

Various flash codes are utilized by the Simplicity Lite unit control board (UCB) and the ignition control board (ICB) 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 boards flashes a 1 second on, 1 second off “heartbeat” during normal operation. This is to verify that the UCB and the ICB are functioning correctly. Do not confuse this with an error flash code. To prevent confusion, a 1-flash, flash code is not used.

Current alarms or active restrictions are flashed on the Simplicity Lite UCB LED.

• LAST ERROR - When this button is pressed and released one time within five seconds, it flashes the last five flash codes on the board’s LED. The most recent alarm is shown first and the oldest alarm is shown last.

When pressed and released twice within a five second span, the fault history is cleared.

• TEST RESET - When this button is pressed and released one time within five seconds, any anti-short cycle delays (ASCD) is by-passed for one cycle.

When this button is pressed twice within five seconds, any active lockouts are reset.

• COMM SET UP - If the board is to be networked with other units, this button is used to set the network address.

The first time the button is pressed within five seconds, it scans the bus, then assigns itself the first available address {starts at 2}. It then flashes that address one time.

Pressing the button two times within five seconds causes the control to flash its address.

Pressing the button three times within five seconds forces the control to reset its address to 1, which is the factory default.

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Figure 27: Simplicity Lite Control Board

Comm Setup

Button

Last Error

Button

Test Reset

Button

Control Board

LED

5742640-TIM-A-0419

Smart Equipment™ Control Board Navigation Components

The following components are needed to access the control points in the Smart Equipment™ control. Installation and operation guides are available from your equipment dealer or distributor.

1. Local LCD on Unit Control Board.

2. Mobile Access Portal (MAP) Gateway (Portable).

• Source 1 P/N S1-JC-MAP1810-OP

3. MAP Gateway Quick Start Guide P/N 24-10737-16

4. MAP Gateway Instruction P/N 24-10737-8

For more information on the Smart Equipment™ unit control board

navigation, refer to the Smart Equipment™ Quick Start Guide.

NOTE: For more in-depth sequence of operation of the Smart

Equipment™ control, refer to the Smart Equipment™ Controls Sequence of Operation Overview LIT-

12011950.

Table 32: Simplicity Lite Unit Control Board Flash Codes

Flash Code Description

On Steady Control Failure - Replace Control Heart Beat Normal Operation

1 Flash Not Applicable 2 Flashes Control waiting ASCD 3 Flashes HPS1 - Compressor Lock out 5 Flashes LPS1 - Compressor Lock out 7 Flashes FS1 - Compressor Lock out

Ignition Control Locked Out/

9 Flashes

10 Flashes

11 Flashes

13 Flashes Compressor Held Off Due To Low Voltage 14 Flashes EEPROM Storage Failure (Control Failure)

OFF No Power or Control Failure

1. These flash codes do not represent alarms.

Ignition Control Failure / Limit Switch Trip / No Jumper Plug in Heat Section Compressors Locked Out On Low Outdoor Air Temperature Compressors Locked Out Because The Economizer Is Using Free Cooling

Table 33: Ignition Control Board Flash Codes

Flash Code Description

Heart Beat Normal Operation

10 Flashes Flame Sense Circuit Failure

1 Flash Not Applicable 2 Flashes Pressure / Centrifugal Switch Open with Inducer On

3 Flashes

4 Flashes Not Applicable 5 Flashes Lock Out From Too Many Flame Losses 6 Flashes High Temperature Switch Open (Primary or Aux.) 7 Flashes Rollout Switch Open 8 Flashes Flame Present With Gas Off 9 Flashes Gas Valve Stuck Off or On

Pressure / Centrifugal Switch Closed with Inducer Off

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W1 W2

OCC

SD-24

THERMOSTAT

WIRED HERE

{

Figure 28: Smart Equipment™ Unit Control Board

Table 34: Smart Equipment™ UCB Details

Limit, 24 VAC power and shutdown connections from unit wiring harness at left on upper edge of UCB

LIMIT

24V

SD 24

SD R

Description Function & Comments

Terminal Directional orientation: viewed with silkscreen labels upright

Monitored 24 VAC input through heat section limit switch(es)

24 VAC, 75 VA transformer Common referenced to cabinet ground

24 VAC, 75 VA transformer hot

24 VAC hot out for factory accessory smoke detector, condensate overflow and/or user shutdown relay switching in series

24 VAC hot return from factory accessory smoke detector, condensate overflow and user shutdown relay switching in series

24 VAC hot for switched inputs to the UCB

If voltage is absent, indicating the heat section is overtemperature, the UCB will bring on the indoor blower

Connects through circuit traces to thermostat connection strip C and indoor blower VFD pin C

Powers the UCB microprocessor, connects through circuit trace to the SD 24 terminal

Connects through circuit trace to thermostat connection strip SD-24. A wiring harness jumper plug connecting SD 24 to SD R is in place if factory accessories for unit shutdown are not used this jumper plug must be removed if the switching of field-added external accessories for unit shutdown are wired between thermostat connection strip SD-24 and R

Connects through circuit trace to the R terminal on the upper left of the board

Connects through circuit trace to the thermostat connection strip R terminal, right FAN OVR pin, right HPS1 pin, right HPS2 pin, lower DFS pin and lower APS pin

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Table 34: Smart Equipment™ UCB Details (Continued)

Description Function & Comments

Terminal Thermostat connection strip on left edge of UCB

OCC

SD-24

POWER

FAULT

1st stage heating request, 24 VAC input switched from R

2nd stage heating request, 24 VAC input switched from R

1st stage cooling request, 24 VAC input switched from R

2nd stage cooling request, 24 VAC input switched from R

Continuous indoor blower request, 24 VAC input switched from R

Occupancy request, 24 VAC input switched from RMust have the OccMode parameter set for External to be

Hard lockout indicator, 24 volt output to a light thermostat LED

24 VAC hot for thermostat switching and power

If field-added external accessories for unit shutdown are used, 24 VAC hot out for smoke detector, condensate over- flow and/or user shutdown relay switching in series

24 VAC common for thermostat power

LEDs on left edge of UCB

Green UCB power indicator Lit indicates 24 VAC is present at C and 24V terminals

Red hard lockout, networking error and firmware error indicator

5742640-TIM-A-0419

Not effective for cooling-only units

Not effective for cooling-only units or units with single-stage heat sections

Visible in the display menu when the #ClgStgs parameter is set for 2 or more, also effective for economizer free cooling supply air temperature reset when the #ClgStgs parameter is set for 1 or more

effective

If field-added external accessories for unit shutdown are used, 24 VAC hot return from smoke detector, condensate overflow and/or user shutdown relay switching in series

Unit wiring harness jumper plug for factory shutdown accessories must be removed if the switching of field-added external accessories for unit shutdown are wired between thermo- stat connection strip SD-24 and R

1/2 second on/off flashing indicates one or more alarm is currently active, 1/10th second on/off flashing indicates a networking error (polarity, addressing, etc.) or a firmware error (likely correctable with re-loading from USB flash drive)

SA BUS

COM

SSO

SAT+

Green UCB SA bus communication transmission indicator

Terminal Space temperature sensor connections at center on upper edge of UCB

Space Temperature sensor input from 10KΩ @ 77°F, Type III negative temperature coefficient thermistor

Common for ST and SSO inputs Negative of VDC circuit for ST and SSO inputs

Space Sensor Offset input from 0 to 20KΩ potentiometer

Pin Temperature sensor connections at right on upper edge of UCB

Supply Air Temperature sensor input from 10KΩ @ 77°F, Type III negative temperature coefficient thermistor

Lit/flickering indicates UCB SA bus communication is currently active, off indicates the UCB is awaiting SA bus communication

Positive of VDC circuit (3.625 VDC reading to COM with open circuit), effective if “Thermo- stat-only Control” parameter is set OFF, space sensor override momentary shorts ST to COM to initiate/terminate temporary occupancy

Positive of VDC circuit (3.625 VDC reading to COM with open circuit), 10KΩ/2.5 VDC is 0°F offset, 0Ω/0 VDC is maximum above offset and 20KΩ/3.4 VDC is maximum below offset from active space temperature setpoint

Input required for operation; 3.625 VDC reading SAT+ to SAT– with open circuit. Used in heat/cool staging cutouts, free cooling operation, demand ventilation operation, comfort ventilation operation, economizer loading operation, VAV cooling operation, hydronic heat operation.

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Table 34: Smart Equipment™ UCB Details (Continued)

Description Function & Comments

RAT+

OAT+

CC1+

EC1+

CC2+

EC2+

RAH+

DCT PRS+

DFS (upper pin)

Return Air Temperature sensor input from 10KΩ @ 77°F, Type III negative temperature coefficient thermistor

Outside Air Temperature sensor input from 10KΩ @ 77°F, Type III negative temperature coefficient thermistor

#1 refrigerant circuit Condenser Coil temperature

sensor input from 10KΩ @ 77°F, Type III negative

temperature coefficient thermistor

#1 refrigerant circuit Evaporator Coil temperature

sensor input from 10KΩ @ 77°F, Type III negative

temperature coefficient thermistor

#2 refrigerant circuit Condenser Coil temperature

sensor input from 10KΩ @ 77°F, Type III negative

temperature coefficient thermistor

#2 refrigerant circuit Evaporator Coil temperature

sensor input from 10KΩ @ 77°F, Type III negative

temperature coefficient thermistor

Pinned connections on right edge of UCB

Return Air Humidity input from 0-10 VDC @ 0-

100% RH sensor

Supply Duct Pressure input from 0-5 VDC @ 0-5”

w.c. sensor

24 VAC hot return from Dirty Filter Switch

Input required for operation; 3.625 VDC reading RAT+ to RAT– with open circuit. Used in return air enthalpy calculation. Substitutes for space temperature if no other space temperature input is present.

Input required for operation but may be a communicated value;

3.625 VDC reading OAT+ to OAT– with open circuit. Used in heat/cool cutouts, low ambient cooling determination, dry bulb free cooling changeover, outside air enthalpy calculation, economizer loading operation, heat pump demand defrost calculation.

Input required for heat pump units, not required for A/C units;

3.625 VDC reading CC1+ to CC1– with open circuit. Used in heat pump demand defrost calculation.

Input required for operation; 3.625 VDC reading EC1+ to EC1– with open circuit. Used in suction line temperature safety.

Input required for 2-compressor heat pump units, not required for 2-compressor A/C units, not active for 1-compressor units;

3.625 VDC reading CC2+ to CC2– with open circuit. Used in heat pump demand defrost calculation.

Input required for operation of 2-compressor units, not active for 1-compressor units; 3.625 VDC reading EC2+ to EC2– with open circuit. Used in suction line temperature safety.

Input required for reheat units, optional in all other units, may be a communicated value. Used in return air enthalpy calculation, temperature/humidity setpoint reset, reheat operation.

Input required for variable air volume units. Used in VAV indoor blower operation.

Optional input; switch closure for greater than 15 seconds during indoor blower operation initiates a notification alarm

DFS (lower pin)

APS (upper pin)

APS (lower pin)

VFD

VFDFLT

24 VAC hot out for Dirty Filter Switch Connects through circuit trace to the R terminal

When this optional input is enabled: the air proving switch must close within 30 seconds of initiation of indoor blower operation and not open for greater than 10 seconds during in- door blower

24 VAC hot return from Air Proving Switch

24 VAC hot out for Air Proving Switch Connects through circuit trace to the R terminal

Common for the VFD output Negative of the VDC circuit for the VFD output

2-10 VDC (0-100%) output for the indoor blower Variable Frequency Drive

24 VAC hot input from the normally open VFD alarm contact

operation to allow heat/cool operation and prevent an “APS open” alarm; the air proving switch must open within 30 seconds of termination of indoor blower operation to prevent an “APS stuck closed” notification alarm

Output is active with indoor blower operation. For CV units: this output provides stepped IntelliSpeed control of the indoor blower VFD based on fan-only, cooling stage and heating stage outputs. For VAV units: this output provides control of the indoor blower VFD based on supply duct static pressure input and setpoint.

The VFD alarm contact switches from R within the unit wiring harness. 24 VAC input results in unit shutdown and a “VFD fault” alarm

68 Johnson Controls Ducted Systems

Page 69

Table 34: Smart Equipment™ UCB Details (Continued)

Description Function & Comments

Terminal at lower right corner of UCB

24V FOR OUTPUTS

CN-FAN

AUX HGR

FAN

Pin Refrigerant circuit safety switch and indoor blower overload connections at center on lower edge of UCB

HPS1

(right pin)

HPS1

(left pin)

LPS1

(right pin)

24 VAC hot for H1, H2, CN-FAN, AUX HGR, FAN C1 and C2 output relay contact switching

Pin Heat section connections at right on lower edge of UCB

24 VAC hot output for heat section stage 1

24 VAC hot output for heat section stage 2

24 VAC hot input confirming heat section operation

Pin Cooling and fan output connections at right on lower edge of UCB

24 VAC hot output for the condenser fan contactor coil

24 VAC hot output for hot gas reheat components Effective only for reheat units, output with reheat operation

24 VAC hot output for indoor blower contactor coil/ indoor blower VFD enable relay coil

24 VAC hot output for compressor 1

24 VAC hot output for compressor 2

24 VAC hot out for refrigerant circuit 1 High Pressure Switch

24 VAC hot return from refrigerant circuit 1 High Pressure Switch

24 VAC hot out for refrigerant circuit 1 Low Pressure Switch

5742640-TIM-A-0419

Output relay circuitry is isolated from other UCB components and the 24 VAC hot source may be from a second transformer in the unit

Not effective for cooling-only units. Output if demand is present and permissions allow one stage or two stages of heat section operation

Not effective for cooling-only units or units with single-stage heat sections. Output if demand is present and permissions allow two stages of heat section operation

Sourced from gas valve in gas heat units or first stage heat contactor in electric heat units. Input within 5 minutes from initiation of H1 output initiates the “Heat On Fan Delay” timer, loss of input following the termination of H1 output initiates the “Heat On Fan Delay” timer, no input within 5 minutes from initiation of H1 output initiates an “Ignition Failure” alarm, input for longer than 5 minutes without H1 output initiates a “Gas Valve Mis-wire” alarm

Output with either C1 or C2 output; interrupted during defrost cycle for heat pump units

Output with heat/cool operation, G input or schedule demand

If demand is present and permissions allow compressor 1 operation; output with compressor cooling, comfort ventilation cooling, reheat or heat pump heating demands

Not effective for one stage compressor UCBs. If demand is present and permissions allow compressor 2 operation; output with compressor cooling, comfort ventilation cooling or heat pump heating demands

Connects through circuit trace to the R terminal

Input is only considered if C1 output is needed; input must be present to allow C1 output. Three HPS1 trips in a two hour period cause a “High Pressure Switch 1 Lockout” and C1 output is then prevented until alarm reset. Connects through circuit trace to the right LPS1 pin.

Connects through circuit trace to the left HSP1 pin

LPS1

(left pin)

HPS2

(right pin)

24 VAC hot return from refrigerant circuit 1 Low Pressure Switch

24 VAC hot out for refrigerant circuit 2 High Pressure Switch

Input is only considered after 30 seconds of C1 output; afterwards, input must be present to allow C1 output. Three LPS1 trips in a one hour period cause a “Low Pressure Switch 1 Lockout” and C1 output is then prevented until alarm reset.

Not effective for one stage compressor UCBs. Connects through circuit trace to the R terminal

Johnson Controls Ducted Systems 69

Page 70

5742640-TIM-A-0419

Table 34: Smart Equipment™ UCB Details (Continued)

Description Function & Comments

HPS2

(left pin)

LPS2

(right pin)

LPS2

(left pin)

FAN OVR (right pin)

FAN OVR

(left pin)

PWR

–

Display

ENTER

CANCEL

JOY

J10

24 VAC hot return from refrigerant circuit 2 High Pressure Switch

24 VAC hot out for refrigerant circuit 2 Low Pressure Switch

24 VAC hot return from refrigerant circuit 2 Low Pressure Switch

24 VAC hot out for indoor blower FAN Overload relay contact/motor protector switch

24 VAC hot return from indoor blower FAN Overload relay contact/motor protector switch

Terminal SA BUS

Power for SA (“Sensor-Actuator”) BUS devices

Common for SA BUS power and communication circuits

Communication for SA BUS devices

6-pin phone jack connector

Item Integrated user interface at lower left corner of UCB

On-board, 2-line x 8-character back-lit display

Button for display menu acknowledgment and navigation

Button for display menu navigation and zeroing of active compressor ASCD timer

4-way Joystick for display menu navigation

Type A female Universal Serial Bus connector

connections on at left on lower edge and center of UCB

Item USB connector at right of UCB

Not effective for one stage compressor UCBs. Input is only considered if C2 output is needed; input must be present to allow C1 output. Three HPS2 trips in a two hour period cause a “High Pressure Switch 1 Lockout” and C2 output is then prevented until alarm reset. Connects through circuit trace to the right LPS2 pin.

Not effective for one stage compressor UCBs. Connects through circuit trace to the left HSP2 pin

Not effective for one stage compressor UCBs. Input is only considered after 30 seconds of C2 output; afterwards, input must be present to allow C2 output. Three LPS2 trips in a one hour period cause a “Low Pressure Switch 2 Lockout” and C2 output is then prevented until alarm reset.

Connects through circuit trace to the R terminal

Input is only considered if FAN output is needed; input must be present to allow FAN output and unit operation. One FAN OVR trip lasting longer than 5 minutes or three FAN OVR trips in a two hour period cause a “Fan Overload Lockout” and unit operation is then prevented until alarm reset.

Also incorporated in the J8 6-pin phone jack connector at the left-center of the board. Positive of the 15 VDC (reading to C) circuit for powering an optional netstat and/or Multi Touch gateway

Also incorporated in the J8 6-pin phone jack connector at the left-center of the board. Negative of the SA BUS circuits

Also incorporated in the J8 6-pin phone jack connector at the left-center of the board. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts lower than +) SA BUS communication circuit to optional economizer board, 4-stage board, fault detection & diagnostics board, netstat and/or Multi Touch gateway

Also incorporated in the J8 6-pin phone jack connector at the left-center of the board. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts higher than –) SA BUS communication circuit to optional economizer board, 4-stage board, fault detection & diagnostics board, netstat and/or Multi Touch gateway

Incorporates the SA BUS terminals for convenience/alternate connection of SA BUS devices, primarily used for temporary service connection of the Multi Touch gateway

On-board display, buttons and joystick allow access to UCB, economizer, 4-stage and FDD board parameters

Used for backup, restoration, & copying of board parameters as well as board software updating through a flash drive

70 Johnson Controls Ducted Systems

Page 71

Table 34: Smart Equipment™ UCB Details (Continued)

Description Function & Comments

5742640-TIM-A-0419

J15

Factory wired SA Bus connector

Optional communication sub-board at center of UCB

connections on left edge of the communication board

Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to COM; at least 0.25 volts higher than –) FC bus BACnet MSTP communication circuit

Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to COM; at least 0.25 volts lower than +) FC bus BACnet MSTP communication circuit

Negative of the VDC FC bus BACnet MSTP communication circuit

Earth ground reference of the cable to prevent interference on the FC bus BACnet MSTP communication circuit

FC+

FC–

COM

SHLD

Terminal FC BUS

FC (“Field Connected”) BUS BACnet MSTP communication

Common for the FC (“Field Connected”) BUS BACnet MSTP communication circuit

Shield for the FC (“Field Connected”) BUS BACnet MSTP communication circuit

Item Selector in red housing at left on top edge of the communication board

EOL

switch

End Of Line selector switch for the FC BUS BACnet MSTP communication circuit

ON selected only for the UCB that is the terminus of the FC bus BACnet MSTP communication cable to prevent signal “bounceback”

LEDs on the communication board

EOL

FC BUS

ISO PWR

Green End Of Line indicator Lit indicates the EOL switch is selected ON

Green FC bus communication transmission indicator

Green communication board Isolated Power indicator

Lit/flickering indicates outgoing UCB FC bus communication is currently active, off indicates the UCB is awaiting incoming FC bus communication

Lit indicates the UCB is supplying power to the communication sub-board

1. When wiring unit and other devices using the SA Bus and FC Bus, see Table 31.

Table 35: Cable for FC Buses and SA Buses in Order of Preference

Bus and Cable Type

FC Bus: 22 AWG Stranded, 3-Wire Twisted Shielded Cable

SA Bus (Terminal Block): 22 AWG Stranded, 4-Wire, 2 TwistedPair Shielded Cable

SA Bus (Modular Jack):

26 AWG Solid 6-Wire, 3 Twisted-Pair Cable

FC Bus: 22 AWG Stranded, 3-Wire Twisted Non-Shielded Cable Belden: B5501UE 0.135 in. Belden: B6501UE 0.131 in.

SA Bus (Terminal Block): 22 AWG Stranded, 4-Wire, 2 Twisted-

Pair Non-Shielded Cable

1. We strongly recommend 3-wire (for FC bus) and 4-wire, 2 twisted-pair (for SA bus), 22 AWG stranded, shielded cable. A 22 gauge cable offers the best performance for various baud rates, cable distances, and number of trunk devices primarily due to lower conductor-toconductor capacitance. Shielded cable offers better overall electrical noise immunity than non-shielded cable. Observe the shield grounding requirements.

2. We recommend 26 AWG solid, 6-wire (3 twisted pairs) cable as the best fit for fabricating modular cables with the modular jack housing assembly. Be sure the cable you use fits the modular jack housing. The preassembled cables that are available from Anixter (Part No. CBL-NETWORKxxx) use 24 gauge wire.

Non-Plenum Applications Plenum Applications

Part Number O.D. Part Number O.D.

Anixter: CBL-22/3-FC-PVC Belden®: B5501FE

Anixter: CBL-22/2P-SA-PVC Belden: B5541FE

0.138 in.

0.209 in.

Anixter: CBL-22/3-FC-PLN Belden: B6501FE

Anixter: CBL-22/2P-SA-PLN Belden: B6541FE

0.140 in.

0.206 in.

Anixter preassembled: CBLNETWORK25 CBL-

——

NETWORK50 CBL-

0.15 in. NETWORK75 CBLNETWORK100

Belden: B5541UE 0.206 in. Belden: B6541UE 0.199 in.

Johnson Controls Ducted Systems 71

Page 72

5742640-TIM-A-0419

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Johnson Controls Ducted Systems 75

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York International Corporation

5005 York Drive

Norman, OK 73069

Johnson Controls TempMaster ZD Series Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General

Installation

Installation Safety Information

Limitations

Location

Rigging And Handling

Ductwork

Compressors

Condensate Drain

Filters

Power And Control Wiring

Typical Field Power and Control Wiring

Typical Power Wiring

Typical Cool/Heat Control Wiring (Smart Equipment™ ZDT03 through TA6)

Optional Electric Heat

Options/Accessories

RRS Economizer Interface Overview

Dry Bulb Changeover

Single Enthalpy Changeover

Smart Equipment™ Economizer Sequences

Dual Enthalpy Changeover

Auto

Free Cooling Operation

Power Exhaust

Operation

Checking Supply Air CFM

Sequence Of Operation

Cooling Sequence Of Operation

No Outdoor Air Options

Cooling Operation Errors

Electric Heating Sequence Of Operations

Electric Heat Operation Errors

Gas Heating Sequence Of Operations

Gas Heat Operation Errors

Error Messages

Resets

Heat Anticipator Setpoints

Start-up (Cooling)

Start-up (Gas Heat)

Checking Gas Input

Start Up For Units Equipped for FER

Direct Drive

Belt Drive

Troubleshooting (Simplicity Lite Only)

Smart Equipment™ Control Board Navigation Components

Start-Up Sheet