YORK® ZJ Series Sunline Magnum™ /ZR Series
MagnaDRY™/ZF Series Sunline™ units are convertible single
package high efficiency rooftops. All models have independent
refrigeration circuits for efficient part load operation.
Although the units are primarily designed for curb mounting on
a roof, they can also be slab-mounted at ground level or set on
steel beams above a finished roof.
All ZJ/ZR/ZF units are self-contained and assembled on rigid
full perimeter base rails allowing for overhead rigging. Every
unit is completely charged, wired, piped, and tested at the
factory to provide a quick and easy field installation.
All models (including those with an economizer) are convertible
between bottom and horizontal duct connections.
ZJ/ZR/ZF units are available in the following configurations:
cooling only, cooling with electric heat, and cooling with gas
heat. Electric heaters are available as factory-installed options
only.
ZJ/ZR Shown
Tested in accordance with:
FOR DISTRIBUTION USE ONLY - NOT TO BE USED AT POINT OF RETAIL SALE
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
A = Std. Motor
B = Std. Motor/Economizer
C = Std. Motor/Economizer/Power Exhaust
(Downflow Only)
D = Std. Motor/Motorized Damper
E = Std. Motor/Motorized Damper/Barometric Relief
J = Std. Motor/Economizer/Barometric Relief
N = Hi Static
P = Hi Static/Economizer
Q = Hi Static/Economizer/Power Exhaust
(Downflow Only)
R = Hi Static/Motorized Damper
K = Hi Static/Motorized Damper/Barometric Relief
S = Hi Static/Economizer/Barometric Relief
2 = Low Static
3 = Low Static/Economizer
4 = Low Static/Economizer/Power Exhaust
EA = ElectroFin Condenser Coil
EJ = ElectroFin Evaporator Coil
ES = ElectroFin Cond & Evap Coils
Nomenclature
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Features and Benefits
Standard Features
• High Efficiency - High efficiency units reach as high as
12.4 EER. Gas/electric units have electronic spark ignition
and power vented combustion with steady state efficiencies
of 80%. These efficiencies exceed all legislated minimum
levels and provide low operating costs.
• Balanced Heating -
• Gas Heat - All gas heat units are built with two heating
sections for two equal stages of capacity control. Each
section includes a durable heat exchanger with
aluminized steel or optional stainless steel tubes, a
redundant gas valve, spark ignition, power venting, an
ignition module for 100% shut-off and all of the safety
controls required to meet the latest ANSI standards.
The gas supply piping can be routed into the heating
compartment through a hole in the base pan of the unit
or through a knockout in the piping panel on the front of
the unit.
• Electric Heat - All electric heat models (factory installed
only) are wired for a single power source and include a
bank of nickel chromium elements mounted at the
discharge of the supply air blower to provide a high velocity
and uniform distribution of air across the heating elements.
Every element is fully protected against excessive current
and temperature by fuses and two thermal limit switches.
The power supply wiring can be routed into the control
box through a threaded pipe connection in the base pan
of the unit or through a knockout in the wiring panel on
the front of the unit.
• BAS Controls - York’s Sunline™ series units offe r factory
mounted BAS controls such as SimplicityII™, Novar, Honeywell, Jo hnson, York Commercial
Comfort System (YCCS) and CPC.
• Convertible Airflow Design - All models (including those
with an economizer) are suitable for either bottom or
horizontal duct connections. Models with factory
installed power exhaust are suitable for bottom duct
connections only. For bottom duct, you remove the sheet
metal panels from the supply and return air openings
through the base of the unit. For horizontal duct, you
replace the supply and return air panels on the rear of the
unit with a side duct flange accessory.
• Factory Mounted Outdoor Air Dampers - All models are
available with these "factory mounted" outdoor air damper
options:
• Single enthalpy economizer with or without power
exhaust
• BAS-ready economizer with or without power exhaust
• Motorized outdoor air damper
• Barometric Relief Damper
A fixed outdoor air intake assembly will be shipped in the
return air compartment of all units ordered without an
economizer or motorized outdoor air damper option. The
assembly includes a rain hood with a damper that can be set
for 10, 15 or 25% outdoor air. With bottom duct connections,
®
Intelli-Comfort
the fixed outdoor air intake assembly should be mounted
over the opening in the return air panel. With horizontal
ductwork, it should be mounted on the return air duct.
• System Protection - Suction line freezestats are supplied
on all units to protect against loss of charge and coil frosting
when the economizer operates at low outdoor air
temperatures while the compressors are running. Every unit
has solid-core liquid line filter-driers and high and lowpressure switches. Internal compressor protection is
standard on all compressors. Phase Monitors are optional
on all units. This accessory monitors the incoming power to
the unit and protects the unit from phase loss and reversed
phase rotation.
• Advanced Controls - Simplicity™ ZJ/ZR/ZF control
boards have standardized a number of features
previously available only as options or by utilizing
additional controls.
• Low Ambient - An integrated low-ambient control
allows all units to operate in the cooling mode down to
0F outdoor ambient without additional assistance.
Optionally, the control board can be programmed to
lockout the compressors when the outdoor air
temperature is low or when free cooling is available.
The Simplicity® control board used in this product
will effectively operate the cooling system down to
0°F when this product is applied in a comfort cooling
application for people. An economizer is typically
included in this type of application. When applying
this product for process cooling applications
(computer rooms, switchgear, etc.), please
reference applications bulletin AE-011-07 or call the
applications department for Unitary Products @ 1877-UPG-SERV for guidance. Additional
accessories may be needed for stable operation at
temperatures below 30°F.
• Anti-Short Cycle Protection - To aid compressor life,
an anti-short cycle delay is incorporated into the
standard controls. Compressor reliability is further
ensured by programmable minimum run times. For
testing, the anti-short cycle delay can be temporarily
overridden with the push of a button.
• Lead-Lag - An integrated Lead-Lag option allows equal
run time hours on all compressors, thereby extending
the life of all compressors. This option is selectable on
the unit control board.
• Fan Delays - Fan on and fan off delays are fully
programmable. Furthermore, the heating and cooling
fan delay times are independent of one another. All units
are programmed with default values based upon their
configuration of cooling and heat.
• Safety Monitoring - The control board monitors the
high and low-pressure switches, the freezestats, the gas
valve, if applicable, and the temperature limit switch on
gas and electric heat units. The unit control board will
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alarm on ignition failures, compressor lockouts and
repeated limit switch trips.
• Nuisance Trip Protection and Strikes - To prevent
nuisance trouble calls, the control board uses a “three
times, you’re out” philosophy. The high and lowpressure switches and the freezestats must trip three
times within two hours before the unit control board will
lock out the associated compressor.
• On Board Diagnostics - Each alarm will energize a
trouble light on the thermostat, if so equipp ed, an d flash
an alarm code on the control board LED. Each high and
low-pressure switch alarm as well as each freezestat
alarm has its own flash code. The control board saves
the five most recent alarms in memory, and these alarms
can be reviewed at any time. Alarms and programmed
values are retained through the loss of power.
• Reliable - From the beginning - All units undergo
computer automated testing before they leave the factory.
Units are tested for refrigerant charge and pressure, unit
amperage, and 100% functionality. For the long term - All
units are painted with a long lasting, powder paint that
stands up over the life of the unit. The paint used has
been proven by a 1000 hour salt spray test.
• Full Perimeter Base Rails - The permanently attached
base rails provide a solid foundation for the entire unit and
protect the unit during shipment. The rails offer rigging
holes so that an overhead crane can be used to place the
units on a roof.
• Easy Installation - Gas and electric utility knockouts are
supplied in the unit underside as well as the side of the
unit. Utility connections can be made quickly and with a
minimum amount of field labor. All units are shipped with
2" throw-away filters installed.
• Wide Range of Indoor Airflows - All supply air blowers
are equipped with a belt drive that can be adjusted to
meet the exact requirements of the job. A high static drive
option is available for applications with a higher CFM and/
or static pressure requirement.
• Warranty - All models include a 1-year limited warranty
on the complete unit. Compressors and electric heater
elements each carry a 5-year warranty. Aluminized steel
and stainless steel tubular heat exchangers carry a 10year warranty.
Factory Installed Options
YORK® offers several equipment options factory installed, for
the ZJ/ZR/ZF Series.
• Single Input Electronic Enthalpy Economizers Includes a slide-in / plug-in damper assembly with fully
modulating spring-return motor actuator capable of
introducing up to 100% outdoor air with nominal 1%
leakage type dampers.
The enthalpy system contains one sensor that monitors
the outdoor air and determines when the air is cool
enough and dry enough to provide free cooling.
The rainhood is painted to match the basic unit and must
be field-assembled before installing.
• BAS-Ready Economizer - Includes a slide-in / plug-in
damper assembly with fully modulating spring-return
motor actuator with zero to 95-degree rotation capable of
introducing up to 100% outdoor air with nominal 1%
leakage type dampers.
Actuator requires 2-10 VDC input from an external source,
such as a field-installed or factory-installed BAS
controller. BAS-ready actuators have an adjustable
auxiliary end-switch for optional power exhaust control.
For units with optional VAV or Simplicity® Intelli-Comfort
II™ control, a factory-installed, dry bulb sensor
determines if outdoor air temperature is low enough to
provide free-cooling operation. (Field-installed humidity
sensors for either outdoor air or outdoor & return air
streams are available for single enthalpy and differential
enthalpy configurations, respectively).
The rain hood is painted to match the basic unit and must
be field-assembled before installing.
• Power Exhaust - Our economizer options are available
with power exhaust. Whenever the outdoor air intake
dampers are opened for free cooling, the exhaust fan will
be energized to prevent the conditioned space from being
over-pressurized during economizer operation.
The exhaust fan, motor and controls are installed and
wired at the factory. The rain hood must be assembled
and installed in the field.
The power exhaust option can only be used on bottom
duct configurations.
• Motorized Outdoor Air Intake Damper - Includes a
slide-in / plug-in damper assembly with a 2- position,
spring return motor actuator which opens to a pre-set
position whenever the supply air blower is operating and
will drive fully closed when the blower unit shuts down.
The rain hood is painted to match the basic unit and must
be field assembled before installing.
• Barometric Relief Damper - This damper option can be
used to relieve internal building air pressure on units with
an economizer without power exhaust. This accessory
includes a rain hood, a bird screen and a fully assembled
damper. With bottom duct connections, the damper
should be mounted over the opening in the return air
panel. With horizontal ductwork, the accessory should be
mounted on the return air duct.
• Technicoat Condenser Coils - The condenser coils are
coated with a phenolic coating for protection against
corrosion due to harsh environments.
• Technicoat Evaporator Coil - The evaporator coils are
coated with a phenolic coating for protection against
corrosion due to harsh environments.
• ElectroFin® E-coat Condenser Coils - The condenser
coils are coated with an epoxy polymer coating to protect
against corrosion.
• ElectroFin® E-coat Evaporator Coils - The evaporator
coils are coated with an epoxy polymer coating to protect
against corrosion.
• Electric Heaters - wired for single point power supply.
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These nickel chromium heater elements are provided with
limit and automatic reset capability to prevent operation at
excessive temperatures.
• Variable Air Volume (VAV) - A factory-installed variable
frequency drive (VFD), mounted in the Blower Access
compartment, is used to control the speed of the indoor
blower motor in order to maintain a constant static
pressure in the supply duct. A pressure transducer and
VAV control board are mounted inside the control box.
The drive comes completely wired and pre-programmed
from the factory.
An optional, factory-installed manual bypass switch
available with factory-installed VFD can be found in the
Blower Motor Access compartment. The switch can be
used to either route power to the VFD for modulating
control of the blower motor, to bypass the drive and
operate the motor at full speed, or to power the drive (and
not the motor) for diagnostic purposes.
Due to space limitations, VAV is not available with any of
the factory-installed BAS options described below, but is
available with ‘BAS-ready’ models. Terminal blocks are
provided in the control box for field wiring of the customerinstalled BAS.
A ‘VFD-ready’ option provides the provisions for a
customer-installed drive. The unit comes with a mounting
bracket installed in the Blower Access compartment which
may accommodate other vendor’s drives depending on
their size. In order to utilize the unit’s mounting bracket,
the maximum recommended drive dimensions are as
follows:
For 5-hp motor applications........................ 13” H x 6” W x 7” D
For 7.5 thru 15-hp motor applications ........ 13” H x 8” W x 8” D
If the drive will not fit in the allotted space, then it will have
to be mounted elsewhere; either within the building on a
perpendicular wall which is not subjected to excessive
temperature, vibration, humidity, dust, corrosive gas,
explosive gas, etc., or within an appropriate enclosure
rated for outside installation to safeguard against
moisture, dust and excessive heat.
A terminal block located in the control box is provided fo r
field connection of the VFD controls.
• Hot Gas Bypass - To allow for low cooling load operation,
a direct-acting pressure-modulating bypass control valve
installed on the system #1 discharge line is used to divert
high temperature, high pressure refrigerant around the
TXV in order to maintain a desired minimum evaporator
pressure. HGBP is standard on all units with VAV and
optional with CV units.
• Filter Options - Standard units are shipped with 2" throwaway filters installed. 2" pleated and 4" pleated filters are
offered as a factory installed option.
• Convenience Outlet - This 110 volt outlet can be
"powered" by the unit with a stepdown transformer or you
may order the unit with a "non-powered" convenience
outlet that can be wired in the field.
• Disconnect Switch - For gas heat units and cooling units
with electric heat, a HACR breaker sized to th e unit is
provided. For cooling only units, a switch sized to the
largest electric heat available for the particular unit is
provided. Factory installed option only.
• Double Wall Construction - Optional double wall
construction is available to provide smooth inner surfaces
for easy and effective cleaning to reduce risk of dirt and
bacterial accumulation. Fiberglass insulation is sandwiched
between heavy gauge steel sheets to form a durable, rigid
casing to withstand higher working pressures and impact
forces. The heavy-duty construction provides excellent
acoustic and thermal insulation and eliminates erosion of
insulation material and contamination of the air stream.
• York Commercial Comfort System (YCCS) - Provides
rooftop system integration for YCCS single zone, changeover bypass and VAV systems.
• Smoke Detectors - (supply air & return air) The smoke
detectors stop operation of the unit by interrupting power
to the control board if smoke is detected within the air
compartment.
Factory installed smoke detectors in the return air, may
be subjected to freezing temperatures during “off” times
due to out side air infiltration. these smoke detectors have
an operational limit of 32°F to 131°F. smoke detectors
installed in areas that could be out side those limitations
will have to be moved to prevent having false alarms.
• Coil Guard - Customers can purchase a coil guard kit to
protect the condenser coil from damage. This is not a hail
guard kit.
• Stainless Steel Heat Exchanger - For applications in
corrosive environments, this option provides a full
stainless steel heat exchanger assembly.
• Stainless Steel Drain Pan - An optional rustproof
stainless steel drain pan is available to provide years of
trouble-free operation in corrosive environments.
• Phase Monitors - Designed to prevent unit damage. The
phase monitor will shut the unit down in an out-of phase
condition.
• High Static Drive - May include a belt, blower pulley,
motor pulley or a motor change to enhance blower
performance.
• Low Static Drive - May include a belt, blower pulley,
motor pulley or a motor change when standard airflow is
not required. (ZJ/ZR/ZF300 only).
• Dirty Filter Switch - This kit includes a differential
pressure switch that energizes the fault light on the unit
thermostat, indicating that there is an abnormally high
pressure drop across the filters. Factory installed option or
field installed accessory.
• Hinged Filter Door/"Tool Free" Blower And Access Panels (Not Hinged) - This option allows for easy access
and maintenance.
NOTE: Knobs are shipped separately within the unit to prevent
shipping damage. These must be field installed for tool
free operation.
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• Hinged/"Tool Free" Blower, Blower Motor, Filter And Electric Access Panels - This option allows for complete
hinged and tool free access to the unit’s blower, blower
motor, filters and electrical panel sections.
Control Options
• BAS - Building Automation System Controls
(available on two-system cooling product only).
Simplicity™ Intelli-Comfort II™ Control - The York
Simplicity™ INTELLI-CO2 sensor to perform Differential
Demand Ventilation. It uses a Patented Comfort
Ventilation algorithm to provide comfortable ventilation air
temperature. The patented economizer-loading algorithm
will protect the equipment when harsh operating
conditions exist. Humidity in the occupied space or return
duct can be monitored and controlled via humidity sensors
and the on-board connection for hot gas re-heat system. It
uses the INTELLI-Start™ algorithm to maximize energy
savings by recovering the building from the Unoccupied
Setpoints to the Occupied Setpoints just in time for the
Occupied Time Period to begin. The Simplicity™ IntelliComfort II™ balances space temperature, ventilation air
temperature, CO
and humidity for ultimate comfort.
2
Simplicity™ Intelli-Comfort II™ with Simplicity™LINC
Control - The York® Simplicity™ Intelli-Comfort II™ with
Simplicity™LINC control is factory installed. It includes all
the features of the Intelli-Comfort II™ control with an
additional control to translate communications from
MODBUS to the BACnet MSTP protocol.
Novar® BAS Control - The Novar® building automation
system controller is factory installed. Incudes supply air
sensor, return air sensor, dirty filter indicator switch, and
air proving switch.
Johnson Controls BAS Control - The Johnson Control
YK-UNT-1126 building automation system controller is
factory installed. Includes supply air sensor, return air
sensor, dirty filter indicator switch, and air proving switch.
CPC BAS Control - The Computer Process Controls
Model 810-3060 ARTC Advanced Rooftop building
automation system controller is factory installed. Includes
supply air sensor, return air sensor, dirty filter indicator
switch and air proving switch.
Honeywell BAS Control - The Honeywell W7750C
building automation system controller is factory installed.
Includes air supply sensor, return air sensor, dirty filter
indicator switch, and air proving switch.
Field Installed Accessories
YORK® offers several equipment accessories for field
installation, for the ZJ/ZR/ZF Series.
• Single Input Electronic Enthalpy Economizers -
Includes a slide-in / plug-in damper assembly with fully
modulating spring-return motor actuator capable of
introducing up to 100% outdoor air with nominal 1%
leakage type dampers.
The enthalpy system contains one sensor that monitors
the outdoor air and determines when the air is cool
enough and dry enough to provide free cooling.
The rain hood is painted to match the basic unit and must
be field-assembled before installing.
• Motorized Outdoor Air Intake Damper - Includes a
slide-in / plug-in damper assembly with a 2-position,
spring return motor actuator which opens to some pre-set
®
position whenever the supply air blower is operating and
will drive fully closed when the blower unit shuts down.
The rain hood is painted to match the basic unit and must
be field assembled before installing.
• Roof Curbs - Fourteen-inch high roof curbs provide a
water-tight seal between the unit and the finished roof.
These full perimeter curbs meet the requirements of the
National Roofing Contractors Association (NRCA) and are
shipped knocked-down for field assembly.
They're designed to fit inside the base rails of the unit and
include both a wood nailing strip and duct hanger supports.
• High Altitude Natural Gas - Burner orifices and pilot
orifices are provided for proper furnace operation at
altitudes up to 6,000 feet.
• Propane - Burner orifices, pilot orifices and gas valve parts
are provided to convert a natural gas furnace to propane.
• High Altitude Propane - Burner orifices and pilot orifices
are provided for proper furnace operation at altitudes up
to 6,000 feet. This accessory supplements the basi c
propane conversion kit.
• Side Duct Flanges - One-inch flanges replace the supply
and return air panels on the rear of the unit to accommodate
horizontal duct connections. These flanges can also be used
individually for bottom supply / horizontal return or horizontal
supply/bottom return. They cannot be used on units with
power exhaust.
• Barometric Relief Damper - This damper accessory can
be used to relieve internal building air pressure on units
with an economizer without power exhaust. This
accessory includes a rain hood, a bird screen and a fully
assembled damper. With bottom duct connections, the
damper should be mounted over the opening in the return
air panel. With horizontal ductwork, the accessory should
be mounted on the return air duct.
• High Static Drive - May include a belt, blower pulley,
motor pulley or a motor change to enhance blower
performance.
• Enthalpy Accessory Control Kit - This kit contains the
required components to convert a single enthalpy
economizer to dual enthalpy.
• Burglar Bars - Mount in the supply and return openings
to prevent entry into the duct work.
• Flue Exhaust Extension Kit - In locations with wind or
weather conditions which may interfere with proper
exhausting of furnace combustion products, this kit can be
installed to prevent the flue exhaust from entering nearby
fresh air intakes.
• Wood Skid - Allows unit to be handled with 90" forks.
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• CO2 Sensor - Senses CO2 levels and automatically
overrides the economizer when levels rise above the
present limits.
• Coil Guard - Customers can purchase a coil guard kit to
protect the condenser coil from damage. This is not a hail
guard kit.
• Phase Monitors - Designed to prevent unit damage. The
phase monitor will shut the unit down in an out-of phase
condition.
Guide Specifications
General
Units shall be manufactured by Johnson Controls Unitary
Products in an ISO 9001 certified facility.
York's ZJ/ZR/ZF units are convertible single package units. ZJ
models have four independent refrigerant circuits and ZR/ZF
models have dual independent refrigerant circuits for efficient
part load operation and maximum comfort control. Although the
units are primarily designed for curb mounting on a roof, they
can also be slab-mounted at ground level or set on steel beams
above a finished roof. Cooling only, cooling with gas heat and
cooling with electric heat models are available with a wide
variety of factory-mounted options and field-installed
accessories to make them suitable for almost every application.
All units are self-contained and assembled on full perimeter
base rails with holes in the four corners for overhead rigging.
Every unit is completely piped, wired, charged and tested at the
factory to simplify the field installation and to provide years of
dependable operation. All models (including those with an
economizer) are suitable for either bottom or horizontal duct
connections. Models with power exhaust are suitable for bottom
duct connections only. For bottom duct, remove the sheet metal
panels from the supply and return air openings through the
base of the unit. For horizontal duct, replace the supply and
return air panels on the rear of the unit with a side duct flange
accessory. All supply air blowers are equipped with a belt drive
that can be adjusted to meet the exact requirements of the job.
A high static drive option is available for applicati ons with a
higher CFM and/or static pressure requirement.
ZJ/ZR models have 4 condenser fan motors and ZF models
have 2 condenser fan motors. All compressors include
crankcase heat and internal pressure relief. Every refrigerant
circuit includes an expansion valve, a liquid line filter-drier, a
discharge line high pressure switch and a suction line with a
freezestat and low pressure/loss of charge switch. The unit
control circuit includes a 75 VA transformer, a 24-volt circuit
breaker and a relay board with two compressor lockout circuits,
a terminal strip for thermostat wiring, plus an additional set of
pin connectors to simplify the interface of additional field
controls. All units have long lasting powder paint cabinets with
1000 hour salt spray test approval under ASTM-B117
procedures. All models are CSA approved. All models include a
1-year limited warranty on the complete unit. Compressors and
electric heater elements carry an additional 4-year warranty.
Aluminized steel tubular heat exchangers carry an additional 9year warranty.
Description
ZJ units shall be factory-assembled, single packaged, ZJ***N
Electric Cooling/Gas Heat, ZJ***C/E Electric Cooling/Optional
Electric Heat, designed for outdoor mounted installation. The 15
ton unit shall have a minimum EER rating of 12.4. The 17.5 ton
unit shall have a minimum EER rating of 12.1. The 20 ton unit
shall have a minimum EER rating of 11.6. The 25 ton unit shall
have a minimum EER rating of 10.4.
ZR units shall be factory-assembled, single packaged, ZR***N
Electric Cooling/Gas Heat, ZR***C/E Electric Cooling/Optional
Electric Heat, designed for outdoor mounted installation. The 15
ton unit shall have a minimum EER rating of 11.6. The 20 ton
unit shall have a minimum EER rating of 12.1. The 25 ton unit
shall have a minimum EER rating of 10.5.
ZF units shall be factory-assembled, single packaged, ZF***N
Electric Cooling/Gas Heat, ZF***C/E Electric Cooling/Optional
Electric Heat, designed for outdoor mounted installation. The 15
and 17.5 ton units shall have a minimum EER rating of 11.0.
The 20 and 25 ton units shall have a minimum EER rating of 10.
They shall have built-in field convertible duct connections for
down discharge supply/return or horizontal discharge supply/
return, and be available with factory installed options or field
installed accessories. The units shall be factory wired, piped,
charged with R-410A refrigerant and factory tested prior to
shipment. All unit wiring shall be both numbered and color
coded. All units shall be manufactured in a facility certified to
ISO 9001 standards and the cooling performance shall be rated
in accordance with DOE and AHRI test procedures. Units shall
be CSA listed, classified to ANSIZ21.47 standards, UL 1995/
CAN/CSA No. 236-M90 conditions.
Unit Cabinet
Unit cabinet shall be constructed of galvanized steel, with
exterior surfaces coated with a non-chalking, powdered paint
finish, certified at 1000 hours salt spray test per ASTM-B117
standards. Indoor blower section shall be insulated with a
minimum 1/2" thick insulation, coated on the airside. Aluminum
foil faced insulation shall be used in the furnace compartment
and be fastened with ridged fasteners to prevent insulation from
entering the air stream. Cabinet panels shall be "large" size,
easily removable for servicing and maintenance. Full perimeter
base rails shall be provided to assure reliable transit of
equipment, overhead rigging and proper sealing on roof curb
applications. Disposable 2" filters shall be furnished and be
accessible through a removable access door, sealed airtight.
Units filter track shall be designed to accommodate either 2" or
4" filters. Fan performance measuring ports shall be provided
on the outside of the cabinet to allow accurate air
measurements of evaporator fan performance without removing
panels or creating air by-pass of the coils. Condensate pan
shall be internally sloped and conform to ASHRAE 62-89 selfdraining standards. Condensate connection shall be a minimum
of 1" I.D. female and be a ridged mount connection. Unit shall
incorporate a fixed outdoor air damper with an outdoor air
intake opening covered with a bird screen and a rain hood
painted to match the exterior of the unit.
Johnson Controls Unitary Products9
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Indoor (Evaporator) Fan Assembly
Fan shall be a belt drive assembly and include an adjustablepitch motor pulley. Job site selected (B.H.P.) brake horsepower
shall not exceed the motors nameplate horsepower rating, plus
the service factor. Units shall be designed not to operate above
service factor. Fan wheel shall be double-inlet type with
forward-curved blades, dynamically balanced to operate
smoothly throughout the entire range of operation. Airflow
design shall be constant air volume.
A variable air volume (VAV) option using a variable frequency
drive (VFD) is available for applications requiring a constant
supply duct static pressure. Units equipped for VAV shall be
controlled by a duct pressure transducer with a 0 - 5” WC
pressure range. The pressure transducer shall provide a 0 - 5
VDC output signal to a VAV control board which, in turn shall
provide a 2 - 10 VDC speed reference signal to the VFD. The
VAV control board shall operate using factory-installed Supply
Air, Return Air and Outside Air Temperature Sensors. Units
equipped with VFD’s shall have factory-installed manual bypass
as an option.
Outdoor (Condenser) Fan Assembly
The outdoor fans shall be of the direct-driven propeller type,
discharge air vertically, have aluminum blades riveted to
corrosion resistant steel spider brackets and shall be
dynamically balanced for smooth operation. The 4 outdoor fan
motors shall be totally enclosed with permanently lubricated
bearings, internally protected against overload conditions and
staged independently.
Refrigerant Components
Compressors:
a. Shall be Scroll compressors internally protected with
internal high-pressure relief and over temperature
protection.
b. Shall have internal spring isolation an d sound muffling to
minimize vibration and noise, and be externally isolated
on a dedicated, independent mounting.
Coils:
a. Evaporator and condenser coils shall have aluminum
plate fins mechanically bonded to seamless internally
enhanced copper tubes with all joints brazed. Special
Phenolic coating shall be available as a factory option.
b. Evaporator and Condenser coils shall be of the direct
expansion, draw-thru, design.
Refrigerant Circuit and Refrigerant Safety Components shall
include:
a. Balance-port thermostatic expansion valve with
independent circuit feed system.
b. Filter drier/strainer to eliminate any moisture or foreign
matter.
c. Accessible service gage connections on both suction
and discharge lines to charge, evacuate, and measure
refrigerant pressure during any necessary servicing or
troubleshooting, without losing charge.
d. The refrigeration system shall provide at least 15° F of
sub-cooling at design conditions.
e. All models shall have four independent circuits.
f. Hot gas bypass option shall be factory-installed on
compressor #1 discharge line to provide cooling in low-
load applications. HGBP shall be a standard featu re on
VAV models and an optional feature on CV models.
Unit Controls
a. Unit shall be complete with self-contained low-voltage
control circuit protected by a resettable circuit breaker on
the 24-volt transformer side.
b. Unit shall incorporate a lockout circuit which provides
reset capability at the space thermostat or base unit,
should any of the following standard safety devices trip
and shut off compressor.
c. Loss-of-charge/Low-pressure switch.
1.High-pressure switch.
2.Freeze-protection thermostat, evaporator coil. If any of
the above safety devices trip, a LED (light-emitting
diode) indicator shall flash a diagnostic code that
indicates which safety switch has tripped.
d. Unit shall incorporate "AUTO RESET" compressor over
temperature, over current protection.
e. Unit shall operate wi th conventional thermostat designs
and have a low voltage terminal strip for easy hook-up.
f. Unit control board shall have on-board diagnostics and
fault code display.
g. Standard controls shall include anti-short cycl e and low
voltage protection, and permit cooling operation down to
0 °F.
h. Control board shall monitor each refrigerant safety switch
independently.
i. Control board shall retain last 5 fault codes in non volatile
memory, which will not be lost in the event of a power
loss.
Gas Heating Section (ZJ/ZR/ZF***N Models)
Shall be designed with induced draft combustion with post purge
logic and energy saving direct spark ignition, redundant main gas
valve. Ventor wheel shall be constructed of stainless steel for
corrosion resistance. The heat exchanger shall be of the tubular
type, constructed of T1-40 aluminized steel for corrosion
resistance and allowing minimum mixed air entering temperature
of 25 °F. Burners shall be of the in-shot type, constructed of
aluminum coated steel and contain air mixture adjustments. All
gas piping shall enter the unit cabinet at a single location through
either the side or curb, without any field modifications. An
integrated control board shall provide timed control of evaporator
10Johnson Controls Unitary Products
251934-YTG-O-0512
fan functioning and burner ignition. Heating section shall be
provided with the following minimum protection:
a. Primary and auxiliary high-temperature limit switches.
b. Induced draft motor speed sensor.
c. Flame roll out switch (automatic reset).
d. Flame proving controls. Unit sha ll have two independent
stages of capacity.
Electric Heating (ZJ/ZR/ZF***C/E Models)
Nickel chromium electric heating elements shall be provided as
required by the application with 1 or 2 stage control, as
required, from 13.5 KW to 72 KW capacities. The heating
section shall have a primary limit control(s) and automatic reset
to prevent the heating element system from operating at an
excessive temperature. Units with Electric Heating shall be
wired for a single point power supply with branch circuit fusing
(where required).
Unit Operating Characteristics
Unit shall be capable of starting and running at 125° F outdoor
temperature, exceeding maximum load criteria of AHRI
Standard 340/360. The compressor, with standard controls,
shall be capable of operation down to 25° F outdoor
temperature. Accessory low ambient kit shall be available for
operation to 0° F. Unit shall be provided with fan time delay to
prevent cold air delivery before heat exchanger warms up (Gas
heat only).
Electrical Requirements
All unit power wiring shall enter unit cabinet at a single factory
provided location and be capable of side or bottom entry, to
minimize roof penetrations and avoid unit field modifications.
Separate side and bottom openings shall be provided for the
control wiring.
Standard Limited Warranties
• Compressor 5 Years
• Heat Exchanger 10 Years
• Electric Heat Element 5 Years
• Other Parts 1 Year
Optional Outdoor Air (Shall be made avai lable by either/or):
• Electronic Enthalpy Automatic Economizer - Outdoor
and return air dampers that are interlocked and positioned
by a fully-modulating, spring-return damper actuator. The
maximum leakage rate for the outdoor air intake dampers
shall not exceed 2% when dampers are fully closed and
operating against a pressure differential of 0.5 IWG. A
unit-mounted potentiometer shall be provided to adjust
the outdoor and return air damper assembly to take in
CFM of outdoor air to meet the minimum ventilation
requirement of the conditioned space during normal
operation. During economizer operation, a mixed-air
temperature control shall modulate the outdoor and return
air damper assembly to prevent the supply air
temperature from dropping below 55°F. Changeover from
compressor to economizer operation shall be provided by
an integral electronic enthalpy control that feeds input into
the basic module. The outdoor intake opening shall be
covered with a rain hood that matches the exterior of the
unit. Water eliminator/filters shall be provided.
Simultaneous economizer/compressor operation is also
possible. Dampers shall fully close on power loss.
• Motorized Outdoor Air Dampers - Outdoor and return
air dampers that are interlocked and positioned by a 2position, spring-return damper actuator. The maximum
leakage rate for the outdoor air intake dampers shall not
exceed 2% when dampers are fully closed and operating
against a pressure differential of 0.5 IWG. A unit-mounted
potentiometer shall be provided to adjust the outdoor and
return air damper assembly to take in the design CFM of
outdoor air to meet the ventilation requirements of the
conditioned space during normal operation. Whenever the
indoor fan motor is energized, the dampers open up to
one of two pre-selected positions - regardless of the
outdoor air enthalpy. Dampers return to the fully closed
position when the indoor fan motor is de-energized.
Dampers shall fully close on power loss.
Other Pre-engineered Accessories Available
• Roof Curb - 14" high, full perimeter curb with wood nailer
(shipped knocked-down).
• 100% Barometric Relief Damper - Contains a rain hood,
air inlet screen, exhaust damper and mounting hardware.
Used to relieve internal air pressure through the unit.
• Propane Conversion Kit - Contains new orifices and gas
valve parts to convert from natural to L.P. gas. One per
unit required.
• High Altitude - Natural Gas - Contains orifices required
for applications between 2000 and 6000 feet altitude.
• High Altitude - Propane Gas - Contains orifice s requ ired
for applications between 2000 and 6000 feet altitude.
Must be used with propane conversion kit.
• Burglar Bars - Designed to work with above roof curbs,
depending on unit model. Fits duct openings of curb
supply and return air openings.
• Side Duct Flange - Supply and return air duct flanges for
side duct applications. Do not use on units with power
exhaust.
• High Static Drive - May include a belt, blower pulley,
motor pulley or a motor change to enhance blower
performance.
• Wood Skid - Allows unit to be handled with 90" forks.
• Economizer/motorized Damper Rain Hood(ZJ/ZR/ZFN/E/C300 only) - Contains all hood panels and
the hardware for assembling.
• Anti-Recycle Timer - Assures 5-minute off time between
compressor cycles.
• Low Ambient Kit - Provides unit cooling operation down
to 0 °F.
• Coil Guard Kit - Guard for cooling coil.
Johnson Controls Unitary Products11
251934-YTG-O-0512
OTHER FACTORY INSTALLED OPTIONS
• Power Exhaust Option - To work in conjunction with
economizers.
• Stainless Steel Heat Exchanger
• Stainless Steel Drain Pan
• Technicoat Phenolic Coated Condenser And
Evaporator Coil
• ElectroFin® E-coat Epoxy Polymer Coated Condenser
And Evaporator Coil
• Electronic Single Enthalpy Economizer
• Dirty Filter Switch
• Double Wall
• Phase Monitor
•Coil Guard
• Powered GFI Convenience Outlet
• Non-powered GFI Convenience Outlet
• Bas Controls - Simplicity
®
Intelli-Comfort II ™, CPC,
JOHNSON, HONEYWELL, NOVAR, YORK
COMMERCIAL COMFORT SYSTEM (YCCS)
• BAS Ready Economizer (2-10 V.D.C. Actuator Without a
Controller)
• Hinged Filter Door Access And Tool Free Access
Panels
(UCB), which engages circuit # 1, resulting in circuit #1 reheat
mode operation.
When the room thermostat calls for first stage cooling, with or
without a call for dehumidification, the RCB senses a signal
through "Y1", de-energizing the HGR, which de-energizes SOL
3 and SOL 2, and energizes SOL 1, engaging circuit # 1,
resulting in circuit #1 cooling mode operation.
When the room thermostat calls for second stage cooling, the
RCB senses a signal through "Y1" & "Y2" and engages circuit
#1 and circuit #2 in the cooling mode.
Indoor blower operation is initiated upon a call for first stage
cooling, second stage cooling or dehumidification.
Anytime there is a call for 2 stages of cooling, the unit will not
operate in the reheat mode, even if there is a call for
dehumidification at "HUM".
The unit will not operate in the reheat mode if there is any call
for heating.
On units with economizers, the unit will not operate in the
reheat mode if there is a call for cooling and the economizer is
operating as first stage of cooling.
All safety devices function as previously described.
"Alternate” Mode
When the RCB detects a need for dehumidification (24VAC) at
"HUM" via the field supplied dehumidistat connected to RHTB-1
and RHTB-2, and there is not a call for cooling, it energizes the
HGR, which energizes the SOL 3, SOL 2, and de-energizes
SOL 1. The unit then operates with circuit #1 in reheat mode
and circuit #2 in cooling mode.
When the room thermostat calls for first stage cooling while
there is still a call for dehumidification, no operational change is
made. The call for cooling is ignored and the unit continues to
operate with circuit #1 in reheat mode and circuit #2 in cooling
mode.
The reheat control board allows the user to select two different
modes of operation via a jumper connection on the board. (See
Reheat Control Board.) Each mode is described below. Refer to
Reheat Controls - Part 1 and Part 2 when reading this section.
“Normal” Mode
When the room thermostat calls for second stage cooling, the
RCB senses a signal through "Y1" & "Y2" and de-energizes the
HGR, which de-energizes SOL 3 and SOL 2, and energizes
SOL 1. Both circuits operate in the cooling mode.
Indoor blower operation is initiated upon a call for first stage
cooling, second stage cooling or dehumidification.
When the reheat control board (RCB) detects a need for
dehumidification (24VAC) at "HUM" via the field supplied
dehumidistat connected to RHTB-1 and RHTB-2 and there is
not a call for cooling, it energizes the hot gas relay (HGR),
which energizes the 3-way valve (SOL 3), the condenser coil
valve (SOL 2), and de-energizes the reheat coil bleed valve
(SOL 1). The Y1 signal is passed to the unit control board
Anytime there is a call for 2 stages of cooling, the unit will not
operate in the reheat mode, even if there is still a call for
dehumidification at "HUM".
The unit will not operate in the reheat mode if there is any call
for heating.
All safety devices function as previously described.
12Johnson Controls Unitary Products
Reheat Control Board
R
Y1
Y2
G
W1
OCC
C
W2
P4
P5
P6
P3
COM
HGRR
HGR
HUM
K1
K2
K4
K3
`
MODE
SELECTION
JUMPER
DEHUMIDISTAT
HARNESS
CONNECTION
251934-YTG-O-0512
Reheat Controls - Part 1
Johnson Controls Unitary Products13
251934-YTG-O-0512
UCB
UNIT CONTROL
BOARD
RHB
REHEAT CONTROL
BOARD
RHTB
REHEAT
TERMINAL
BLOCK
HUM
HUMIDIFY
TERMINAL
RHR
REHEAT
RELAY
REHEAT
SOLENOID
3
REHEAT
SOLENOID
1
REHEAT
SOLENOID
2
RHB
REHEAT
CONTROL
BOARD
UCB
UNIT CONTROL
BOARD
Reheat Controls - Part 2
14Johnson Controls Unitary Products
Physical Data
ZJ180-300 Physical Data
251934-YTG-O-0512
Component
Nominal Tonnage1517.52025
AHRI COOLING PERFORMANCE
Gross Capacity @ AHRI A point (Btu)183500213700242000290000
AHRI net capacity (Btu)178500206000235000280000
EER12.412.011.510.5
SEER---IEER14.013.413.010.6
Nominal CFM6000580062007000
System power (KW)14.4017.1020.1026.67
Refrigerant typeR-410aR-410aR-410aR-410a
Refrigerant charge (lb-oz)
System 112-812-812-012-4
System 212-813-812-012-8
System 312-812-812-012-8
System 412-812-812-012-8
AHRI HEATING PERFORMANCE
Heating model2432243224322432
Heat input (K Btu)300400300400300400300400
Heat output (K Btu)240320240320240320240320
AFUE %-------Steady state efficiency (%)8080808080808080
No. burners68686868
No. stages22222222
Temperature Rise Range (ºF)20-5030-6020-5030-6020-5030-6020-5030-60
Gas Limit Setting (ºF)195195195195195195195195
Gas piping connection (in.)11111111
Face area (Sq. Ft.)63.863.863.863.8
Rows2222
Fins per inch20202020
Tube diameter (in.)3/83/83/83/8
Circuitry TypeSplit-faceSplit-faceSplit-faceSplit-face
EVAPORATOR COIL DATA
Face area (Sq. Ft.)25252525
Rows4444
Fins per inch13.513.513.513.5
Tube diameter3/83/83/83/8
Circuitry TypeSplit-faceSplit-faceSplit-faceSplit-face
Refrigerant controlTXVTXVTXVTXV
ZJ180ZJ210ZJ240ZJ300
Models
Johnson Controls Unitary Products15
251934-YTG-O-0512
ZJ180-300 Physical Data (Continued)
Component
ZJ180ZJ210ZJ240ZJ300
Models
Nominal Tonnage1517.52025
CONDENSER FAN DATA
Quantity4444
Fan diameter (Inch)24243030
TypePropPropPropProp
Drive typeDirectDirectDirectDirect
No. speeds1111
Number of motors4444
Motor HP each1/31/31/31/3
RPM850850870870
Nominal total CFM4000400050005000
BELT DRIVE EVAP FAN DATA
Quantity1111
Fan Size (Inch)15 X 1518 X 1518 X 1518 X 15
TypeCentrifugalCentrifugalCentrifugalCentrifugal
Motor Sheave1VP651VP651VP601VP601VP601VP601VP60 1VP75X 1VP75X
Blower SheaveBK110BK090BK110BK090BK110BK0901B5V94 1B5V110 1B5V94
BeltBX85BX81BX78BX75BX78BX75BX785VX840 5VX860
Motor HP each5557.557.57.51015
RPM172517251725172517251725172517251725
Frame size184T184T184T213T184T213T213T215T254T
Gross Capacity @ AHRI A point (Btu)189243303
AHRI net capacity (Btu)183235288
EER11.612.110.0
SEER--IEER12.412.910.5
Nominal CFM600080007600
System power (KW)14.4020.1028.50
Refrigerant typeR-410aR-410aR-410a
Refrigerant charge (lb-oz)
System 1222425
System 2222424-8
AHRI HEATING PERFORMANCE
Heating model243224322432
Heat input (K Btu)300400300400300400
Heat output (K Btu)240320240320240320
AFUE %-----Steady state efficiency (%)808080808080
No. burners686868
No. stages222222
Temperature Rise Range (ºF)20-5030-6020-5030-6020-5030-60
Gas Limit Setting (ºF)195195195195195195
Gas piping connection (in.)111111
Face area (Sq. Ft.)63.863.863.8
Rows222
Fins per inch202020
Tube diameter (in.)3/83/83/8
Circuitry TypeSplit-faceSplit-faceSplit-face
EVAPORATOR COIL DATA
Face area (Sq. Ft.)202020.52
Rows344
Fins per inch13.513.513.5
Tube diameter3/83/83/8
Circuitry TypeIntertwinedIntertwinedIntertwined
Refrigerant controlTXVTXVTXV
REHEAT COIL DATA
Face area (Sq. Ft.)17.217.217.2
Rows222
Fins per inch131313
Tube diameter3/83/83/8
ZR180ZR240ZR300
Models
Johnson Controls Unitary Products17
251934-YTG-O-0512
ZR180-300 Physical Data (Continued)
Component
ZR180ZR240ZR300
Models
Nominal Tonnage152025
CONDENSER FAN DATA
Quantity444
Fan diameter (Inch)243030
TypePropPropProp
Drive typeDirectDirectDirect
No. speeds111
Number of motors444
Motor HP each1/33/43/4
RPM850870870
Nominal total CFM400050005000
BELT DRIVE EVAP FAN DATA
Quantity111
Fan Size (Inch)15 X 1518 X 1518 X 15
TypeCentrifugalCentrifugalCentrifugal
Motor Sheave1VP651VP651VP601VP601VP60 1VP75X 1VP75X
Blower SheaveBK110BK090BK110BK0901B5V94 1B5V110 1B5V94
BeltBX85BX81BX78BX75BX785VX840 5VX860
Motor HP each57.57.5107.51015
RPM1725172517251725172517251725
Frame size184T213T213T215T213T215T254T
Gross Capacity @ AHRI A point (K Btu)181208259279
AHRI net capacity (K Btu)174203250270
EER11.011.010.010.0
SEER---IEER12.111.910.810.2
Nominal CFM60007000800010000
System power (KW)15.818.525.027.0
Refrigerant typeR-410aR-410aR-410aR-410a
Refrigerant charge (lb-oz)
System 120-823-82222
System 220-823-82323-4
AHRI HEATING PERFORMANCE
Heating model2432243224322432
Heat input (K Btu)300400300400300400300400
Heat output (K Btu)240320240320240320240320
AFUE%-------Steady state efficiency (%)8080808080808080
No. burners68686868
No. stages22222222
Temperature Rise Range (ºF)20-5030-6020-5030-6020-5030-6020-5030-60
Gas Limit Setting (ºF)195195195195195195195195
Gas piping connection (in.)11111111
Face area (Sq. Ft.)36.043.343.343.3
Rows3333
Fins per inch13.5151515
Tube diameter (in.)3/83/83/83/8
Circuitry TypeSplit-faceSplit-faceSplit-faceSplit-face
EVAPORATOR COIL DATA
Face area (Sq. Ft.)15.5252025
Rows4444
Fins per inch13.513.513.513.5
Tube diameter3/83/83/83/8
Circuitry TypeIntertwinedSplit-faceIntertwinedSplit-face
Refrigerant controlTXVTXVTXVTXV
ZF180ZF210ZF240ZF300
Models
Johnson Controls Unitary Products19
251934-YTG-O-0512
ZF180-300 Physical Data (Continued)
Component
ZF180ZF210ZF240ZF300
Models
Nominal Tonnage1517.52025
CONDENSER FAN DATA
Quantity2222
Fan diameter (Inch)30243030
TypePropPropPropProp
Drive typeDirectDirectDirectDirect
No. speeds1111
Number of motors2222
Motor HP each1.251.251.251.25
RPM1140114011401140
Nominal total CFM5765700070007000
BELT DRIVE EVAP FAN DATA
Quantity1111
Fan Size (Inch)15 X 1518 X 1518 X 1518 X 15
TypeCentrifugalCentrifugalCentrifugalCentrifugal
Motor Sheave1VP651VP651VP601VP601VP601VP601VP60 1VP75X 1VP75X
Blower SheaveBK110BK090BK110BK090BK110BK0901B5V94 1B5V110 1B5V94
BeltBX85BX81BX78BX75BX78BX75BX785VX840 5VX860
Motor HP each5557.557.57.51015
RPM172517251725172517251725172517251725
Frame size184T184T184T213T184T213T213T215T254T
FILTERS
Quantity - Size
5 - (18 x 24 x 2)
--4 - (16 x 20 x 2)
5 - (18 x 24 x 4)
-4 - (24 x 24 x 4)
1,2
12 - (12 x 24 x 2)
3
2 - (20 x 24 x 4),4 - (16 x 25 x 4),2 - (20 x 24 x 4),
1. These capacities are gross ratings. For net capacity, deduct air blower motor, MBh = 3.415 x kW. Refer to the appropriate Blower
Performance Table for the kW of the supply air blower motor.
2. These ratings include the condenser fan motors (total 1 kW) and the compressor motors but not the supply air blower motor.
1. These capacities are gross ratings. For net capacity, deduct air blower motor, MBh = 3.415 x kW. Refer to the appropriate Blower
Performance Table for the kW of the supply air blower motor.
2. These ratings include the condenser fan motors (total 1 kW) and the compressor motors but not the supply air blower motor.
1. These capacities are gross ratings. For net capacity, deduct air blower motor, MBh = 3.415 x kW. Refer to the appropriate Blower
Performance Table for the kW of the supply air blower motor.
2. These ratings include the condenser fan motors (total 1 kW) and the compressor motors but not the supply air blower motor.
1. These capacities are gross ratings. For net capacity, deduct air blower motor, MBh = 3.415 x kW. Refer to the appropriate Blower
Performance Table for the kW of the supply air blower motor.
2. These ratings include the condenser fan motors (total 1 kW) and the compressor motors but not the supply air blower motor.
1. These capacities are gross ratings. For net capacity, deduct air blower motor, MBh = 3.415 x kW. Refer to the appropriate Blower
Performance Table for the kW of the supply air blower motor.
2. These ratings include the condenser fan motors (total 1 kW) and the compressor motors but not the supply air blower motor.
Temperature of Air on Condenser Coil
Total
1
Capacity
(MBh)
(kW)
Total
Input
Sensible Capacity (MBh)
2
30Johnson Controls Unitary Products
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