York ZF Sunline R410A 13 SEER Technical Guide

®

723389-XTG-C-0214

TECHNICAL GUIDE

R-410A
ZF SERIES
3 - 6.3 TON
50 Hz
Export Only

Description

YORK® ZF Series units are convertible single package high
efficiency rooftops with a common roof curb for the 3, 4, 5 and

6.3 Ton sizes. 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 ZF Series units are self-contained and asse mb le d 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.

ZF Series units are available in the following configurations:
cooling only, cooling with electric heat, and cooling with one
stage gas heat. Electric heaters are available as factory­installed option or field install e d accessory.

FOR DISTRIBUTION USE ONLY - NOT TO BE USED AT POINT OF RETAIL SALE

723389-XTG-C-0214

Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Guide Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Capacity Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Component Location

Gas/Electric

2 Johnson Controls Unitary Products

Electric/Electric

723389-XTG-C-0214

Johnson Controls Unitary Products 3

723389-XTG-C-0214

Z F 048 N04 A 7 A AA 1 0 1 2 4 A

Z = A/C, Single Pkg., R-410A

Product Category

Airflow

Product Generation

1 = First Generation

C00 = Cooling Only. Suitable for Field

Installed Electric Heat

Heat Type and Nominal Heat Capacity

E05 = 5 KW
E07 = 7 KW
E10 = 10 KW
E15 = 15 KW
E20 = 20 KW
E30 = 30 KW

Gas Heat Options

Electric Heat Options

036 = 3.0 Ton

Nominal Cooling Capacity

048 = 4.0 Ton
060 = 5.0 Ton
076 = 6.3 Ton

Product Identifier

F = 13.0 SEER, A/C

= 11.0 EER, A/C

Voltage

7 = 380/415-3-50

Product Style

A = Style A

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

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

Options

SS Drain Pan

Configuration Options (not required for all units)

These four digits will not be assigned until a quote is requested, or an order placed.

CPC Controller, DFS, APS

Johnson Controller UNT 1126 (N2 protocol), DFS, APS

Honeywell Controller, DFS, APS

Novar Controller, DFS, APS

Simplicity IntelliComfort Controller

Simplicity IntelliComfort Controller w/ModLinc

2" Pleated filters

BAS Ready Economizer (2-10 V.D.C. Actuator Without a Controller)

Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned

AA = None

Standard Cabinet

AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
AS = Bottom Drain Connection
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator and Condenser Coil

Additional Options

Hinged & Toolless Access Cabinet

BA = Hinged & Toolless Filter, Motor and Electrical
Access Panels
BB = Phase Monitor, Hinged & Toolless Filter, Motor
and Electrical Access Panels
BC = Coil Guard, Hinged & Toolless Filter, Motor and
Electrical Access Panels

BD = Dirty Filter Switch, Hinged & Toolless Filter,
Motor and Electrical Access Panels
BE = Phase Monitor & Coil Guard, Hinged & Toolless
Filter, Motor and Electrical Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged &
Toolless Filter, Motor and Electrical Access
Panels
BG = Coil Guard & Dirty Filter Switch, Hinged &
Toolless Filter, Motor and Electrical Access
Panels

BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged & Toolless Filter, Motor and Electrical
Access Panels

York Commercial Comfort System (YCCS) Rtu Controller

1

1. 3 thru 6.3 Ton Units

EA = ElectroFin Condenser Coil
EJ = ElectroFin Evaporator Coil
ES = ElectroFin Cond & Evap Coils

A = Direct Drive

B = Direct Drive/Economizer
D = Direct Drive/Motorized Damper
N = Belt Drive
P = Belt Drive/Economizer
R = Belt Drive/Motorized Damper

N04 = 40 MBH Output Aluminized Steel, 1 Stage (036)
N06 = 60 MBH Output Aluminized Steel, 1 Stage (048)
N08 = 80 MBH Output Aluminized Steel, 1 Stage

(060, 076)
S04 = 40 MBH Output Stainless Steel, 1 Stage (036)
S06 = 60 MBH Output Stainless Steel, 1 Stage (048)
S08 = 80 MBH Output Stainless Steel, 1 Stage

(060, 076)

Nomenclature

4 Johnson Controls Unitary Products

723389-XTG-C-0214

Features and Benefits

Standard Features

• High Efficiency - High efficiency 3 thru 5 Ton units reach

13.0 SEER, 6.3 Ton reach 10.9 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.

• Coil Technology – All ZF condensers utilize Micro­Channel “all-aluminum” condensers which provide
improved heat transfer capabilities and reduced charge
volumes. All evaporators utilize a conventional copper
tube/aluminum fin design for proven reliability and
performance.

• Convertible Airflow Design - All models (including those
with an economizer) are suitable for either bottom or
horizontal duct connections. For bottom duct, remove the
sheet metal panels from the supply and return air openings
through the base of the unit. For horizontal duct, remove
the supply and return air panels on the rear of the unit.

• 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.

• Advanced Controls - The Simplicity
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
0F outdoor ambient without additional assistance.
Optionally, the control board can be pro g r a mme d to
lockout the compressors when the outdoor air
temperature is low or when free cooling is available.

The

Simplicity

will effectively operate the cooling system down to
0°F when this product is applied in a comfort cool­ing application for people. An economizer is typi­cally included in this type of application. When
applying this product for process cooling applica­tions (computer rooms, switchgear, etc.), please
reference applications bulletin AE-011-07 or call
the applications department for Unitary Products
@ 1-877-UPG-SERV for guidance. Additional
accessories may be needed for stable operation at
temperatures below 30° F.

• Anti-Short Cycle Protection - To aid compressor life,

an anti-short cycle delay is incorporated into the

® control board used in this product

®

Lite™ control

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.

• 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
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 equipped, and 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
ZF Series 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.

• Flexible Placement - All models and configurations share
the same cabinet/footprint and thus the same roof curb.
You have the flexibility to set one curb and choose the
correct tonnage size and heating option after the internal
loads have been determined.

• 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 forklift
access from 3 sides, and rigging holes are available 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. A clearly identified location is provided to mount a
field supplied electrical disconnect switch. Utility
connections can be made quickly and with a minimum
amount of field labor.

• Wide Range of Indoor Airflows - Indoor fan motors are
direct-drive 3 and 4 ton or belt-drive 5 and 6.3 ton type
providing maximum flexibility to handle most airflow
requirements.

• Gas Heat Operation - All three phase models with gas
heat have minimum steady state efficiency of 80%. Each
section includes a durable heat exchanger with

Johnson Controls Unitary Products 5

723389-XTG-C-0214

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 Operation - All electric heat models 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
temperature by thermal limit switches.

The power supply wiring can be routed into the control
box through a threaded pipe connection (field supplied) in
the base pan of the unit or through a knockout in the
wiring panel on the side of the unit.

• 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

• 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 slide­in / 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.

• 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.
These nickel chromium heater elements are provided with
limit and automatic reset capability to prevent operation at
excessive temperatures.

• Filter Options - Standard units are shipped with 1" throw­away filters installed. 2" pleated filters are offered as a
factory installed option.

• Disconnect Switch - For gas heat units and cooling units
with electric heat, a HACR breaker sized to the 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.

• 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.

• Bottom Drain Connection - An optional bottom drain
connection is available for inside the curb connections for
applications in cold environments to reduce freezing drain
lines.

• Phase Monitors - Designed to prevent unit damage. The
phase monitor will shut the unit down in an out-of phase
condition.

• 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 & Toolless Filter, Motor and Electrical Access
Panels - This option allows for easy access and
maintenance.

NOTE: Knobs are shipped inside the unit to prevent shipping

damage. These must be field installed for tool-less
operation.

6 Johnson Controls Unitary Products

723389-XTG-C-0214

• High Static Drive - May include a belt, blower pulley,
motor pulley or a motor change to enhance blower
performance.

Control Options

• BAS - Building Automation System Controls Simplicity®
INTELLI-Comfort™ Control - The York® Simplicity®

INTELLI-Comfort™ control is factory installed. It includes a
supply air sensor, a return air sensor, and an outside air
sensor. There are provisions for a field installed dirty filter
indicator switch, an air-proving switch, an Outside Air
Humidity sensor, a Return Air Humidity sensor, an Inside
IAQ sensor, and an Outside Air IAQ sensor. Construction
mode operation, 365-day real time clock with 7 day
programming plus holiday scheduling is built-in. Two
different modes of demand ventilation are achieved through
the INTELLI-Comfort™ using CO
inside CO2 sensor to perform Demand Ventilation. It can
also use an Outside 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 on­board 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
balances space temperature, ventilation air temperature,

and humidity for ultimate comfort.

CO

2

• Simplicity

®

INTELLI-Comfort™ with ModLINC

Control - The York® Simplicity® INTELLI-Comfort™ with

ModLINC control is factory installed. It includes all the
features of the INTELLI-Comfo rt™ co ntrol 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.

sensors. It uses an

2

®

INTELLI-Comfort™

• York Commercial Comfort System (YCCS) - Provides
rooftop system integration for YCCS single zone and
change-over bypass systems.

Field Installed Accessories

• 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 slide­in / 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.

• Electric Heaters - wired for single point power supply.
These nickel chromium heater elements are provided with

limit and automatic reset capability to prevent operation at
excessive temperatures.

• Roof Curbs - Eight and 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.

Roof curbs are 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.

• Low Nox Kit - Required to reduce the emission of
nitrogen oxides below 40 nano grams per joule.

• Power Exhaust - Our single input 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 power exhaust option can only be used on bottom
duct configurations.

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723389-XTG-C-0214

• 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.

• 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.

Sensor - Senses CO2 levels and automatically

• CO

2

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.

• Hail Guard - Hail Guard kit is available to prevent unit
from hail damage. This is a sloped hood that fits above
the coil.

• Gas Piping Kit - This kit supplies all necessary fittings
and shut off valve.

Guide Specifications

General

Units shall be manufactured by Johnson Controls Unitary
Products in an ISO 9001 certified facility.

York's ZF units are convertible single package units. 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, remove the supply and
return air panels on the rear of the unit.

All non-Scroll compressors include crankcase heaters and all
compressors have internal pressure relief. Every refrigerant
circuit includes 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 a compressor lockout circuit, a terminal strip for thermostat
wiring, plus an additional set of pin connectors to simplify the
interface of additional field controls. All models include a 1-year
limited warranty on the complete unit. Compressors and electric
heater elements carry a 5-year warranty. Aluminized steel and
Stainless steel tubular heat exchangers carry a 10-year
warranty.

Description

Units shall be factory-assembled, single packaged, Electric
Cooling/Gas Heat, Electric Cooling/Optional Electric Heat are
designed for outdoor mounted installation.

The 3 ton, 4 ton and 5 ton units shall have minimum SEER
rating of 13.0. The 6.3 Ton shall have 10.9 EER. 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
the cooling performance shall be rated in accordance with DOE
and ARI test procedures.

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 ASTMB117
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 1" filters shall be furnished and be
accessible through a removable access door, sealed airtight.
Units filter track shall be designed to accommodate either 1" or
2" 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 3/4” I.D. female and be a ridged mount connection.

8 Johnson Controls Unitary Products

723389-XTG-C-0214

Indoor (Evaporator) Fan Assembly

The indoor fan shall be a factory installed direct-drive or belt­drive assembly that includes an adjustable pitch motor pulley.
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.
Bearings shall be sealed and permanently lubricated for longer
life and no maintenance.

Outdoor (Condenser) Fan Assembly

The outdoor fan shall be of the direct-driven propeller type,
discharge air vertically, have aluminum blades riveted to a
corrosion resistant steel spider bracket and shall be
dynamically balanced for smooth operation. The outdoor fan
motor shall be totally enclosed with permanently lubricated
bearings, internally protected against overload conditions and
staged independently.

Refrigerant Components

Compressor:

a. Shall be internally protected with internal high-pressure

relief and over temperature protection.

b. Shall have internal spring isolation and sound muffling to

minimize vibration and noise, and be externally isolated
on a dedicated, independent mounting.

Coils:

a. Evaporator 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 coils shall be of the direct expansion, draw-

thru design.

c. Condenser coils shall have Micro-Channel aluminum

tube, aluminum fins.

d. Condenser coils shall be of the direct expansion, draw-

thru design.

Refrigerant Circuit and Refrigerant Safety Components shall
include:

a. Independent fixed-orifice devices.
b. Filter drier/strainer to eliminate any moisture or foreign

matter.

c. Accessible service gage connections on both suction

and liquid 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.

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 devi ces trip

and shut off compressor.
c. Loss-of-charge/Low-pressure switch.
d. High-pressure switch.
e. Freeze-protection thermostat, evaporator coil.
f. Unit shall incorporate “AUTO RESET” compressor over

temperature, over current protection.
g. Unit shall operate with conventional thermostat designs

and have a low voltage terminal strip for easy hook-up.
h. Unit control board shall have on-board diagnostics and

fault code display.
i. Standard controls shall include anti-short cycle and low

voltage protection, and permit cooling operation down to

0°F.
j. Control board shall monitor each refrigerant safety switch

independently.
k. 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

Shall be designed with induced draft combustion with post
purge logic, energy saving direct spark ignition, and redundant
main gas valve. Venter 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 inshot 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. Integrated control boards shall provide timed
control of evaporator 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.
d. Flame proving controls.
e. 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.

Johnson Controls Unitary Products 9

723389-XTG-C-0214

Electric Heating Section

An electric heating section, with nickel chromium elements,
shall be provided in a range of 5 thru 30 KW, offering two
stages of capacity - 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.
The heating section assembly shall slide out of the unit for easy
maintenance and service. 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 ARI Standard
210/240. The compressor, with standard controls, shall be
capable of operation down to 0°F outdoor temperature. 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 available 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 unit­mounted 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 air dampers
are positioned by a 2-position, 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 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 de­energized. Dampers shall fully close on power loss.

Other Pre-engineered Accessories Available

• Roof Curb - 14"and 8” high, full perimeter curb with wood
nailer (shipped knocked-down).

• 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.

• Low Nox - Required to reduce the emission of nitrogen
oxides below 40 nanograms per joule.

• Gas Piping - Contains 1/2” pipe nipples, fittings and gas
cock (including panel assess gaskets) required for bottom
gas supply connection with external shut off.

• Power Exhaust Option - To work in conjunction with
economizers.

• Electric Heaters

• Economizer/motorized Damper Rain Hood - Contains
all hood panels and the hardware for assembling.

• Manual Outdoor Air Damper

• Coil Guard Kit - Guard for cooling coil.

• Hail Guard

• Flue Exhaust Extension

10 Johnson Controls Unitary Products

723389-XTG-C-0214

OTHER FACTORY INSTALLED OPTIONS

• Power Exhaust Option - To work in conjunction with
economizers.

• Stainless Steel Heat Exchanger

• Stainless Steel Drain Pan

• Bottom Drain Connection

• Technicoat Phenolic Coated Condenser And
Evaporator Coil

• Electronic Single Enthalpy Economizer

• Dirty Filter Switch

• Phase Monitor

•Coil Guard

• Non-powered GFI Convenience Outlet

• BAS Controls (Simplicity

®

INTELLI-Comfort™, 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 Toolless Access
Panels

• 2" Pleated Filters

• Disconnect Switch

• Supply Air Smoke Detector

• Return Air Smoke Detector

• Direct Drive Or Belt Drive Blower

Johnson Controls Unitary Products 11

723389-XTG-C-0214

Physical Data

ZF036-076 Physical Data

2-pass

Models

2-pass

Microchannel

2-pass

Microchannel

Component

Nominal Tonnage 3.0 4.0 5.0 6.3

ARI COOLING PERFORMANCE

Gross Capacity @ ARI A point (Btu)
ARI net capacity (Btu)
EER (Net)
SEER
Nominal CFM
System power (KW)
Refrigerant type
Refrigerant charge (lb-oz)

System 1 4-12 5-4 5-4 6-8

ARI HEATING PERFORMANCE

Heating model
Heat input (K Btu)
Heat output (K Btu)
AFUE %
Steady state efficiency (%)
No. burners
No. stages
Temperature Rise Range (ºF) 15-45 45-75 25-70 45-75 25-55 35-75 25-55 30-75
Gas Limit Setting (ºF) - Direct Drive 240170210165---­Gas Limit Setting (ºF) - Belt Drive ----210210210210
Gas piping connecting (in.)

DIMENSIONS (inches)

Length
Width
Height

OPERATING WT. (lbs.)

COMPRESSORS

Type
Quantity
Unit Capacity Steps (%)

CONDENSER COIL DATA

Face area (Sq. Ft.) 16.3 16.3 16.3 16.3
Rows
Fins per inch
Tube diameter (in./mm)

Circuitry Type

EVAPORATOR COIL DATA

Face area (Sq. Ft.)
Rows
Fins per inch
Tube diameter
Circuitry Type
Refrigerant control

ZF036 ZF048 ZF060 ZF076

36400 51300 60400 72600
35200 47000 57800 69100

11.5 11.5 11.5 10.9

13.0 13.0 13.0 -

1200 1600 2000 2500

4.2 4.2 4.9 6.3

R-410A R-410A R-410A R-410A

N04 N08 N06 N10 N08 N10 N08 N10

50 100 75 125 100 125 100 125
40 80 60 100 80 100 80 100

80.9 80.5 80.9 80.3 80.5 80.3 80.5 80.3

- - - - - --­2 4 3 5 4 545
1 1 1 1 1 111

1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2

82 1/4 82 1/4 82 1/4 82 1/4
44 7/8 44 7/8 44 7/8 44 7/8
32 5/8 32 5/8 32 5/8 32 5/8

468 541 569 640

Recip Recip Scroll Scroll

1 1 11

100 100 100 100

1 1 11

23 23 23 23

0.71 / 18 0.71 / 18 0.71 / 18 1.0 / 25.4
2-pass

Microchannel

5.06 5.06 5.06 5.06
3 4 44

13 13 13 13

0.375 0.375 0.375 0.375

Intertwined Intertwined Intertwined Intertwined

Fixed Orifice Fixed Orifice Fixed Orifice Fixed Orifice

Microchannel

12 Johnson Controls Unitary Products

ZF036-076 Physical Data (Continued)

723389-XTG-C-0214

Component

Nominal Tonnage 3.0 4.0 5.0 6.3

CONDENSER FAN DATA

Quantity
Fan diameter (Inch)
Type
Drive type
Quantity of motors
Motor HP each
No. speeds
RPM
Nominal total CFM

BELT DRIVE EVAP FAN DATA

Quantity
Fan Size (Inch)
Type
Motor Sheave - - 1VL44 IVM50
Blower Sheave - - AK54 AK56
Belt - - A35 A36
Motor HP each - - 1-1/2 1-1/2
RPM
Frame size

DIRECT DRIVE EVAP FAN DATA

Quantity
Fan Size (Inch)
Type
Motor HP each
RPM

FILTERS

15” x 20” x 1” or 2”
14” x 25” x 1” or 2”

ZF036 ZF048 ZF060 ZF076

1 1 11

24 24 24 24

Prop Prop Prop Prop

Direct Direct Direct Direct

1 1 11

1/2 1/2 1/2 3/4

1 1 11

1090 1090 1090 1090
3450 3450 3450 3750

- - 11

- - 12 x 10 12 x 11

- - Centrifugal Centrifugal

- - 1450 1450

- - 56 56

1 1 --

12 x 10 12 x 10 --

Centrifugal Centrifugal --

1/2 3/4 --

1050 1050 --

2 2 22
1 1 11

Models

ZF036-076 Unit Limitations

Size

(Tons)

ZF036

(3.0)

ZF048

(4.0)

ZF060

(5.0)

ZF076

(6.3)

Unit Voltage

380/415-3-50 342 456 125

380/415-3-50 342 456 125

380/415-3-50 342 456 125

380/415-3-50 342 456 125

Applied Voltage Outdoor DB Temp

Min Max Max (°F)

Unit Limitations

Johnson Controls Unitary Products 13

723389-XTG-C-0214

Capacity Performance

ZF036-076 Cooling Capacities

ZF036 (3.0 Ton) Imperial

Air on

Evaporator Coil

CFM

900

1050

1200

1350

1500

900

1050

1200

1350

1500

WB
(°F)

Total

Capacity

(MBh)

77 49.0 2.3 24.0 20.4 16.8 - - - 44.0 2.5 22.1 18.5 14.8 - - ­72 44.0 2.3 28.2 24.7 21.1 17.5 - - 39.5 2.6 26.3 22.7 19.1 15.4 - ­67 39.1 2.4 32.5 28.9 25.3 21.7 18.1 - 35.0 2.6 30.5 26.9 23.3 19.7 16.0 ­62 36.7 2.2 36.7 36.7 32.4 28.8 25.3 21.7 32.1 2.5 32.1 32.1 28.7 25.1 21.5 17.9
57 37.4 2.2 37.4 37.4 36.0 32.4 28.8 25.3 33.1 2.5 33.1 33.1 31.6 28.0 24.4 20.8
77 49.5 2.3 24.0 21.0 17.3 - - - 44.9 2.6 22.7 19.1 15.5 - - ­72 44.5 2.4 29.0 25.3 21.7 18.0 - - 40.3 2.6 27.4 23.6 19.9 16.2 - ­67 39.4 2.4 34.0 29.7 26.0 22.3 18.6 - 35.7 2.6 32.0 28.2 24.3 20.5 16.6 ­62 37.1 2.3 37.1 37.1 33.4 29.3 25.2 21.1 32.7 2.5 32.7 32.7 30.0 25.9 21.7 17.6
57 37.8 2.3 37.8 37.8 37.1 33.0 28.8 24.7 33.8 2.5 33.8 33.8 33.0 28.8 24.6 20.5
77 50.0 2.4 24.0 21.5 17.8 - - - 45.7 2.6 23.3 19.7 16.1 - - ­72 44.9 2.4 29.8 26.0 22.3 18.5 - - 41.1 2.7 28.4 24.6 20.7 16.9 - ­67 39.8 2.5 35.5 30.5 26.7 22.9 19.1 - 36.4 2.7 33.5 29.4 25.3 21.2 17.2 ­62 37.5 2.4 37.5 37.5 34.3 29.8 25.2 20.6 33.4 2.6 33.4 33.4 31.3 26.6 21.9 17.3
57 38.2 2.4 38.2 38.2 38.2 33.5 28.8 24.0 34.4 2.6 34.4 34.4 34.4 29.7 24.9 20.2
77 51.9 2.3 25.9 23.4 19.1 - - - 47.3 2.6 25.8 21.5 17.2 - - ­72 46.6 2.4 32.6 28.2 23.9 19.6 - - 42.4 2.6 31.0 26.6 22.1 17.7 - ­67 41.4 2.4 39.2 33.0 28.7 24.3 19.9 - 37.6 2.7 36.1 31.6 27.0 22.5 17.9 ­62 38.9 2.3 38.9 38.9 37.3 32.5 27.8 23.0 34.5 2.5 34.5 34.5 33.4 28.5 23.7 18.8
57 39.6 2.3 39.6 39.6 39.6 34.8 30.0 25.2 35.5 2.5 35.5 35.5 35.5 30.7 25.8 20.9
77 53.8 2.3 27.9 25.3 20.4 - - - 48.8 2.6 28.4 23.3 18.3 - - ­72 48.3 2.3 35.4 30.4 25.5 20.6 - - 43.8 2.6 33.6 28.6 23.5 18.5 - ­67 42.9 2.4 42.9 35.5 30.6 25.7 20.8 - 38.8 2.6 38.8 33.8 28.7 23.7 18.7 ­62 40.3 2.2 40.3 40.3 40.2 35.3 30.3 25.4 35.6 2.5 35.6 35.6 35.5 30.4 25.4 20.4
57 41.1 2.2 41.1 41.1 41.1 36.1 31.2 26.3 36.7 2.5 36.7 36.7 36.7 31.7 26.6 21.6

77 39.1 2.7 20.2 16.5 12.9 - - - 34.1 3.0 18.3 14.6 10.9 - - ­72 35.0 2.8 24.4 20.7 17.1 13.4 - - 30.5 3.0 22.5 18.8 15.1 11.4 - ­67 31.0 2.8 28.6 24.9 21.3 17.6 13.9 - 27.0 3.0 26.7 23.0 19.3 15.5 11.8 ­62 27.5 2.7 27.5 27.5 25.0 21.4 17.7 14.0 22.9 2.9 22.9 22.9 21.4 17.6 13.9 10.2
57 28.8 2.7 28.8 28.8 27.3 23.6 19.9 16.3 24.6 2.9 24.6 24.6 22.9 19.2 15.5 11.7
77 40.3 2.8 21.3 17.2 13.7 - - - 35.7 3.0 20.0 15.3 11.8 - - ­72 36.1 2.8 25.7 21.9 18.1 14.4 - - 32.0 3.0 24.1 20.2 16.4 12.5 - ­67 32.0 2.8 30.1 26.6 22.6 18.6 14.6 - 28.2 3.0 28.1 25.1 20.9 16.8 12.6 ­62 28.4 2.7 28.4 28.4 26.6 22.4 18.2 14.0 24.0 2.9 24.0 24.0 23.2 18.9 14.7 10.4
57 29.7 2.7 29.7 29.7 29.0 24.7 20.5 16.3 25.7 2.9 25.7 25.7 24.9 20.6 16.3 12.1
77 41.5 2.8 22.5 17.9 14.5 - - - 37.3 3.1 21.7 16.1 12.8 - - ­72 37.2 2.9 27.0 23.1 19.2 15.3 - - 33.4 3.1 25.6 21.7 17.7 13.7 - ­67 33.0 2.9 31.5 28.3 24.0 19.6 15.3 - 29.5 3.1 29.5 27.2 22.6 18.0 13.4 ­62 29.2 2.8 29.2 29.2 28.2 23.4 18.7 13.9 25.1 3.0 25.1 25.1 25.1 20.2 15.4 10.6
57 30.6 2.8 30.6 30.6 30.6 25.9 21.1 16.3 26.9 3.0 26.9 26.9 26.9 22.0 17.2 12.4
77 42.6 2.9 25.7 19.6 15.3 - - - 38.0 3.1 25.6 17.7 13.4 - - ­72 38.2 2.9 29.4 24.9 20.4 15.9 - - 34.0 3.1 27.8 23.2 18.6 14.0 - ­67 33.8 2.9 33.1 30.2 25.4 20.7 15.9 - 30.1 3.1 30.1 28.7 23.8 18.9 13.9 ­62 30.0 2.8 30.0 30.0 29.5 24.5 19.6 14.6 25.6 3.0 25.6 25.6 25.6 20.5 15.5 10.5
57 31.5 2.8 31.5 31.5 31.5 26.5 21.6 16.6 27.4 3.0 27.4 27.4 27.4 22.4 17.3 12.3
77 43.7 2.9 28.9 21.4 16.2 - - - 38.7 3.2 29.4 19.4 14.1 - - ­72 39.2 2.9 31.8 26.7 21.5 16.4 - - 34.7 3.2 30.0 24.8 19.5 14.3 - ­67 34.7 2.9 34.7 32.0 26.9 21.7 16.6 - 30.7 3.2 30.7 30.2 25.0 19.7 14.5 ­62 30.8 2.8 30.8 30.8 30.8 25.6 20.5 15.4 26.1 3.1 26.1 26.1 26.1 20.8 15.6 10.3
57 32.3 2.8 32.3 32.3 32.3 27.2 22.0 16.9 27.9 3.1 27.9 27.9 27.9 22.7 17.4 12.2

Total

1

Input

2

(kW)

Sensible Capacity (MBh)

Return Dry Bulb (°F) Return Dry Bulb (°F)

90 85 80 75 70 65 90 85 80 75 70 65

85°F 95°F

105°F 115°F

Temperature of Air on Condenser Coil

Total

Capacity

(MBh)

Total

1

Input

(kW)

Sensible Capacity (MBh)

2

14 Johnson Controls Unitary Products