ZX
USER’S, MAINTENANCE
and
SERVICE INFORMATION
MANUAL
3 THRU 12.5 TON
SINGLE PACKAGE
AIR CONDITIONER
GAS/ELECTRIC
& ELECTRIC/ELECTRIC
1046287-UUM-A-1013
CONTENTS
SAFETY INFORMATION . . . . . . . . . . . . . . . . 2
FOR YOUR SAFETY . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM OPERATION. . . . . . . . . . . . . . . . . . 2
THERMOSTATS. . . . . . . . . . . . . . . . . . . . . . . . . .2
INTERMITTENT IGNITION DEVICE . . . . . . . . . . 2
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . .3
EXPLAIN UNIT FUNCTION . . . . . . . . . . . . . . 4
GENERAL MAINTENANCE. . . . . . . . . . . . . . 4
HEATING SYSTEM INSPECTION . . . . . . . . . . . . 4
AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 5
MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . 6
REGISTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 6
BEFORE CALLING A SERVICE TECHNICIAN:. . 6
The “User” must read all sections of this manual and keep the manual for future ref-
erence.
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property damage.
- Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediatel y.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
- Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
1046287-UUM-A-1013
2 Johnson Controls Unitary Products
SAFETY INFORMATION
FOR YOUR SAFETY
• Make sure that the furnace area is clear and free of
combustible materials, gasoline and other flamma-
ble vapors and liquids.
• Be sure the furnace is clear and free of insulating
material. Examine the furnace area after installa-
tion of the furnace or the installation of additional
insulation. Some types of insulation maybe com-
bustible.
• For proper and safe operation, the furnace needs
air for combustion and ventilation. Do not block or
obstruct air openings on the furnace or the space
around the furnace. Maintain the required unit
clearances.
• For lighting or shutting down this furnace, refer to
the lighting instructions provided adjacent to the
burners in the unit and also located in this manual
on Pages 7 and 8.
• A blocked vent roll-out switch is provided in the
burner compartment. This switch is a manual reset.
If the furnace fails to operate, contact a qualified
service technician.
• Should the gas supply fail to shut off or if overheat-
ing occurs, shut off the gas valve to the furn ace
before shutting off the electrical supply. Then call a
qualified service technician.
• Do not use this furnace if any part has been under
water. A flood-damaged furnace is extremely dan-
gerous. Attempts to use the furnace can result in
fire or explosion. A qualified service technician
should be contacted to inspect th e fu rn ace and to
replace all gas controls, control system parts, elec-
trical parts that have been wet or the furnace if
deemed necessary.
• Determine the integrity of the installation regarding
the flue gas vent, the return and supply air duct. All
flue gas carrying areas external to the furnace must
be clear and free of obstructions. The external vent
should be attached and physically sound without
holes or excessive corrosion. The return-air duct
connection(s) should be physically sound and
sealed to the furnace casing. The physical support
of the furnace should be sound without sagging,
cracks, gaps with no obvious signs of deterioration.
The burner flames in operation should appear as
detailed in figure 3. The manufacturer recommends
that main burner, ignition device and controls are
inspected by a qualified service technician before
each heating season.
SYSTEM OPERATION
THERMOSTAT S
Set your thermostat for either heating or cooling then set it for
the desired temperature. DO NOT ADJUST THE THERMO-
STAT RAPIDLY ON AND OFF, OR BACK AND FORTH
FROM HEAT TO COOL. THIS COULD DAMAGE YOUR
EQUIPMENT.
Always allow at least 5 minutes between changes. Find the
temperature that is most comfortable to you and then LEAVE
YOUR THERMOSTAT ALONE. (Exception is for night or
vacation “set back” to conserve energy).
Manually moving the thermostat up or down will not speed up
temperature changes in your rooms. This only causes the
thermostat switch to function at your command rather than
responding to room temperature.
Heat generated by devices other than the furnace may inter-
fere with thermostat performance. Therefore, lamps, radios,
television sets, etc. should not be placed near the thermostat.
INTERMITTENT IGNITION DEVICE
When the thermostat calls for heat, gas is supplied and at the
same time, sparking occurs to light the burner. With the
burner lit, the flame sensor rod closes a circuit to the ign iter
control which allows the burner to continue to fire.
When the room thermostat is satisfied, the electrical circuit to
the gas valve is opened, closing main burner gas. If the
burner should fail to light, contact your heating contractor or
gas utility for service to insure that proper operating condi-
tions are restored.
FIGURE 1- TYPICAL THERMOSTAT
This furnace is equipped with an intermittent auto-
matic ignition system. Do Not attempt to manually
relight the burners. Personal injury could result.
1046287-UUM-A-1013
Johnson Controls Unitary Products 3
INPUT
The correct heat capacity of the furnace is regulated by the
burner orifices and the gas pressure. The proper orifices are
furnished but the gas pressure regulator must be adjusted by
the installer or gas utility service technician.
OPERA T ING INSTRUCTIONS
TO SHUT DOWN THE FURNACE:
1. Close the main gas shutoff valve(s).
2. Turn off the electric power supply.
TO LIGHT THE FURNACE:
1. Do not attempt to light manually.
2. Open the main gas shutoff valve(s).
3. Adjust the set point of the room thermostat above the
temperature in the space.
4. Turn on the electric power supply.
5. The draft fan will operate. After an adequate purge time,
the electric spark igniter will light the burners.
6. The burners will extinguish and relight automatically
upon the demand of the room thermostat.
VENT SAFETY SYSTEM:
This gas furnace is equipped with a manual reset high tem-
perature sensor or rollout sw itch wh ich in the unlik ely eve nt of
a sustained main burner flame rollout will shut off the flow of
gas by closing the main gas valve. The ignition modules will
also be disabled, preventing the flow of gas to the valve. The
switch is located inside the gas heat access panel above the
burner inlet. Flame rollout can be caused by blockage of the
power vent system, improper gas pressure or adjustment. If
this event occurs the furnace will not operate properly. The
gas supply to the furnace should be shut off and no attempt
should be made to place the furnace in operation. The sys-
tem should be inspected by a qualified service technician.
Refer to Figure 2 for a typical installation.
100% SHUT OFF:
The ignition modules are designed for 100% shut-off. If the
furnace fails to ignite after three ignition attempts, the flow of
gas will be shut off and the ignition module will lock out. The
module can be reset by:
A. Turning the system switch on the room thermost at to the
“OFF” position and back to the “HEAT” position.
B. Decreasing the set point of the room thermostat below
the temperature in the conditioned space and returning it
to its original setting.
C. Opening and closing the unit's main disconnect switch.
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property damage.
- Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
- Installation and service must be per formed by a
qualified installer, service agency or the gas
supplier.
FIGURE 2- TYPICAL INSTALLATION
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