Johnson Controls 20 J ZJ Series - User Manual

R-410A
ZU SERIES
3 - 5 Ton
60 Hertz
689670-BIM-A-0311
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Standard Economizer and Power Exhaust Set Point
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 42
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 42
Electric Heating Sequence Of Operations . . . . . . . . . . . . 44
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 44
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 45
Ignition Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 45
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fan On And Off Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
LIST OF TABLES
1 ZU-A3 thru -A5 Unit Limitations . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZU-A3 thru -A5 Unit Accessory Weights . . . . . . . . . . . . . . 8
4 ZU-A3 thru -A5 Unit Physical Dimensions . . . . . . . . . . . 11
5 ZU-A3 thru -A5 Unit Clearances . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . 27
11 Gas Pipe Sizing - CapacIty of Pipe . . . . . . . . . . . . . . . . . 28
12 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . 29
13 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . 34
15 Airflow Performance - Side Duct Application . . . . . . . . . 36
16 Airflow Performance - Bottom Duct Application . . . . . . . 37
17 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
18 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . 38
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 38
20 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . 40
21 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 41
22 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . 44
23 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 45
24 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 47
25 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . 49
26 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
27 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 55
28 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . 55
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Component Location (ZU-A4 Shown) . . . . . . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZU-A3 thru -A4 Physical Dimensions . . . . . . . . . . . . . . . . 9
9 ZU-A5 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . 10
10 ZU-A3 thru -A5 Unit Bottom Duct Openings . . . . . . . . . 12
11 ZU-A3 thru -A5 Unit Electrical Entry . . . . . . . . . . . . . . . 13
12 ZU-A3 thru -A5 Unit Side Duct Openings . . . . . . . . . . . 13
13 ZU-A3 thru -A5 Unit Left Duct Opening . . . . . . . . . . . . . 14
14 ZU-A3 thru -A5 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZU-A3 thru -A5 Transition Roof Curb . . . . . . . . . . . . . . . 15
16 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 15
17 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 16
18 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . 16
19 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 18
21 Typical Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 19
22 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 28
23 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 28
24 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 32
25 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 32
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . 34
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
29 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
30 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . 50
31 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . 50
32 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Johnson Controls 20 J ZJ Series Specifications

General

Brand	Johnson Controls
Model	20 J ZJ Series
Category	Air Conditioner
Language	English

Summary

General Unit Information

Safety Considerations

Explains safety alert symbols, DANGER, WARNING, and CAUTION signal words.

Installation Process

Installation Safety Information

Read instructions, unit rating plate, location, gas leak testing, operating temperature range.

Preceding Installation Steps

Steps for removing shipping brackets and protective covering before installation.

Installation Limitations and Approvals

Reference Documents

Lists related technical guides and accessory installation documents for further reference.

Product Approvals

Details CSA design certifications for cooling, heating, and installation requirements.

Unit Nomenclature

Site Selection and Clearances

Clearances for Operation and Service

Required distances for operation, servicing, and combustible construction.

Rigging and Handling Procedures

Procedures for lifting and moving the unit safely using chains, slings, or forklifts.

Physical Specifications

Ductwork Design and Covers

Duct Covers Handling

Instructions for removing and reusing side duct covers for bottom duct applications.

Compressor Details

Power and Control Wiring

Electrical Safety and Transformer Tap Adjustments

Warnings about electrical hazards and adjusting transformer taps for different voltage supplies.

Thermostat Wiring

Typical Control Wiring Diagrams

Illustrates typical wiring connections for cooling only, heating, and multi-stage systems.

Optional Gas Heat Installation

Gas Piping Guidelines

Guidelines for proper gas pipe sizing, installation, and local code adherence.

Accessory Options

Electric Heat Installation

Description of factory-installed or field-installed electric heaters and their mounting.

Smoke Detector Considerations

Limitations and installation considerations for duct smoke detectors.

Economizer and Power Exhaust Adjustments

Minimum Position Adjustment

Procedure to adjust the minimum position of economizer damper blades.

Enthalpy Set Point Adjustment

Steps for setting the economizer's enthalpy set point based on desired cooling strategy.

Blower System Setup

Blower Rotation Check

Procedure to check and correct supply air blower rotation direction.

Belt Tension Adjustment

Procedure for setting correct belt tension for optimal blower performance.

Performance Adjustments and Data

Altitude and Temperature Corrections

Factors for adjusting performance data based on altitude and temperature.

Drive Selection and Airflow Performance

Drive Selection Process

Steps to select the appropriate motor and drive based on airflow and static pressure.

Airflow Performance Tables

Data tables showing blower performance at various airflow and static pressure conditions.

System Balancing and Airflow Measurement

Air Balance Procedure

Guidance for balancing airflow in supply and return duct systems for proper distribution.

Checking Air Quantity (Method One)

Details using a manometer to measure airflow via duct pressure drop.

Supply Air Drive Adjustment

CAUTION on Blower Speed Changes

Warns about the impact of blower speed changes and requires qualified personnel.

Unit Operation Modes

Cooling Sequence Of Operation

Describes how the thermostat, UCB, compressor, and fan interact during cooling.

Economizer Operation Modes

Explains economizer function with single/dual enthalpy sensors and power exhaust.

Cooling Operation Errors

Overview of how cooling system errors are monitored and handled.

Safety Controls and Protections

Limit Switches and Freezestat

Details high/low pressure limit switches and freezestat function.

Compressor Protection Features

Explains compressor protection mechanisms like ASCD and minimum run time.

Heating Sequences and Operations

Electric Heating Sequence

Describes the sequence of operation for two-stage electric heating.

Gas Heating Sequence

Details gas heating stages, retry, recycle, and error handling.

Start-Up Procedures

Cooling Start-Up Checklist

Essential checks before powering the unit for cooling operation.

Gas Heat Start-Up Checklist

Checks required before initiating gas heat operation.

Gas Pressure and Burner Adjustments

Manifold Gas Pressure Adjustment

Step-by-step guide for adjusting gas manifold pressures for first and second stages.

Troubleshooting Guides

General Troubleshooting Steps

General guidance and systematic checks for resolving operational issues.

Unit Flash Codes Explanation

Explains how the unit control board uses flash codes to indicate system status and errors.