Johnson Controls 5 J ZE Series - User Manual

R-410A
SERIES 5 J**ZE
3 - 6 Ton
60 Hertz
5742639-JIM-C-0220
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . 15
Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical Cool/Heat Control Wiring (Simplicity Lite J03 through
05ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical Cool/Heat Control Wiring (Smart Equipment™ J03
through A6ZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RRS Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 35
Smart Equipment™ Economizer Sequences. . . . . . . . . . . . . .36
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 50
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 52
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 54
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 57
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 58
Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Smart Equipment™ Control Board Navigation Components . . . . 66
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LIST OF TABLES
1 J03 through A6ZE Unit Limitations . . . . . . . . . . . . . . . . . . . . . 6
2 J03 through A6ZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 J03 through A6ZE Unit Accessory Weights . . . . . . . . . . . . . . 8
4 J03 through A6ZE Unit Clearances . . . . . . . . . . . . . . . . . . . . 10
5 J03 through A6ZE Utilities Entry . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Electrical data: single-phase gas heat, belt drive . . . . . . . . . 29
9 J03 through A6ZE Physical Data. . . . . . . . . . . . . . . . . . . . . . 30
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 32
11 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 33
13 Smart Equipment™ Economizer Board Details . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
15 J**ZE Blower Performance Side Duct . . . . . . . . . . . . . . . . . . 45
16 J**ZE Blower Performance Bottom Duct . . . . . . . . . . . . . . . . 46
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48
19 Power Exhaust Specifications. . . . . . . . . . . . . . . . . . . . . . . . 48
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53
23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 54
24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 54
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 57
27 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
28 J03ZE (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
29 J04ZE (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
30 J05ZE (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
31 JA6ZE (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
32 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 66
33 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66
34 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 67
35 Cable for FC Buses and SA Buses in Order of Preference . 72
LIST OF FIGURES
1 J03 through A6ZE Component Location . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 J03 - A6ZE Cooling Only/Electric Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 J03 - A6ZE Cooling Only/Gas Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 J03 through A6ZE Fixed Outdoor Air Motorized Damper Rain
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 J03 through A6ZE Disconnect Location . . . . . . . . . . . . . . . . 10
9 J03 through A6ZE Unit Side Duct Openings . . . . . . . . . . . . 11
10 J03 through A6ZE Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13
13 Typical Field Power and Simplicity Lite Control Wiring . . . .15
14 Typical Smart Equipment™ Control Wiring . . . . . . . . . . . . . 16
15 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
16 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
17 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 35
18 RRS Economizer LCD and Keypad Layout. . . . . . . . . . . . . 35
19 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38
20 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
21 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
22 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 49
23 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
24 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 56
25 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 56
26 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 56
28 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
29 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 67

Johnson Controls 5 J ZE Series Specifications

General

Brand	Johnson Controls
Model	5 J ZE Series
Category	Air Conditioner
Language	English

Summary

General

Safety Considerations

Key safety alerts, warnings, and cautions for installation and service procedures.

Installation

Installation Safety Information

Instructions and precautions to ensure safe and proper unit installation.

Limitations

Constraints and requirements for installing the unit in accordance with codes and standards.

Location

Guidelines for selecting a suitable and safe installation location for the unit.

Rigging And Handling

Procedures and precautions for safely moving and lifting the unit.

Clearances

Required clearances for proper operation, servicing, and ventilation.

Ductwork

Condensate Drain

Plumbing requirements for the condensate drain line, including trapping.

Power And Control Wiring

Typical Field Power and Control Wiring

Diagrams and instructions for field power and Simplicity Lite control wiring.

Operation

Cooling Sequence Of Operation

Detailed steps for cooling operation with Simplicity Lite or Smart Equipment controls.

Continuous Blower

Operation of the supply air blower continuously when the thermostat fan switch is set to ON.

Intermittent Blower

Blower operation based on thermostat fan switch set to AUTO during cooling or heating calls.

No Outdoor Air Options

Cooling operation sequence for units without outdoor air or economizer options.

Economizer With Single Enthalpy Sensor

Operation of economizer with single enthalpy or dry bulb sensor control.

Economizer With Dual Enthalpy Sensors

Operation of economizer using dual enthalpy sensors for efficiency.

Economizer With Power Exhaust

Operation of economizer combined with power exhaust system.

Motorized Outdoor Air Dampers

Operation of units with motorized outdoor air dampers for ventilation control.

Cooling Operation Errors

High-Pressure Limit Switch

Action taken by UCB when high-pressure limit switch opens during cooling.

Low-Pressure Limit Switch

UCB actions for low-pressure limit switch opening during cooling operation.

Freezestat (Simplicity Lite Control)

UCB response to a freezestat opening during cooling operation.

Evaporator Low Limit (Simplicity SE Control)

UCB response to low evaporator temperatures detected by the EC1 sensor.

Low Ambient Cooling

Operation of the unit in low ambient temperature conditions.

Electric Heating Sequence Of Operations

Electric Heat Operation Errors

Errors related to electric heat operation, including temperature limit issues.

Temperature Limit

Monitoring of the high temperature limit switch for electric heat.

Gas Heating Sequence Of Operations

Gas Valve

UCB monitoring of the gas valve for proper operation and fault detection.

Centrifugal Switch

Function of the centrifugal switch and its role in furnace operation.

Roll-out Switch

Function of the roll-out switch to protect the furnace from heat damage.

Flame Sense Circuit

Detection of pilot flame stability and operation of the flame sense circuit.

Checking Gas Input

Natural Gas

Procedure for checking natural gas input to the furnace.

Start-up (Cooling)

Pre-start and post-start checklist for cooling system startup.

Start-up (Gas Heat)

Pre-start and post-start checklist for gas heating startup.

Troubleshooting (Simplicity Lite Only)

Blower Motor Not Energizing

Diagnosing why the supply air blower motor isn't energizing during cooling calls.

Compressor Not Operating

Troubleshooting when the compressor isn't operating during a cooling call with blower active.

Gas Heat Troubleshooting Guide

Flash Code Troubleshooting

Procedures for identifying and resolving faults using flash codes.

Ignition Control Board

Troubleshooting steps for the ignition control board and its related components.

Centrifugal Switch

Troubleshooting the centrifugal switch, draft motor, and associated wiring.

Pilot Flame Lockout

Diagnosing and resolving issues related to pilot flame lockout.

Primary or Aux Temperature Limit

Troubleshooting temperature limit faults and ensuring proper airflow.

Roll-out Switch

Identifying and resolving issues related to the roll-out switch.

Unit Control Board

Smart Equipment Control Board Navigation Components

Components for accessing and navigating the Smart Equipment™™ control board.

START-UP & SERVICE DATA INSTRUCTION

EQUIPMENT STARTUP

Instructions for completing the equipment startup using LCD or MAP Gateway.

SAFETY WARNINGS

DESIGN APPLICATION INFORMATION

Information required from the specifying engineer for equipment application and setup.

REFERENCE

General Inspection

Checklist for general inspection of the unit for shipping, installation, and components.

Air Moving Inspection

Inspection procedures for blower alignment, belt tension, and pulleys.

Exhaust Inspection

Inspection steps for exhaust fan components like hub, blade, and rotation.

Economizer Inspection

Inspection points for economizer settings, CO2 sensor, and operation.

Operating Measurements - Air Flow

Final Adjusted Supply Air CFM

Procedure to measure and adjust supply air CFM using the dry coil chart.

OPERATING MEASUREMENTS - COOLING

OPERATING MEASUREMENTS - GAS HEATING

Measurements for gas heating operation including manifold pressure and temperature rise.

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

FINAL - INSPECTION

Final checks of control setpoints, option parameters, and access panels.