Johnson Controls J ZB Series - User Manual

R-410A
J**ZB SERIES W/SMART EQUIPMENT™
6.5 - 12.5 Ton
60 Hertz
5808011-JIM-A-0320
Table of contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 44
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling operation 2 fan cooling operation . . . . . . . . . . . . . . . . . . 60
Cooling operation 4 fan cooling operation . . . . . . . . . . . . . . . . . . 60
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 62
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 62
Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 63
Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 63
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Navigation components for the Smart Equipment™ control board . . 67
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 68
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
List of tables
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 J06-12ZB unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 J06-12ZB standard unit weights . . . . . . . . . . . . . . . . . . . . . . 11
4 J06-12ZB unit accessory weights . . . . . . . . . . . . . . . . . . . . . 11
5 J06-12ZB unit physical dimensions . . . . . . . . . . . . . . . . . . . . 13
6 J06-12ZB unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 J06-10ZB side duct dimensions . . . . . . . . . . . . . . . . . . . . . . 16
8 J12ZB side duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 Left/end duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
13 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 36
14 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 37
15 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 37
16 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
17 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 49
18 Airflow performance - side duct application . . . . . . . . . . . . . . 51
19 Airflow performance - bottom duct application . . . . . . . . . . . 54
20 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
21 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 56
22 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 56
23 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 58
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
25 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 63
26 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 64
27 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 66
28 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
29 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 67
30 Cable for FC buses and SA buses in order of preference . . 74
31 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 74
32 J06ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 75
33 J06ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 75
34 J07ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 76
35 J07ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 76
36 J08ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 77
37 J08ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 77
38 J10ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 78
39 J10ZB charging table - system 2 . . . . . . . . . . . . . . .
. . . . . . 78
40 J12ZB charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 79
41 J12ZB charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 79
List of figures
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Barometric relief hood - shipping location . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 4 point and 6 point load weight for J12ZB units . . . . . . . . . . 10
6 4 point and 6 point load weight for J06-10ZB units . . . . . . . 10
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 J06-10ZB physical dimensions . . . . . . . . . . . . . . . . . . . . . . . 12
9 J12ZB physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 J06-12ZB unit bottom duct openings . . . . . . . . . . . . . . . . . . 15
11 J06-12ZB unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . . 16
12 J06-12ZB unit left/end duct opening . . . . . . . . . . . . . . . . . . . 17
13 J06-12ZB roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14 J06-12ZB transition roof curb . . . . . . . . . . . . . . . . . . . . . . . . 18
15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 19
16 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 19
17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 20
19 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
20 Field wiring disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
21 Typical control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
22 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
23 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
24 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 44
26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 49
28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
30 Typical two stage gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 67
31 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Johnson Controls J ZB Series Specifications

General

Refrigerant	R410A
Type	Split System Air Conditioner
Cooling Capacity	9, 000 - 36, 000 BTU/h
Heating Capacity	9, 000 - 36, 000 BTU/h
Operating Temperature (Cooling)	18°C - 46°C
Operating Temperature (Heating)	-15°C - 24°C

Summary

General Unit Information

Safety Considerations

Understand and pay attention to signal words DANGER, WARNING, or CAUTION.

Installation Guidelines

Installation Safety Information

Crucial safety points for unit installation, including gas leak testing.

Installation Site and Clearances

Contaminant Exposure Hazard

Warning about the effects of contaminated combustion air on equipment and personnel.

Rigging and Handling Procedures

Rigging and Handling Safety Precautions

Filters and Electrical Wiring

Power and Control Wiring Instructions

Instructions for correct electrical connections, conforming to codes and using waterproof connectors.

Thermostat and Control Wiring

Thermostat Wiring Installation Guide

Gas Supply Connection and Safety

Gas Supply Connection Procedure

Propane Gas Handling Warning

Warning about propane's properties and necessary precautions for installation.

Unit Components and Features

Smoke Detector Installation and Limits

Economizer Operational Sequences

Economizer Minimum Position Sequences

Free Cooling Operation Details

Low Ambient Economizer Operation

Free Cooling Changeover Methods

Free Cooling Method Specifics

Smart Equipment Economizer Board Guide

Economizer Board Analog Input Terminals

Detailed description of all analog input terminals and their functions.

Economizer Board LED Status Indicators

Economizer Board LED Status Indicators

Economizer Board SA Bus and Analog Outputs

Economizer Board SA Bus and Analog Outputs

Economizer Board Binary Outputs and Inputs

Economizer Board Binary Outputs and Inputs

Blower Motor and Drive Adjustments

Motor Phasing and Rotation Check

Belt Tension Adjustment Procedure

Altitude and Temperature Performance Corrections

Altitude;Temperature Correction Factors Table

Blower Drive Selection Process

Drive Selection Procedure Steps

Steps for selecting the appropriate motor and drive based on airflow and static pressure.

Airflow Performance Data

Airflow Performance - Side Duct Application

Air Balancing and Quantity Measurement

Air Quantity Measurement Methods

Supply Air Drive Adjustment

Blower Speed Adjustment Safety

Caution regarding blower speed changes and their impact on system performance.

Motor Sheave Datum Diameters

Unit Operation Sequences

Cooling Operation Sequences (2;4 Fan)

Detailed sequences for 2-fan and 4-fan cooling operations.

Free Cooling with Economizer Operation

Cooling Operation Error Conditions

High-Pressure Limit Switch Function

Function and effect of the high-pressure limit switch.

Low-Pressure Limit Switch Function

Function and effect of the low-pressure limit switch.

Evaporator Low Limit Sensor Function

Function of the evaporator low limit sensor for compressor protection.

Low Ambient Cooling Operation Mode

Compressor Protection and Electric Heat Operation

Compressor Protection Features

Internal protectors, ASCD, and minimum run times for compressor longevity.

Electric Heat Sequence of Operations

Electric Heat Limit Switch Functionality

Function and reset of the electric heat limit switch.

Gas Heating Operation Details

Ignition Control Board Role

Role of the ICB in controlling gas heating ignition and operation.

Gas Heating Sequence of Operations

Details first stage, retry, and recycle operations for gas heating.

Gas Heating Operation Error Handling

Description of lockout, temperature limit, flame sense, and gas valve errors.

Gas Heat Safety Controls and Startup Checklist

Gas Heat Safety Control Monitoring

Monitors limit, pressure, and roll-out switches for safety.

Microprocessor Failure and Flash Codes

Actions taken upon internal microprocessor failure or flash code detection.

Gas Heat Anticipator Setpoint Adjustment

Gas Heat Start-up and Input Verification

Gas Heat Start-up Procedures

Main Burner Lighting Procedure

Checking Gas Heat Input Measurement

How to measure and verify the furnace's gas heat input.

Manifold Gas Pressure Adjustment

Gas Flow Rate Determination

Temperature Rise Adjustment and Burner Service

Temperature Rise Adjustment Method

Burner and Orifice Inspection

Smart Equipment Control Board Navigation

Smart Equipment Control Board Navigation

Smart Equipment Unit Control Board Overview

UCB Thermostat Connection Terminals

Details the terminals on the UCB for thermostat connections.

UCB Connections: Limits, Power, and Shutdowns

UCB Limit, Power, and Shutdown Connections

Describes UCB connections for limit switches, power, and accessory shutdowns.

UCB Space Temperature Sensor Connections

UCB Temperature Sensor Connections

UCB Pinned Connections Description

UCB Pinned Connections Description

UCB Heat Section and Cooling;Fan Connections

UCB Heat Section and Cooling;Fan Connections

UCB Safety Switch and Blower Overload Connections

Covers UCB connections for refrigerant circuit safety switches.

UCB User Interface Elements

UCB User Interface Elements

UCB LEDs and Communication Sub-board

UCB LEDs and Communication Sub-board

Unit Refrigerant Charging Procedures

Charging Tables for J06 ZB System 1

Equipment Start-up Procedures

Start-up Checklist

A comprehensive checklist for initial equipment startup.

Equipment Startup Guidance

Instructions on how to perform the equipment startup using available tools.

Safety Warnings and Design Data

Critical Safety Warnings

Critical safety warnings for technicians performing startup procedures.

Air Flow Operating Measurements

Air Flow Measurement Procedures

Electrical Data Summary

Operating Measurements: Cooling and Gas Heating

Refrigerant Safety Verification

Procedures to verify refrigerant circuit safety.

Gas Heating Measurement Procedures

Procedures for checking gas leaks and manifold pressure.

Staging Controls and Final Inspection

Staging Control Verification Steps

Final Inspection Procedures

Final checks of setpoints, options, panels, and saving backup files.