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Johnson Controls York ZD Series - User Manual

Johnson Controls York ZD Series
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R-410A
ZD SERIES
3 - 6 Ton
60 Hertz
5742638-BIM-D-0620
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 ZD-03 through -
05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical Cool/Heat Control Wiring (Smart Equipment™ ZD-03
through -A6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Field Installed 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
Field Installed 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start Up For Units Equipped for FER. . . . . . . . . . . . . . . . . . . . . . 57
Direct Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting (Simplicity Lite Only) . . . . . . . . . . . . . . . . . . . . . 57
Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Smart Equipment™ Control Board Navigation Components . . . . 66
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LIST OF TABLES
1 ZD-03 through -A6 Unit Limitations . . . . . . . . . . . . . . . . . . . . . 6
2 ZD-03 through -A6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZD-03 through -A6 Unit Accessory Weights . . . . . . . . . . . . . . 8
4 ZD-03 through -A6 Unit Clearances . . . . . . . . . . . . . . . . . . . 10
5 ZD-03 through -A6 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Electrical data: single-phase gas heat, belt drive . . . . . . . . . 29
9 ZD-03 through -A6 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 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45
16 ZD 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 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 54
25 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 56
26 Fan setup commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
27 ZD-03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
28 ZD-04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 60
29 ZD-05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
30 ZD-A6 (6.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
31 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 66
32 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 66
33 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 67
34 Cable for FC Buses and SA Buses in Order of Preference . 72
LIST OF FIGURES
1 ZD-03 through -A6 Component Location . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZD-03 through -A6 Cooling Only Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 ZD-03 through -A6 Cooling Only/Gas Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 ZD-03 through -A6 Fixed Outdoor Air Motorized Damper Rain
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZD-03 through -A6 Disconnect Location . . . . . . . . . . . . . . . 10
9 ZD-03 through -A6 Unit Side Duct Openings . . . . . . . . . . . . 11
10 ZD-03 through -A6 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 . . . . . . . . . . . . . . . . . . . . . 55
25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 56
26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
28 Smart Equipment™ Unit Control Board . . . . . . . . . . . . . . . . 67

Table of Contents

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Overview

  1. Function Description
  2. Important Technical Specifications
  3. Usage Features
  4. Maintenance Features

This document describes the R-410A ZD Series 3-6 Ton Ducted Systems commercial package unit, a rooftop or slab-mounted heating and cooling system. These units are designed for outdoor installation only and are available in single package gas-fired electric heating and cooling configurations, or single package gas-fired electric heating and cooling configurations with a cooling unit.

Function Description:

The ZD Series units provide heating and cooling for commercial spaces. They are available in various tonnages (3, 4, 5, and 6 tons) and can be configured with different heating capacities (MBH) and electric heat (kW). The units are designed for efficient operation with R-410A refrigerant. They can be controlled by a thermostat or a Building Automation System (BAS) via a Smart Equipment™ control board.

Important Technical Specifications:

  • Refrigerant: R-410A
  • Tonnages: 3, 4, 5, 6 tons
  • Heating Options: Single-stage natural gas heat, single-stage LP gas heat, or electric heat (5 kW to 30 kW).
  • Cooling Options: Single-stage cooling.
  • Electrical: Available in 208/230-1-60, 208/230-3-60, 460-3-60, and 575-3-60 volt configurations.
  • Compressors: Scroll type, 1 or 2 stages.
  • Condenser Fan: Direct drive, Prop type, 1/2 or 1/3 HP.
  • Evaporator Fan: Centrifugal type, 1/2 to 3 HP, with various sheave and belt options.
  • Dimensions (approximate): Length 82-1/4 inches, Width 44-7/8 inches, Height 32-5/8 inches.
  • Weight (approximate): Shipping weights range from 475 lbs (3 tons) to 700 lbs (6 tons).
  • Airflow: Various CFM options depending on tonnage and static pressure.
  • Gas Pressure: Nominal inlet gas pressure for natural gas is 7.0-10.5 inches W.C., and for LP gas is 11.0-13.0 inches W.C.

Usage Features:

  • Outdoor Installation: Designed exclusively for outdoor use, typically on rooftops or concrete slabs.
  • Flexible Ductwork Connections: Units can be configured for side or bottom supply and return air duct connections.
  • Economizer Option: An optional economizer/field installed motorized damper rain hood can be added for free cooling, which uses outside air to cool the space when conditions are favorable.
  • Power Convenience Outlet: An optional 115V or 230V power outlet can be installed for convenience during service.
  • Smart Equipment™ Control: The Smart Equipment™ control board provides advanced control capabilities, including fault detection, alarms, and detailed status information. It allows for integration with Building Automation Systems (BAS) for remote monitoring and control.
  • Thermostat Compatibility: Compatible with standard thermostats, including those with Smart Equipment™ capabilities.
  • Gas Heat Operation: Features an intermittent pilot and automatic re-ignition system for gas heating.
  • Adjustable Blower: The centrifugal blower allows for adjustment of airflow by changing the motor pulley and belt.
  • Filters: Units are equipped with one or two-inch filters that should be regularly cleaned or replaced.

Maintenance Features:

  • Easy Access: The units are designed with access panels for routine maintenance tasks such as filter changes, blower adjustments, and electrical connections.
  • Troubleshooting: The Smart Equipment™ control board provides flash codes and error messages to assist in diagnosing operational issues. A detailed troubleshooting section in the manual helps identify and resolve common problems.
  • Pre-start Checklist: A comprehensive checklist is provided to ensure proper installation and initial setup, covering general inspection, air moving inspection, exhaust inspection, economizer inspection, and humidity sensor checks.
  • Operating Measurements: Detailed procedures are outlined for taking operating measurements for air flow, cooling, gas heating, and staging controls, which are crucial for verifying proper unit performance.
  • Refrigerant Charge: The manual provides guidelines for checking and adjusting the refrigerant charge.
  • Gas Pressure Adjustment: Instructions are included for adjusting the manifold gas pressure for optimal gas heating performance.
  • Belt Tension Adjustment: Procedures for checking and adjusting the belt tension for the evaporator blower are provided to ensure proper airflow and prevent premature wear.
  • Cleaning: The manual emphasizes the importance of cleaning filters and condenser coils to maintain efficiency.
  • Electrical Data: Comprehensive electrical data tables are provided for various unit configurations, aiding in electrical troubleshooting and component replacement.
  • Serviceability: The design allows for relatively straightforward replacement of components such as compressors, fan motors, and control boards.

Johnson Controls York ZD Series Specifications

General IconGeneral
BrandJohnson Controls
ModelYork ZD Series
CategoryAir Conditioner
LanguageEnglish

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