Johnson Controls ZS-07 User Manual

R-410A
ZS SERIES W/SMART EQUIPMENT™
6-1/2 - 12-1/2 Ton
60 Hertz
5566019-BIM-B-1118
Table of contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Roof curbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Condensate drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Optional gas heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Optional variable air volume. . . . . . . . . . . . . . . . . . . . . . . . . . .37
Optional hot gas bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . . . 39
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Single enthalpy changeover. . . . . . . . . . . . . . . . . . . . . . . . . . .39
Dual enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Free cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 41
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . 55
Cooling operation errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 58
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 58
Gas heating sequence of operations . . . . . . . . . . . . . . . . . . . . 59
Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checking gas heat input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Navigation components for the Smart Equipment™ control board . . . 64
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 65
Start-up sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
List of tables
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ZS-06 through -12 unit limitations . . . . . . . . . . . . . . . . . . . . . . 8
3 ZS-06 through -12 weights and dimensions . . . . . . . . . . . . . . 9
4 ZS-06 through -12 unit accessory weights . . . . . . . . . . . . . . 10
5 ZS-06 through -10 unit physical dimensions . . . . . . . . . . . . . 10
6 ZS-12 unit physical dimensions . . . . . . . . . . . . . . . . . . . . . . . 11
7 Gas inlet and drain components . . . . . . . . . . . . . . . . . . . . . . 12
8 ZS-06 through -12 unit clearances. . . . . . . . . . . . . . . . . . . . . 12
9 ZS-06 through -10 side duct dimensions . . . . . . . . . . . . . . . . 15
10 ZS-12 side duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 15
11 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
12 Roof curb components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14 Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15 ZS-06 through -12 physical data . . . . . . . . . . . . . . . . . . . . . . 31
16 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 33
17 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 34
18 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 35
19 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
20 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 46
21 Airflow performance - side duct application . . . . . . . . . . . . . 48
22 Airflow performance - bottom duct application . . . . . . . . . . . 50
23 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 52
25 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 52
26 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . . 54
27 Additional static resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 55
28 Electric heat limit setting 50 in. cabinet . . . . . . . . . . . . . . . . . 59
29 Electric heat limit setting 42 in. cabinet . . . . . . . . . . . . . . . . . 59
30 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 59
31 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 61
32 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . 61
33 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 63
34 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
35 Cable for FC buses and SA buses in order of preference . . 71
36 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 71
List of figures
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 ZS component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Unit 4 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Unit 6 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 ZS-06 through -10 physical dimensions . . . . . . . . . . . . . . . . 10
9 ZS-12 physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 ZS-06 through -12 unit bottom duct openings . . . . . . . . . . . . 13
11 ZS-06 through -12 unit electrical entry . . . . . . . . . . . . . . . . . . 14
12 ZS-06 through -10 unit side duct openings . . . . . . . . . . . . . . 15
13 ZS-12 unit side duct openings . . . . . . . . . . . . . . . . . . . . . . . . 15
14 ZS-06 through -12 unit left duct opening . . . . . . . . . . . . . . . . 16
15 ZS-06 through -12 roof curb. . . . . . . . . . . . . . . . . . . . . . . . . . 17
16 ZS-06 through -12 transition roof curb . . . . . . . . . . . . . . . . . . 17
17 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 18
18 Return downflow plenum with panel . . . . . . . . . . . . . . . . . . . 18
19 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
20 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 19
21 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
22 Field wiring disconnect - cooling unit with or without electric heat
and all units with a VFD option . . . . . . . . . . . . . . . . . . . . . . . 21
23 Field wiring disconnect - cooling unit with gas heat without a
VFD option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
24 Typical electronic thermostat field wiring. . . . . . . . . . . . . . . . 22
25 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
26 Bottom entry gas piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
27 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
28 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 41
29 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
30 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 46
31 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
32 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
33 Typical gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
34 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Johnson Controls ZS-07 Specifications

General

Brand	Johnson Controls
Model	ZS-07
Category	Air Conditioner
Language	English

Summary

General

Safety considerations

Discusses safety alert symbols and warnings.

Installation

Installation safety information

Crucial safety precautions for installing the unit.

Limitations

Rigging and handling

Ductwork

Power and control wiring

Power wiring detail

Thermostat wiring

Optional electric heat

Optional gas heat

Gas connection

Factory-installed VFD

Economizer sequences

Smart Equipment™™ economizer board

Smart Equipment™™ economizer board - analog inputs (continued)

Smart Equipment™™ economizer board - SA bus details

Smart Equipment™™ economizer board - analog outputs

Phasing

Drive selection

Air balance

Supply air drive adjustment

Operation

Cooling sequence of operation

Detailed step-by-step process of the cooling operation.

Optional VAV startup and control

Cooling operation errors

High-pressure limit switch

Function and fault condition of the high-pressure limit switch.

Low-pressure limit switch

Function and fault condition of the low-pressure limit switch.

Evaporator low limit

Safety function for low evaporator temperature.

Electric heating sequence of operations

Two-stage heating

Details on how two-stage electric heating functions.

Electric heat operation errors

Gas heating sequence of operations

First stage of heating

Second stage of heating

Retry operation

Recycle operation

Gas heating operation errors

Lockout

Conditions that lead to a gas heating lockout.

Temperature limit

How temperature limits affect gas heating operation.

Flame sense

The process of flame sensing in gas heating.

Gas valve

Operation and monitoring of the gas valve.

Safety controls

Limit switch

Function of the gas heat limit switch.

Auxiliary limit switch

Pressure switch

Roll-out switch

Internal microprocessor failure

Flash codes

Cooling start-up

Post-start checklist

Essential checks after initiating cooling start-up.

Gas heat start-up

Pre-start checklist

Essential checks before initiating gas heat start-up.

Operating instructions

Lighting the main burners

Post start checklist

Shutting down the unit

Checking gas heat input

Determining the rate of gas flow (second stage)

Determining the rate of gas flow (first stage)

Adjusting the manifold gas pressure

Adjusting the temperature rise

Inspecting and servicing burners and orifices

Charging the unit

Navigation components for the Smart Equipment™™ control board

Smart Equipment™™ unit control board

Smart Equipment™™ UCB - limit, 24 VAC power, and shutdown connections

Smart Equipment™™ UCB - space temperature sensor connections

Smart Equipment™™ UCB - temperature sensor connections

Smart Equipment™™ UCB - temperature sensor connections (continued)

Smart Equipment™™ UCB - pinned connections

Smart Equipment™™ UCB - heat section connections

Smart Equipment™™ UCB - pin cooling and fan output

Smart Equipment™™ UCB - refrigerant circuit safety switch and indoor blower overload connections

Smart Equipment™™ UCB - refrigerant circuit safety switch and indoor blower overload connections (continued)

Smart Equipment™™ UCB - SA BUS¹ connections

Start-up sheet

START-UP CHECKLIST

A checklist of procedures for equipment start-up.

EQUIPMENT STARTUP

SAFETY WARNINGS

Operating Measurements - Air Flow

OPERATING MEASUREMENTS - COOLING

REFRIGERANT SAFETIES

Checks related to refrigerant circuit safety.

OPERATING MEASUREMENTS - GAS HEATING

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

FINAL - INSPECTION