Johnson Controls ZS Series 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 Series Specifications

General

Series	ZS Series
Phase	1
Refrigerant	R410A
HSPF	Up to 10
Voltage	208/230V
Coefficient of Performance (COP)	Up to 4.0
Dimensions (H x W x D)	Varies by model
Weight	Varies by model

Summary

General Information

Safety Considerations

Details safety alert symbols, signal words, and potential hazards for user awareness.

Installation Warnings

Highlights risks associated with improper installation, adjustment, alteration, or maintenance.

Inspection and Approvals

Inspection Procedure

Instructions for inspecting the unit for transit damage and filing claims.

Installation Compliance

CAUTION regarding strict compliance with installation instructions and codes.

Nomenclature

Model Number Breakdown

Explanation of the model number structure for ZS Series units.

Installation Procedures

Installation Safety Information

General safety guidelines and precautions for installing the appliance.

Preceding Installation Steps

Steps to perform before the main unit installation, like removing brackets.

Limitations and Clearances

Installation Requirements

Lists codes and standards that must be followed for installation.

Clearances

Specifies required clearances for unit operation and servicing.

Unit Components and Specifications

ZS Component Location

Visual guide and table identifying key components of the ZS unit.

Unit Limitations

Operational constraints including applied voltage and outdoor temperature limits.

Weights and Dimensions

Provides weight and load point data for various unit sizes.

Duct Connections

Bottom Duct Openings

Diagram showing bottom duct opening locations and dimensions.

Side Duct Openings

Diagrams detailing side duct opening dimensions for different models.

Unit Electrical Entry

Illustrates the points of entry for electrical power and control wiring.

Power Wiring Detail

Wiring diagrams for field power connections to the unit.

Heating Options

Optional Electric Heat

Information on factory-installed electric heaters and their power supply.

Optional Gas Heat

Details on optional gas-fired heaters, including heat exchanger types.

Gas Piping Guidelines

Recommendations for gas pipe sizing, materials, and installation.

Economizer and VFD Control

Economizer Sequences

Describes control logic for economizer operation including free cooling.

Factory-Installed VFD

Information on factory-installed Variable Frequency Drives and their setup.

VFD-Ready Installation

Guidance for installing a customer-provided VFD.

Blower and Airflow Management

Phasing and Rotation Checks

Ensuring correct compressor and blower motor rotation.

Airflow Performance Data

Performance data tables for side duct applications.

Supply Air Drive Adjustment

Procedure for adjusting fan speed using motor sheave settings.

Operation Sequences

Cooling Sequence of Operation

Step-by-step description of the unit's cooling operation.

Electric Heating Sequence of Operations

Description of the electric heat section's operational sequence.

Gas Heating Sequence of Operations

Description of the gas heating section's operational sequence.

Troubleshooting and Safety

Cooling Operation Errors

Details on identifying and resolving cooling system operational errors.

Gas Heating Operation Errors

Details on identifying and resolving gas heating operational errors.

Safety Warnings

General warnings regarding electrical hazards and moving parts.

Startup and Final Checks

Cooling Start-up Procedures

Checklists and steps for initiating the cooling system.

Gas Heat Start-up Procedures

Checklists and steps for initiating the gas heating system.

Final Inspection

Final checks to verify proper installation and configuration.