Johnson Controls ZU Seies

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R-410A

ZU SERIES W/SMART EQUIPMENT™

6-1/2 - 12-1/2 Ton

60 Hertz

5566218-TIM-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

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Optional variable air volume . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Optional hot gas bypass (HGBP). . . . . . . . . . . . . . . . . . . . . . . 37

Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Single enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Dual enthalpy changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Free cooling operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Power exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 39

Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . 53

Cooling operation errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Electric heating sequence of operations . . . . . . . . . . . . . . . . . 56

Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 56

Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 57

Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 58

Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Navigation components for the Smart Equipment™ control board . . . 62

Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 63

Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

List of tables

1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 ZUT06 through T12 unit limitations . . . . . . . . . . . . . . . . . . . . . 8

3 Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 ZUT06 through T12 unit accessory weights . . . . . . . . . . . . . 10

5 ZUT06 through T12 unit physical dimensions . . . . . . . . . . . . 11

6 Gas inlet and drain components . . . . . . . . . . . . . . . . . . . . . . 12

7 ZUT06 through T12 unit clearances . . . . . . . . . . . . . . . . . . . 12

8 Side duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 Left/end duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

10 Roof curb components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

12 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

13 ZUT06 through T12 physical data . . . . . . . . . . . . . . . . . . . . . 30

14 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 32

15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 33

16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 33

17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 44

19 Airflow performance - side duct application . . . . . . . . . . . . . 46

20 Airflow performance - bottom duct application . . . . . . . . . . . 48

21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

22 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 50

23 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 50

24 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 52

25 Additional static resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 53

26 Electric heat limit setting 50 in. cabinet . . . . . . . . . . . . . . . . . 56

27 Electric heat limit setting 42 in. cabinet . . . . . . . . . . . . . . . . . 57

28 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 57

29 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 59

30 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 59

31 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 61

32 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

33 Cable for FC buses and SA buses in order of preference . . 69

34 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 69

List of figures

1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Condenser covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 ZU component location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Unit 4 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Unit 6 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8 ZUT06 through T10 physical dimensions . . . . . . . . . . . . . . . 10

9 ZUT12 physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 11

10 ZUT06 through T12 unit bottom duct openings . . . . . . . . . . 13

11 ZUT06 through T12 unit electrical entry . . . . . . . . . . . . . . . . 14

12 ZUT06 through T10 unit side duct openings . . . . . . . . . . . . 14

13 ZUT12 unit side duct openings . . . . . . . . . . . . . . . . . . . . . . . 15

14 ZUT06 through T12 unit left/end duct opening . . . . . . . . . . . 15

15 ZUT06 through T12 roof curb . . . . . . . . . . . . . . . . . . . . . . . . 16

16 ZUT06 through T12 transition roof curb . . . . . . . . . . . . . . . . 16

17 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 17

18 Return downflow plenum with panel . . . . . . . . . . . . . . . . . . . 17

19 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

20 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 18

21 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

22 Field wiring disconnect - cooling unit with or without electric

heat and all units with a VFD option . . . . . . . . . . . . . . . . . . . 20

23 Field wiring disconnect - cooling unit with gas heat without a

VFD option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

24 Typical electronic thermostat field wiring . . . . . . . . . . . . . . . 21

25 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

26 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

27 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

28 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 39

29 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

30 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 44

31 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

32 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

33 Typical gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

34 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Need help?

Do you have a question about the Johnson Controls ZU Seies and is the answer not in the manual?

This document describes the TempMaster ZU series of single-package air conditioners, designed for outdoor installation on rooftops or slabs in non-residential settings. These units are available with optional gas heating or can be equipped with factory or field-installed electric heaters.

Function Description:

The TempMaster ZU units provide heating and cooling for non-residential applications. They are fully assembled with rigid, permanently attached base rails, factory-installed and tested piping, refrigerant charge, and electrical wiring. The units require external electric power, gas supply (if applicable), and duct connections. Electric heaters, if installed, feature nickel-chrome elements and use a single-point power connection.

The units are designed for outdoor installation only, with condenser coils requiring an unlimited air supply. Optimal placement is on the north or east side of a building. For ground-level installations, a level concrete slab with a minimum thickness of 4 inches is recommended, extending at least 6 inches beyond the unit's base rails. Roof structures must support the unit's weight, including options and accessories, and the unit must be installed on a solid, level roof curb or appropriate angle iron frame, maintaining a level tolerance of 1/2 inch across its width and length.

Important Technical Specifications:

Refrigerant: R-410A, operating at higher pressures than R-22. Only R-410A compatible servicing equipment should be used.
Compressor Oil: Polyolester (POE) oil, which is highly hygroscopic and absorbs water readily. Precautions must be taken to prevent exposure to the atmosphere.
Heating Options:
- Natural Gas: Available with 120, 180, or 240 MBH input. Units can be converted to LP gas with a kit.
- Electric Heat: Available in 9, 18, 24, 36, or 54 kW.
Airflow: Units are available with standard or high static motors, and various airflow configurations including motorized dampers, low-leak economizers, and power exhaust.
Electrical: Available in 208/230-3-60, 460-3-60, and 575-3-60 voltages. Control transformers are factory-wired for 230V and 415V power supply, with tap changes required for 208-3-60 or 380-3-50 operation.
Ductwork: Designed according to ACCA Manual D or other recognized authorities like ASHRAE or SMACNA. Closed return duct systems are recommended, with flexible joints at unit connections to minimize noise.
Filters: Two-inch filters are supplied as standard; one-inch filters can be used without modification. Four-inch pleated filters (MERV 13) are an optional accessory.
Capacities:
- Cooling: Nominal tonnages from 6.5 to 12.5 tons.
- Heating: Natural gas heat input from 120 to 240 KBTU, electric heat from 9 to 54 kW.
Dimensions & Weights: Vary by model (ZUT06 to ZUT12), with shipping weights ranging from 900 to 1285 lbs and operating weights from 895 to 1280 lbs.
Clearances: Specific clearances are required for proper operation and service, including 72 inches from the top, 36 inches from the front and rear, and 12 inches from the right side.
Control System: Smart Equipment™ control board manages unit operation, including cooling, heating, and economizer functions.

Usage Features:

Rigging and Handling: Units can be moved with a forklift using slotted openings in the base rails (forks must be at least 60 inches long). Chain or cable slings can be attached to lifting holes, with spreader bars required across the top.
Ductwork Connections: Units support both bottom and side duct applications. Side duct openings are covered upon shipment and require removal for side duct applications.
Condensate Drain: Reversible and re-orientable to the rear, with a connection available through the base pan for piping inside the roof curb. Must be trapped and protected from freezing.
Thermostat Wiring: Thermostat should be installed on an inside wall, approximately 56 inches above the floor, away from drafts, sun exposure, or heat sources.
Economizer Options:
- Dry Bulb Changeover: Outside air suitable for free cooling if its temperature is 1°F below the Economizer OAT Enable setpoint and 1°F below the Return Air Temperature.
- Single Enthalpy Changeover: Outside air suitable for free cooling if its enthalpy is at least 1 BTU/lb below the Economizer Outside Air Enthalpy setpoint and its temperature is no greater than RAT plus 9°F.
- Dual Enthalpy Changeover: Outside air suitable if its enthalpy is lower than return air enthalpy by 1 btu/lb AND its temperature is no greater than RAT plus 9°F.
- Auto: Control determines the type of free cooling based on available sensors.
Power Exhaust: Factory-installed or field-installed accessory for downflow or horizontal flow applications.
Variable Air Volume (VAV) Option: Uses a variable frequency drive (VFD) to maintain constant supply-duct static pressure. Includes a differential pressure transducer to monitor static pressure.
Hot Gas Bypass (HGBP): Optional feature for low cooling load operation, diverting high-temperature, high-pressure refrigerant around the TXV to maintain minimum evaporator pressure.
Gas Heat Start-up: Includes pre-start checks for gas supply, electrical power, and thermostat settings. Manifold gas pressure adjustment is detailed for both first and second stages.
Cooling Start-up: Includes pre-start checks for electrical supply, thermostat settings, indoor blower rotation, belt tension, and supply air CFM.

Maintenance Features:

Filter Replacement: Filters must be kept clean and replaced with the same size and type to prevent reduced capacity and frosted coils.
Blower Belt Tension Adjustment: Detailed steps for adjusting belt tension using a tension checker, with re-tightening of belt nuts.
Airflow Performance Checks: Methods for determining unit CFM using dry coil delta P measurements or static pressure readings, with instructions for adjusting supply air drive if needed.
Compressor Protection: Internal protection against abnormal temperature rise, Anti-Short Cycle Delay (ASCD) to minimize wear, and minimum run times.
Safety Controls: Monitoring of evaporator low limit sensors, high-pressure switches, low-pressure switches, temperature limit switches (for electric and gas heat), and flame sensing.
Ignition Control Board (ICB): Monitors gas valve, pressure, and rollout switches for gas heat units. Includes retry and lockout operations for ignition failures.
Smoke Detectors: Optional factory-installed or field-installed, with specific installation and maintenance guidelines, including relocation if exposed to extreme temperatures.
Troubleshooting: Flash codes are provided for diagnosing errors in the ignition control system.
Smart Equipment™ Control Board: Local LCD and Mobile Access Portal (MAP) Gateway provide access to control points, parameters, and diagnostics.