Johnson Controls Unitary Products YORK ZR Series User manual

R-410A
ZR SERIES
3 - 5 Ton
60 Hertz
403134-YIM-E-0311
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
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Economizer And Power Exhaust Set Point
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Checking Supply Air CFM. . . . . . . . . . . . . . . . . . . . . . . . . 40
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Sequence Of Operations Overview. . . . . . . . . . . . . . . . . . 41
Cooling Sequence Of Operation. . . . . . . . . . . . . . . . . . . . 41
Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . 41
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 42
Electric Heating Sequence Of Operations . . . . . . . . . . . . 43
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 43
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 44
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 45
Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Resets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Heat Anticipator Setpoints. . . . . . . . . . . . . . . . . . . . . . . . . 46
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Start-up (Gas Heat). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking Gas Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Charging The Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fan On And Off Delays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
LIST OF TABLES
1 ZR036-060 Unit Limitations. . . . . . . . . . . . . . . . . . . . . . . . 6
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZR036-060 Unit Accessory Weights. . . . . . . . . . . . . . . . . 8
4 ZR036-060 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10
5 ZR036-060 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 ZR036-060 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Electric Heat Minimum Supply Air. . . . . . . . . . . . . . . . . . 30
10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . 30
11 Gas Pipe Sizing - CapacIty of Pipe. . . . . . . . . . . . . . . . . 31
12 Altitude/Temperature Correction Factors . . . . . . . . . . . . 35
13 ZR Blower Performance Side Duct . . . . . . . . . . . . . . . . . 37
14 ZR Blower Performance Bottom Duct. . . . . . . . . . . . . . . 38
15 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . 39
16 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . 39
17 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . 40
18 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 41
19 Electric Heat Limit Setting. . . . . . . . . . . . . . . . . . . . . . . . 44
20 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . 44
21 Single Stage Gas Heat Limit Control Setting . . . . . . . . . 46
22 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . 46
23 Gas Heat Anticipator Setpoints. . . . . . . . . . . . . . . . . . . . 46
24 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . 49
25 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 57
26 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . 57
LIST OF FIGURES
1 ZR036-060 Component Location. . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZR036-060 Cooling Only/Electric Heat Front View
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 ZR036-060 Cooling Only/Gas Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 ZR036-060 Fixed Outdoor Air Motorized Damper Rain
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 10
8 ZR036-060 Disconnect Location . . . . . . . . . . . . . . . . . . 10
9 ZR036-060 Unit Side Duct Openings. . . . . . . . . . . . . . . 11
10 ZR036-060 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . 13
13 Typical Field Power and Control Wiring. . . . . . . . . . . . . 15
14 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 31
16 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . 33
17 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 34
18 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 34
19 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
20 Altitude/Temperature Correction Factors. . . . . . . . . . . . 35
21 Pressure Drop Across Coil. . . . . . . . . . . . . . . . . . . . . . . 40
22 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
23 Typical Single Stage Gas Valves. . . . . . . . . . . . . . . . . . 47
24 Typical 2 Stage Gas Valves. . . . . . . . . . . . . . . . . . . . . . 47
25 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . 48
26 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . 48
27 ZR036 (3.0 Ton) Operating Pressures. . . . . . . . . . . . . . 51
28 ZR048 (4.0 Ton) Operating Pressures. . . . . . . . . . . . . . 52
29 ZR060 (5.0 Ton) Operating Pressures. . . . . . . . . . . . . . 52
30 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

403134-YIM-E-0311
2Johnson Controls Unitary Products
General
YORK®Model ZR units are either single package cooling units
equipped with optional factory installed electric heaters, or single
package gas-fired central heating furnaces with cooling unit.
Both are designed for outdoor installation on a rooftop or slab.
The units are completely assembled on rigid, permanently
attached base rails. All piping, refrigerant charge, and electrical
wiring is factory installed and tested. The units require electric
power, gas connection, duct connections, installation of
combustion air inlet hood, flue gas outlet hoods and fixed
outdoor air intake damper (units without economizer or
motorized damper option only) at the point of installation.
The supplemental electric heaters have nickel-chrome
elements and utilize single point power connection.
The gas-fired heaters have aluminized-steel (or optional
stainless steel) tubular heat exchangers. The units have spark
ignition with proven pilot. All gas heaters are shipped from the
factory equipped for natural gas use, but can be field converted
to L.P./ Propane with Kit Model #1NP0440 for single stage and
Kit Model #1NP0485 for 2 stage.
Safety Considerations
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention the signal words
DANGER, WARNING or CAUTION.
DANGER indicates an imminently hazardous situation, which,
if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if
not avoided may result in minor or moderate injury.It is also
used to alert against unsafe practices and hazards involving
only property damage.
Due to system pressure, moving parts, and electrical
components, installation and servicing of air conditioning
equipment can be hazardous. Only qualified, trained service
personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions
of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags
accompanying the equipment whenever working on air
conditioning equipment. Be sure to follow all other applicable
safety precautions and codes including ANSI Z223.1 or CSA-
B149.1- latest edition.
Wear safety glasses and work gloves. Use quenching cloth and
have a fire extinguisher available during brazing operations.
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage. Improper installation, adjustment,
alteration, service or maintenance can cause injury or
property damage. Refer to this manual for assistance or
for additional information, consult a qualified contractor,
installer or service agency.
This product must be installed in strict compliance with
the installation instructions and any applicable local,
state and national codes including, but not limited to
building, electrical, and mechanical codes.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury. Improper installation,
adjustment, alteration, service or maintenance can
cause injury or property damage. Refer to this manual.
For assistance or additional information consult a
qualified installer, service agency or the gas supplier.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system. Gage sets, hoses, refrigerant
containers and recovery systems must be designed to
handle R-410A. If you are unsure, consult the equipment
manufacturer. Failure to useR-410A compatible servicing
equipment may result in property damage or injury.
If the information in this manual is not followed exactly, a
fire or explosion may result causing property damage,
personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
a. Do not try to light any appliance.
b. Do not touch any electrical switch; do not use any
phone in your building.
c. Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
d. If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.

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Johnson Controls Unitary Products 3
Inspection
As soon as a unit is received, it should be inspected for possible
damage during transit. If damage is evident, the extent of the
damage should be noted on the carrier’s freight bill. A separate
request for inspection by the carrier’s agent should be made in
writing.
Reference
Additional information is available in the following reference
forms:
• Technical Guide - ZR036-060, 251933
• General Installation - ZR036-060, 403134
Renewal Parts
Contact your local York® parts distribution center for authorized
replacement parts.
Approvals
Design certified by CSA as follows:
1. For use as a cooling only unit, cooling unit with
supplemental electric heat or a forced air furnace.
2. For outdoor installation only.
3. For installation on combustible material.
4. For use with natural gas (convertible to LP with kit).
This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state and national codes including, but not limited
to, building, electrical, and mechanical codes.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system during
any pressure testing at pressures in excess of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas valve
damage resulting in a hazardous condition. If it is
subjected to a pressure greater than 1/2 PSIG, the gas
valve must be replaced.
The furnace must be isolated from the gas supply piping
system by closing its individual manual shut-off valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state, and national codes including, but not limited
to, building, electrical, and mechanical codes.
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.

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4Johnson Controls Unitary Products
Nomenclature
Z R 048 N04 A 2 A AA 1 0 1 2 4 A
Z = A/C, Single Pkg., R-410A
Product Category
Airflow
N = Belt Drive
P = Belt Drive/Economizer
R = Belt Drive/Motorized Damper
A = Direct Drive
B = Direct Drive/Economizer
D = Direct Drive/Motorized Damper
Product Generation
2 = Second Generation
C00 = Cooling Only. Suitable for Field
Installed Electric Heat
Heat Type and Nominal Heat Capacity
N04 = 40 MBH Output Aluminized Steel, 1 Stage (036)
N06 = 60 MBH Output Aluminized Steel, 1 Stage (048)
N08 = 80 MBH Output Aluminized Steel, 1 Stage
(036, 060)
N10 = 100 MBH Output Aluminized Steel, 1 Stage
(048, 060)
D06 = 60 MBH Output Aluminized Steel, 2 Stage
(036, 048, 060)
D10 = 100 MBH Output Aluminized Steel, 2 Stage
(036*, 048, 060)
S04 = 40 MBH Output Stainless Steel, 1 Stage (036)
S06 = 60 MBH Output Stainless Steel, 1 Stage (048)
S08 = 80 MBH Output Stainless Steel, 1 Stage
(036, 060)
S10 = 100 MBH Output Stainless Steel, 1 Stage
(048, 060)
T06 = 60 MBH Output Stainless Steel, 2 Stage
(036, 048, 060)
T10 = 100 MBH Output Stainless Steel, 2 Stage
(036*, 048, 060)
*(D, T)10 = 92 MBH Output on 036 Models
E05 = 5 KW
E07 = 7 KW
E10 = 10 KW
E15 = 15 KW
E20 = 20 KW
E30 = 30 KW
Gas Heat Options
Electric Heat Options
036 = 3.0 Ton
Nominal Cooling Capacity
048 = 4.0 Ton
060 = 5.0 Ton
Product Identifier
R = 13.0 SEER, Reheat
Voltage
1 = 208/230-1-60
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
Product Style
A = Style A
A = No Options Installed
Installation Options
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Options
SS Drain Pan
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
CPC Controller, DFS, APS
Johnson Controller, DFS, APS
Honeywell Controller, DFS, APS
Novar Controller, DFS, APS
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/ModLinc
2" Pleated filters
BAS Ready Economizer (2-10 V.D.C. Actuator without a Controller)
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
AA = None
Standard Cabinet
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
AS = Bottom Drain Connection
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator and Condenser Coil
Additional Options
Hinged Filter Door & Toolless Access Cabinet
BB = Phase Monitor, Hinged Filter Door & Toolless
Access Panels
BC = Coil Guard, Hinged Filter Door & Toolless
Access Panels
BD = Dirty Filter Switch, Hinged Filter Door &
Toolless Access Panels
BE = Phase Monitor & Coil Guard, Hinged Filter
Door & Toolless Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged
Filter Door & Toolless Access Panels
BG = Coil Guard & Dirty Filter Switch, Hinged Filter
Door & Toolless Access Panels
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged Filter Door & Toolless Access Panels
BA = Hinged Filter Door & Toolless Access Panels
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
T = Belt Drive High Static
U = Belt Drive High Static/Economizer
V = Belt Drive High Static/Motorized Damper

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Johnson Controls Unitary Products 5
Installation
Installation Safety Information
Read these instructions before continuing this appliance
installation. This is an outdoor combination heating and cooling
unit. The installer must assure that these instructions are made
available to the consumer and with instructions to retain them
for future reference.
1. Refer to the unit rating plate for the approved type of gas
for this product.
2. Install this unit only in a location and position as specified
on Page 7 of these instructions.
3. Never test for gas leaks with an open flame. Use
commercially available soap solution made specifically for
the detection of leaks when checking all connections, as
specified on Pages 5, 32, 32 and 47 of these instructions.
4. Always install furnace to operate within the furnace's
intended temperature-rise range with the duct system and
within the allowable external static pressure range, as
specified on the unit name/rating plate, specified on
page 30 of these instructions.
5. This equipment is not to be used for temporary heating of
buildings or structures under construction.
6. If a factory option convenience outlet is installed, the
weatherproof outlet cover must be field installed. The cover
shall be located behind the blower access panel. To install
the cover, remove the shipping label covering the
convenience outlet and attach the cover to the unit using
the (4) screws provided.
Limitations
These units must be installed in accordance with the following:
In U.S.A.:
1. National Electrical Code, ANSI/NFPA No. 70 - Latest
Edition
2. National Fuel Gas Code, ANSI Z223.1 - Latest Edition
3. Gas-Fired Central Furnace Standard, ANSI Z21.47a. -
Latest Edition
4. Local building codes, and
5. Local gas utility requirements
In Canada:
1. Canadian Electrical Code, CSA C22.1
2. Installation Codes, CSA - B149.1.
3. Local plumbing and waste water codes, and
4. Other applicable local codes.
Refer to unit application data found in this document.
After installation, gas fired units must be adjusted to obtain a
temperature rise within the range specified on the unit rating
plate.
If components are to be added to a unit to meet local codes,
they are to be installed at the dealer’s and/or customer’s
expense.
Size of unit for proposed installation should be based on heat
loss/heat gain calculation made according to the methods of Air
Conditioning Contractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings
or structures under construction.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
208/230-3-60 and 380/415-3-50 units with factory
installed Powered Convenience Outlet Option are wired
for 230v and 415v power supply respectively. Change
tap on transformer for 208-3-60 or 380-3-50 operation.
See unit wiring diagram.
The Simplicity® control board used in this product will
effectively operate the cooling system down to 0°F when
this product is applied in a comfort cooling application
for people. An economizer is typically included in this
type of application. When applying this product for
process cooling applications (computer rooms,
switchgear, etc.), please reference applications bulletin
AE-011-07 or call the applications department for
Unitary Products @ 1-877-UPG-SERV for guidance.
Additional accessories may be needed for stable
operation at temperatures below 30° F.

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Figure 1: ZR036-060 Component Location
3/4 " PVC female
condensate drain
Knockout for
side power and
control entry
GFCI
convenience outlet
Smoke
detector
Slide-in
economizer
Economizer
hood
HACR
breaker
Belt drive or
Direct drive
blower
20 Gauge aluminized
steel tubular heat exchanger
Electric heat
accessory location
Power ventor motor with
post purge cycle
High efficiency
compressor
Knockout for side
gas supply entry
Simplicity®
control board
Copper tube/
aluminum fin
condensing coil
Full perimeter baserails
with forklift slots and
lifting holes
Table 1: ZR036-060 Unit Limitations
Size
(Tons) Unit Voltage Unit Limitations
Applied Voltage Outdoor DB Temp
Min Max Max (°F)
036
(3.0)
208/230-1-60 187 252 125
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
048
(4.0)
208/230-1-60 187 252 125
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
060
(5.0)
208/230-1-60 187 252 125
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125

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Johnson Controls Unitary Products 7
Location
Use the following guidelines to select a suitable location for
these units:
1. Unit is designed for outdoor installation only.
2. Condenser coils must have an unlimited supply of air.
Where a choice of location is possible, position the unit on
either north or east side of building.
3. Suitable for mounting on roof curb.
4. For ground level installation, use a level concrete slab with
a minimum thickness of 4 inches. The length and width
should be at least 6 inches greater than the unit base rails.
Do not tie slab to the building foundation.
5. Roof structures must be able to support the weight of the
unit and its options/accessories. Unit must be installed on a
solid, level roof curb or appropriate angle iron frame.
6. Maintain level tolerance to 1/2” across the entire width and
length of unit.
Clearances
All units require particular clearances for proper operation and
service. Installer must make provisions for adequate
combustion and ventilation air in accordance with section 5.3 of
Air for Combustion and Ventilation of the National Fuel Gas
Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2,
7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) -
Latest Edition, and/or applicable provisions of the local building
codes. Refer to Table 4 for clearances required for combustible
construction, servicing, and proper unit operation.
Rigging And Handling
Exercise care when moving the unit. Do not remove any
packaging until the unit is near the place of installation. Rig the
unit by attaching chain or cable slings to the lifting holes
provided in the base rails. Spreader bars, whose length
exceeds the largest dimension across the unit, MUST be used
across the top of the unit.
Units may be moved or lifted with a forklift. Slotted openings in
the base rails are provided for this purpose.
LENGTH OF FORKS MUST BE A MINIMUM OF 42 INCHES.
Excessive exposure of this furnace to contaminated
combustion air may result in equipment damage or
personal injury. Typical contaminates include:
permanent wave solution, chlorinated waxes and
cleaners, chlorine based swimming pool chemicals,
water softening chemicals, carbon tetrachloride,
Halogen type refrigerants, cleaning solvents (e.g.
perchloroethylene), printing inks, paint removers,
varnishes, hydrochloric acid, cements and glues,
antistatic fabric softeners for clothes dryers, masonry
acid washing materials.
Do not permit overhanging structures or shrubs to
obstruct condenser air discharge outlet, combustion air
inlet or vent outlets.
If a unit is to be installed on a roof curb other than a
York®roof curb, gasketing must be applied to all
surfaces that come in contact with the unit underside.
Before lifting, make sure the unit weight is distributed
equally on the rigging cables so it will lift evenly.
All panels must be secured in place when the unit is
lifted.
The condenser coils should be protected from rigging
cable damage with plywood or other suitable material.

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8Johnson Controls Unitary Products
Figure 2: Unit 4 Point Load Weight Figure 3: Unit 6 Point Load Weight
Figure 4: Center of Gravity
A
D
B
Front
C
A
F
C
BFront
D
E
XY
LEFT FRONT
Table 2: Weights and Dimensions
Size
(Tons) Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.) 6 Point Load Location (lbs.)
ShippingOperatingX Y ABCDABCDEF
036
(3.0) 580 575 40 20 132 125 155 164 89 85 82 102 106 110
048
(4.0) 590 585 40 20 134 127 158 167 90 87 84 104 108 112
060
(5.0) 595 590 40 20 135 128 159 168 91 88 84 105 109 113
Table 3: ZR036-060 Unit Accessory Weights
Unit Accessory Weight (lbs.)
Shipping Operating
Economizer 55 50
Power Exhaust 55 50
Electric Heat128 28
Gas Heat270 70
1. Weight given is for the maximum heater size available (30KW).
2. Weight given is for the maximum number of tube heat exchangers
available (5 tube).

403134-YIM-E-0311
Johnson Controls Unitary Products 9
Figure 5: ZR036-060 Cooling Only/Electric Heat Front View Physical Dimensions
Figure 6: ZR036-060 Cooling Only/Gas Heat Front View Physical Dimensions

403134-YIM-E-0311
10 Johnson Controls Unitary Products
Figure 7: ZR036-060 Fixed Outdoor Air Motorized Damper Rain Hood Physical Dimensions
Figure 8: ZR036-060 Disconnect Location
Detail “A”
27-1/2
27-1/2
1-5/8
19-1/2 44-7/8
19-3/4
Rear View
Detail “B”
Dimension “A”
Fixed
Outdoor
Air Damper 12
16-1/2
Motorized
Damper
LH End View
27-1/2
27-1/2
7-1/4
“A” 44-7/8
4-3/8
8-1/4
3-1/2
10-1/4
19-1/8
Table 4: ZR036-060 Unit Clearances
Location Clearance
Front 24” (Cooling/Electric Heat)
32” (Gas Heat)
Rear 12” (Less Economizer) 36” (With Economizer or Fixed
Air/Motorized Damper)
Left Side (Filter Access) 24” (Less Economizer)
36” (With Economizer)
Right Side (Cond. Coil) 24”
Below Unit1
1. Units may be installed on combustible floors made from
wood or class A, B, or C roof covering material.
0”
Above Unit2
2. Units must be installed outdoors. Overhanging structures
or shrubs should not obstruct condenser air discharge
outlet.
72” (For
Condenser Air Discharge)
Disconnect Switch Location
and Motor Access Panel for
Unit with “Belt-Drive” Option
Control Box Access
A,B
Wiring Entry
(See Detail “B”)
Mounting Bracket for
Disconnect Switch
(Field Supplied)
Field-Supplied Disconnect
Switch Location
Blower Motor Access
Filter Access
Dot Plugs