Johnson Controls ZQ Series User manual

6150259-UIM-A-1021
A-1021
York International Corporation, 5005
York Drive, Norman, OK 73069
2021-09-30
Johnson Controls Ducted Systems
INSTALLATION MANUAL ZQ SERIES 3ton
to5ton 60 Hertz R-410A

2 INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A
Johnson Controls Ducted Systems

Contents
ContentsGeneral.............................................................................5
Safety considerations............................................... 5
Inspection.................................................................. 6
Reference................................................................... 6
Renewal parts............................................................ 7
Approvals................................................................... 7
Nomenclature............................................................8
Installation....................................................................... 9
Installation safety information................................9
Preceding installation...............................................9
Limitations......................................................... 11
Location....................................................................11
Clearances..........................................................12
Rigging and handling............................................. 12
ZQ04-06 unit weights..............................................13
Ductwork..................................................................17
Duct covers........................................................ 18
Condensate drain....................................................18
Compressors............................................................19
Filters........................................................................ 19
Power and control wiring.......................................19
Thermostat wiring.............................................20
Typical field power and control wiring.......................21
Typical power wiring...............................................21
Electrical data.......................................................... 23
ZQ04 to 06 standard indoor blower -
without powered convenience outlet.............23
ZQ04 to 06 standard indoor blower - with
powered convenience outlet........................... 25
ZQ04 to 06 medium indoor blower -
without powered convenience outlet.............27
ZQ04 to 06 medium indoor blower - with
powered convenience outlet........................... 29
ZQ04 to 06 high indoor blower - without
powered convenience outlet........................... 31
ZQ04 to 06 high indoor blower - with
powered convenience outlet........................... 32
ZQ04 to ZQ06 physical data................................... 33
Optional gas heat....................................................39
Gas piping.......................................................... 39
Gas connection..................................................39
Combustion air and flue exhaust....................40
Options/accessories............................................... 41
Economizer........................................................ 41
Power Exhaust...................................................41
Rain hood........................................................... 41
Blower phasing........................................................41
Blower rotation..................................................42
Belt tension........................................................ 43
Altitude and temperature correction for
CFM, static pressure and power......................43
Airflow performance...............................................45
ZQ04-06 side duct application (belt
drive)...................................................................46
ZQ04-06 side duct application (direct
drive)...................................................................47
ZQ04-06 bottom duct application (belt
drive)...................................................................48
ZQ04-06 bottom duct application (direct
drive)...................................................................49
RPM selection.................................................... 50
Supply air drive adjustment.............................51
Everyday Thermostat Control (ETC)................53
Smart Equipment™ unit control board...........56
Operation.......................................................................61
Cooling sequence of operation............................. 61
Smart Equipment™ economizer board
details....................................................................... 64
Indoor air quality AQ.............................................. 66
Gas heating operation............................................66
Gas heat ignition control board function (non
Ultra-Low NOx models only)....................................... 68
Ignition control board on standby........................68
Call for heat..............................................................68
Pressure switch proving.........................................68
Pre-purge................................................................. 68
Ignition trial period.................................................68
Flame stabilization period......................................68
Main burner operation...........................................68
Post purge................................................................69
Lockout.....................................................................69
High temperature limit switch...............................69
Roll-out switch......................................................... 69
Power interruptions................................................69
Flame present with gas off.................................... 69
Welded gas valve relay response..........................69
Gas heat ignition control board function
(Ultra-Low NOx)............................................................ 70
Ignition control board on standby........................70
Call for heat..............................................................70
Johnson Controls Ducted Systems
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 3

Combustion air proving.................................................. 70
Pre-purge.......................................................................... 70
Ignition trial period..........................................................70
Main burner operation....................................................70
Post purge.........................................................................70
Ignition failures................................................................ 70
High temperature limit switches....................................70
Burner inlet pressure switch.......................................... 71
Power interruptions.........................................................71
Flame present with gas off............................................. 71
Gas valve fault.................................................................. 71
Diagnostic fault code storage and retrieval................. 71
Start-Up (cooling)...................................................................72
Prestart check list.............................................................72
Cooling operating instructions.......................................72
Post start check list.......................................................... 72
Start-up (gas heat).................................................................73
Pre-start check list............................................................73
Gas heat operating instructions.....................................73
Lighting the main burners..............................................73
Post start checklist........................................................... 73
Shut down......................................................................... 73
Checking gas heat input....................................................... 74
Single stage gas heat.......................................................74
Two stage gas heat..........................................................74
Manifold gas pressure adjustment................................75
Single stage.......................................................................75
Two stage..........................................................................75
Adjustment of temperature rise.................................... 76
Burners/orifices inspection/servicing (non
Ultra-Low NOx models only)...........................................77
Start up for units equipped for FER............................... 77
Direct drive........................................................................77
Troubleshooting.....................................................................79
Charging tables................................................................ 84
Control board navigation components...............................86
Start-up sheet.........................................................................87
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A4
Johnson Controls Ducted Systems

General
ZQ units are single package air conditioners
with optional gas heating designed for outdoor
installation on a rooftop or slab and for non-
residential use.
These 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 supply (where applicable),
and duct connections.
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.
WARNING
Incorrect 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.
CAUTION
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.
WARNING
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.
CAUTION
This system uses R-410A Refrigerant which
operates at higher pressures than R-22. No
other refrigerant may be used in this system.
Gauge sets, hoses, refrigerant containers
and recovery systems must be designed to
handle R-410A. If you are unsure, consult the
equipment manufacturer. Failure to use R-410A
compatible servicing equipment may result in
property damage or injury.
5INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A
Johnson Controls Ducted Systems

WARNING
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.
WARNING
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, serious injury, death or property
damage.Improper servicing could result in dangerous
operation, serious injury, death or property damage.
• Before servicing, disconnect all electrical power to
furnace.
• When servicing controls, label all wires prior to
disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
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. The
installation must conform with local building codes
or, in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or the
National Gas and Propane Installation Code, CSA
B149.1.
Wear safety glasses and work gloves. Use
quenching cloth and have a fire extinguisher
available during brazing operations.
Inspection
As soon as a unit is received, inspect it 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.
CAUTION
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.
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
Reference
Additional information is available in the following
reference forms:
• Technical Guide - ZX/ZQ/ZL/ZY04-14 1068152
• General Installation - ZQ04-06 6150259
• • Economizer Accessory -
Vertical Flow Dry Bulb Economizer Field
Installed
Horizontal Flow Dry Bulb Economizer
Field Installed
• • Power Exhaust -
Vertical Flow Dry Bulb Economizer Field
Installed
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A6
Johnson Controls Ducted Systems

Horizontal Flow Dry Bulb Economizer
Field Installed
Renewal parts
Contact your local Ducted Systems 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 a forced air furnace.
2. For outdoor installation only.
3. For installation on combustible material
and can be installed directly on combustible
flooring or, in the U.S., on wood flooring
or Class A, Class B, or Class C roof covering
materials.
4. For use with natural gas.
CAUTION
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.
WARNING
Improper installation may create a condition where the
operation of the product could cause personal injury
or property damage.
CAUTION
This system uses R-410A Refrigerant which operates
at higher pressures than R-22. No other refrigerant
may be used in this system.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 7
Johnson Controls Ducted Systems

Nomenclature
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A8
Johnson Controls Ducted Systems

Installation
Installation safety information
Read these instructions before installing this
appliance. 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 in Location.
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.
4. Always install the furnace to operate within
the furnace's intended temperature-rise
range with the duct system and within the
allowable external static pressure range
noted on the unit name or rating plate and in
Electrical data.
5. Do not use this equipment for temporary
heating of buildings or structures under
construction.
WARNING
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.
Preceding installation
1. Remove the two screws that hold the brackets
in the forklift slots on the side of the unit.
Figure 1: Unit shipping bracket
A Bracket screws
B Bracket
2. Turn each bracket toward the ground. The
protective plywood covering drops to the
ground.
3. Remove the protective covering from the
condenser coil before to operation.
Figure 2: Protective condenser covering
4. If a factory option convenience outlet is
installed, you must install the weatherproof
outlet cover in the field. The cover is located
behind the filter access panel.
a. Remove the shipping label that covers
the convenience outlet.
b. Follow the instructions on the back of
the cover box.
c. Attach the cover to the unit with the
four screws provided.
CAUTION
208/230-3-60 and units with factory installed
Powered Convenience Outlet Option are
wired for 230 V power supply. Change tap on
transformer for 208-3-60 operation. See the
unit wiring diagram.
5. For gas heating models equipped with
Smart Equipment™ control, you must move
the supply air temperature (SAT) sensor to
the working position to ensure proper SAT
readings. The SAT sensor is shipped in the
supply air compartment.
a. Move the SAT sensor to the inside of the
supply air duct. See item A in Figure 5.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 9
Johnson Controls Ducted Systems

b. Use the excess wire available to its full
length to drop or mount the SAT sensor
in the duct. Avoid close contact with the
gas heat exchanger.
c. Use the shipping bracket to hold the
SAT sensor in the supply air stream.
See Figure 3 for the factory SAT sensor
location and Figure 5 for the sensor
relocation.
Figure 3: Supply air temperature sensor
6. For units equipped with an economizer or
motorized OD air damper, you must move
the return air temperature (RAT) sensor to
the working position to ensure proper RAT
readings. See item B in Figure 5
a. Move the RAT sensor to the inside of
the return air duct verifying that the
sensor is at least 6 in. below the unit
duct opening. The sensor must read the
return air temperature not mixed return
air and outdoor air temperatures.
b. Use the excess wire available to its full
length to drop or mount the RAT sensor
in the duct.
c. You can use the shipping bracket to
hold the RAT sensor in the return air
stream. See Figure 4 for the factory RAT
sensor location and Figure 5 for the
sensor relocation.
Figure 4: Factory-mounted return air
temperature sensor
A Filter rack and filters
B RAT sensor
Figure 5: Supply and return air ducts
A Supply air duct
B Return air duct
7. If an optional return air smoke detector is
installed, you must move the return air sensor
from the factory-shipped position (upside
down) to the working position (right side up).
Then slide the flex tube over the stub and
tighten, see Figure 7.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A10
Johnson Controls Ducted Systems

Figure 6: Return air smoke detector - shipped
position
A Flex tube
secured to the
bracket
C Controller
B Return air
sensor
D Wire tie
Figure 7: Return air smoke detector - working
position
A Controller
B Return air sensor
C Flex tube in the
working position
Limitations
These units must be installed in accordance with the
following codes and regulations:
In U.S.A. and Canada:
• Gas-Fired Central Furnace Standard , ANSI
Z21.47 - CSA 2.3 - Latest Edition
In U.S.A.:
• National Electrical Code, ANSI/NFPA No. 70 -
Latest Edition
• National Fuel Gas Code, ANSI Z223.1 - Latest
Edition
• Local building codes, and
• Local gas utility requirements
In Canada:
• Canadian Electrical Code, CSA C22.1
• Installation Codes, CSA - B149.1.
• Local plumbing and waste water codes, and
• 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).
Do not use this furnace for temporary heating of
buildings or structures under construction.
Table 1: ZQ04-06 unit limitations
Unit limitations
Applied voltage Outdoor
DB temp
Model Size
(tons)
Unit voltage SCCR (kVA)
Min Max Max (°F)
208/230-1-60 5 187 252 125
208/230-3-60 5 187 252 125
460-3-60 5 432 504 125
ZQ 04 (3)
575-3-60 5 540 630 125
208/230-1-60 5 187 252 125
208/230-3-60 5 187 252 125
460-3-60 5 432 504 125
ZQ 05 (4)
575-3-60 5 540 630 125
208/230-1-60 5 187 252 125
208/230-3-60 5 187 252 125
460-3-60 5 432 504 125
ZQ 06 (5)
575-3-60 5 540 630 125
Location
Use the following guidelines to select a suitable
location for these units:
1. Unit is designed for outdoor installation only.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 11
Johnson Controls Ducted Systems

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
in. The length and width should be at least 6
in. 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 or
accessories. Unit must be installed on a solid,
level roof curb or appropriate angle iron
frame.
6. Maintain level tolerance to 1/2 in. across the
entire width and length of unit.
WARNING
Excessive exposure of this furnace to contaminated
combustion air will result in safety and performance
related problems. Typical contaminates include:
permanent wave solution, chlorinated waxes and
cleaners, chlorine based swimming pool chemicals,
water softening chemicals, de-icing salts or chemicals,
carbon tetrachloride, Halogen type refrigerants,
cleaning solvents (e.g. perchloroethylene), printing
inks, paint removers, varnishes, hydrochloric acid,
cements and glues, anti-static fabric softeners for
clothes dryers, masonry acid washing materials.
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.
WARNING
Do not permit overhanging structures or shrubs to
obstruct condenser air discharge outlet, combustion
air inlet or vent outlets.
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.
CAUTION
If a unit is to be installed on a roof curb other than a
Ducted Systems roof curb, gasketing must be applied
to all surfaces that come in contact with the unit
underside.
CAUTION
Before lifting, make sure the unit weight is distributed
equally on the rigging cables so it will lift evenly.
Units can 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 60
INCHES.
CAUTION
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.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A12
Johnson Controls Ducted Systems

ZQ04-06 unit weights
Figure 8: Unit 4 point load weight Figure 9: Unit 6 point load weight
Figure 10: Center of gravity
Table 2: ZQ04-06 corner weights
Weight (lb) Center of Gravity 4 Point Load Location (lbs.) 6 Point Load Location (lbs.)Model Size
(Tons) Shipping Operating X Y A B C D A B C D E F
ZQE 04 (3) 484 469 37 26 123 120 112 115 82 81 80 74 75 77
ZQE 05 (4) 503 498 36 25 129 123 120 126 87 84 82 79 82 84
ZQE 06 (5) 590 561 36 24 140 134 140 147 94 91 89 93 96 99
ZQG 04 (3) 530 515 35 27 145 132 113 125 98 92 87 74 79 84
ZQG 05 (4) 557 552 36 27 154 144 123 131 104 99 95 81 85 89
ZQG 06 (5) 639 610 36 26 165 157 141 147 111 107 104 93 96 99
Table 3: ZQ04-06 unit accessory
weights
Unit Accessory Weights (lb)
Vertical Flow Dry Bulb Economizer Small
Footprint
55
Horizontal Flow Dry Bulb Economizer
Small Footprint Short
74
Horizontal Flow Dry Bulb Economizer
Small Footprint Tall
76
Power Exhaust Vert Flow Small Footprint 55
Power Exhaust Horiz Flow Small Footprint 40
Hail Guard Kit Small Short Factory
Installed
18
Hail Guard Kit Small Tall Factory Installed 23
Flue Extension Kit (1FE0414) 15
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 13
Johnson Controls Ducted Systems

Table 3: ZQ04-06 unit accessory
weights
Unit Accessory Weights (lb)
Flue Extension Kit (1FE0415) 17
Curb Rigid 14 in. Small Footprint 94
Curb Rigid 24 in. Small Footprint 148
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A14
Johnson Controls Ducted Systems

Figure 11: ZQ04-05 unit dimensions
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 15
Johnson Controls Ducted Systems

Figure 12: ZQ06 unit dimensions
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A16
Johnson Controls Ducted Systems

Table 4: ZQ04-06 unit clearances
Direction Distance (in.) Direction Distance (in.)
1 Top172 Right 18
Front 36 Left 12
Rear 2,3 182/3634 Bottom41
1 Units must be installed outdoors. Over hanging structure or
shrubs should not obscure condenser air discharge outlet.
2 Units without economizer or power exhaust.
3 Units equipped with an Economizer or Power Exhaust. Flue
products must not be discharged within 10 Feet of the rear
of the unit.
4 Units may be installed on combustible floors made from
wood or class A, B or C roof covering materials.
Figure 13: 1RC0456, 1RC0458 roof curb dimensions
Table 5: Unit models used with 1RC0456, 1RC0458
roof curb
• ZQ04
• ZQ05
• ZQ06
Note: If utilities are required through the
base of the unit or through the roof curb the
following field installed accessories can be
purchased through your dealer or contractor:
1TB0401 - Thru the base electrical and thru the
curb gas
1TB0403 - Thru the base electrical and gas
Ductwork
Ductwork should be designed and sized according
to the methods in Manual D of the Air Conditioning
Contractors of America (ACCA) or as recommended
by any other recognized authority such as ASHRAE
or SMACNA.
Use a closed return duct system. This will not
preclude use of economizers or outdoor fresh air
intake. The supply and return air duct connections
at the unit should be made with flexible joints to
minimize noise.
The supply and return air duct systems should
be designed for the CFM and static pressure
requirements of the job. They should NOT be sized
to match the dimensions of the duct connections on
the unit.
Refer to Figure 11 and Figure 12 for bottom and side
air duct openings.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 17
Johnson Controls Ducted Systems

Duct covers
Units are shipped with the side duct openings
covered and a covering over the bottom of the unit.
For side duct application, remove the side duct
covers and install over the bottom duct openings.
The panels removed from the side duct connections
are designed to be reused by securing each panel
to its respective bottom duct opening. But keep
in mind that the supply and return panels are
installed with the painted surface DOWN, facing the
bottom duct opening. The gasket must be removed
from the insulation side of the duct cover so it is
not directly exposed to the heating elements. The
panels are secured by sliding them into slots in the
back of the duct openings and screwing them to the
base of the unit with screws (use screws removed
from original panel location). Seals around duct
openings must be tight.
CAUTION
When fastening ductwork to side duct flanges on unit,
insert screws through duct flanges only. DO NOT
insert screws through casing. Outdoor ductwork must
be insulated and water-proofed.
Figure 14: Side duct cover panels
Note: Shown with duct connection cover panel
as shipped.
Figure 15: Bottom return opening for side duct
conversion
Figure 16: Bottom supply opening for side duct
conversion
Condensate drain
A side condensate drain is provided to facilitate
condensate piping. A condensate drain connection
is available through the base pan for piping inside
the roof curb. Trap the connection per Figure 17.
The trap and drain lines should be protected from
freezing.
Plumbing must conform to local codes. Use a
sealing compound on male pipe threads. Install
condensate drain line from the 3/4 in. NPT female
connection on the unit to an open drain.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A18
Johnson Controls Ducted Systems

Figure 17: Condensate drain
Compressors
The compressor used in this product is specifically
designed to operate with R-410A Refrigerant and
cannot be interchanged.
CAUTION
This system uses R-410A Refrigerant which operates
at higher pressures than R-22. No other refrigerant
may be used in this system.
The compressor also uses a refrigerant oil that is
extremely hygroscopic, meaning it absorbs water
readily. They can absorb 15 times as much water as
other oils designed for HCFC and CFC refrigerants.
Take all necessary precautions to avoid exposure of
the oil to the atmosphere.
CAUTION
Do not leave the system open to the atmosphere. Unit
damage could occur due to moisture being absorbed
by the refrigerant in the system. This type of oil is
highly susceptible to moisture absorption.
R-410A compressor lubricants are known to cause
long term damage to some synthetic roofing
materials.
CAUTION
Exposure, even if immediately cleaned up, may cause
embrittlement (leading to cracking) to occur in one
year or more. When performing any service that
may risk exposure of compressor oil to the roof, take
precautions to protect roofing.
Procedures which risk oil leakage include, but are
not limited to, compressor replacement, repairing
refrigerant leaks, replacing refrigerant components
such as filter drier, pressure switch, metering device
or coil.
Units are shipped with compressor mountings
which are factory-adjusted and ready for operation.
CAUTION
Do not loosen compressor mounting bolts.
Filters
Two-inch filters are supplied with each unit. Four-
inch filters may be used with no modification to the
filter racks. Filters must always be installed ahead of
evaporator coil and must be kept clean or replaced
with same size and type. Dirty filters reduce the
capacity of the unit and result in frosted coils or
safety shutdown. Refer to physical data tables, for
the number and size of filters needed for the unit.
The unit should not be operated without filters
correctly installed.
Power and control wiring
Field wiring to the unit, fuses, and disconnects must
conform to provisions of National Electrical Code
(NEC), ANSI/NFPA No. 70 – Latest Edition (in U.S.A.),
current Canadian Electrical Code C221, and/or local
ordinances. The unit must be electrically grounded
in accordance with NEC and CEC as specified above
and/or local codes.
Voltage tolerances which must be maintained at the
compressor terminals during starting and running
conditions are indicated on the unit rating plate and
Table 1.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A 19
Johnson Controls Ducted Systems

CAUTION
208/230-3-60 and 208/230-1-60 units control
transformers are factory wired for 230 V. Change tap
on transformer for 208 V operation. See unit wiring
diagram.
The internal wiring harnesses furnished with this
unit are an integral part of the design certified
unit. Field alteration to comply with electrical codes
should not be required. If any of the wire supplied
with the unit must be replaced, replacement wire
must be of the type shown on the wiring diagram
and the same minimum gauge as the replaced wire.
A disconnect must be used for these units. Factory
installed disconnects are available. If installing a
disconnect (field supplied), refer to Figure 11 and
Figure 12 for the recommended mounting location.
CAUTION
Avoid damage to internal components if drilling holes
for disconnect mounting.
Note: Since not all local codes allow the
mounting of a disconnect on the unit, please
confirm compliance with local code before
mounting a disconnect on the unit.
Electrical line must be sized correctly to carry the
load. USE COPPER CONDUCTORS ONLY. Each unit
must be wired with a separate branch circuit fed
directly from the meter panel and correctly fused.
CAUTION
When connecting electrical power and control wiring
to the unit, water-proof connectors must be used so
that water or moisture cannot be drawn into the unit
during normal operation. The above water-proofing
conditions will also apply when installing a field
supplied disconnect switch.
CAUTION
When installing equipment in a facility with a 3-phase
high-leg delta power supply, care must be taken to
ensure that the high-leg conductor is not attached to
either of the two legs of the (single phase, direct drive)
X13 or ECM motors. Failure to do so can result in the
motor acting erratically or not running at all.
Check for the high leg conductor by checking voltage
of each phase to ground.
Example: A or L1 phase to ground, voltage reading
is 120 V. B or L2 phase to ground, voltage reading
is 195 V to 208 V. C or L3 phase to ground, voltage
reading is 120 V. Therefore B or L2 phase is the high
Leg. The high should always be wired to the center or
B or L2 tap.
Note: Check all three phase motors and compressors
for proper rotation after making a change. If it is
necessary to change 3 phase motor rotation, swap A
or L1 and C or L3 only.
Thermostat wiring
A two-stage thermostat must be used and should
be located on an inside wall approximately 56 in.
above the floor where it will not be subject to drafts,
sun exposure, or heat from electrical fixtures or
appliances. Follow the manufacturer's instructions
enclosed with thermostat for general installation
procedure. Color-coded, insulated wires should be
used to connect the thermostat to the unit. Refer to
Table 6 for control wire sizing and maximum length.
Table 6: Control wire sizes
Wire size Maximum length (ft)1
20 AWG < 150
18 AWG 150 to 250
16 AWG 250 to 500
Note:
1. From the unit to the thermostat and back
to the unit.
INSTALLATION MANUAL ZQ SERIES 3 ton to 5 ton 60 Hertz R-410A20
Johnson Controls Ducted Systems