York Predator ZR series Installaton Manual Download Page 1

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R-410A
ZR SERIES W/SMART EQUIPMENT™

3 - 5 Ton

60 Hertz

5167540-YIM-H-0518

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Economizer Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 46

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . . . . 48

Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 49

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 49

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 50

Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 50

Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Control Board Navigation Components . . . . . . . . . . . . . . . . . . . . 55

Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

LIST OF TABLES

1 ZR037-061 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZR037-061 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 8

4 ZR037-061 Unit Physical Dimensions . . . . . . . . . . . . . . . . . . 11

5 ZR037-061 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 11

6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 27

12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 28

13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 29

14 Smart Equipment™ Economizer Board Details . . . . . . . . . . 33

15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

16 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38

17 ZR037-061 Side Duct Application . . . . . . . . . . . . . . . . . . . . . 40

18 ZR037-061 Bottom Duct Application. . . . . . . . . . . . . . . . . . . 41

19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 42

21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 42

22 Motor Sheave Datum Diameters. . . . . . . . . . . . . . . . . . . . . . 44

23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 45

24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 49

26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 51

27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 53

28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 56

30 Cable for FC Buses and SA Buses in Order of Preference . 61

31 Flash Codes for the Gas Heat Ignition Control Board . . . . . 62

32 ZR037 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

33 ZR049 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

34 ZR061 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

LIST OF FIGURES

1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Condenser Covering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Predator

Component Location (ZR037 Shown) . . . . . . . . . . 6

5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8 ZR037 Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 9

9 ZR049-061 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . 10

10 ZR037-061 Unit Bottom Duct Openings . . . . . . . . . . . . . . . . 12

11 ZR037-061 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . . 13

12 ZR037-061 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 13

13 ZR037-061 Unit Left/End Duct Opening . . . . . . . . . . . . . . . . 14

14 ZR037-061 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

15 ZR037-061 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . . 15

16 Side Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

17 Return Panel In Place For Side Duct Conversion . . . . . . . . 16

18 Supply Panel In Place For Side Duct Conversion . . . . . . . . 16

19 Save Side Panels For Economizer Hood Tops . . . . . . . . . . 16

20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

22 Typical Low Voltage Field Wiring . . . . . . . . . . . . . . . . . . . . . 19

23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 33

26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

27 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38

28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

29 Reheat Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48

30 Cooling Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48

31 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

32 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . . 55

33 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . 55

34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Summary of Contents for Predator ZR series

Page 1: ...037 061 Bottom Duct Application 41 19 RPM Selection 42 20 Indoor Blower Specifications 42 21 Power Exhaust Specifications 42 22 Motor Sheave Datum Diameters 44 23 Additional Static Resistance 45 24 Electric Heat Limit Setting 49 25 Electric Heat Anticipator Setpoints 49 26 Gas Heat Anticipator Setpoints 51 27 Gas Rate Cubic Feet Per Hour 53 28 Gas Heat Stages 54 29 Smart Equipment UCB Details 56 3...

Page 2: ...est 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 o...

Page 3: ...ly 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 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 it...

Page 4: ...d Filters Merv 8 3 4 Pleated Filters Merv 13 4 Coil Guard CG STD Filter 5 2 Pleated Filter CG 6 4 Pleated Filter CG A Std Cabinet E SSD SST Drain Pan R Reverse Drain Pan A No Economizer B Economizer w Barometric RLF D Economizer w Power EXH H Motorized Damper Outdoor Air Option 1 No Service Options 2 DSC Disconnect Switch 3 NCO Non PWR Conv Outlet 4 PCO Powered Conv Outlet 5 DSC NCO 6 DSC PCO A No...

Page 5: ... Bracket 2 Turn each bracket toward the ground and the protective plywood covering will drop to the ground 3 Remove the condenser coil external protective covering prior to operation 4 Remove the toolless doorknobs and instruction packet prior to installation Figure 2 Condenser Covering Figure 3 Compressor Section 5 If a factory option convenience outlet is installed the weatherproof outlet cover ...

Page 6: ...rate 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 call the applications department for Ducted Systems 1 877 874 SERV for guidance Additional accessories may be needed for stable operation...

Page 7: ...g 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 MINI...

Page 8: ...ght lbs Center of Gravity 4 Point Load Location lbs 6 Point Load Location lbs Shipping Operating X Y A B C D A B C D E F 037 3 ZR 887 867 40 3 25 5 205 170 223 269 141 124 110 144 163 185 049 4 ZR 900 880 40 9 25 1 202 172 232 273 139 124 112 151 168 187 061 5 ZR 887 867 41 25 198 169 230 269 136 122 110 150 166 184 Table 3 ZR037 061 Unit Accessory Weights Unit Accessory Weight lbs Shipping Operat...

Page 9: ... Johnson Controls Ducted Systems 9 Figure 8 ZR037 Physical Dimensions Ø 25 31 59 00 15 51 29 75 59 LEFT 11 3 8 21 3 16 89 27 5 16 4 3 16 FRONT See detail A for gas inlet A See detail B for drain location B C D E F 29 52 ...

Page 10: ...n Controls Ducted Systems Figure 9 ZR049 061 Physical Dimensions Ø 24 47 TYP 2 PL 15 38 15 38 59 00 15 25 29 69 59 LEFT 11 3 8 21 3 16 89 27 5 16 4 3 16 FRONT See detail A for gas inlet A See detail B for drain location B C D E F ...

Page 11: ...16 15 3 16 6 3 16 42 CABINET Ø 3 126 Ø 2 000 3 184 4 727 7 705 14 594 Gas Pipe Inlet Gas Exhaust Vent 5 3 8 3 4 FPT Table 5 ZR037 061 Unit Clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser air discharge outlet 72 Right 12 Front 36 Left 36 Rear 36 Bottom2 2 Units may be installed on combustabl...

Page 12: ...t Bottom Duct Openings Bottom condensate drain Bottom gas supply entry FRONT RETURN AIR SUPPLY AIR RIGHT LEFT 20 1 8 19 1 8 17 1 8 6 13 16 6 13 16 32 11 16 14 1 2 16 3 8 18 1 16 25 9 16 12 5 16 27 1 2 24 21 18 89 Ø 2 469 3X Ø 0 875 Bottom power control and convenience outlet wiring entry ...

Page 13: ...er Power Entry Ø 2 1 2 Control Entry Ø 7 8 Power Entry Ø 2 1 2 Convenience Outlet Cover Convenience Outlet Power Entry Ø 7 8 FRONT Dot Plugs 5 5 32 31 11 16 2 31 32 18 1 4 Return Air Supply Air A B C D Table 6 Side Duct Dimensions Unit Model Number Dimension in A B C D ZR037 27 3 4 12 1 16 27 1 2 16 ZR049 27 3 4 12 1 16 27 1 2 16 ZR061 27 3 4 12 1 16 27 1 2 16 ...

Page 14: ...61 Roof Curb Table 7 Left End Duct Dimensions Unit Model Number Dimension in A B C ZR037 30 357 13 365 22 516 ZR049 30 357 13 365 22 516 ZR061 30 357 13 365 22 516 4 5 16 A C B 8 or 14 50 1 2 30 20 20 80 5 8 6 2 TYP INSULATED DECK UNDER COMPRESSOR SECTION INSULATED DECK UNDER CONDENSER SECTION FRONT RIGHT SUPPLY RETURN ...

Page 15: ... bottom duct application no duct cover changes are necessary 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 panel is installed with the painted surface UP facing the heat exchanger ...

Page 16: ...bing must conform to local codes Use a sealing compound on male pipe threads Install condensate drain line from the 1 inch NPT female connection on the unit to an open drain Figure 20 Condensate Drain Compressors The compressor used in this product is specifically designed to operate with R 410A Refrigerant and cannot be interchanged The compressor also uses a refrigerant oil that is extremely hyg...

Page 17: ...ired 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 utilized for these units Factory installed disconnects are available NOTE Since not all local codes allow the mounting of a disconnect on the unit please confirm compliance with local code before mounti...

Page 18: ...the unit nameplate Refer to Electrical Data Table 9 to size power wiring fuses and disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the curb Figure 21 Field Wiring Disconnect THREE PHASE POWER SUPPLY FACTORY OR FIELD SUPPLIED DISCONNECT GROUND LUG TERMINAL BLOCK TB1 ...

Page 19: ...Size Maximum Length1 1 From the unit to the thermostat and back to the unit 18 AWG 150 Feet OCC C RC G Y2 Y1 W2 W1 X R THERMOSTAT TERMINALS CONTROL TERMINAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 4 Second stage ŚĞĂƟŶŐ Ŷot required on single stage heĂƟŶg units Jumper is required for any coŵďŝŶĂƟŽŶ of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied ĐŽ...

Page 20: ... 2 41 6 58 5 65 4 60 70 230 11 9 88 0 18 5 2 1 5 2 5 5 0 0 None 24 3 29 8 35 40 E06 6 0 1 14 4 24 5 31 4 35 40 E09 9 0 1 21 7 33 6 40 4 35 45 E15 15 0 2 36 1 51 6 58 5 60 60 E20 20 0 2 48 1 66 6 73 5 70 80 460 5 2 44 0 8 1 1 3 2 6 2 2 0 0 None 11 6 13 8 15 15 E06 6 0 1 7 2 12 3 15 0 15 15 E09 9 0 1 10 8 16 8 19 5 20 20 E15 15 0 2 18 0 25 8 28 6 30 30 E20 20 0 2 24 1 33 3 36 1 35 40 575 4 8 36 0 7 ...

Page 21: ... 8 1 18 9 30 1 37 0 35 40 E15 11 3 2 31 4 45 7 52 6 50 60 E20 15 0 2 41 6 58 5 65 4 60 70 230 11 9 88 0 18 5 2 1 5 2 5 5 0 0 None 24 3 29 8 35 40 E06 6 0 1 14 4 24 5 31 4 35 40 E09 9 0 1 21 7 33 6 40 4 35 45 E15 15 0 2 36 1 51 6 58 5 60 60 E20 20 0 2 48 1 66 6 73 5 70 80 460 5 2 44 0 8 1 1 3 2 6 2 2 0 0 None 11 6 13 8 15 15 E06 6 0 1 7 2 12 3 15 0 15 15 E09 9 0 1 10 8 16 8 19 5 20 20 E15 15 0 2 18...

Page 22: ... 1 18 9 42 6 49 5 45 50 E15 11 3 2 31 4 58 2 65 1 60 70 E20 15 0 2 41 6 71 0 77 9 80 80 230 11 9 88 0 18 5 2 1 5 2 5 5 10 0 None 34 3 39 8 45 50 E06 6 0 1 14 4 37 0 43 9 45 50 E09 9 0 1 21 7 46 1 52 9 50 60 E15 15 0 2 36 1 64 1 71 0 70 80 E20 20 0 2 48 1 79 1 86 0 80 90 460 5 2 44 0 8 1 1 3 2 6 2 2 5 0 None 16 6 18 8 20 20 E06 6 0 1 7 2 18 5 21 3 20 25 E09 9 0 1 10 8 23 0 25 8 25 30 E15 15 0 2 18 ...

Page 23: ... 1 18 9 42 6 49 5 45 50 E15 11 3 2 31 4 58 2 65 1 60 70 E20 15 0 2 41 6 71 0 77 9 80 80 230 11 9 88 0 18 5 2 1 5 2 5 5 10 0 None 34 3 39 8 45 50 E06 6 0 1 14 4 37 0 43 9 45 50 E09 9 0 1 21 7 46 1 52 9 50 60 E15 15 0 2 36 1 64 1 71 0 70 80 E20 20 0 2 48 1 79 1 86 0 80 90 460 5 2 44 0 8 1 1 3 2 6 2 2 5 0 None 16 6 18 8 20 20 E06 6 0 1 7 2 18 5 21 3 20 25 E09 9 0 1 10 8 23 0 25 8 25 30 E15 15 0 2 18 ...

Page 24: ...8 No stages 1 1 1 1 1 1 1 1 1 Temperature Rise Range ºF 20 50 F 25 65 F 50 80 F 20 50 F 25 65 F 50 80 F 25 65 F 35 65 F 45 75 F Gas Limit Setting ºF 235 200 255 235 200 255 200 245 240 Gas piping connection in 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 DIMENSIONS inches Length 89 89 89 Width 59 59 59 Height 42 42 42 OPERATING WT lbs 867 880 867 COMPRESSORS1 Type Recip Recip Recip Quantity 1 1 1 Unit Capa...

Page 25: ...ype Centrifugal Centrifugal Centrifugal Motor Sheave 1VP34 1VL44 1VP34 1VL44 1VP34 1VL44 Blower Sheave AK61 AK59 AK61 AK59 AK61 AK59 Belt A47 A47 A47 A47 A47 A47 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 RPM 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56 56 56 FILTERS Quantity Size 4 24 x 16 x 2 2 3 4 24 x 16 x 2 2 3 4 24 x 16 x 2 2 3 4 24 x 16 x 4 4 4 24 x 16 x 4 4 4 24 x 16 x 4 4 1 ZR0...

Page 26: ... 22 21 22 22 22 22 22 Temperature Rise Range ºF 20 50 F 25 65 F 50 80 F 20 50 F 25 65 F 50 80 F 25 65 F 35 65 F 45 75 F Gas Limit Setting ºF 235 200 255 235 200 255 200 245 240 Gas piping connection in 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 DIMENSIONS inches Length 89 89 89 Width 59 59 59 Height 42 42 42 OPERATING WT lbs 867 880 867 COMPRESSORS3 Type Recip Recip Recip Quantity 1 1 1 Unit Capacity Ste...

Page 27: ...e Centrifugal Centrifugal Centrifugal Motor Sheave 1VP34 1VL44 1VP34 1VL44 1VP34 1VL44 Blower Sheave AK61 AK59 AK61 AK59 AK61 AK59 Belt A47 A47 A47 A47 A47 A47 Motor HP each 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 2 RPM 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56 56 56 FILTERS Quantity Size 4 24 x 16 x 2 4 5 4 24 x 16 x 2 4 5 4 24 x 16 x 2 4 5 4 24 x 16 x 4 6 4 24 x 16 x 4 6 4 24 x 16 x 4 6 1 1st S...

Page 28: ...with the local gas utility Figure 23 Side Entry Gas Piping NOTE Routing of gas piping must not interfere with the flue or heat compartment access Figure 24 Bottom Entry Gas Piping NOTE Maximum capacity of pipe in cubic feet of gas per hour based upon a pressure drop of 0 3 inch W C and 0 6 specific gravity gas NOTE There may be a local gas utility requirement specifying a minimum diameter for gas ...

Page 29: ...del numbers 1NP0454 or 1NP0455 All LP gas equipment must conform to the safety standards of the National Fire Protection Association Table 13 Gas Heat Minimum Supply Air Size Tons Model Heat Size Supply Air CFM Heating Min Max 037 3 ZR H06 N06 890 2220 H08 N08 915 2370 H12 N12 1130 1800 049 4 ZR H06 N06 890 2220 H08 N08 915 2370 H12 N12 1290 2250 061 5 ZR H08 N08 915 2370 H12 N12 1380 2570 H16 N16...

Page 30: ...at least once a year For specific troubleshooting and maintenance procedures please refer to the smoke detector s installation instructions which accompanies the unit Motorized Outdoor Damper The Motorized Outdoor Damper can be a factory installed option or a field installed accessory If factory installed refer to the instructions included with the outdoor air hood to complete the assembly Field i...

Page 31: ...ly fan system both set points should be set to the same value Free Cooling Four types of free cooling options are available dry bulb changeover single enthalpy dual enthalpy changeover and Auto Dry Bulb Changeover For dry bulb economizer operation the outside air is suitable for free cooling if the outside air temperature is 1 F below the Economizer OAT Enable Setpoint and 1 F below the Return Air...

Page 32: ...ne stage of cooling If the economizer output goes to minimum position and the SAT is less than Economizer Setpoint 1 F the control starts a 12 minute timer to de energize a compressor output If at any time the economizer output goes above the minimum position the timer stops and resets when the economizer output returns to minimum position If the demand for cooling from the space return is satisfi...

Page 33: ...ermistor MAT parameter reports input status F C 3 65 VDC reading MAT to COM with open circuit Read only use in current control revision IN1 MAT LEDs at left on upper edge of economizer board POWER POWER Green UCB power indicator Lit indicates 24 VAC is present at 24V IN COM and HOT pins FAULT FAULT Red networking error and firmware error indicator 1 10th second on off flashing indicates a networki...

Page 34: ... power exhaust actuator and economizer actuator Connects through circuit trace to 24V IN pin HOT ECON 2 10 VDC output for the Economizer actuator Econ parameter reports output status 0 100 Used to position the economizer actuator for minimum position free cooling demand ventilation cooling economizer loading and purge functions COM 24 VAC common 0 10 VDC negative for economizer actuator Connects t...

Page 35: ...negative for the indoor air quality sensor Connects through circuit trace to 24V IN pin COM R 24V 24 VAC hot supplied for the outdoor air quality sensor Connects through circuit trace to 24V IN pin HOT IN6 OAQ 0 10 VDC positive input from the Outdoor Air Quality sensor OAQRange parameter sets the CO2 parts per million measured by the outdoor air quality sensor when it outputs 10 VDC OAQ parameter ...

Page 36: ... field supplied disconnect to obtain proper rotation Blower Rotation Check for proper supply air blower rotation If the blower is rotating backwards the line voltage at the unit point of power connection is misphased See PHASING Belt Tension The tension on the belt should be adjusted as shown in Figure 26 Figure 26 Belt Adjustment C COM 24 VAC common 0 5 VDC negative for the building pressure sens...

Page 37: ...ce the air at high altitude is less dense less static pressure will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Table 16 and Figure 27 Procedure for adjusting belt tension 1 Loosen six nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one...

Page 38: ...iven is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 0 6 832 0 72 Enter the blower table at 1 400 sCFM and static pressure of 0 72 The rpm listed will be the same rpm needed at 5 000 ft Suppose that the corresponding BHP listed in the table is 0 7 This value must be corrected for elevation BHP at 5 000 ft...

Page 39: ...or and drive 5 turns open will achieve 1230 RPM Example Supply Air Blower Performance Air Flow CFM Available External Static Pressure IWG 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1 5 HP Field Supplied Drive Standard 1 5 HP Drive Hi Static 2 HP Drive 2100 759 0 65 819 0 77 881 0 87 943 0 98 1005 1 08 1065 1 18 1121 1 28 ...

Page 40: ...27 0 5 719 0 6 801 0 6 876 0 7 943 0 8 1005 0 9 1063 1 0 1117 1 1 1169 1 2 1400 537 0 5 639 0 5 731 0 6 813 0 7 888 0 7 955 0 8 1017 0 9 1075 1 0 1129 1 1 1181 1 2 1500 549 0 5 650 0 6 742 0 6 824 0 7 899 0 8 966 0 9 1028 0 9 1086 1 0 1140 1 1 1192 1 2 1600 558 0 6 660 0 6 752 0 7 834 0 8 909 0 8 976 0 9 1038 1 0 1096 1 1 1150 1 2 1202 1 3 1700 566 0 6 668 0 7 760 0 7 842 0 8 917 0 9 984 1 0 1046 ...

Page 41: ... 0 8 942 0 8 994 0 9 1046 1 0 1100 1 2 1157 1 3 1400 617 0 5 705 0 6 781 0 6 847 0 7 907 0 8 962 0 9 1014 1 0 1066 1 1 1119 1 2 1177 1 3 1500 637 0 6 724 0 6 800 0 7 867 0 8 927 0 8 981 0 9 1034 1 0 1085 1 1 1139 1 2 1196 1 4 1600 655 0 6 743 0 7 819 0 7 885 0 8 945 0 9 1000 1 0 1052 1 1 1104 1 2 1158 1 3 1215 1 4 1700 672 0 7 760 0 7 836 0 8 902 0 9 962 1 0 1017 1 0 1069 1 1 1121 1 2 1175 1 3 123...

Page 42: ... Size Tons Model Airflow Option HP Max BHP Motor Sheave Blower Sheave 6 Turns Open 5 Turns Open 4 Turns Open 3 Turns Open 2 Turns Open 1 Turn Open Fully Closed 037 3 0 ZR Std 1 5 1 5 1VP34 AK61 N A 575 636 696 757 817 878 H Static 1 5 1 5 1VL44 AK59 N A 878 941 1004 1066 1129 1192 049 4 0 ZR Std 1 5 1 5 1VP34 AK61 N A 575 636 696 757 817 878 H Static 1 5 1 5 1VL44 AK59 N A 878 941 1004 1066 1129 1...

Page 43: ...le motor sheave is open 5 Select the correct blower performance table for the unit from Tables 16 and 18 Tables are presented for side and downflow configuration 6 Determine the unit Measured CFM from the Blower Performance Table External Static Pressure and the number of turns the variable motor sheave is open 7 To adjust Measured CFM to Required CFM see SUPPLY AIR DRIVE ADJUSTMENT 8 After readin...

Page 44: ...allation errors leaks or undesirable systems effects that can result in loss of airflow Even small changes in blower speed can result in substantial changes in static pressure and BHP BHP and AMP draw of the blower motor will increase by the cube of the blower speed Static pressure will increase by the square of the blower speed Only qualified personnel should make blower speed changes strictly ad...

Page 45: ...02 0 03 0 01 0 01 0 01 0 02 0 02 0 02 1200 0 04 0 00 0 04 0 01 0 01 0 01 0 02 0 02 0 02 1300 0 03 0 01 0 05 0 01 0 01 0 01 0 03 0 03 0 03 1400 0 03 0 03 0 07 0 02 0 02 0 02 0 03 0 03 0 03 1500 0 03 0 04 0 08 0 02 0 02 0 02 0 04 0 04 0 04 049 4 061 5 ZR 1200 0 01 0 10 0 05 0 01 0 01 0 01 0 02 0 02 0 02 1300 0 01 0 11 0 06 0 01 0 01 0 01 0 03 0 03 0 03 1400 0 01 0 12 0 06 0 02 0 02 0 02 0 03 0 03 0 ...

Page 46: ...e economizer The dampers will modulate to maintain a constant supply air temperature as monitored by the discharge air sensor If the outdoor air enthalpy is above the setpoint Y1 energizes the compressor and condenser fan motor only When there is a call for Y2 the low voltage control circut from R to Y2 is completed The UCB energizes the compressor If the outdoor air is below the set point fo the ...

Page 47: ...s calling for cooling the UCB will operate in the low ambient mode Low ambient mode operates the compressors in this manner 10 minutes on 5 minutes off The indoor blower is operated throughout the cycle The 5 minute off period is necessary to defrost the indoor coil Low ambient mode always begins with compressor operation Compressor minimum run time may extend the minutes of compressor operation T...

Page 48: ...he unit continues to operate with refrigerant flow in the reheat coil and condenser coil 1 See Figure 29 Indoor blower operation is initiated upon a call for first stage cooling second stage cooling or dehumidification Anytime there is a call for a second stage of cooling the unit will not operate in the reheat mode even if there is still a call for dehumidification The unit will not operate in th...

Page 49: ...s The control circuit includes the following safety controls Limit Switch LS This control is located inside the heater compartment and is set to open at the temperature indicated in the Electric Heat Limit Setting Table 24 It resets automatically The limit switches operate when a high temperature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the...

Page 50: ... attempts the furnace is locked out for one hour The furnace is monitored during this one hour period for unsafe conditions Recycle Operation When a flame is lost after the flame stabilization period a recy cle operation occurs If the unit fails after five recycle attempts the furnace is locked out for one hour Gas Heating Operation Errors Lock Out A one hour lockout occurs following three retries...

Page 51: ... 2 seconds the GV will be de energized the ignition cycle is aborted and the ICB flashes the appropriate code See Table 31 Ignition Control Flash Codes The draft motor is energized until the pressure switch closes or W1 is lost Roll out Switch ROS The roll out switch is wired in series with the pressure switch As such the ICB cannot distinguish the roll out switch operation from that of the pressu...

Page 52: ...ck for correct manifold gas pressures See CHECKING GAS INPUT 3 Check the supply gas pressure It must be within the limits shown on the rating nameplate Supply pressure should be checked with all gas appliances in the building at full fire At no time should the standby gas pressure exceed 10 5 in or the operating pressure drop below 4 5 in for natural gas units If gas pressure is outside these limi...

Page 53: ... a 1 cubic foot test dial 5 Using the number of seconds it takes for one revolution of the dial calculate the cubic feet of gas consumed per hour See example below 6 If necessary adjust the low pressure regulator as discussed in the section Manifold Gas Pressure Adjustment Be sure not to under fire the furnace on first stage If in doubt it is better to leave the first stage of the furnace slightly...

Page 54: ...unit on first stage 9 Once pressure has been checked replace the plastic cap covering the HI and LO pressure adjustment screws NOTE When using natural gas the manifold pressure for second stage 100 input should be 3 5 IWG 0 3 The manifold pressure for first stage 70 or 75 input when using natural gas should be 1 5 IWG 0 3 Adjustment Of Temperature Rise The temperature rise the difference of temper...

Page 55: ...Source 1 P N S1 JC MAP1810 OP 3 MAP Gateway Quick Start Guide P N 24 10737 16 4 MAP Gateway Instruction P N 24 10737 8 For more information on the Smart Equipment unit control board navigation refer to the Smart Equipment Quick Start Guide NOTE For more in depth sequence of operation of the Smart Equipment control refer to the Smart Equipment Controls Sequence of Operation Overview LIT 12011950 HE...

Page 56: ...B microprocessor connects through circuit trace to the SD 24 terminal SD 24 24 VAC hot out for factory accessory smoke detector condensate overflow and or user shutdown relay switching in series Connects through circuit trace to thermostat connection strip SD 24 A wiring harness jumper plug connecting SD 24 to SD R is in place if factory accessories for unit shutdown are not used this jumper plug ...

Page 57: ...indicates 24 VAC is present at C and 24V terminals FAULT Red hard lockout networking error and firmware error indicator 1 2 second on off flashing indicates one or more alarm is currently active 1 10th second on off flashing indicates a networking error polarity addressing etc or a firmware error likely correctable with re loading from USB flash drive SA BUS Green UCB SA bus communication transmis...

Page 58: ...5 VDC reading EC2 to EC2 with open circuit Used in suction line temperature safety Pinned connections on right edge of UCB RAH Return Air Humidity input from 0 10 VDC 0 100 RH sensor Input required for reheat units optional in all other units may be a communicated value Used in return air enthalpy calculation temperature humidity setpoint reset reheat operation DCT PRS Supply Duct Pressure input f...

Page 59: ...put for indoor blower contactor coil indoor blower VFD enable relay coil Output with heat cool operation G input or schedule demand C1 24 VAC hot output for compressor 1 If demand is present and permissions allow compressor 1 operation output with compressor cooling comfort ventilation cooling reheat or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage com...

Page 60: ...ter of the board Positive of the 15 VDC reading to C circuit for powering an optional netstat and or Multi Touch gateway C Common for SA BUS power and communication circuits Also incorporated in the J8 6 pin phone jack connector at the left center of the board Negative of the SA BUS circuits Communication for SA BUS devices Also incorporated in the J8 6 pin phone jack connector at the left center ...

Page 61: ...t indicates the UCB is supplying power to the communication sub board 1 When wiring unit and other devices using the SA Bus and FC Bus see Table 30 Table 29 Smart Equipment UCB Details Continued Description Function Comments Table 30 Cable for FC Buses and SA Buses in Order of Preference Bus and Cable Type Non Plenum Applications Plenum Applications Part Number O D Part Number O D FC Bus 22 AWG St...

Page 62: ... incline manometer digital manometer or Magnehelic gauge teed into the pressure switch sensing line verify that the negative pressure exceeds the setting listed on the induced draft pressure switch label and the switch s contacts correctly close at the setting listed 4 Flashes Open Limit 24v AC has been lost to the control s L terminal Verify proper gas manifold pressure Correct the inadequate ind...

Page 63: ... 16 6 7 95 171 71 383 102 14 7 3 400 Cfm Ton 75 63 75 138 62 288 82 21 6 3 85 141 62 321 90 20 6 7 95 144 61 372 98 18 7 2 Table 33 ZR049 Charging Table Air Flow Indoor Db Wb Outdoor DB Suction Pressure Suction Temp Liquid Pressure Liquid Temp DeltaT Db Compr amps 300 Cfm Ton 80 62 75 135 69 312 77 26 9 4 85 139 66 299 87 25 10 1 95 143 64 342 96 24 10 8 300 Cfm Ton 80 67 75 151 77 314 76 19 9 4 8...

Page 64: ... 102 22 11 4 300 Cfm Ton 80 72 75 151 72 278 84 20 9 6 85 156 71 309 93 19 10 3 95 162 69 354 102 18 11 5 300 Cfm Ton 75 63 75 131 58 279 87 24 9 8 85 135 58 300 92 22 10 1 95 140 56 347 100 21 11 2 400 Cfm Ton 80 62 75 136 64 279 87 26 9 7 85 141 65 303 93 25 10 3 95 145 62 348 102 24 11 3 400 Cfm Ton 80 67 75 147 68 279 86 22 9 6 85 151 68 307 93 21 10 3 95 156 65 351 102 19 11 4 400 Cfm Ton 80 ...

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