York ZF 180 Series Installation Manual Download Page 58 | Manualshive

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Subject to change without notice. Printed in U.S.A.

5168276-XIM-B-0216

Copyright

©

2016 by Johnson Controls, Inc. All rights reserved.

Supersedes: 5168276-XIM-A-1115

York International Corporation

5005 York Drive

Norman, OK 73069

OPERATIONAL MEASUREMENTS - STAGING CONTROLS

FINAL - INSPECTION

OBSERVED PRODUCT DIFFICIENCIES & CONCERNS:

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Verify Proper Operation of Heating/Cooling Staging Controls

Create a cooling demand at the Thermostat, BAS System or Simplicity SE
Verify that cooling/economizer stages are energized.

Create a heating demand at the Thermostat, BAS System or Simplicity SE
Verify that heating stages are energized.

Verify Proper Operation of the Variable Frequency Drive (If Required)

Verify that motor speed modulates with duct pressure change.

Verify that all operational control set points have been set to desired value
Scroll through all setpoints and change as may be necessary to suit the occupant requirements.

Verify that all option parameters are correct
Scroll through all option parameters and ensure that all installed options are enabled in the software and all
others are disabled in the software. (Factory software settings should match the installed options)

Verify that all access panels have been closed and secured

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Summary of Contents for ZF 180 Series

Page 1: ...tion Factors Metric 28 18 Air Flow Performance Side Duct Application 31 19 Air Flow Performance Bottom Duct Application 33 20 RPM Selection 35 21 Indoor Blower Specifications 35 22 Power Exhaust Specifications 35 23 Additional Static Resistance Imperial 36 24 Additional Static Resistance Metric 36 25 Limit Control Setting 39 26 Electric Heat Anticipator Setpoint 40 27 Gas Heat Limit Control Settin...

Page 2: ...tions 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 Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alterat...

Page 3: ...e 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 ca...

Page 4: ...r J Motorized Damper w Baro RLF1 Outdoor Air Option 1 No Service Options 2 DSC Disconnect Switch Refrigeration A Standard Refrigeration B ECC E Coat Cond Coil C EEC E Coat Evap Coil F ECC EEC Service Options A Stand Alone Simplicity SE C BACnet MSTP Mdbs N2 COM Card D CPC Control DFS APS F Fault Detection Diagnostics G Novar UCM Ctrl DFS APS H Hnywll Excel 10 CTRL DFS APS J CCS Single Zone K CCS C...

Page 5: ...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 ...

Page 6: ... COPPER TUBE ALUMINUM FIN CONDENSER COILS ELECTRICAL DISCONNECT MOUNTING LOCATION Field installed KNOCKOUT FOR SIDE CONTROL WIRING ENTRY KNOCKOUT FOR SIDE POWER WIRING ENTRY SIDE KNOCKOUTS FOR SIDE GAS SUPPLY ENTRY HOLE FOR BOTTOM GAS SUPPLY ENTRY POWER VENTOR MOTOR WITH POST PURGE CYCLE BELT DRIVE BLOWER MOTOR FULL PERIMETER 14 GAUGE BASE RAILS WITH LIFTING HOLES 1 NPTI CONDENSATE DRAIN 2 DISPOSA...

Page 7: ...er 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 fork...

Page 8: ... 764 1689 1161 178 202 204 180 116 126 137 139 128 118 240 20 ZF 1093 1091 1778 1118 254 268 292 277 168 174 180 197 189 183 Table 4 ZF180 240 Unit Accessory Weights Metric Unit Accessory Weight kg Shipping Operating Economizer 74 8 72 6 Power Exhaust 40 8 40 8 Gas Heat1 1 Weight given is for the maximum number of tube heat exchangers available 8 tube 108 9 108 9 Motorized Damper 68 68 Barometric ...

Page 9: ... 240 616 24 1 4 180 895 35 1 4 240 1235 48 5 8 180 1337 52 5 8 240 3181 125 1 4 180 3461 136 1 4 240 616 24 1 4 180 895 35 1 4 240 RETURN AIR OUTDOOR AIR Economizer SUPPLY AIR OUTDOOR AIR Discharge 5168276 XIM B 0216 Johnson Controls Unitary Products 9 Figure 6 Unit Dimensions ZF Gas Heat Figure 5 Unit Dimensions ZF Cooling Only ...

Page 10: ... accessory flange kit panels 2 Connect ductwork to the flanges on those panels Table 6 Utilities Entry Data HOLE OPENING SIZE DIA MM IN USED FOR A 29 1 1 8 KO Control Wiring Side 19 3 4 NPS Fem Bottom B 92 3 5 8 KO Power Wiring Side 76 3 NPS Fem Bottom C 60 2 3 8 KO Gas Piping Front 1 D 43 1 11 16 Hole Gas Piping Bottom 1 2 1 One inch gas piping NPT required 2 Opening in the bottom of the unit can...

Page 11: ...on Distance mm in Direction Distance mm in Top1 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser air discharge outlet 1829 72 With 914 36 Maximum Horizontal Overhang For Condenser Air Discharge Right 914 36 Front 914 36 Bottom2 2 Units may be installed on combustable floors made from wood or class A B or C roof covering materials 0 Rear 610 24 W O Ec...

Page 12: ...h the dimensions of the duct connections on the unit Refer to Figure 5 for bottom air duct openings Refer to Figure 7 for side air duct openings NOTE It is recommended that in Canada the outlet duct be provided with a removable access panel It is recommended that this opening be accessible when the unit is installed in service and of a size such that smoke or reflected light may be observed inside...

Page 13: ... an opening 16 inches high by 18 inches wide in the ductwork to accommodate the damper Using the holes in the hood flanges as a template drill 9 64 inch diameter 26 drill holes into the ductwork and secure with the screws provided Figure 12 Fixed Outdoor Air Damper Condensate Drain Plumbing must conform to local codes Use a sealing compound on male pipe threads Install a condensate drain line from...

Page 14: ...agram and the same minimum gauge as the replaced wire A disconnect must be utilized for these units Factory installed disconnects are available If installing a disconnect field supplied or York International supplied accessory refer to Figure 1 for the recommended mounting location NOTE Since not all local codes allow the mounting of a disconnect on the unit please confirm compliance with local co...

Page 15: ...ded insulated wires should be used to connect the thermostat to the unit Refer to Table 8 for control wire sizing and maximum length Space Sensor The space sensor if used should be located on an inside wall approximately 56 inches above the floor where it will not be subject to drafts sun exposure or heat from electrical fixtures or appliances Follow manufacturer s instructions enclosed with senso...

Page 16: ...ot required on single stage heĂƟŶg units Jumper is required if there is no Smoke Detector circuit Jumper is required for any coŵďŝŶĂƟŽŶ of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupied ĐŽŶĚŝƟon X is an input to the thermostat to display Error Status condiƟons 3 W2 Y1 G OCC Y2 X R SD 24 C W1 2 24V C 24 VAC Class 2 SD 24 Jumper Located on Harness Smoke Detector SD R 24...

Page 17: ...CA1 Amps 1 Minimum Circuit Ampacity Max Fuse2 Breaker3 Size Amps 2 Dual Element Time Delay Type 3 HACR type per NEC RLA LRA MCC C1 C2 C1 C2 C1 C2 FLA FLA FLA Model kW Stages Amps 180 15 380 3 50 16 7 13 111 101 26 20 3 2 1 6 3 0 NONE 44 4 60 415 3 50 16 7 13 111 101 26 20 3 2 1 6 7 0 NONE 44 8 60 240 20 380 3 50 18 6 17 9 118 118 29 28 2 1 8 2 0 NONE 53 6 70 415 3 50 18 6 17 9 118 118 29 28 2 1 9 ...

Page 18: ...at output K Btu 240 320 240 320 AFUE Steady state efficiency 80 80 80 80 No burners 6 8 6 8 No stages 2 2 2 2 Temperature Rise Range ºF 20 50 35 65 20 50 35 65 Gas Limit Setting ºF 195 195 195 195 Gas piping connection in 1 1 1 1 DIMENSIONS inches Length 125 1 4 136 1 4 Width 92 92 Height 48 5 8 52 5 8 OPERATING WT lbs 1680 2400 COMPRESSORS Type Scroll Scroll Quantity 2 2 Unit Capacity Steps 50 10...

Page 19: ...nch 15 X 15 18 X 15 Type Centrifugal Centrifugal Motor Sheave 1VP62 1VP75 Blower Sheave BK75 BK100 Belt BX68 BX75 Motor HP each 4 0 6 3 RPM 1450 1450 Frame size 184T 213T FILTERS Quantity Size 5 18 x 24 x 2 1 2 12 12 x 24 x 2 1 2 5 18 x 24 x 4 3 2 20 x 24 x 4 4 24 x 24 x 4 3 1 2 In Throwaway Standard MERV Minimum Efficiency Reporting Value 3 2 2 In Pleated Optional MERV 8 3 4 In Pleated Optional M...

Page 20: ...let location Typical supply piping arrangements are shown in Figures 16 and 17 All pipe nipples fittings and the gas cock are field supplied Gas piping recommendations 1 A drip leg and a ground joint union must be installed in the gas piping 2 Where required by local codes a manual shut off valve must be installed outside of the unit 3 Use wrought iron or steel pipe for all gas lines Pipe dope sho...

Page 21: ...E Natural gas may contain some propane Propane is an excellent solvent and will quickly dissolve white lead and most standard commercial compounds A special pipe dope must be used when assembling wrought iron or steel pipe Shellac based compounds such as Gaskolac or Stalastic and compounds such as Rectorseal 5 Clydes s or John Crane may be used FIRE OR EXPLOSION HAZARD Failure to follow the safety...

Page 22: ...s can drive the economizer including minimum position free cooling economizer loading and minimum outdoor air supply Economizer Minimum Position The economizer minimum position is set during occupied mode when outside air is not suitable for free cooling The position of the damper is set proportionally between the Economizer Minimum Position and the Economizer Minimum Position Low Speed Fan set po...

Page 23: ...onomizer output returns to 100 Once a compressor output is turned ON the economizer dampers continue to modulate to control the supply air temperature to the Economizer Setpoint At no time will a compressor output be turned ON if the economizer output is less than 100 even if the differential between zone or return temperature and the current cooling setpoint is great enough to demand more than on...

Page 24: ...nomizer actuator position feedback Connects through circuit trace to 24V IN pin HOT C COM Mixed Air Temperature sensor input from 10KΩ 77 F Type III negative temperature coefficient thermistor 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 pow...

Page 25: ...mper Used to ramp the power exhaust fan VFD position the discharge damper actuator COM 24 VAC common 0 10 VDC negative for the power exhaust variable frequency drive discharge damper modulating power exhaust actuator Connects through circuit trace to 24V IN pin COM 24V 24 VAC hot supplied for the discharge damper modulating power exhaust actuator and economizer actuator Connects through circuit tr...

Page 26: ... positive input from the Indoor Air Quality sensor IAQRange parameter sets the CO2 parts per million measured by the indoor air quality sensor when it outputs 10 VDC IAQ parameter reports input status 0 5000ppm Used for demand ventilation functions if the NetIAQ parameter indicates Unrel C COM 24 VAC common 0 10 VDC negative for the indoor air quality sensor Connects through circuit trace to 24V I...

Page 27: ... or Variable Frequency Fan C COM 24 VAC common 0 5 VDC negative for the building pressure sensor Connects through circuit trace to 24V IN pin COM BINARY INPUTS at right on lower edge of economizer board IN9 PURGE 24 VAC hot input from the PURGE dry contact Purge parameter reports input status False with 0 VAC input True with 24 VAC input When Purge status is True heating and cooling operation is p...

Page 28: ...flection force is as follows Tension new belts at the max deflection force recommended for the belt section Check the belt tension at least two times during the first 24 hours of operation Any retensioning should fall between the min and max deflection force values 5 After adjusting re tighten nuts A Table 16 Altitude Temperature Correction Factors Imperial Air Temp F Altitude Ft 0 1000 2000 3000 ...

Page 29: ...er 6 000 CFM if the rpm is unchanged However Table 16 must be used to determine the static pressure and BHP Since no temperature data is given we will assume an air temperature of 70 F Table 16 shows the correction factor to be 0 832 0 600 0 650 0 700 0 750 0 800 0 850 0 900 0 950 1 000 1 050 1 100 40 50 60 70 80 90 100 Air Temperature ºF Correction Factor Sea Level 1000 ft 2000 ft 3000 ft 4000 ft...

Page 30: ...appropriate drive if multiple drives are available for the chosen motor 8 Determine turns open to obtain the desired operation point Example 1 6800 CFM 2 2 0 iwg 3 Using the supply air blower performance table below the following data point was located 1020 RPM 5 92 BHP 4 Using the RPM selection table below Size X and Model Y is found 5 5 92 BHP exceeds the maximum continuous BHP rating of the 5 0...

Page 31: ...ters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP 3 kW BHP x 0 838 ZF180 15 Ton Side Duct Metric Air Flow M3 sec Available External Static Pressure Pa1 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See...

Page 32: ...117 8 79 9200 936 7 19 972 7 67 1009 8 12 1045 8 54 1080 8 93 9600 969 8 03 1005 8 50 1042 8 96 10000 1003 8 91 Field Supplied Motor Drive ZF240 20 Ton Side Duct Metric Air Flow M3 sec Available External Static Pressure Pa1 1 Blower performance includes gas heat exchangers and 2 filters See STATIC RESISTANCE table for additional applications 2 See RPM SELECTION table to determine desired motor she...

Page 33: ...8 4 70 1181 4 99 1236 5 24 1282 5 46 6400 965 4 09 1002 4 41 1038 4 68 1081 4 93 1153 5 25 1217 5 54 6800 1002 4 67 1039 4 99 1075 5 27 1117 5 51 7200 1040 5 28 1077 5 60 ZF180 15 Ton Bottom Duct Metric Air Flow M3 sec Available External Static Pressure Pa1 100 149 199 249 299 349 399 448 498 548 598 648 RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW High Stati...

Page 34: ...61 8 05 1096 8 41 1130 8 74 9200 987 7 60 1023 8 05 1059 8 47 1094 8 86 9600 1021 8 45 1057 8 90 10000 546 4 89 564 5 11 Field Supplied Motor Drive ZF240 20 Ton Bottom Duct Metric Air FlowM3 sec Available External Static Pressure Pa1 100 149 199 249 299 349 399 448 498 548 598 648 RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW RPM kW High Static 6 3 HP Field Supplied ...

Page 35: ...p across a dry coil the actual CFM through the unit can be determined from the curve in Pressure Drop vs Supply Air CFM Figure 23 After readings have been obtained remove the tubes and reinstall the two 5 16 dot plugs that were removed in Step 1 NOTE De energize the compressors before taking any test measurements to assure a dry indoor coil Table 20 RPM Selection Size Tons Model HP Max BHP Motor S...

Page 36: ...c resistance in the respective Blower Performance Tables Economizer2 3 2 Deduct these values from the available external static pressure shown in the respective Blower Performance Tables 3 The pressure drop through the economizer is greater for 100 outdoor air than for 100 return air If the resistance of the return air duct is less than 0 25 IWG the unit will deliver less CFM during full economize...

Page 37: ...ed Compressor 2 is energized provided it has not been locked out and condenser fan motor 1 and condenser fan motor 2 remain energized If the ambient temperature is above 60ºF To be available a compressor must not be locked out due to a high or low pressure switch or freezestat trip and the Anti Short Cycle Delay ASCD must have elapsed These units utilize a lead lag feature that results in an equal...

Page 38: ...mpressor is idle stop the condenser fans If the LPS is still open after the ASCD the compressor will not be energized for 30 seconds The second and third times that the UCB sees an open LPS will count towards the three occurrences that will cause a UCB lock out Once the low pressure switch has been proven closed during the 30 second monitor period described above the UCB will monitor the low press...

Page 39: ... MUST use a two stage thermostat a Upon a call for heat by the thermostat the heater contactor M6 will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor b The thermostat will cycle the electric heat to satisfy the heating requirements of the conditioned space Two stage heating applies to all heaters except 18 KW a Upon a call for first stag...

Page 40: ...s energized The RW2 1 contact is closed energizing the second stage ignition module IC2 IC2 will immediately start the second stage igniter sparking and will open the redundant valve located inside the second stage main gas valve GV2 to allow a flow of gas to the second stage carryover tube Only after the pilot flame has been ignited and the presence of pilot flame detected at IC2 by a signal sent...

Page 41: ...ch operates when a high temperature condition caused by inadequate supply air flow occurs thus shutting down the heater and energizing the blower Auxiliary Limit Switch AUX This control is located inside the heat exchanger compartment and is set to open at 190 F It is a manual reset switch If AUX trips then the primary limit has not functioned correctly Replace the primary limit NOTE Access to LS ...

Page 42: ...space Refer to Table 28 for the required gas heat anticipator setting Start Up Cooling Prestart Check List After installation has been completed 1 Check the electrical supply voltage being supplied Be sure that it is the same as listed on the unit nameplate 2 Set the room thermostat to the off position 3 Turn unit electrical power on 4 Set the room thermostat fan switch to on 5 Check indoor blower...

Page 43: ...e time needed for one revolution of the hand on the smallest dial on the meter A typical gas meter usually has a 1 2 or a 1 cubic foot test dial 3 Using the number of seconds for each revolution and the size of the test dial increment find the cubic feet of gas consumed per hour from the Gas Rate Cubic Feet Per Hour Table 29 If the actual input is not within 5 of the furnace rating with allowance ...

Page 44: ... Figure 28 Proper Pilot Flame Adjustment Pilot Checkout The pilot flame should envelope the end of the flame sensor To adjust pilot flame 1 remove pilot adjustment cover screw 2 increase or decrease the clearance for air to the desired level 3 be sure to replace cover screw after adjustment to prevent possible gas leakage Put the system into operation and observe through complete cycle to be sure ...

Page 45: ... is on the top Status line hit the ENTER button This action steps the LCD display into the status mode Hit ENTER to view the status menu Press Enter Step 2 7KH UVW LWHP XQGHU WKH status menu is DVent Mode This is the demand ventilation mode ENTER CANCEL JOY C PWR 7 7 77 DVent Mode OprST Press Enter Step 3 When the cursor is on the DVent Mode hit ENTER to view the status of this mode In this case a...

Page 46: ...ER CANCEL JOY C PWR 7 7 77 Clg Engaged LeadLag Engaged Press Enter Joy Stick Down 2 Step 6 By toggling down twice the screen reaches the ClgOcc SP screen or Cooling Occupied Set Point ENTER CANCEL JOY C PWR 7 7 77 LeadLag Engaged ClgOcc SP Press Enter T Step 8 In order to change set points push the toggle switch left or right Note The screen ÀDVKHV HIW GHFUHDVHV WKH YDOXH ULJKW increases In this d...

Page 47: ...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 48: ...t 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 transm...

Page 49: ...ermistor Input required for operation of 2 compressor units not active for 1 compressor units 3 625 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 cal...

Page 50: ...s reheat components Effective only for reheat units output with reheat operation FAN 24 VAC hot output 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...

Page 51: ...A Sensor Actuator BUS devices Also incorporated in the J8 6 pin phone jack connector at the left center 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 Communi...

Page 52: ...unication circuit Negative of the VDC FC bus BACnet MSTP communication circuit SHLD Shield for the FC Field Connected BUS BACnet MSTP communication circuit Earth ground reference of the cable to prevent interference on the FC bus BACnet MSTP communication circuit Item Selector in red housing at left on top edge of the communication board EOL switch End Of Line selector switch for the FC BUS BACnet...

Page 53: ...ade at initial start up This confidence is supported by the 30 day dealer protection coverage portion of our standard warranty policy which states that Johnson Controls UPG will cover parts and labor on new equipment start up failures that are caused by a defect in factory workmanship or material for a period of 30 days from installation Refer to current standard warranty policy and warranty manua...

Page 54: ...ull open position and the frequency drive is operating at 60 HZ Do not proceed with the equipment start up without the design CFM information Design Supply Air CFM __________________________ Design Return Air CFM ______________________________________ Design Outdoor Air CFM At Minimum Position ________________________________________________________ Total External Static Pressure _________________...

Page 55: ... and control complete Air Moving Inspection Completed See Notes Alignment of drive components Belt tension adjusted properly Blower pulleys tight on shaft bearing set screws tight wheel tight to shaft Pressure switch or transducer tubing installed properly Exhaust Inspection Powered Barometric Relief Completed See Notes Check hub for tightness Check fan blade for clearance Check for proper rotatio...

Page 56: ...y to increase of decrease the airflow to meet the design conditions If the motor pulley size was changed measure the outside diameters of the motor and blower pulleys and record those diameters here Blower Motor HP _______________________________ FLA________ RPM________ Pulley Pitch Diameter ______________Turns Out________ Final Turns Out________ Blower Pulley Pitch Diameter ________________ Fixed...

Page 57: ... Return Air Temperature ________________ F db ________________ F wb ________________ RH Mixed Air Temperature ________________ F db ________________ F wb ________________ RH Supply Air Temperature ________________ F db ________________ F wb ________________ RH Action Completed See Notes Prove Compressor Rotation 3 phase only by gauge pressure Prove High Pressure Safety All Systems Prove Low Pressu...

Page 58: ...___________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ _______________________________________________________________________________________________________ ____________________...

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