York ZF078-150 Instruction Manual Download Page 13

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5464597-YIM-B-0518

Johnson Controls Ducted Systems

Figure 11: ZF078-150 Unit Electrical Entry

Figure 12: ZF078-120 Unit Side Duct Openings

Disconnect Swith Cover

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

D o t P l u g s

5 - 5 /3 2

3 1 - 1 1 /1 6

2 - 3 1 /3 2

1 8 - 1 /4

Return

Air

Supply Air

Summary of Contents for ZF078-150

Page 1: ...pplication 46 18 Airflow Performance Bottom Duct Application 48 19 RPM Selection 49 20 Indoor Blower Specifications 50 21 Power Exhaust Specifications 50 22 Motor Sheave Datum Diameters 52 23 Addition...

Page 2: ...ning 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 o...

Page 3: ...allation only 3 For installation on combustible material and may 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 Fo...

Page 4: ...il 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 Motori...

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 tooll...

Page 6: ...lication for people An economizer is typically included in this type of application When applying this product for process cooling applications computer rooms switchgear etc please call the applicatio...

Page 7: ...e 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...

Page 8: ...ifted The condenser coils should be protected from rigging cable damage with plywood or other suitable material D A C B LEFT FRONT D A C B E F LEFT FRONT X Y LEFT FRONT Table 2 Weights and Dimensions...

Page 9: ...t given is for the maximum heater size available 54KW 49 49 Gas Heat2 2 Weight given is for the maximum number of tube heat exchangers available 8 tube 110 110 Variable Frequency Drive3 3 Weight inclu...

Page 10: ...10 Johnson Controls Ducted Systems Figure 9 ZF150 LEFT 59 00 A C D E F 4 19 27 31 89 00 21 19 FRONT SEE DETAIL B FOR DRAIN LOCATION 11 38 SEE DETAIL A FOR GAS INLET B 29 95 30 11 14 92 58 09 14 92 14...

Page 11: ...3 16 24 3 16 17 3 16 6 3 16 42 CABINET 3 126 2 000 3 184 4 727 7 705 14 594 Gas Pipe Inlet Gas Exhaust Vent 50 3 4 CABINET 3 126 2 000 3 184 4 737 7 715 17 541 Gas Pipe Inlet Gas Exhaust Vent 5 3 8 3...

Page 12: ...it 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...

Page 13: ...t Electrical Entry Figure 12 ZF078 120 Unit Side Duct Openings Disconnect Swith Cover Power Entry 2 1 2 Control Entry 7 8 Power Entry 2 1 2 Convenience Outlet Cover Convenience Outlet Power Entry 7 8...

Page 14: ...ions Unit Model Number Dimension in A B C D ZF078 27 3 4 12 1 16 27 1 2 16 ZF090 27 3 4 12 1 16 27 1 2 16 ZF102 28 1 4 18 1 16 28 1 4 18 1 4 ZF120 28 1 4 18 1 16 28 1 4 18 1 4 ZF150 28 1 4 18 1 16 28...

Page 15: ...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...

Page 16: ...Figure 17 Side Panels With Hole Plugs NOTE Orientation Panel is insulation side up Figure 18 Return Downflow Plenum With Panel Figure 19 Discharge Panel In Place Side Panels Units are shipped with sid...

Page 17: ...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 main...

Page 18: ...Units are factory wired for the voltage shown on the unit nameplate Refer to Electrical Data Table 8 to size power wiring fuses and disconnect switch Power wiring is brought into the unit through the...

Page 19: ...Johnson Controls Ducted Systems 19 Figure 23 Field Wiring Disconnect Cooling Unit With Gas Heat Without VFD Option L1 T1 L2 T2 T3 L3 THREE PHASE POWER SUPPLY FACTORY OR FIELD SUPPLIED DISCONNECT GROUN...

Page 20: ...e 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 2 4 Second sta...

Page 21: ...one 40 5 46 50 50 E09 6 8 1 18 9 40 5 46 50 50 E18 13 5 2 37 5 53 4 60 3 60 70 E24 18 2 50 69 75 9 70 80 E36 25 5 2 70 8 95 101 9 100 110 230 13 8 83 1 22 2 1 5 2 5 5 None 40 5 46 50 50 E09 9 1 21 7 4...

Page 22: ...100 E24 18 2 50 74 5 81 4 90 100 E36 25 5 2 70 8 100 5 107 4 110 110 E54 40 6 2 112 7 152 9 159 8 175 175 230 23 1 160 36 3 03 9 6 5 5 None 73 7 79 2 90 100 E18 18 2 43 3 73 7 79 2 90 100 E24 24 2 57...

Page 23: ...50 4 50 60 E09 6 8 1 18 9 44 9 50 4 50 60 E18 13 5 2 37 5 58 9 65 8 60 70 E24 18 2 50 74 5 81 4 80 90 E36 25 5 2 70 8 100 5 107 4 110 110 230 13 8 83 1 22 2 1 9 6 5 5 None 44 9 50 4 50 60 E09 9 1 21...

Page 24: ...0 100 E24 18 2 50 80 86 9 100 100 E36 25 5 2 70 8 106 112 9 110 125 E54 40 6 2 112 7 158 4 165 3 175 175 230 23 1 160 36 3 03 14 5 5 None 78 1 83 6 100 100 E18 18 2 43 3 78 1 83 6 100 100 E24 24 2 57...

Page 25: ...9 6 8 1 18 9 50 5 56 60 60 E18 13 5 2 37 5 65 9 72 8 70 80 E24 18 2 50 81 5 88 4 90 90 E36 25 5 2 70 8 107 5 114 4 110 125 230 13 8 83 1 22 2 1 5 2 5 5 20 None 50 5 56 60 60 E09 9 1 21 7 50 5 56 60 60...

Page 26: ...89 2 100 110 E24 18 2 50 87 93 9 100 110 E36 25 5 2 70 8 113 119 9 125 125 E54 40 6 2 112 7 165 4 172 3 175 175 230 23 1 160 36 3 03 9 6 5 5 20 None 83 7 89 2 100 110 E18 18 2 43 3 83 7 89 2 100 110 E...

Page 27: ...70 E09 6 8 1 18 9 54 9 60 4 60 70 E18 13 5 2 37 5 71 4 78 3 80 80 E24 18 2 50 87 93 9 90 100 E36 25 5 2 70 8 113 119 9 125 125 230 13 8 83 1 22 2 1 9 6 5 5 20 None 54 9 60 4 60 70 E09 9 1 21 7 54 9 6...

Page 28: ...110 110 E24 18 2 50 92 5 99 4 110 110 E36 25 5 2 70 8 118 5 125 4 125 150 E54 40 6 2 112 7 170 9 177 8 175 200 230 23 1 160 36 3 03 14 5 5 20 None 88 1 93 6 110 110 E18 18 2 43 3 88 1 93 6 110 110 E2...

Page 29: ...44 144 192 144 192 AFUE Steady state efficiency 80 80 80 80 80 80 80 80 80 80 No burners 4 6 4 6 4 6 6 8 6 8 No stages 23 23 23 23 23 23 23 23 23 23 Temperature Rise Range F 20 50 35 65 15 45 30 60 10...

Page 30: ...AK89 AK74 AK84 AK74 AK74 BK77 Belt A49 A49 A49 A49 A56 A54 A56 A54 A54 BX55 Motor HP each 1 1 2 2 1 1 2 3 2 3 2 3 3 5 RPM 1725 1725 1725 1725 1725 1725 1725 1725 1725 1725 Frame size 56 56 56 56 56 56...

Page 31: ...minimum CFM limitations and to Table 8 for electrical data Table 10 Electric Heat Minimum Supply Air Size Tons Model Voltage Minimum Supply Air CFM Heater kW 9 18 24 36 54 078 6 5 ZF 208 230 3 60 1950...

Page 32: ...r to the Pipe Sizing Table 11 The heating value of the gas may differ with locality The value should be checked with the local gas utility Figure 25 Side Entry Gas Piping Figure 26 Bottom Entry Gas Pi...

Page 33: ...safety standards of the National Fire Protection Association Table 12 Gas Heat Minimum Supply Air Size Tons Model Heat Size Supply Air CFM Cooling Heating Min Max Min Max 078 6 5 ZF N12 1950 3250 1950...

Page 34: ...ing to NFPA 72 requirements and cleaned at least once a year For specific troubleshooting and maintenance procedures please refer to the smoke detector s installation instructions which accompanies th...

Page 35: ...plastic tubing 1 4 diameter must be field supplied and installed from the transducer to both the ductwork and to the atmosphere Connect the tubing from the HIGH pressure tap of the transducer to a sta...

Page 36: ...ize the unit s mounting bracket the maximum recommended drive dimensions are limited to approximately 9 H x 5 W x 7 5 D If the drive will not fit in the allotted space then it will need to be mounted...

Page 37: ...r single enthalpy economizer operation the outside air is suitable for free cooling if the outside air enthalpy is at least 1 BTU lb below the Economizer Outside Air Enthalpy Setpoint and the outside...

Page 38: ...output returns to minimum position If the demand for cooling from the space return is satisfied the economizer output will modulate to minimum position and the compressor outputs will be de energized...

Page 39: ...mistor 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...

Page 40: ...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 posi...

Page 41: ...atus 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 2...

Page 42: ...heck 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 IN8 BLDG PRES 0 5 VDC positive input from...

Page 43: ...ity of the air However since 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 correctio...

Page 44: ...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 1 5 832 1 80 Enter the blower table at 6000 sCFM and...

Page 45: ...s found 5 1 95 BHP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1268 RPM is within the range of the 2 HP drives 7 Using the 2 HP motor and drive 5 turns o...

Page 46: ...925 0 90 982 1 06 1038 1 21 1092 1 35 1147 1 48 1203 1 61 1259 1 73 1317 1 87 2400 835 0 66 897 0 87 956 1 06 1013 1 22 1069 1 37 1124 1 51 1178 1 64 1234 1 77 1290 1 90 1348 2 03 2600 869 0 84 931 1...

Page 47: ...ressure IWG1 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 sheave setting...

Page 48: ...4 1210 1 49 1286 1 65 1365 1 81 1447 1 98 1532 2 18 2400 878 0 78 953 1 00 1027 1 19 1100 1 36 1174 1 52 1250 1 67 1327 1 82 1405 1 98 1487 2 16 1572 2 36 2600 923 0 98 997 1 20 1071 1 39 1145 1 56 12...

Page 49: ...RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 3 HP Field Supplied Drive Standard 3 HP Drive Hi Static 5 HP Drive 3200 823 1 28 861 1 47 906 1 64 955 1 80 1007 1 95 1...

Page 50: ...after 10 12 hrs run time is recommended Table 19 Indoor Blower Specifications Size Tons Model Motor Motor Sheave Blower Sheave Belt HP RPM Eff SF Frame Datum Dia in Bore in Model Datum Dia in Bore in...

Page 51: ...en 5 Select the correct blower performance table for the unit from Tables 16 and 17 Tables are presented for side and down flow configuration 6 Determine the unit Measured CFM from the Blower Performa...

Page 52: ...allation for any installation 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...

Page 53: ...liver less CFM during full economizer operation 4 Filter2 Electric Heat kW2 9 18 24 36 54 078 6 5 090 7 5 ZF 1900 0 00 0 07 0 10 0 05 0 06 0 07 0 08 0 10 2100 0 01 0 09 0 11 0 06 0 07 0 08 0 09 0 11 2...

Page 54: ...t 5 degrees of the VAV Cooling Supply Air Temp Upper Set point When the Outdoor air condition is sufficient for free cooling the economizer will modulate to control the SAT to 1 degrees of the operati...

Page 55: ...override minimum run times for compressors NOTE The following components are needed to access the control points in the Smart Equipment control 1 Local LCD on Unit Control Board OR 2 Mobile Access Por...

Page 56: ...ition to the external pressure switches the compressors also have inherent internal protection If there is an abnormal temperature rise in a compressor the protector will open to shut down the compres...

Page 57: ...lame was not detected the GV closes and a retry operation begins During the flame stabilization period a loss of the flame for 2 seconds will cause the GV to close and the retry operation to begin Aft...

Page 58: ...rcuitry to be faulty the ICB will not permit an ignition sequence and the draft motor is energized If this failure should occur during an ignition cycle the failure is counted as a recycle Gas Valve T...

Page 59: ...les and a greater temperature swing in the conditioned space Reducing the value below the correct setpoint will give shorter ON cycles and may result in the lowering of the temperature within the cond...

Page 60: ...other gas appliances connected to the gas meter 2 Turn on the furnace and make sure the thermostat is calling for Second stage 100 input heat 3 Measure the time needed for one revolution of the hand o...

Page 61: ...the manifold pressure 3 Remove plastic cap covering HI and LO pressure adjustment screws 4 Turn on power to the unit 5 Set thermostat to call for second stage heat and start furnace 6 If necessary usi...

Page 62: ...or replaced To service burners complete step 4 4 Remove the heat shield on top of the manifold supports Burners are now accessible for inspection and or replacement NOTE Reverse the above procedure t...

Page 63: ...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 Connec...

Page 64: ...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 1...

Page 65: ...C 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 re...

Page 66: ...ut 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 permis...

Page 67: ...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 M...

Page 68: ...us 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...

Page 69: ...air Cable2 2 We recommend 26 AWG solid 6 wire 3 twisted pairs cable as the best fit for fabricating modular cables with the modular jack housing assembly Be sure the cable you use fits the modular jac...

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