York ZJ078 Installation Manual Download Page 1

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R-410A
ZJ SERIES

6-1/2 - 12-1/2 Ton

60 Hertz

524581-YIM-I-0512

TABLE OF CONTENTS

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7
Rigging And Handling  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7
Ductwork  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15
Condensate Drain  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
Optional Electric Heat  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31
Options/Accessories  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  33
Optional Variable Air Volume (VAV)  . . . . . . . . . . . . . . . . . . . .  34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . .  36
Standard Economizer And Power Exhaust Set Point
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  36
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  41

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Electric Heating Sequence Of Operations . . . . . . . . . . . . . . . . 53

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54

Ignition Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 54

Start-Up (Cooling)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Start-Up (Gas Heat)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Checking Gas Heat Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Charging The Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Unit Control Board Option Setup

. . . . . . . . . . . . . . . . . . . . . . . . . 61

Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

LIST OF TABLES

ZJ078-150 Unit Limitations

. . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Weights and Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ZJ078-150 Unit Accessory Weights

. . . . . . . . . . . . . . . . . . . . 9

ZJ078-150 Unit Physical Dimensions

. . . . . . . . . . . . . . . . . . 11

ZJ078-150 Unit Clearances

. . . . . . . . . . . . . . . . . . . . . . . . . . 11

Side Duct Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Control Wire Sizes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Electrical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Physical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electric Heat Minimum Supply Air

. . . . . . . . . . . . . . . . . . . . . 30

Gas Pipe Sizing - Capacity of Pipe

. . . . . . . . . . . . . . . . . . . . 31

Gas Heat Minimum Supply Air

. . . . . . . . . . . . . . . . . . . . . . . 32

Supply Air Limitations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Altitude/Temperature Correction Factors

. . . . . . . . . . . . . . . 40

Airflow Performance - Side Duct Application

. . . . . . . . . . . . . 42

Airflow Performance - Bottom Duct Application

. . . . . . . . . . 44

RPM Selection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Indoor Blower Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . 46

Power Exhaust Specifications

. . . . . . . . . . . . . . . . . . . . . . . . 46

Motor Sheave Datum Diameters

. . . . . . . . . . . . . . . . . . . . . . 48

Additional Static Resistance

. . . . . . . . . . . . . . . . . . . . . . . . . 49

Electric Heat Limit Setting

. . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Electric Heat Anticipator Setpoints

. . . . . . . . . . . . . . . . . . . . 54

Gas Heat Limit Control Settings

. . . . . . . . . . . . . . . . . . . . . . 55

Gas Heat Anticipator Setpoints

. . . . . . . . . . . . . . . . . . . . . . . 56

Gas Rate Cubic Feet Per Hour

. . . . . . . . . . . . . . . . . . . . . . . 58

Gas Heat Stages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Unit Control Board Flash Codes

. . . . . . . . . . . . . . . . . . . . . . 60

Heat Delay

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Ignition Control Flash Codes

. . . . . . . . . . . . . . . . . . . . . . . . . 62

VAV Control Board Flash Codes

. . . . . . . . . . . . . . . . . . . . . 62

LIST OF FIGURES

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

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

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

Predator

Component Location (ZJ120 Shown) . . . . . . . . . . 6

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

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

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

ZJ078-120 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 9

ZJ150 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10

ZJ078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . . . 12

ZJ078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . . 13

ZJ078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 13

ZJ150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . 14

ZJ078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . . . . 14

ZJ078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ZJ078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . . 15

Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16

Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . 16

Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Field Wiring Disconnect - Cooling Unit With/Without Electric
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . 18

Field Wiring Disconnect - Cooling Unit With Gas Heat Without
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . . 19

Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . . . . 19

Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Honeywell Economizer Control W7212 . . . . . . . . . . . . . . . . 38

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 40

Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Occupied Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . 63

Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Summary of Contents for ZJ078

Page 1: ...ower Exhaust Specifications 46 20 Motor Sheave Datum Diameters 48 21 Additional Static Resistance 49 22 Electric Heat Limit Setting 53 23 Electric Heat Anticipator Setpoints 54 24 Gas Heat Limit Control Settings 55 25 Gas Heat Anticipator Setpoints 56 26 Gas Rate Cubic Feet Per Hour 58 27 Gas Heat Stages 58 28 Unit Control Board Flash Codes 60 29 Heat Delay 62 30 Ignition Control Flash Codes 62 31...

Page 2: ...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 alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified contractor ...

Page 3: ...ation 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 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 bu...

Page 4: ...ctor S A 4 Smoke Detector R A 5 Pwr d Conv Outlet Options AA None AB Phase Monitor AC Coil Guard AD Dirty Filter Switch AE Phase Monitor Coil Guard AF Phase Monitor Dirty Filter Switch AG Coil Guard Dirty Filter Switch AH Phase Monitor Coil Guard Dirty Filter Switch Additional Options RC Coil Guard Shipping Bag American Flag TA Technicoat Condenser Coil TJ Technicoat Evaporator Coil TS Technicoat ...

Page 5: ...he 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 must be field installed The cover shall be located behind the filter access panel To install the ...

Page 6: ...lications computer rooms switchgear etc please reference applications bulletin AE 011 07 or call the applications department for Unitary Products 1 877 UPG SERV for guidance Additional accessories may be needed for stable operation at temperatures below 30 F Roof curbs in eight and fourteen inch heights Roof curbs for transitioning from York Sunline footprint to the ZJ Series footprints are also a...

Page 7: ...ise 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 Table 1 ZJ078 150 Unit Limitations Size Tons Model Unit Voltage Unit Limitations App...

Page 8: ...ted 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 Size Tons Model Weight 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 078 6 5 ZJ 1035 1030 39 25 245 191 260 333 170 144 122 167 195...

Page 9: ...t1 1 Weight 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 includes mounting hardware controls and manual bypass option 30 30 LEFT A 59 00 C D E F 4 19 27 31 89 00 21 19 11 38 15 38 59 00 15 38 29 69 15 25 FRONT SEE DETAIL B FOR DRAIN LOCATION SEE DETAIL...

Page 10: ...Unitary Products Figure 9 ZJ150 Physical Dimensions 15 23 29 03 14 85 29 03 14 85 15 23 28 86 29 66 44 09 Ø 24 58 TYP 4 PL FRONT See detail B for drain location See detail A for gas inlet C D E F B 4 3 16 27 5 16 89 21 3 16 11 3 8 A LEFT 59 ...

Page 11: ... 30 3 16 24 3 16 17 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 50 3 4 CABINET Ø 3 126 Ø 2 000 3 184 4 737 7 715 17 541 Gas Pipe Inlet Gas Exhaust Vent 5 3 8 3 4 FPT Table 5 ZJ078 150 Unit Clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser ai...

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: ...Electrical Entry Figure 12 ZJ078 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 Dot Plugs 5 5 32 31 11 16 2 31 32 18 1 4 Return Air Supply Air A B C D ...

Page 14: ... Left Duct Opening Dot Plugs 2 7 8 5 5 32 D C 31 5 8 18 1 4 B A Table 6 Side Duct Dimensions Unit Model Number Dimension in A B C D ZJ078 28 1 4 18 1 16 28 1 4 18 1 4 ZJ090 28 1 4 18 1 16 28 1 4 18 1 4 ZJ102 28 1 4 18 1 16 28 1 4 18 1 4 ZJ120 28 1 4 18 1 16 28 1 4 18 1 4 ZJ150 28 1 4 18 1 16 28 1 4 18 1 4 4 5 16 30 3 8 ...

Page 15: ...e 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 10 for bottom air duct openings Refer to Figures 12 13 and Table 6 for sid...

Page 16: ...With Panel Figure 19 Discharge Panel In Place Condensate Drain The side condensate drain is reversible and maybe re oriented to the rear of the cabinet 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 20 The trap and drain lines should be protected from freezing Plumbing must conform to lo...

Page 17: ...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 If installing a disconnect field supplied or York International supplied accessory refer to Figure 4 for the recommended mounting location NOTE Since not all local codes allow the mounting...

Page 18: ...nto the unit through the side of the unit or the basepan inside the curb Figure 21 Field Wiring Disconnect Cooling Unit With Without Electric Heat and All Units With VFD Option Figure 22 Field Wiring Disconnect Cooling Unit With Gas Heat Without VFD Option THREE PHASE POWER SUPPLY FACTORY OR FIELD SUPPLIED DISCONNECT GROUND LUG TERMINAL BLOCK TB1 L1 T1 L2 T2 T3 L3 THREE PHASE POWER SUPPLY FACTORY ...

Page 19: ...Wiring 24 Volt Thermostat Table 7 Control Wire Sizes Wire Size Maximum Length1 1 From the unit to the thermostat and back to the unit 18 AWG 150 Feet 208 230 3 60 and 380 415 3 50 units control transformers are factory wired for 230v and 415v power supply respectively Change tap on transformer for 208 3 60 or 380 3 50 operation See unit wiring diagram W2 RC RH Y1 Y2 W1 G C X1 X3 X4 A1 A2 T T W2 Y1...

Page 20: ...39 8 45 3 50 50 E09 6 8 1 18 9 39 8 45 3 50 50 E18 13 5 2 37 5 54 3 61 2 60 70 E24 18 2 50 0 70 76 8 70 80 E36 25 5 2 70 8 96 102 9 100 110 230 11 9 88 18 5 3 5 6 0 5 5 0 0 None 39 8 45 3 50 50 E09 9 1 21 7 39 8 45 3 50 50 E18 18 2 43 3 61 6 68 5 70 70 E24 24 2 57 7 79 7 86 5 80 90 E36 34 2 81 8 109 7 116 6 110 125 460 5 2 44 8 1 1 6 3 0 2 2 0 0 None 17 9 20 1 20 25 E09 9 1 10 8 17 9 20 1 20 25 E1...

Page 21: ...6 73 1 90 90 E24 18 2 50 0 74 5 81 3 90 90 E36 25 5 2 70 8 100 5 107 4 110 110 E54 40 6 2 112 7 152 9 159 7 175 175 230 23 1 160 36 1 5 9 6 5 5 0 0 None 67 6 73 1 90 90 E18 18 2 43 3 67 6 73 1 90 90 E24 24 2 57 7 84 2 91 90 100 E36 34 2 81 8 114 2 121 1 125 125 E54 54 2 129 9 141 9 148 8 175 175 460 12 2 87 19 0 8 4 8 2 2 0 0 None 35 5 37 7 45 45 E18 18 2 21 7 35 5 37 7 45 45 E24 24 2 28 9 42 1 44...

Page 22: ... 60 E09 6 8 1 18 9 43 4 48 9 50 60 E18 13 5 2 37 5 58 8 65 7 60 70 E24 18 2 50 0 74 5 81 3 80 90 E36 25 5 2 70 8 100 5 107 4 110 110 230 11 9 88 18 5 3 5 9 6 5 5 0 0 None 43 4 48 9 50 60 E09 9 1 21 7 43 4 48 9 50 60 E18 18 2 43 3 66 1 73 70 80 E24 24 2 57 7 84 2 91 90 100 E36 34 2 81 8 114 2 121 1 125 125 460 5 2 44 8 1 1 6 4 8 2 2 0 0 None 19 7 21 9 20 25 E09 9 1 10 8 19 7 22 3 20 25 E18 18 2 21 ...

Page 23: ... 7 90 100 E24 18 2 50 0 81 5 88 3 90 100 E36 25 5 2 70 8 107 5 114 4 110 125 E54 40 6 2 112 7 159 9 166 7 175 175 230 23 1 160 36 1 5 15 2 5 5 0 0 None 73 2 78 7 90 100 E18 18 2 43 3 73 2 80 90 100 E24 24 2 57 7 91 2 98 100 100 E36 34 2 81 8 121 2 128 1 125 150 E54 54 2 129 9 148 9 155 8 175 175 460 12 2 87 19 0 8 7 6 2 2 0 0 None 38 3 40 5 50 50 E18 18 2 21 7 38 3 40 5 50 50 E24 24 2 28 9 45 6 48...

Page 24: ...E09 6 8 1 18 9 49 8 55 3 60 60 E18 13 5 2 37 5 66 8 73 7 70 80 E24 18 2 50 0 82 5 89 3 90 90 E36 25 5 2 70 8 108 5 115 4 110 125 230 11 9 88 18 5 3 5 6 0 5 5 10 0 None 49 8 55 3 60 60 E09 9 1 21 7 49 8 55 3 60 60 E18 18 2 43 3 74 1 81 80 90 E24 24 2 57 7 92 2 99 100 100 E36 34 2 81 8 122 2 129 1 125 150 460 5 2 44 8 1 1 6 3 0 2 2 5 0 None 22 9 25 1 25 30 E09 9 0 1 10 8 23 5 26 3 25 30 E18 18 2 21 ...

Page 25: ...77 6 83 1 100 100 E24 18 2 50 0 87 93 8 100 100 E36 25 5 2 70 8 113 119 9 125 125 E54 40 6 2 112 7 165 4 172 2 175 175 230 23 1 160 36 1 5 9 6 5 5 10 0 None 77 6 83 1 100 100 E18 18 2 43 3 78 6 85 5 100 100 E24 24 2 57 7 96 7 103 5 100 110 E36 34 2 81 8 126 7 133 6 150 150 E54 54 2 129 9 154 4 161 3 175 175 460 12 2 87 19 0 8 4 8 2 2 5 0 None 40 5 42 7 50 50 E18 18 2 21 7 40 5 42 7 50 50 E24 24 2 ...

Page 26: ... 70 E09 6 8 1 18 9 53 4 58 9 60 70 E18 13 5 2 37 5 71 3 78 2 80 80 E24 18 2 50 0 87 93 8 90 100 E36 25 5 2 70 8 113 119 9 125 125 230 11 9 88 18 5 3 5 9 6 5 5 10 0 None 53 4 58 9 60 70 E09 9 1 21 7 53 4 58 9 60 70 E18 18 2 43 3 78 6 85 5 80 90 E24 24 2 57 7 96 7 103 5 100 110 E36 34 2 81 8 126 7 133 6 150 150 460 5 2 44 8 1 1 6 4 8 2 2 5 0 None 24 7 26 9 25 30 E09 9 1 10 8 25 8 28 5 30 30 E18 18 2...

Page 27: ...8 7 100 110 E24 18 2 50 0 94 100 8 100 110 E36 25 5 2 70 8 120 126 9 125 150 E54 40 6 2 112 7 172 4 179 2 175 200 230 23 1 160 36 1 5 15 2 5 5 10 0 None 83 2 88 7 100 110 E18 18 2 43 3 85 6 92 5 100 110 E24 24 2 57 7 103 7 110 5 110 125 E36 34 2 81 8 133 7 140 6 150 150 E54 54 2 129 9 161 4 168 3 175 175 460 12 2 87 19 0 8 7 6 2 2 5 0 None 43 3 45 5 50 50 E18 18 2 21 7 43 3 45 6 50 50 E24 24 2 28 ...

Page 28: ... 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 ºF 20 50 35 65 15 45 30 60 10 40 25 55 20 50 35 65 10 40 25 55 Gas Limit Setting ºF 165 165 165 165 215 195 195 160 195 160 Gas piping connection in 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 DIMENSIONS inches Length 89 89 89 89 119 1 2 Width 59 59 59 59 59 Height 50 3 4 50 3 4 50 3 4 50 3 4 50 3 4...

Page 29: ...1VM50 1VP56 Blower Sheave AK74 AK74 AK69 AK69 AK89 AK74 AK84 AK74 AK74 BK77 Belt A53 A54 A53 A54 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 56 56 56 184T FILTERS Quantity Size 4 24 x 20 x 2 4 5 4 24 x 20 x 2 4 5 4 24 x 20 x 2 4 5 4 24 x 20 x 2 4 5 4 24 x 20 x 2 4 5 4 24 x 20 x 4 6 4 24 x 20 x...

Page 30: ... 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 ZJ 208 230 3 60 1950 1950 1950 1950 460 3 60 1950 1950 1950 1950 600 3 60 1950 1950 1950 1950 090 7 5 ZJ 208 230 3 60 2250 2250 2250 2250 460 3 60 2250 2250 2250 2250 600 3 60 2250 2250 2250 2250 102 8 5 ZJ 208 230 3 60...

Page 31: ...er 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 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...

Page 32: ... 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 ZJ 10 1950 3250 1950 3250 15 1950 3250 1950 3250 090 7 5 ZJ 10 2250 3750 2250 3750 15 2250 3750 2250 3750 102 8 5 ZJ 10 2550 4250 2550 4250 15 2550 4250 2550 4250 120 10 ZJ 15 3000 5000 3000 5000 20 3000 5000 3000 5000 1...

Page 33: ...rding 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 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...

Page 34: ... ductwork and to the atmosphere Connect the tubing from the HIGH pressure tap of the transducer to a static pressure tap field supplied in the supply duct located at a point where constant pressure is expected To prevent an unstable signal due to air turbulence there should be no obstructions turns or VAV terminal boxes up or down stream of the sensing tube location for at least a distance of 6 10...

Page 35: ... connections run permit signal speed reference signal fault signal All required drive parameters are pre programmed at the factory except in the case of 208 volt applications in which the parameter that defines motor nameplate voltage must be changed to a value of 208 00 and the parameter that defines motor rated current must be changed to the appropriate value appearing on the motor s nameplate R...

Page 36: ...lsewhere either within the building on a perpendicular wall which is not subjected to excessive temperature vibration humidity dust corrosive gas explosive gas etc or within an appropriate enclosure rated for outside installation to safeguard against moisture dust and excessive heat The power leads to the drive L1 L2 L3 and from the motor T1 T2 T3 have been temporarily spliced together with wire n...

Page 37: ...t With no power exhaust option adjust the Exhaust Air Adjustment Screw fully clockwise This will allow 2nd stage cooling to operate With power exhaust option each building pressurization requirement will be different The point at which the power exhaust comes on is determined by the economizer damper position Percent Open The Exhaust Air Adjustment Screw should be set at the Percent Open of the ec...

Page 38: ...ischarge pressures or producing a high noise level the scroll is misphased 40 4 70 21 50 10 55 13 60 16 65 18 35 2 45 7 75 24 80 27 35 2 40 4 45 7 50 10 55 13 60 16 65 18 70 21 75 24 80 27 85 29 85 29 90 32 90 32 105 41 110 43 100 38 95 35 95 35 100 38 105 41 110 43 APPROXIMATE DRY BULB TEMPERATURE 0 F 0 C D D C C B B A A CONTROL CURVE CONTROL POINT APPROX 0 F 0 C AT 50 RH A D C B 63 17 73 23 70 2...

Page 39: ... will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Table 14 and Figure 31 Scroll compressors require proper rotation to operate correctly Units are properly phased at the factory Do not change the internal wiring to make the blower condenser fans or compressor rotate correctly Table 13 Supply Air Limitations Unit S...

Page 40: ...given 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 static pressure of 1 8 The rpm listed will be the same rpm needed at 5 000 ft Suppose that the corresponding BHP listed in the table is 3 2 This value must be corrected for elevation BHP at 5 000 ft ...

Page 41: ...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 open will achieve 1268 RPM Airflow Performance 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 ...

Page 42: ...400 631 0 16 682 0 41 736 0 66 793 0 90 852 1 14 911 1 36 970 1 58 1028 1 78 1084 1 97 1136 2 13 2600 642 0 27 692 0 52 747 0 76 804 1 01 862 1 24 922 1 47 981 1 69 1039 1 89 1094 2 07 1146 2 24 2800 652 0 39 703 0 64 757 0 88 814 1 13 873 1 36 932 1 59 992 1 81 1049 2 01 1105 2 19 1157 2 36 3000 663 0 53 714 0 77 768 1 02 825 1 26 884 1 50 943 1 73 1003 1 94 1060 2 14 1116 2 33 1168 2 49 3200 675...

Page 43: ...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 and to determine the maximum continuous BHP 3 kW BHP x 0 932 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 Field Supplied Drive Stand...

Page 44: ...1 1012 1 61 1065 1 81 1113 2 02 1153 2 24 2400 689 0 42 743 0 69 800 0 93 859 1 16 919 1 37 978 1 57 1035 1 77 1088 1 97 1135 2 18 1176 2 40 2600 712 0 60 766 0 87 823 1 11 882 1 34 942 1 55 1002 1 75 1058 1 95 1111 2 15 1159 2 36 1199 2 58 2800 736 0 80 790 1 06 847 1 31 906 1 53 967 1 74 1026 1 94 1082 2 14 1135 2 34 1183 2 55 1223 2 78 3000 761 1 00 815 1 27 872 1 52 931 1 74 991 1 95 1051 2 15...

Page 45: ...RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard 3 HP Drive Hi Static 5 HP Drive 3200 797 1 32 851 1 46 903 1 60 953 1 74 1001 1 86 1048 1 99 1093 2 11 1138 2 23 1181 2 35 1224 2 48 3400 828 1 52 882 1 67 934 1 81 983 1 94 1032 2 07 1078 2 19 1124 2 32 1168 2 44 1212 2 56 1254 2 68 3600 861 1 75 915 1 90 967 2 04 1017 2 17 1065 2 30 1112 2 42 1157 2 54 1201 2 6...

Page 46: ... screws after 10 12 hrs run time is recommended Table 18 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 Model 078 6 5 ZJ 1 1 2 1725 0 8 1 15 56 2 6 3 6 7 8 1VL40 7 0 1 AK74 A53 2 1725 0 8 1 15 56 3 6 4 6 7 8 1VM50 7 0 1 AK74 A54 090 7 5 ZJ 1 1 2 1725 0 8 1 15 56 2 6 3 6 7 8 1VL40 6 5 1 AK69 A53 ...

Page 47: ...open 5 Select the correct blower performance table for the unit from Tables 15 and 16 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 reading has been obtained...

Page 48: ...stallation 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 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 sp...

Page 49: ...stance 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 economizer oper...

Page 50: ...plicity Freenet USB Adapter S1 03101967000 5 Freenet service cable S1 02538682000 No Outdoor Air Options When the thermostat calls for the first stage of cooling the low voltage control circuit from R to Y1 and G is completed The UCB energizes the economizer if installed and free cooling is available or the first available compressor and the condenser fans For first stage cooling compressor 1 is e...

Page 51: ... Outside Air Temperature sensor and will allow free cooling when the outdoor temperature is less than both the First Stage SAT Control set point plus 5 F and the Economizer OAT Enable set point Single Enthalpy optional A field installed Outdoor Air Humidity sensor is connected to the control When the measured outdoor enthalpy is below the Outside Air Enthalpy set point and the outdoor temperature ...

Page 52: ...he UCB will de energize the associated compressor initiate the ASCD and if the other compressor is idle stop the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB will re energize the halted compressor Should a freezestat open three times within two hours of operation the UCB will lock out the associated compressor and flash a code Table 28 If the other ...

Page 53: ...peration status i e the limit is monitored at all times If the temperature limit opens three times within one hour it will lock on the indoor blower motor and a flash code is initiated See Table 28 Safety Controls The UCB monitors the temperature limit switch of electric heat units The control circuit includes the following safety controls Limit Switch Ls This control is located inside the heater ...

Page 54: ...n After this 60 seconds the ICB will then use the call for the second stage of heat to control second stage operation of the GV When W1 is satisfied both valves are closed Second Stage Of Heating When the ICB receives a call for the second stage of heating W2 the ICB conducts a complete first stage ignition sequence If this sequence is satisfied the second main valve of the GV is opened When W2 is...

Page 55: ...t Switch LS This control is located inside the gas heat compartment and is set to open at the temperature indicated in the Gas Heat Limit Control Settings Table 24 It resets automatically The limit switch 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 ALS This control is located i...

Page 56: ... room thermostat fan switch to off 9 Turn unit electrical power off Operating Instructions 1 Turn unit electrical power on NOTE Prior to each cooling season the crankcase heaters must be energized at least 10 hours before the system is put into operation 2 Set the room thermostat setting to lower than the room temperature 3 First stage compressors will energize after the built in time delay five m...

Page 57: ...number of seconds it takes for one revolution of the dial calculate the cubic feet of gas consumed per hour See example below 5 If necessary adjust the high pressure regulator as discussed in the section Manifold Gas Pressure Adjustment Be sure not to over fire the furnace on Second stage If in doubt it is better to leave the Second stage of the furnace slightly under fired Repeat Steps 1 5 To det...

Page 58: ...r 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 using a screwdriver turn the second stage adjustment screw adjacent to the HI marking on the valve clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure Be sure not ...

Page 59: ...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 to replace the assemblies Make sure that burners are level and seat at the rear of the gas orifice Figure 34 Typical Flame Figure 35 Typical Gas Valve Charging The Unit All ZJ units use Thermal Expansion Devices Charge the unit to nameplate c...

Page 60: ...cases it may be necessary to zero the ASCD for the compressors in order to perform troubleshooting To reset all ASCDs for one cycle press and release the UCB TEST RESET button once Flash codes that do and do not represent alarms are listed in Table 28 Table 28 Unit Control Board Flash Codes Flash Code Description Green LED 16 Red LED 8 Red LED 4 Red LED 2 Red LED 1 On Steady This is a Control Fail...

Page 61: ...ameters for the currently displayed mode Option Byte or Heat Delay Heat Delay Setup Enter the Option Setup mode by pushing the OPTION SETUP STORE button and holding it for at least 2 seconds The green status LED Option Byte will be turned on and the red status LED Heat Delay is turned off Press the COMM SETUP SELECT button to toggle into the Heat Delay Setup the green LED will turn off and the red...

Page 62: ...X Limit 5 Flame Present With Gas Off First Stage Gas Valve Energized With W1 Off Second Stage Gas Valve Energized With First Stage Gas Valve Off Gas Valve 6 Ignition Lockout Gas Flow Gas Pressure Gas Valve Flame Sensor STEADY OFF No Power Or Control Failure 24VAC or Control Table 31 VAV Control Board Flash Codes Flash Codes Description On Steady This is a Control Failure 1 Flash Not Applicable 2 F...

Page 63: ...First Stage Call for 2nd Stage Cooling Yes Yes Loss of Call for Heating Loss of Call for Cooling Heat Off Cool Off Yes Yes No Call for ID Blower Fan off 10 secs Energize ID Blower Motor Yes Yes No Programming Program Unit Control Board Trip Failure No No Lossof Call for ID Blower Turn off ID Blower Motor Fan on 30 secs Yes No Yes No No Yes Yes No Power to Unit Initialize ASCD Call for heat Voltage...

Page 64: ...524581 YIM I 0512 64 Johnson Controls Unitary Products Figure 39 Trip Failure Flow Chart ...

Page 65: ... the UCB and for loose wiring 10 If the thermostat and UCB are properly wired replace the UCB On calls for cooling the supply air blower motor is operating but compressor 1 is not the room thermostat fan switch is in the AUTO position 1 If installed check the position of the economizer blades If the blades are open the economizer is providing free cooling and the compressors will not immediately o...

Page 66: ...he C1 terminal wire and jumper it to the Y1 terminal DO NOT jump the Y1 to C1 terminals If the compressor engages the UCB has faulted 16 If none of the above correct the error replace the UCB On calls for the second stage of cooling the supply air blower motor and compressor 1 are operating but compressor 2 is not the room thermostat fan switch is in the AUTO position 1 If installed check the posi...

Page 67: ...volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal If 24 volts are not present at the UCB Y1 terminal the UCB may have faulted Check for 24 volts at the Y1 ECON terminal If 24 volts is not present at Y1 ECON the UCB has faulted The UCB should de energize all compressors on a loss of call for the first stage of cooling i e a loss if 24 volts a...

Page 68: ... operate replace the motor 6 If 24 volts is not present at M3 check that 24 volts is present at the supply air blower motor terminal on the UCB If 24 volts is present at the UCB terminal check for loose wiring between the UCB and M3 a If 24 volts is not present at the UCB supply air blower motor terminal check for 24 volts from the room thermostat If 24 volts is not present from the room thermosta...

Page 69: ...temperature limit open wait for limit reset 5 If all are intact replace the ICB The draft motor runs and the spark ignitor sparks at the burner but the burner does not ignite and a gas odor is not detected at the draft motor outlet 1 Check to ensure gas is being supplied to the unit Confirm that the gas pressure to the unit is within the proper limits as described in the POST START CHECKLIST 2 Che...

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York ZJ078, Installation Manual

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