York ZR SERIES User Manual Download

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R-410A

ZR SERIES W/SMART EQUIPMENT™

6-1/2 - 12-1/2 Ton
60 Hertz

5167531-YIM-J-1019

Table of contents

Ge neral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Unit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Single enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dual enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Free cooling operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Power exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 35

Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . 50

Cooling operation errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Reheat mode sequence of operation . . . . . . . . . . . . . . . . . . . 52

Electric heating sequence of operations . . . . . . . . . . . . . . . . . 53

Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 54

Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 54

Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 55

Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Navigation components for the Smart Equipment™ control board . . 59

Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 60

Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

List of tables

1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 ZR078-150 unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 ZR078-150 unit accessory weights . . . . . . . . . . . . . . . . . . . . 10

5 ZR078-150 unit physical dimensions. . . . . . . . . . . . . . . . . . . 11

6 ZR078-150 unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7 Side duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9 Roof curb components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

11 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

12 ZR078-150 physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

13 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 30

14 Gas application data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 31

16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 31

17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 40

19 Airflow performance - side duct application . . . . . . . . . . . . . 42

20 Airflow performance - bottom duct application . . . . . . . . . . . 44

21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

22 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 46

23 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 46

24 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 48

25 Additional static resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 49

26 Dehumidification sequence in normal and alternate mode . . 53

27 Electric heat limit setting 50 in. cabinet . . . . . . . . . . . . . . . . . 54

28 Electric heat limit setting 42 in. cabinet . . . . . . . . . . . . . . . . . 54

29 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 54

30 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 56

31 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 56

32 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 58

33 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

34 Cable for FC buses and SA buses in order of preference . . 66

35 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 66

List of figures

1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Condenser covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Unit 4 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Unit 6 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8 ZR078-120 physical dimensions . . . . . . . . . . . . . . . . . . . . . 10

9 ZR150 physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10

10 ZR078-150 unit bottom duct openings . . . . . . . . . . . . . . . . . 11

11 ZR078-150 unit electrical entry. . . . . . . . . . . . . . . . . . . . . . . 12

12 ZR078-120 unit side duct openings . . . . . . . . . . . . . . . . . . . 12

13 ZR150 unit side duct openings . . . . . . . . . . . . . . . . . . . . . . . 13

14 ZR078-150 unit/end left duct opening . . . . . . . . . . . . . . . . . 13

15 ZR078-150 roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

16 ZR078-150 transition roof curb . . . . . . . . . . . . . . . . . . . . . . . 14

17 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 15

18 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 15

19 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

20 Save side panels for economizer hood tops . . . . . . . . . . . . 16

21 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

22 Typical field wiring disconnect - cooling unit with or without

electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

23 Typical field wiring disconnect - cooling unit with gas heat . 18

24 Typical low voltage field wiring . . . . . . . . . . . . . . . . . . . . . . . 19

25 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

26 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

27 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 35

28 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

29 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 40

30 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

31 Cooling operation piping schematic - circuit #1 shown . . . . 52

32 Reheat operation piping schematic - circuit #1 shown . . . . . 53

33 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

34 Typical gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

35 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Summary of Contents for ZR SERIES

Page 1: ...formance side duct application 42 20 Airflow performance bottom duct application 44 21 RPM selection 45 22 Indoor blower specifications 46 23 Power exhaust specifications 46 24 Motor sheave datum diameters 48 25 Additional static resistance 49 26 Dehumidification sequence in normal and alternate mode 53 27 Electric heat limit setting 50 in cabinet 54 28 Electric heat limit setting 42 in cabinet 54...

Page 2: ...y precautions and codes including ANSI Z223 1 or CSA B149 1 latest 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 ...

Page 3: ...installed directly on combustible flooring or in the U S on wood flooring or Class A Class B or Class C roof covering materials For use with natural gas The unit can be converted to LP with a 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 mecha...

Page 4: ... 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 Sensors B PHM Phase Monitor...

Page 5: ...gure 1 Unit shipping bracket 2 Turn each bracket toward the ground The protective plywood covering drops to the ground 3 Remove the condenser coil protective covering 4 Remove the toolless doorknobs and instruction packet see Figure 3 Figure 2 Condenser covering Figure 3 Compressor section 5 If a factory option convenience outlet is installed you must install the weatherproof outlet in the field T...

Page 6: ...late If components are added to a unit to meet local codes they are installed at the dealer s and or customer s expense The size of the unit for the proposed installation must be based on a heat loss heat gain calculation made according to the methods of the Air Conditioning Contractors of America ACCA This furnace is not to be used for temporary heating of buildings or structures under constructi...

Page 7: ... D Filter access 2 in or 4 in filter options O Compressor 1 access high efficiency compressor E Filter drier solid core P Side entry power and control knockouts F Micro channel aluminum tube aluminum fin condenser Q Toolless door latch G Slide out motor and blower assembly for easy adjustment and service R Roof curbs in eight inch and fourteen inch heights1 1 Roof curbs for transitioning from York...

Page 8: ...ing and proper unit operation Rigging and handling Exercise care when you move the unit Do not remove any packaging until the unit is near the place of installation To rig the unit attach chain or cable slings to the lifting holes provided in the base rails You must use spreader bars across the top of the unit The spreader bars must have a length that exceeds the largest dimension across the unit ...

Page 9: ...cables so that it lifts evenly All panels must be secured in place when the unit is lifted The condenser coils must 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 3 Weights and dimensions Size tons Model Weight lbs Center of gravity 4 point load location lbs 6 point load location lbs Shipping Operating X...

Page 10: ...0 1 Weight given is for the maximum heater size available 54KW 2 Weight given is for the maximum number of tube heat exchangers available 8 tube 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 A FOR GAS INLET B 2X Ø 24 38 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 dra...

Page 11: ...6 5 1 4 Base Pan 17 13 16 View of Wall Across from Coil Gas Pipe Inlet 5 3 8 Table 6 ZR078 150 unit clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Make sure that overhanging structures or shrubs do not obscure the condenser air discharge outlet 72 Right 12 Front 36 Left 36 Rear 36 Bottom2 2 Units may be installed on combustable floors made from wood ...

Page 12: ...gure 12 ZR078 120 unit side duct openings Item Description A Disconnect switch cover B Power entry Ø 2 1 2 C Control entry Ø 7 8 D Power entry Ø 2 1 2 E Convenience outlet cover F Convenience outlet power entry Ø 7 8 A B C D E F Dot Plugs 5 5 32 31 11 16 2 31 32 18 1 4 Return Air Supply Air A B C D ...

Page 13: ...t model number Dimension in A B C D ZR078 27 3 4 12 1 16 27 1 2 16 ZR090 27 3 4 12 1 16 27 1 2 16 ZR102 28 1 4 18 1 16 28 1 4 18 1 4 ZR120 28 1 4 18 1 16 28 1 4 18 1 4 ZR150 28 1 4 18 1 16 28 1 4 18 1 4 4 5 16 A C B Table 8 Left end duct dimensions Unit model number Dimension in A B C ZR078 30 357 13 365 22 516 ZR090 30 357 13 365 22 516 ZR102 30 358 22 580 22 330 ZR120 30 358 22 580 22 330 ZR150 ...

Page 14: ... 8 or 14 50 1 2 30 20 20 80 5 8 6 A B E G D F C Roof curb components Item Description A Return air B Supply air C Right side of the unit D Front side of the unit E 2 typ F Insulated deck under the condenser section G Insulated deck under the compressor section 76 5 8 94 50 1 2 30 1 2 64 1 4 59 1 4 10 23 4 26 80 5 8 B A C E D ...

Page 15: ...the following steps 1 Remove the side duct covers 2 Orient the supply panel with the painted surface up 3 Slide the supply panel between the heat exchanger and the unit bottom The painted surface must face the heat exchanger The space is narrow but there is adequate room to install the panel 4 Secure the supply panel with the factory installed bracket and two screws 5 Orient the return panel with ...

Page 16: ...here POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials Procedures that risk oil leakage include but are not limited to the following Compressor replacement Repairing refrigerant leaks Replacing refrigerant components such as the filter drier pressure switch metering device or coil Units are shipped with compressor mountings that are facto...

Page 17: ... of a disconnect on the unit Confirm compliance with local code before you install a disconnect on the unit Electrical line must be sized properly to carry the load Note Use copper conductors only Each unit must be wired with a separate branch circuit fed directly from the meter panel and properly fused See Figures 22 23 and 24 for typical field wiring Refer to the appropriate unit wiring diagram ...

Page 18: ...ng unit with or without electric heat Figure 23 Typical field wiring disconnect cooling unit with gas heat 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 OR FIELD SUPPLIED DISCONNECT GROUND LUG CONTACTOR 1M ...

Page 19: ...e 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 24V COM OUT Return or Space Humidity Sensor 0 10VDC TB4 3 823 R RAH DCT PRS P4 1 2 3 4 825 W 824 BK S4 24V C 24 VAC Class 2 SD 24 Jumper Located on Harness Smoke Detector SD R 24V Output R If No Smoke Detector If Smoke Detector Is Used 2 Jumper is require...

Page 20: ... E09 6 8 1 18 9 38 9 44 4 50 50 E18 13 5 2 37 5 53 3 60 2 60 70 E24 18 0 2 50 0 69 0 75 8 70 80 E36 25 5 2 70 8 95 0 101 9 100 110 230 13 1 83 1 20 5 2 1 5 2 5 5 0 0 None 38 9 44 4 50 50 E09 9 0 1 21 7 38 9 44 4 50 50 E18 18 0 2 43 3 60 6 67 5 70 70 E24 24 0 2 57 7 78 7 85 5 80 90 E36 34 0 2 81 8 108 7 115 6 110 125 460 6 1 41 0 9 5 1 3 2 6 2 2 0 0 None 18 8 21 0 20 25 E09 9 0 1 10 8 18 8 21 0 20 ...

Page 21: ... 73 9 90 90 E24 18 0 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 22 4 149 0 35 0 2 1 9 6 5 5 0 0 None 68 4 73 9 90 90 E18 18 0 2 43 3 68 4 73 9 90 90 E24 24 0 2 57 7 84 2 91 0 90 100 E36 34 0 2 81 8 114 2 121 1 125 125 E54 54 0 2 129 9 141 9 148 8 175 175 460 10 6 75 0 16 5 1 3 4 7 2 2 0 0 None 33 6 35 8 40 45 E18 18 0 2 21 7 33 6 35 8 40 45 ...

Page 22: ... 9 43 3 48 8 50 60 E18 13 5 2 37 5 58 8 65 7 60 70 E24 18 0 2 50 0 74 5 81 3 80 90 E36 25 5 2 70 8 100 5 107 4 110 110 230 13 1 83 1 20 5 2 1 9 6 5 5 0 0 None 43 3 48 8 50 60 E09 9 0 1 21 7 43 3 48 8 50 60 E18 18 0 2 43 3 66 1 73 0 70 80 E24 24 0 2 57 7 84 2 91 0 90 100 E36 34 0 2 81 8 114 2 121 1 125 125 460 6 1 41 0 9 5 1 3 4 7 2 2 0 0 None 20 9 23 1 25 25 E09 9 0 1 10 8 20 9 23 1 25 25 E18 18 0...

Page 23: ...8 3 90 100 E24 18 0 2 50 0 80 0 86 8 90 100 E36 25 5 2 70 8 106 0 112 9 110 125 E54 40 6 2 112 7 158 4 165 2 175 175 230 22 4 149 0 35 0 2 1 14 0 5 5 0 0 None 72 8 78 3 90 100 E18 18 0 2 43 3 72 8 78 5 90 100 E24 24 0 2 57 7 89 7 96 5 90 100 E36 34 0 2 81 8 119 7 126 6 125 150 E54 54 0 2 129 9 147 4 154 3 175 175 460 10 6 75 0 16 5 1 3 6 6 2 2 0 0 None 35 5 37 7 45 45 E18 18 0 2 21 7 35 5 38 1 45 ...

Page 24: ...48 9 54 4 60 60 E18 13 5 2 37 5 65 8 72 7 70 80 E24 18 0 2 50 0 81 5 88 3 90 90 E36 25 5 2 70 8 107 5 114 4 110 125 230 13 1 83 1 20 5 2 1 5 2 5 5 10 0 None 48 9 54 4 60 60 E09 9 0 1 21 7 48 9 54 4 60 60 E18 18 0 2 43 3 73 1 80 0 80 80 E24 24 0 2 57 7 91 2 98 0 100 100 E36 34 0 2 81 8 121 2 128 1 125 150 460 6 1 41 0 9 5 1 3 2 6 2 2 5 0 None 23 8 26 0 25 30 E09 9 0 1 10 8 23 8 26 0 25 30 E18 18 0 ...

Page 25: ...4 83 9 100 100 E24 18 0 2 50 0 87 0 93 8 100 100 E36 25 5 2 70 8 113 0 119 9 125 125 E54 40 6 2 112 7 165 4 172 2 175 175 230 22 4 149 0 35 0 2 1 9 6 5 5 10 0 None 78 4 83 9 100 100 E18 18 0 2 43 3 78 6 85 5 100 100 E24 24 0 2 57 7 96 7 103 5 100 110 E36 34 0 2 81 8 126 7 133 6 150 150 E54 54 0 2 129 9 154 4 161 3 175 175 460 10 6 75 0 16 5 1 3 4 7 2 2 5 0 None 38 6 40 8 45 50 E18 18 0 2 21 7 39 2...

Page 26: ... 53 3 58 8 60 70 E18 13 5 2 37 5 71 3 78 2 80 80 E24 18 0 2 50 0 87 0 93 8 90 100 E36 25 5 2 70 8 113 0 119 9 125 125 230 13 1 83 1 20 5 2 1 9 6 5 5 10 0 None 53 3 58 8 60 70 E09 9 0 1 21 7 53 3 58 8 60 70 E18 18 0 2 43 3 78 6 85 5 80 90 E24 24 0 2 57 7 96 7 103 5 100 110 E36 34 0 2 81 8 126 7 133 6 150 150 460 6 1 41 0 9 5 1 3 4 7 2 2 5 0 None 25 9 28 1 30 30 E09 9 0 1 10 8 25 9 28 4 30 30 E18 18...

Page 27: ...88 3 100 110 E24 18 0 2 50 0 92 5 99 3 100 110 E36 25 5 2 70 8 118 5 125 4 125 150 E54 40 6 2 112 7 170 9 177 7 175 200 230 22 4 149 0 35 0 2 1 14 0 5 5 10 0 None 82 8 88 3 100 110 E18 18 0 2 43 3 84 1 91 0 100 110 E24 24 0 2 57 7 102 2 109 0 110 110 E36 34 0 2 81 8 132 2 139 1 150 150 E54 54 0 2 129 9 159 9 166 8 175 175 460 10 6 75 0 16 5 1 3 6 6 2 2 5 0 None 40 5 42 7 50 50 E18 18 0 2 21 7 41 6...

Page 28: ...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 24 24 24 24 24 24 24 24 24 24 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 7 16 Width 59 59 59 59 59 Hei...

Page 29: ... Blower sheave AK74 AK64 AK74 AK61 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 56 56 56 184T Filters Quantity size 4 24 x 16 x 2 6 7 4 24 x 16 x 2 6 7 4 24 x 20 x 2 6 7 4 24 x 20 x 2 6 7 4 24 x 20 x 2 6 7 4 24 x 16 x 4 8 4 24 x 16 x 4 8 4 24 x...

Page 30: ...superseded by local codes or gas utility requirements See Table 14 Gas pipe sizing capacity of pipe on page 31 The heating value of the gas may vary by locality You must check the value with the local gas utility Figure 25 Side entry gas piping Table 12 Electric heat minimum supply air Size tons Model Voltage Minimum supply air CFM Heater kW 9 18 24 36 54 078 6 5 ZR 208 230 3 60 1950 1950 1950 195...

Page 31: ... and scale Hammer on the outside of the pipe and blow out loose particles Before initial start up make sure that all gas lines external to the unit are purged of air The gas supply must be a separate line and installed in accordance with all safety codes as prescribed under Limitations OPTIONAL COIL GUARD SHOWN Table 14 Gas pipe sizing capacity of pipe Length of pipe ft Nominal iron pipe size 3 4 ...

Page 32: ... compartment with the heating elements extending into the supply air chamber All electric heaters are fused and intended for use with single point power supply 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 installe...

Page 33: ...ints 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 Temperature Free cooling...

Page 34: ...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 satisfied the ec...

Page 35: ...ects 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 The 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 H R 24V 24 VAC hot supplied for the outdoor air humidity sensor Connects through circuit trace to 24V IN pi...

Page 36: ...station sensor MOA Range parameter sets the cubic feet per minute liters per second measured by the air monitoring station sensor when it outputs 10 VDC Fr Air parameter reports input status 0 50000CFM 23595lps Used for economizer minimum position reset in speed controlled indoor blower applications C COM 24 VAC common 0 10 VDC negative for the air monitoring station sensor Connects through circui...

Page 37: ...to the 4 stage board and or fault detection diagnostics board 1 When wiring the unit and other devices using the SA Bus and FC Bus see Table 32 Smart Equipment economizer board analog outputs Location Board label Cover label Description Function and comments D J4 EX VFD 2 10 VDC positive output for the modulating power Exhaust fan Variable Frequency Drive discharge damper modulating power exhaust ...

Page 38: ... economizer actuator Connects through circuit trace to 24V IN pin COM EX FAN 24 VAC hot output to energize power exhaust fan contactor coil VFD enable relay coil ExFan parameter reports output status Off On when ExFType selection is Non Modulating Modulating Damper or Variable Frequency Fan Used to turn on enable the power exhaust fan motor COM 24 VAC common 0 10 VDC negative for economizer actuat...

Page 39: ...flection force recommended for the belt section 5 Re tighten the belt nuts Figure 28 Belt adjustment CFM static pressure and power altitude and temperature corrections Use the information below to assist in the application of the product at altitudes at or exceeding 1000 feet above sea level The air flow rates listed in the standard blower performance tables are based on standard air at sea level ...

Page 40: ...e 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 in 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 00...

Page 41: ... 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 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...

Page 42: ...094 1 43 1147 1 56 1201 1 67 1254 1 78 1309 1 90 1366 2 02 2600 902 0 97 962 1 16 1020 1 33 1076 1 47 1130 1 61 1183 1 73 1237 1 85 1291 1 96 1346 2 07 1402 2 19 2800 941 1 16 1002 1 35 1059 1 52 1115 1 67 1169 1 80 1222 1 92 1276 2 04 1330 2 15 1385 2 26 1442 2 38 3000 983 1 37 1043 1 56 1101 1 73 1157 1 88 1211 2 01 1264 2 13 1318 2 25 1372 2 36 1427 2 47 1483 2 59 3200 1028 1 60 1088 1 79 1145 ...

Page 43: ...G1 1 Blower performance includes gas heat exchangers and 2 in filters See the static resistance table for additional applications 2 See the RPM selection table to determine the required 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 3 HP and fie...

Page 44: ...0 1347 1 84 1424 1 98 1503 2 14 1586 2 31 2600 957 1 10 1030 1 30 1102 1 47 1174 1 62 1246 1 76 1320 1 89 1394 2 03 1471 2 17 1551 2 33 1634 2 51 2800 1009 1 32 1082 1 51 1154 1 69 1225 1 84 1298 1 98 1371 2 11 1446 2 25 1523 2 39 1602 2 55 1685 2 73 3000 1064 1 56 1137 1 75 1208 1 92 1280 2 08 1353 2 22 1426 2 35 1501 2 49 1578 2 63 1657 2 79 1740 2 96 3200 1122 1 82 1194 2 02 1266 2 19 1338 2 34...

Page 45: ...BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 3 HP and field supplied drive Standard 3 HP and drive High static 5 HP and drive 3200 837 1 44 889 1 57 940 1 69 989 1 81 1036 1 93 1081 2 04 1125 2 14 1168 2 25 1211 2 36 1252 2 47 3400 870 1 65 922 1 78 973 1 90 1022 2 02 1069 2 13 1114 2 24 1158 2 35 1202 2 46 1244 2 57 1286 2 68 3600 906 1 88 959 2 01 1009 2 13 1058 2 25 1105 ...

Page 46: ...er 10 12 hours run time Method two 1 Drill two 5 16 inch holes one in the return air duct as close to the inlet of the unit as possible and another in the supply air duct as close to the outlet of the unit as possible Table 21 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 ZR 1 1 2...

Page 47: ... are presented for side and bottom duct 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 on page 48 8 After you note the reading remove the tubes and seal the holes 9 Tighten the blower pulley and motor sheave s...

Page 48: ... review the installation 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 increase by the cube of the blower speed Static pressure increases by the square of the blower speed Only qualified personnel can make blower ...

Page 49: ...1 0 17 0 18 0 21 0 22 0 26 3900 0 09 0 29 0 23 0 19 0 20 0 23 0 24 0 28 4100 0 09 0 31 0 24 0 21 0 22 0 25 0 26 0 31 4300 0 10 0 30 0 25 0 23 0 24 0 28 0 29 0 34 4500 0 11 0 35 0 26 0 25 0 26 0 30 0 31 0 37 102 8 5 120 10 150 12 5 ZR 1900 0 06 0 02 0 12 0 05 0 06 0 07 0 08 0 10 2100 0 07 0 02 0 13 0 06 0 07 0 08 0 09 0 11 2300 0 08 0 04 0 14 0 07 0 08 0 09 0 10 0 13 2500 0 09 0 11 0 16 0 08 0 09 0...

Page 50: ...pressor 1 is energized If compressor 1 is active for first stage cooling or the first compressor is locked out compressor 2 is energized In free cooling mode if the call for the second stage of cooling continues for 20 minutes compressor 2 is energized provided it has not been locked out If there is an initial call for both stages of cooling the UCB delays energizing compressor 2 by 30 seconds in ...

Page 51: ...essure switch opens for greater than 5 seconds the UCB de energizes the associated compressor initiates the ASCD and if the other compressor is idle stops the condenser fans If the call for cooling is still present at the conclusion of the ASCD the UCB re energizes the halted compressor If a low pressure switch opens three times within one hour of operation the UCB locks out the associated compres...

Page 52: ...on within the Smart Equipment Controller menu Those modes consist of a Normal Alternate and Aux each mode is described below Normal cooling mode When there is a call for first stage cooling with or without a call for dehumidification the UCB de energizes the HGR relay de energizing SOL 2 SOL 3 HGRH and energizes SOL 1 engaging cooling circuit 1 resulting in circuit 1 cooling mode operation The uni...

Page 53: ... is a call for cooling and the economizer is operating as first stage of cooling All safety devices function as previously described Optional Aux mode The Aux mode available with hot gas reheat units introduces an operating mode that considers the dry bulb temperature in the space when choosing hot gas reheat staging The Aux mode reduces the amount of over cooling while maintaining humidity contro...

Page 54: ...ace Reducing the value below the correct setpoint gives shorter ON cycles and may result in the lowering of the temperature within the conditioned space See Table 28 for the required electric heat anticipator setting Gas heating sequence of operations When the thermostat calls for the first stage of heating the low voltage control circuit from R to W1 is completed A call for heat passes through th...

Page 55: ... Flame sense Flame sensing occurs at all times If W1 is not present and a flame is sensed for 2 seconds the draft motor is energized and the GV is kept off The ICB halts any operation until a flame is not detected Once the flame detection is lost the ICB performs a post purge Normal operation is allowed concurrently with the purge That is this purge can be considered the purge associated with a ca...

Page 56: ...he thermostat setting lower than the conditioned space temperature This resets any flash codes Gas heat anticipator setpoints The anticipator setpoint must be correct Too high of a setting results in longer heat cycles and a greater temperature swing in the conditioned space Reducing the value below the correct setpoint gives shorter ON cycles and may result in the lowering of the temperature with...

Page 57: ...his unit has two stages of gas heat The first stage is 60 of the full fire input and is considered the minimum input for the furnace The intended input for each furnace is shown in Table 32 The table applies to units operating on 60 Hz power only Determining the rate of gas flow second stage 1 Turn off all other gas appliances connected to the gas meter 2 Turn on the furnace and verify that the th...

Page 58: ...djust the second stage 100 input pressure first then adjust first stage 60 input pressure 1 Turn off electrical power to the unit 2 Using the outlet pressure port on the gas valve connect a manometer to monitor the manifold pressure 3 Remove the plastic cap that covers the HI and LO pressure adjustment screws 4 Turn on electrical power to the unit 5 Set the thermostat to call for second stage heat...

Page 59: ...ce Figure 33 Typical flame Figure 34 Typical gas valve Charging the unit All ZR units use thermal expansion devices Charge the unit to nameplate charge Navigation components for the Smart Equipment control board The following components are needed to access the control points in the Smart Equipment control Installation and operation guides are available from your equipment dealer or distributor 1 ...

Page 60: ...re also effective for economizer free cooling supply air temperature reset when the ClgStgs parameter is set for 1 or more G Continuous indoor blower request 24 VAC input switched from R OCC Occupancy request 24 VAC input switched from R Must have the OccMode parameter set for External to be effective X Hard lockout indicator 24 volt output to a light thermostat LED R 24 VAC hot for thermostat swi...

Page 61: ...inate temporary occupancy COM Common for ST and SSO inputs Negative of VDC circuit for ST and SSO inputs SSO Space Sensor Offset input from 0 to 20KΩ potentiometer Positive of VDC circuit 3 625 VDC reading to COM with open circuit 10KΩ 2 5 VDC is 0 F offset 0Ω 0 VDC is maximum above offset and 20KΩ 3 4 VDC is maximum below offset from active space temperature setpoint Smart Equipment UCB temperatu...

Page 62: ...AC hot return from Air Proving Switch When this optional input is enabled the air proving switch must close within 30 seconds of initiation of indoor blower operation and not open for greater than 10 seconds during indoor blower operation to allow heat cool operation and prevent an APS open alarm the air proving switch must open within 30 seconds of termination of indoor blower operation to preven...

Page 63: ...entilation cooling reheat or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage compressor UCBs If demand is present and permissions allow compressor 2 operation output with compressor cooling comfort ventilation cooling or heat pump heating demands Smart Equipment UCB refrigerant circuit safety switch and indoor blower overload connections Location Label D...

Page 64: ...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 of the board Positive of t...

Page 65: ... than FC bus BACnet MSTP communication circuit FC FC Field Connected BUS BACnet MSTP communication Positive of the VDC typically a fluctuating 1 5 to 3 5 volts reading to COM at least 0 25 volts lower than FC bus BACnet MSTP communication circuit COM Common for the FC Field Connected BUS BACnet MSTP communication circuit Negative of the VDC FC bus BACnet MSTP communication circuit SHLD Shield for ...

Page 66: ...Pair 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 jack housing The preassembled cables that are available from Anixter Part No CBL NETWORKxxx use 24 gauge wire Anixter preassembled CBL NETWORK25 CBL NETWORK50 CBL NETWORK75 CBL NETWORK100 0 15 in FC Bus...

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