York ZS Series Installation Manual Download Page 1

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R-410A
ZS SERIES

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

60 Hertz

518676-BIM-C-0610

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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



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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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

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

LIST OF TABLES

ZS-06 thru -12 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . 7

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

ZS-06 thru -12 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9

ZS-06 thru -12 Unit Physical Dimensions . . . . . . . . . . . . . . . 11

ZS-06 thru -12 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . 11

Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

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

ZS-06 thru -12 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 50” Cabinet . . . . . . . . . . . . . . . . . 53

Electric Heat Limit Setting 42” Cabinet . . . . . . . . . . . . . . . . . 54

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

ZS Component Location (ZS-10 Shown) . . . . . . . . . . . . . . . . 6

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

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

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

ZS-06 thru -10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

ZS-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ZS-06 thru -12 Unit Bottom Duct Openings . . . . . . . . . . . . . 12

ZS-06 thru -12 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . 13

ZS-06 thru -10 Unit Side Duct Openings . . . . . . . . . . . . . . . 13

ZS-12 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . . 14

ZS-06 thru -12 Unit Left Duct Opening . . . . . . . . . . . . . . . . . 14

ZS-06 thru -12 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ZS-06 thru -12 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

Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

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

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 ZS Series

Page 1: ...pecifications 46 19 Power Exhaust Specifications 46 20 Motor Sheave Datum Diameters 48 21 Additional Static Resistance 49 22 Electric Heat Limit Setting 50 Cabinet 53 23 Electric Heat Limit Setting 42 Cabinet 54 24 Electric Heat Anticipator Setpoints 54 25 Gas Heat Limit Control Settings 55 26 Gas Heat Anticipator Setpoints 56 27 Gas Rate Cubic Feet Per Hour 58 28 Gas Heat Stages 58 29 Unit Contro...

Page 2: ...ng 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 alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or...

Page 3: ...on 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 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 ...

Page 4: ...s 3 5 Y Options 4 5 Z Options 3 4 5 1 Disconnect 2 Non Pwr d Conv Outlet 3 Smoke Detector 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 TA Technicoat Condenser Coil ...

Page 5: ...1 Unit Shipping Bracket 2 Turn each bracket toward the ground and the protective plywood covering will drop to the ground 3 Remove the condenser coil external protective covering prior to operation 4 Remove the toolless doorknobs and instruction packet prior to installation Figure 2 Condenser Covering Figure 3 Compressor Section 5 If a factory option convenience outlet is installed the weatherproo...

Page 6: ...cally included in this type of application When applying this product for process cooling applications 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 Ro...

Page 7: ...cise 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 ZS 06 thru 12 Unit Limitations Size Tons Model Unit Voltage Unit Limitation...

Page 8: ...is lifted 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 06 6 5 ZS 865 860 38 24 200 149 218 292 140 114 95 138 1...

Page 9: ...ht 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 Ø 24 47 TYP 2 PL 15 38 15 38 59 00 15 25 29 69 59 LEFT 11 3 8 21 3 16 89 27 5 16 4 3 16 FRONT See detail A for gas inlet A See detail B f...

Page 10: ...ohnson Controls Unitary Products Figure 9 ZS 12 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 14 92 58 09 14 92 14 92 29 95 30 11 45 64 Ø 24 47 TYP 4 PL ...

Page 11: ... 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 ZS 06 thru 12 Unit Clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Over hanging structure or shrubs should not obscure condenser air...

Page 12: ...nit Bottom Duct Openings Bottom power control and convenience outlet wiring entry 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 ...

Page 13: ...Electrical Entry Figure 12 ZS 06 thru 10 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: ...2 Unit 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 ZS 06 27 3 4 12 1 16 27 1 2 16 ZS 07 27 3 4 12 1 16 27 1 2 16 ZS 08 28 1 4 18 1 16 28 1 4 18 1 4 ZS 10 28 1 4 18 1 16 28 1 4 18 1 4 ZS 12 28 1 4 18 1 16 28 1 4 18 1 4 4 5 16 30 3 8 ...

Page 15: ...ntake 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...

Page 16: ...ide 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 local codes Use a sealing compound on male pipe threads Install conden...

Page 17: ...utilized for these units Factory installed disconnects are available If installing a disconnect field supplied or Unitary Products supplied accessory refer to Figure 4 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 code before mounting a disconnect on the unit Electrical line must be sized pro...

Page 18: ...eld 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 OR FIELD SUPPLIED DISCONNECT GROUND LUG CONTACTOR 1M ...

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: ...one 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 None 39 8 45 3 50 50 E09 9 1 22 6 39 8 45 3 50 50 E18 18 2 45 2 61 6 68 5 70 70 E24 24 2 60 2 79 7 86 5 80 90 E36 34 2 85 3 109 7 116 6 110 125 460 5 2 44 8 1 1 6 3 0 2 2 0 None 17 9 20 1 20 25 E09 9 1 11 3 17 9 20 1 20 25 E1...

Page 21: ... 2 50 0 75 6 81 3 90 100 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 3 5 9 6 5 5 0 None 75 6 81 1 90 100 E18 18 0 2 45 2 75 6 81 1 90 100 E24 24 0 2 60 2 84 2 91 0 90 100 E36 34 0 2 85 3 114 2 121 1 125 125 E54 54 0 2 135 6 141 9 148 8 175 175 460 12 2 87 19 1 6 4 8 2 2 0 None 38 7 40 9 50 50 E18 18 0 2 22 6 38 7 40 9 50 50 E24 24 0 2 30 1 42 1 44 8 50 ...

Page 22: ... 50 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 None 43 4 48 9 50 60 E09 9 1 22 6 43 4 48 9 50 60 E18 18 2 45 2 66 1 73 70 80 E24 24 2 60 2 84 2 91 90 100 E36 34 2 85 3 114 2 121 1 125 125 460 5 2 44 8 1 1 6 4 8 2 2 0 None 19 7 21 9 20 25 E09 9 1 11 3 19 7 22 3 20 25 E18 18 2 22 6...

Page 23: ... 50 0 81 5 88 3 100 100 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 3 5 15 2 5 5 0 None 81 2 86 7 100 100 E18 18 0 2 45 2 81 2 86 7 100 100 E24 24 0 2 60 2 91 2 98 0 100 100 E36 34 0 2 85 3 121 2 128 1 125 150 E54 54 0 2 135 6 148 9 155 8 175 175 460 12 2 87 19 1 6 7 6 2 2 0 None 41 5 43 7 50 50 E18 18 0 2 22 6 41 5 43 7 50 50 E24 24 0 2 30 1 45 6 48 3 ...

Page 24: ...0 60 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 None 49 8 55 3 60 60 E09 9 1 22 6 49 8 55 3 60 60 E18 18 2 45 2 74 1 81 80 90 E24 24 2 60 2 92 2 99 100 100 E36 34 2 85 3 122 2 129 1 125 150 460 5 2 44 8 1 1 6 3 0 2 2 5 None 22 9 25 1 25 30 E09 9 1 11 3 23 5 26 3 25 30 E18 18 2 22 6...

Page 25: ...18 0 2 50 0 87 0 93 8 100 110 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 23 1 160 36 3 5 9 6 5 5 10 None 85 6 91 1 100 110 E18 18 0 2 45 2 85 6 91 1 100 110 E24 24 0 2 60 2 96 7 103 5 100 110 E36 34 0 2 85 3 126 7 133 6 150 150 E54 54 0 2 135 6 154 4 161 3 175 175 460 12 2 87 19 1 6 4 8 2 2 5 None 43 7 45 9 50 50 E18 18 0 2 22 6 43 7 45 9 50 50 E24 24 0 2 30 1 48 ...

Page 26: ... 60 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 None 53 4 58 9 60 70 E09 9 1 22 6 53 4 58 9 60 70 E18 18 2 45 2 78 6 85 5 80 90 E24 24 2 60 2 96 7 103 5 100 110 E36 34 2 85 3 126 7 133 6 150 150 460 5 2 44 8 1 1 6 4 8 2 2 5 None 24 7 26 9 25 30 E09 9 1 11 3 25 8 28 5 30 30 E18 18 2 ...

Page 27: ...0 2 50 0 94 0 100 8 110 110 E36 25 5 2 70 8 120 0 126 9 125 150 E54 40 6 2 112 7 172 4 179 2 175 200 230 23 1 160 36 3 5 15 2 5 5 10 None 91 2 96 7 110 110 E18 18 0 2 45 2 91 2 96 7 110 110 E24 24 0 2 60 2 103 7 110 5 110 125 E36 34 0 2 85 3 133 7 140 6 150 150 E54 54 0 2 135 6 161 4 168 3 175 175 460 12 2 87 19 1 6 7 6 2 2 5 None 46 5 48 7 50 60 E18 18 0 2 22 6 46 5 48 7 50 60 E24 24 0 2 30 1 51 ...

Page 28: ...ers 4 6 4 6 4 6 6 8 6 8 No stages 21 21 21 21 21 21 21 21 21 21 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 42 42 50 3 4 50 3 4 50 3 4 OPERATING WT lbs 860 880...

Page 29: ... 1VM50 1VM50 1VM50 1VM50 1VM50 1VP56 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 2 3 4 24 x 16 x 2 2 3 4 24 x 20 x 2 2 3 4 24 x 20 x 2 2 3 4 24 x 20 x 2 2 3 4 ...

Page 30: ...for 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 06 6 5 ZS 208 230 3 60 1950 1950 1950 1950 460 3 60 1950 1950 1950 1950 600 3 60 1950 1950 1950 1950 07 7 5 ZS 208 230 3 60 2250 2250 2250 2250 460 3 60 2250 2250 2250 2250 600 3 60 2250 2250 2250 2250 08 8 5 ZS 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: ...he 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 06 6 5 ZS 12 1950 3250 1950 3250 18 1950 3250 1950 3250 07 7 5 ZS 12 2250 3750 2250 3750 18 2250 3750 2250 3750 08 8 5 ZS 12 2550 4250 2550 4250 18 2550 4250 2550 4250 10 10 ZS 18 3000 5000 3000 5000 24 3000 5000 3000 5000 12 ...

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: ...onnect 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 times the duct diameter Tubing m...

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: ...osive 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 along with the respective ground wires are supplied with the unit and need to be connected after the drive is installed A terminal block located in the control box is provided for field ...

Page 37: ...ensor input Terminal AQ accepts a 2 to 10 Vdc signal with respect to the AQ1 terminal When the signal is below it s set point the actuator is allowed to modulate normally in accordance with the enthalpy and mixed air sensor inputs When the AQ signal exceeds it s set point setting and there is no call for free cooling the actuator is proportionately modulated from the 2 to 10 Vdc signal with 2 Vdc ...

Page 38: ...he unit point of power connection is misphased See PHASING Belt Tension The tension on the belt should be adjusted as shown in Figure 29 Figure 29 Belt Adjustment N1 N P1 P EXH Set EXH Min Pos IAQ Max IAQ IAQ Min Free Cool T T1 AQ1 AQ SO SO SR SR A B C D TR TR1 24 Vac HOT 24 Vac COM EF EF1 2 3 4 5 1 Exhaust Air Adjustment Screw Exhaust Air LED Damper Min Position Screw Indoor Air Quality Max Adjus...

Page 39: ...e the air at high altitude is less dense less static pressure will be generated and less power will be required than a similar application at sea level Air density correction factors are shown in Table 14 and Figure 30 Procedure for adjusting belt tension 1 Loosen six nuts top and bottom A 2 Adjust by turning B 3 Never loosen nuts C 4 Use belt tension checker to apply a perpendicular force to one ...

Page 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: ... 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 05 990 1 24 1047 1 40 1103 1 55 1158 1 69 1212 1 82 1268 1 95 1324 2 07 1382 2 21 2800 906 1 03 968 1 25 1027 1 43 1084 1 60 1139 1 75 1194 1 89 1249 2 02 1304 2 14 1361 2 27 1419 2 40 3000 945 1 25 1007 1 46...

Page 43: ... Pressure 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 3 HP Field Suppl...

Page 44: ... 34 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 1219 1 72 1294 1 87 1371 2 02 1450 2 18 1532 2 36 1617 2 56 2800 971 1 20 1046 1 42 1119 1 61 1193 1 78 1267 1 94 1343 2 09 1419 2 24 1498 2 40 1580 2 58 1665 2 78 3000 1023 1 44 1097 1 66 1171 1 85 1...

Page 45: ... 2 0 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 1059 2 12 1109 2 29 1155 2 50 1194 2 73 1225 3 01 3400 860 1 48 898 1 67 942 1 84 992 2 00 1044 2 16 1095 2 32 1145 2 50 1191 2 70 1231 2 94 1262 3 22 3600 898 1 71 935 1 90 980 2 07 1030 2 23 1081...

Page 46: ...set 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 06 6 5 ZS 1 1 2 1725 0 8 1 15 56 3 4 4 4 7 8 1VM50 7 0 1 AK74 A49 2 1725 0 8 1 15 56 3 4 4 4 7 8 1VM50 6 0 1 AK64 A49 07 7 5 ZS 1 1 2 1725 0 8 1 15 56 3 4 4 4 7 8 1VM50 7 0 1 AK74 A49...

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: ... 5 ZS 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 2300 0 01 0 11 0 12 0 07 0 08 0 09 0 10 0 13 2500 0 02 0 13 0 14 0 08 0 09 0 10 0 11 0 14 2700 0 03 0 16 0 15 0 09 0 10 0 12 0 13 0 16 2900 0 04 0 18 0 16 0 10 0 11 0 13 0 14 0 18 3100 0 05 0 20 0 18 0 12 0 13 0 15 0 16 0 20 3300 0 06 0 22 0 19 0 13 0 14 0 17 0 18 0 22 3500 0 07 0 24 0 20 0 15 0 16 0 19...

Page 50: ...tion is sufficient for free cooling the economizer will modulate to control the SAT to 1 degrees of the operational set point The following components are needed to access the control points in the Simplicity controller Installation and operation guide is located on UPGNET 1 Computer running Windows software with a standard USB port 2 Simplicity PC Software http www yorkupg com software asp 3 Free...

Page 51: ... always the R to G connection provides minimum position but does not provide power exhaust operation Economizer With Optional VAV OR Intelli Comfort Control The position of the outside air and return air dampers are controlled through a 2 10 VDC signal from the VAV or Intelli Comfort control board The economizer is enabled only in Occupied or Recovery mode When the control is not powered or is in ...

Page 52: ...e UCB will de energize the associated compressor initiate the ASCD and if the other compressor is idle stop the condenser fans Once the low pressure switch has been proven closed during the 30 second monitor period described above the UCB will monitor the low pressure limit switch for any openings If the low pressure switch opens for greater than 5 seconds the UCB will de energize the associated c...

Page 53: ...a Upon a call for first stage heat by the thermostat the heater relay RA will be energized After completing the specified fan on delay for heating the UCB will energize the blower motor If the second stage of heat is required heater relay RB 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...

Page 54: ...ected the ICB enters a flame stabilization period If flame 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 After the flame stabilization period a loss of flame for 3 4 second will cause the GV to close and the retry operation to begin At the conclusion of ...

Page 55: ... the ICB will energize the draft motor The ICB will not operate the furnace until voltage is no longer sensed at the GV The draft motor is stopped when voltage is not sensed at the GV Any time the UCB senses voltage at the GV without a call for heat for a continuous five minute period the UCB will lock on the indoor blower and a flash code is initiated Table 29 When voltage is no longer sensed at ...

Page 56: ... 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 conditioned space Refer to Table 26 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 a...

Page 57: ... Measure the time needed for one revolution of the hand on the smallest dial on the meter A typical gas meter has a 1 2 or a 1 cubic foot test dial 4 Using the number of seconds it takes for one revolution of the dial calculate the cubic feet of gas consumed per hour See example below 5 If necessary adjust the high pressure regulator as discussed in the section Manifold Gas Pressure Adjustment Be ...

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 32 Typical Flame Figure 33 Typical Gas Valve Charging The Unit All ZS units use Thermal Expansion Devices Charge the unit to nameplate c...

Page 60: ...es 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 29 Table 29 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 Failure...

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 32 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: ...518676 BIM C 0610 64 Johnson Controls Unitary Products Figure 37 Trip Failure Flow Chart ...

Page 65: ... 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 operate I...

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: ... 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 thermostat check ...

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 ZS Series, Installation Manual

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