York ZZ Seies Installation Manual Download Page 1

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R-410A

ZZ SERIES W/SMART EQUIPMENT™

15 Ton
60 Hertz (Export Only)

5835254-YIM-A-1119

Table of contents

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

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

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

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

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

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

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

Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Single enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Dual enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Free cooling operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 30

Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . 41

Cooling operation errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Electric heating sequence of operations . . . . . . . . . . . . . . . . . 43

Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 43

Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 44

Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 44

Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Navigation components for the Smart Equipment™ control board . . 49

Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 50

Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

List of tables

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

2 ZZ15 unit limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

4 ZZ15 unit accessory weights . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 ZZ15 unit physical dimensions . . . . . . . . . . . . . . . . . . . . . . . 10

6 Gas inlet and drain components . . . . . . . . . . . . . . . . . . . . . . 11

7 ZZ15 unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8 Side duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10 Roof curb components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

11 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

12 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

13 ZZ15 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

14 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 25

15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 25

16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 26

17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 35

19 Airflow performance - side duct application . . . . . . . . . . . . . 37

20 Airflow performance - bottom duct application . . . . . . . . . . . 37

21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

22 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 38

23 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 38

24 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 40

25 Additional static resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 41

26 Electric heat limit setting 50 in. cabinet . . . . . . . . . . . . . . . . . 44

27 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 44

28 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 45

29 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 46

30 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 47

31 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

32 Cable for FC buses and SA buses in order of preference . . 56

33 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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 ZZ15 physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9 ZZ15 unit bottom duct openings . . . . . . . . . . . . . . . . . . . . . . 12

10 ZZ15 unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

11 ZZ15 unit side duct openings . . . . . . . . . . . . . . . . . . . . . . . . 13

12 ZZ15 unit left/end duct opening . . . . . . . . . . . . . . . . . . . . . . 14

13 ZZ15 roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

14 ZZ15 transition roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 16

16 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 16

17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 16

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

20 Field wiring disconnect - cooling unit with or without electric

heat and all units with a VFD option . . . . . . . . . . . . . . . . . . . 18

21 Field wiring disconnect - cooling unit with gas heat without a

VFD option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

22 Typical electronic thermostat field wiring . . . . . . . . . . . . . . . 20

23 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

24 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 30

26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 35

28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

29 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

30 Typical gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

31 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Summary of Contents for ZZ Seies

Page 1: ...eat minimum supply air 26 17 Supply air limitations 34 18 Altitude temperature correction factors 35 19 Airflow performance side duct application 37 20 Airflow performance bottom duct application 37 2...

Page 2: ...ecautions 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...

Page 3: ...ed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes The furnace...

Page 4: ...untry L Latin America A Std Cabinet E SSD SST Drain Pan R Reverse Drain Pan 1 STD Throwaway Filter 2 2 Pleated Filters Merv 8 3 4 pleated Filters Merv 13 4 Coil Guard CG STD Filter 5 2 Pleated Filter...

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 a...

Page 6: ...ate 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 h...

Page 7: ...e D Filter access 2 in or 4 in filter options N 20 gauge aluminized steel tubular heat exchanger for long life stainless steel option E Toolless door latch O Dual stage cooling for maximum comfort F B...

Page 8: ...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...

Page 9: ...igure 7 Center of gravity 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 lo...

Page 10: ...m 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 15 23 29 03 14 85 29 03 14 85 15 23 28 86 29 66 44 09 24 58 TYP 4...

Page 11: ...C Item Description A Gas pipe inlet B Gas exhaust vent C 1 in FPT Table 6 ZZ15 unit clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Make sure that overha...

Page 12: ...Top view Figure 9 ZZ15 unit 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...

Page 13: ...Figure 11 ZZ15 unit side duct openings Item Description A Disconnect switch cover B Power entry 2 1 2 C Control entry 7 8 D Power entry 2 1 2 E Convenience outlet cover F Convenience outlet power ent...

Page 14: ...Ducted Systems Figure 12 ZZ15 unit left end duct opening Figure 13 ZZ15 roof curb 4 5 16 A C B Table 8 Left end duct dimensions Unit model number Dimension in A B C ZZ15 30 358 22 580 22 330 8 or 14...

Page 15: ...ation no duct cover changes are necessary For a side duct application complete the following steps 1 Remove the side duct covers 2 Orient the supply panel with the painted surface up 3 Slide the suppl...

Page 16: ...ndensate 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...

Page 17: ...uring starting and running conditions The voltage tolerances are indicated on the unit rating plate and in Table 2 The internal wiring harnesses furnished with this unit are an integral part of the de...

Page 18: ...disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the curb Figure 20 Field wiring disconnect cooling unit with or without electric heat and al...

Page 19: ...ohnson Controls Ducted Systems 19 Figure 21 Field wiring disconnect cooling unit with gas heat without a VFD option L1 T1 L2 T2 T3 L3 THREE PHASE POWER SUPPLY FACTORY OR FIELD SUPPLIED DISCONNECT GROU...

Page 20: ...equired on single stage he g units Jumper is required if there is no Smoke Detector circuit Jumper is required for any co of R RC or RH 5 5 OCC is an output from the thermostat to indicate the Occupie...

Page 21: ...None 37 1 39 3 45 50 E18 18 2 21 7 37 1 39 3 45 50 E24 24 2 28 9 40 8 43 0 45 50 E36 34 2 40 9 55 8 58 0 60 60 E54 54 2 65 86 0 88 2 90 90 ZZ15 Hi Static Motor Without Powered Convenience Outlet Size...

Page 22: ...60 E18 18 2 21 7 57 1 59 3 60 60 E24 24 2 28 9 60 8 63 0 65 70 E36 34 2 40 9 75 8 78 0 90 90 E54 54 2 65 106 0 108 2 110 110 ZZ15 Hi Static Motor With Powered Convenience Outlet Size Tons Volt Compres...

Page 23: ...180 240 1st Stage Heat input K Btu 144 192 AFUE Steady State Efficiency 80 80 No burners 6 8 No stages2 2 2 Temperature Rise Range F 10 40 25 55 Gas Limit Setting F 195 160 Gas piping connection in 3...

Page 24: ...heave 1VM50 1VP56 Blower Sheave AK74 BK77 Belt A54 BX55 Motor HP each 3 5 RPM 1725 1725 Frame size 56 184T FILTERS Quantity Size 4 24 x 20 x 2 4 5 4 24 x 20 x 4 6 1 Cooling Only Unit or Cooling Unit w...

Page 25: ...w required specific gravity of the gas and the length of run Follow the National Fuel Gas Code Z223 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada in all cases unless they are s...

Page 26: ...se Never use a flame LP units tanks and piping All gas heat units are shipped from the factory equipped for natural gas use only The unit may be converted in the field for use with LP gas with accesso...

Page 27: ...in the return air compartment You must test and maintain the detector on a regular basis according to NFPA 72 requirements You must clean the detector at least once a year For specific troubleshootin...

Page 28: ...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 make sure that there are no obstructions turn...

Page 29: ...he Economizer setpoint 1 F the control starts a 12 minute timer to energize a compressor output If at any time the economizer output drops below 100 the timer stops and resets when the economizer outp...

Page 30: ...cts through circuit trace to 24V IN pin HOT C COM Mixed air temperature sensor input from 10K 77 F Type III negative temperature coefficient thermistor The MAT parameter reports input status F C 3 65...

Page 31: ...tation 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...

Page 32: ...o 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...

Page 33: ...nnects 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 sel...

Page 34: ...tion force is as follows Tension new belts at the max deflection force recommended for the belt section 5 Re tighten the belt nuts Figure 26 Belt adjustment CFM static pressure and power altitude and...

Page 35: ...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 a...

Page 36: ...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 ach...

Page 37: ...00 1032 4 16 1084 4 37 1133 4 57 1181 4 75 1227 4 93 1271 5 11 1315 5 28 1357 5 45 1398 5 62 6000 1067 4 54 1119 4 75 1168 4 95 1216 5 13 1262 5 31 1306 5 49 1350 5 66 6200 1103 4 94 1155 5 15 1204 5...

Page 38: ...ulley and motor sheave set screws after any adjustments Re check the set screws after 10 12 hours run time Table 19 RPM selection Size tons Model HP Max BHP Motor sheave Blower sheave 6 turns open 5 t...

Page 39: ...e the number of turns the variable motor sheave is open 5 Select the correct blower performance table for the unit from Tables 17 and 18 Tables are presented for side and bottom duct configuration 6 D...

Page 40: ...anges 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 i...

Page 41: ...ls 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 com...

Page 42: ...or dual enthalpy and a power exhaust operates as specified above with one addition The power exhaust motor is energized 45 seconds after the actuator position exceeds the exhaust fan setpoint on the e...

Page 43: ...50 5 psig The above pressure switches are hard soldered to the unit The refrigeration systems are independently monitored and controlled On any fault only the associated system is affected by any safe...

Page 44: ...is not detected the GV closes and a retry operation begins During the flame stabilization period a loss of the flame for 2 seconds causes the GV to close and the retry operation to begin After the fla...

Page 45: ...an on delay for heating and GV voltage or W1 is lost the indoor blower is forced on for the length of the fan off delay for heating During a call for heat if the UCB does not sense voltage at the GV f...

Page 46: ...ze the crankcase heaters at least 10 hours before the system is put into operation 2 Set the room thermostat setting lower than the room temperature First stage compressors energize after the built in...

Page 47: ...te Do not over fire the furnace on second stage If in doubt it is better to leave the second stage of the furnace slightly under fired 6 Repeat Steps 1 5 Determining the rate of gas flow first stage 1...

Page 48: ...e heat 8 If necessary use a screwdriver to turn the first stage adjustment screw clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure Note Do not under fire the un...

Page 49: ...it control board 2 Mobile Access Portal MAP Gateway Portable Source 1 P N S1 JC MAP1810 OP 3 MAP Gateway Quick Start Guide P N 24 10737 16 4 MAP Gateway Instruction P N 24 10737 8 For more information...

Page 50: ...e 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...

Page 51: ...erminate 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 20K potentiometer Positive of VDC circuit 3 625 VDC...

Page 52: ...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 se...

Page 53: ...ntilation 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 operatio...

Page 54: ...f 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 connecto...

Page 55: ...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...

Page 56: ...air Cable2 2 We recommend 26 AWG solid 6 wire 3 twisted pairs cable as the best fit for fabricating modular cables with the modular jack housing assembly Be sure the cable you use fits the modular jac...

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