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R-410A
ZB SERIES W/SMART EQUIPMENT™
6.5 - 12.5 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 44
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ZB078-150 unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZB078-150 standard unit weights . . . . . . . . . . . . . . . . . . . . . 11
4 ZB078-150 unit accessory weights . . . . . . . . . . . . . . . . . . . . 11
5 ZB078-150 unit physical dimensions . . . . . . . . . . . . . . . . . . . 13
6 ZB078-150 unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 ZB078-120 side duct dimensions . . . . . . . . . . . . . . . . . . . . . 16
8 ZB150 side duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
13 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 36
14 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 37
15 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 37
16 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
17 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 49
18 Airflow performance - side duct application . . . . . . . . . . . . . . 51
19 Airflow performance - bottom duct application . . . . . . . . . . . 54
20 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
21 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 56
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Barometric relief hood - shipping location . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 4 point and 6 point load weight for ZB150 units . . . . . . . . . . 10
6 4 point and 6 point load weight for ZB078-120 units . . . . . . 10
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZB078-120 physical dimensions . . . . . . . . . . . . . . . . . . . . . . 12
9 ZB150 physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 ZB078-150 unit bottom duct openings . . . . . . . . . . . . . . . . . 15
11 ZB078-150 unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . 16
12 ZB078-150 unit left/end duct opening . . . . . . . . . . . . . . . . . . 17
13 ZB078-150 roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14 ZB078-150 transition roof curb . . . . . . . . . . . . . . . . . . . . . . . 18
15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 19
16 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 19
Table of contents
Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling operation 2 fan cooling operation . . . . . . . . . . . . . . . . . . 60
Cooling operation 4 fan cooling operation . . . . . . . . . . . . . . . . . . 60
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 62
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 62
Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 63
Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 63
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Navigation components for the Smart Equipment™ control board .
67
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 68
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
List of tables
22 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 56
23 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 58
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
25 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 63
26 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 64
27 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 66
28 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
29 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 67
30 Cable for FC buses and SA buses in order of preference . . 74
31 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 74
32 ZB078 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 75
33 ZB078 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 75
34 ZB090 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 76
35 ZB090 charging table - system 2. . . . . . . . . . . . . . . . . . . . . . 76
36 ZB102 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 77
37 ZB102 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 77
38 ZB120 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 78
39 ZB120 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 78
40 ZB150 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 79
41 ZB150 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 79
List of figures
17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 20
19 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
20 Field wiring disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
21 Typical control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
22 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
23 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
24 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 44
26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 49
28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
30 Typical two stage gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 67
31 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5808009-YIM-A-0320
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Related Manuals for York ZB Series
Summary of Contents for York ZB Series
- Page 1 R-410A ZB SERIES W/SMART EQUIPMENT™ 6.5 - 12.5 Ton 60 Hertz Table of contents General ..........2 Air balance.
- Page 2 5808009-YIM-A-0320 General ® York ZB078-150 units are single package air conditioners with optional gas heating designed for outdoor installation on a Before you perform service or maintenance operations rooftop or slab and for non-residential use. The units can be on the unit, turn off the main power switch to unit.
- Page 3 Inspection Renewal parts ® As soon as you receive a unit, you must inspect it for possible Contact your local York parts distribution center for authorized damage during transit. If damage is evident, note the extent of replacement parts. the damage on the carrier’s freight bill. You must make a Approvals separate request for inspection by the carrier’s agent in writing.
- Page 4 5808009-YIM-A-0320 Nomenclature ® 6.5-12.5 Ton York Model Number Nomenclature Z B 078 C A 2 A 1 Product Generation Product Category 1 = First Generation Z = A/C, Single Pkg., R-410A Cabinet Options Product Identifier A = Std Cabinet E = SSD (SST Drain Pan)
- Page 5 5808009-YIM-A-0320 Installation Installation safety information FIRE OR EXPLOSION HAZARD Read the following instructions before you install this appliance. This is an outdoor combination heating and cooling unit. The Failure to follow the safety warning exactly could result installer must assure that these instructions are made available in serious injury, death, or property damage.
- Page 6 5808009-YIM-A-0320 National Fuel Gas Code, ANSI Z223.1 - Latest Edition Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edition Local building codes, and Local gas utility requirements In Canada: Toolless Doorknobs Canadian Electrical Code, CSA C22.1 Installation Codes, CSA - B149.1. Local plumbing and waste water codes, and Other applicable local codes.
- Page 7 20-gauge aluminized steel tubular heat exchanger for long life Second model nameplate inside hinged access panel (stainless steel option) 1. Roof curbs for transitioning from York Sunline™ footprint to the ZB Series footprints are also available (field-installed accessory). Johnson Controls Ducted Systems...
- Page 8 5808009-YIM-A-0320 Table 2: ZB078-150 unit limitations Unit limitations Size Model Unit voltage SCCR (kVA Applied voltage Outdoor DB temp (tons) Minimum Maximum Maximum (°F) 208/230-3-60 460-3-60 (6.5) 575-3-60 208/230-3-60 460-3-60 (7.5) 575-3-60 208/230-3-60 460-3-60 (8.5) 575-3-60 208/230-3-60 460-3-60 (10) 575-3-60 208/230-3-60 460-3-60 (12.5)
- Page 9 The condenser coils must be protected from rigging ® If a unit is installed on a roof curb other than a York roof cable damage with plywood or another suitable material. curb, you must apply gasketing to all surfaces that come in contact with the unit underside.
- Page 10 5808009-YIM-A-0320 LEFT LEFT FRONT FRONT Figure 5: 4 point and 6 point load weight for ZB150 units FRONT FRONT LEFT LEFT Figure 6: 4 point and 6 point load weight for ZB078-120 units FRONT LEFT Figure 7: Center of gravity Johnson Controls Ducted Systems...
- Page 11 5808009-YIM-A-0320 Table 3: ZB078-150 standard unit weights Center of Weight (lbs.) 4 point Load Location (lbs.) 6 point Load Location (lbs.) Size Gravity Model (Tons) Shipping Operating 1035 1030 39.6 25.3 (6.5) 1085 1080 38.7 23.7 (7.5) 1089 1084 38.4 24.4 (8.5) 1090...
- Page 12 5808009-YIM-A-0320 29.69 15.25 15.38 59.00 15.38 2X Ø 24.38 SEE DETAIL A FOR GAS INLET 11.38 SEE DETAIL B 59.00 4.19 FOR DRAIN LOCATION LEFT 27.31 21.19 89.00 FRONT Figure 8: ZB078-120 physical dimensions Johnson Controls Ducted Systems...
- Page 13 5808009-YIM-A-0320 28.86 29.66 44.09 15.23 14.85 29.03 29.03 14.85 Ø 24.58 TYP. 4 PL. 15.23 See detail A for gas inlet 11 3/8 See detail B for drain location 21 3/16 LEFT 4 3/16 FRONT 27 5/16 Figure 9: ZB150 physical dimensions Table 5: ZB078-150 unit physical dimensions Dimension (in.) Unit model number...
- Page 14 5808009-YIM-A-0320 Detail A Detail B 3.184 Gas Pipe Inlet Ø 2.000 Gas Exhaust Vent 5-3/8 Ø 3.126 17.541 1” FPT 7.715 4.737 50 3/4” CABINET Table 6: ZB078-150 unit clearances Direction Distance (in.) Direction Distance (in.) Right Front Left Rear Bottom 1.
- Page 15 5808009-YIM-A-0320 32 11/16 6 13/16 6 13/16 RETURN SUPPLY 27 1/2 LEFT RIGHT 20 1/8 19 1/8 17 1/8 12 5/16 Bottom condensate drain 14 1/2 25 9/16 Bottom gas supply entry 16 3/8 18 1/16 FRONT Top view Bottom power, control and convenience outlet wiring entry 3X Ø...
- Page 16 5808009-YIM-A-0320 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 Figure 11: ZB078-150 unit electrical entry ZB078-120 unit side duct openings 1 8 - 1 /4 D o t P l u g s Return Supply Air...
- Page 17 5808009-YIM-A-0320 ZB120-150 unit side duct openings Dot Plugs 18-1/4 5-5/32 2-7/8 31-5/8 Table 8: ZB150 side duct dimensions Dimension (in.) Unit model number ZB150 28 1/4 18 1/16 28 1/4 18 1/4 4-5/16 Figure 12: ZB078-150 unit left/end duct opening Table 9: Left/end duct dimensions Dimension (in.) Unit model number...
- Page 18 5808009-YIM-A-0320 RIGHT 80-5/8 INSULATED DECK UNDER CONDENSER SECTION SUPPLY RETURN 2 TYP. 50-1/2 INSULATED DECK UNDER COMPRESSOR SECTION FRONT 8 or 14 Figure 13: ZB078-150 roof curb 2 TYP 23 4 30-1/2 50-1/2 80-5/8 RETURN SUPPLY 76-5/8 59-1/4 FRONT RIGHT 64-1/4 Figure 14: ZB078-150 transition roof curb Johnson Controls Ducted Systems...
- Page 19 5808009-YIM-A-0320 Ductwork You must design and size ductwork according to the methods in Manual D of the Air Conditioning Contractors of America (ACCA) or as recommended by any other recognized authority such as ASHRAE or SMACNA. When you design the duct system, apply the following recommendations.
- Page 20 5808009-YIM-A-0320 Compressors The scroll compressors used in this product is specifically designed to operate with R-410A refrigerant and cannot be interchanged. This system uses R-410A refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. The compressors also use a polyolester (POE oil), Mobil 3MA POE.
- Page 21 If you install a disconnect, you must number and size of filters needed for the unit. ® use a field supplied or York International supplied accessory. Do not operate the unit without filters properly installed. See Figure 4 for the recommended mounting location.
- Page 22 5808009-YIM-A-0320 Power wiring detail Units are factory wired for the voltage shown on the unit Power wiring is brought into the unit through the side of the unit nameplate. See Table 11, Electrical data, on page 24 to size or the basepan inside the curb. power wiring, fuses, and the disconnect switch.
- Page 23 5808009-YIM-A-0320 Thermostat wiring Table 10: Control wire sizes Install the thermostat on an inside wall approximately 56 inches Wire size Maximum length above the floor. The thermostat must not be subject to drafts, 20 AWG < 150 feet sun exposure, or heat from electrical fixtures or appliances. 18 AWG 150-250 feet Follow the manufacturer's instructions enclosed with thermostat...
- Page 24 5808009-YIM-A-0320 Table 11: Electrical data ZB078-150 Standard Indoor Blower - With Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps)
- Page 25 5808009-YIM-A-0320 ZB078-150 Standard Indoor Blower - With Powered Convenience Outlet (Continued) Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps)
- Page 26 5808009-YIM-A-0320 ZB078-150 Standard Indoor Blower - With Powered Convenience Outlet (Continued) Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps)
- Page 27 5808009-YIM-A-0320 ZB078-150 Standard Indoor Blower - Without Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps) (Amps)
- Page 28 5808009-YIM-A-0320 ZB078-150 Standard Indoor Blower - Without Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps) (Amps)
- Page 29 5808009-YIM-A-0320 ZB078-150 Standard Indoor Blower - Without Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps) (Amps)
- Page 30 5808009-YIM-A-0320 ZB078-150 High Static Indoor Blower - Without Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps)
- Page 31 5808009-YIM-A-0320 ZB078-150 High Static Indoor Blower - Without Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps)
- Page 32 5808009-YIM-A-0320 ZB078-150 High Static Indoor Blower - With Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps)
- Page 33 5808009-YIM-A-0320 ZB078-150 High Static Indoor Blower - With Powered Convenience Outlet Max Fuse OD Fan Supply Compressors Max fuse Breaker Motors Blower Conv Electric Heat Option Size w/Pwr (each) Volt breaker size Size w/ (each) Motor Motor Outlet (Tons) (Amps) (amps) Pwr Exh (Amps)
- Page 34 5808009-YIM-A-0320 Table 12: Physical data ZB078-150 Physical Data Models Component ZB078 ZB090 ZB102 ZB120 ZB150 Nominal Tonnage 12.5 AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 78000 89000 103000 117500 145000 AHRI net capacity (Btu) 76000 87000 98000 114000 142000 12.2/12...
- Page 35 5808009-YIM-A-0320 ZB078-150 Physical Data (Continued) Models Component ZB078 ZB090 ZB102 ZB120 ZB150 Nominal Tonnage 12.5 CONDENSER FAN DATA Quantity of fans Fan diameter (Inch) Type Prop Prop Prop Prop Prop Drive type Direct Direct Direct Direct Direct Quantity of motors Motor HP each No.
- Page 36 5808009-YIM-A-0320 Optional electric heat These CSA approved heaters are located within the central compartment of the unit with the heater elements extending in The factory-installed heaters are wired for single point power to the supply air chamber. supply. You only need to bring the power supply into the single Fuses are supplied, where required, by the factory.
- Page 37 5808009-YIM-A-0320 Table 14: Gas pipe sizing - capacity of pipe Nominal iron pipe size Length of pipe (ft.) 3/4 in. 1 in. 1-1/4 in. 1050 OPTIONAL COIL GUARD SHOWN Note: Maximum capacity of pipe in cubic feet of gas per hour based upon a pressure drop of 0.3 inch W.C.
- Page 38 5808009-YIM-A-0320 • You must install a 1/8-inch NPT plugged tapping, • The proper pressure regulation. Two-stage regulation is accessible for test gage connection, immediately recommended. upstream of the gas supply connection to the unit. • The pressure drop in the lines between regulators and •...
- Page 39 5808009-YIM-A-0320 Smoke detectors assembly. Field-installed motorized outdoor damper accessories include complete instructions for installation. Economizer The economizer can be a factory-installed option or a field- The use of duct smoke detectors have specific limitations installed accessory. If factory installed, refer to the instructions as established by the National Fire Protection included with the economizer to complete the assembly.
- Page 40 5808009-YIM-A-0320 Economizer sequences Manual bypass An optional, factory-installed manual bypass switch is available Several functions can drive the economizer, including: minimum with factory-installed VFD. The manual bypass switch is located position, free cooling, economizer loading, and minimum in the blower motor access compartment. The manual bypass outdoor air supply.
- Page 41 5808009-YIM-A-0320 Low ambient minimum position Note: The exception to this rule occurs when hydronic heat enable and SAT tempering with hydronic heat enable The low ambient economizer minimum position overrides all (40°F default) are both on. Hydronic heat is used to other minimum position functions.
- Page 42 5808009-YIM-A-0320 Dry bulb When each cooling demand is removed, the compressor outputs de-energize in reverse order without time delays. When The control determines the type of free cooling changeover only a Y1 input remains, the economizer controls the SAT to the based on which sensors are present and reliable.
- Page 43 5808009-YIM-A-0320 If the SAT drops to less than the operating VAV SAT setpoint - Economizer loading 1.8°F, the staged percent command begins to decrease. The economizer loading function only works when only one If the staged percent command remains at 0% for 5 consecutive compressor is operating.
- Page 44 5808009-YIM-A-0320 Smart Equipment™ economizer board Figure 25: SE-ECO1001-0 economizer controller The following tables describe the details of the economizer board. See Figure 25 for connection locations. Smart Equipment™ economizer board - analog inputs Board Cover Location Description Function and comments label label 24 VAC common/0-10 VDC negative for...
- Page 45 5808009-YIM-A-0320 Smart Equipment™ economizer board - analog inputs (Continued) Board Cover Location Description Function and comments label label 24 VAC common/0-10 VDC negative for the Connects through circuit trace to 24V~ IN pin COM supply air humidity sensor 24 VAC hot supplied for the indoor air quality 24V~ Connects through circuit trace to 24V~ IN pin HOT sensor...
- Page 46 5808009-YIM-A-0320 Smart Equipment™ economizer board - SA bus details Board Cover Location Description Function and comments label label EconCtrlr parameter reports UCB-to-economizer board SA bus communication status. Negative of the SA BUS communication Common for SA BUS power and circuit to the UCB. Through the unit wiring harness, may continue on communication circuits to the 4-stage board and/or fault detection &...
- Page 47 5808009-YIM-A-0320 Smart Equipment™ economizer board - binary outputs Board Cover Location Description Function and comments label label 24 VAC hot supplied for an incremental 24V~ Connects through circuit trace to 24V~ IN pin HOT (floating control) economizer actuator 24 VAC hot outputs to position an incremental ACT-A Unused in current control revision (floating control) economizer actuator...
- Page 48 5808009-YIM-A-0320 Phasing ZB078-150 units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the phasing of the field line connection at the factory or field supplied disconnect to obtain proper rotation.
- Page 49 5808009-YIM-A-0320 Table 17: Altitude/temperature correction factors Altitude (ft.) Air temp. 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 1.060 1.022 0.986 0.950 0.916 0.882 0.849 0.818 0.788 0.758 0.729 1.039 1.002 0.966 0.931 0.898 0.864 0.832 0.802 0.772 0.743 0.715 1.019...
- Page 50 5808009-YIM-A-0320 Drive selection Determine side or bottom supply duct application. Determine desired airflow. Calculate or measure the amount of external static pressure. With the operating point determined from steps 1, 2, and 3, locate this point on the appropriate supply air blower performance table.
- Page 51 5808009-YIM-A-0320 Airflow performance Table 18: Airflow performance - side duct application ZB078 (6.5 ton) side duct Available external static pressure - IWG Air flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied drive Standard 1.5 HP and drive High static 3 HP and drive...
- Page 52 5808009-YIM-A-0320 ZB102 (8.5 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard 2 HP & Drive Hi Static 3 HP &...
- Page 53 5808009-YIM-A-0320 ZB150 (12.5 Ton) Side Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard 3 HP & Drive 3200 0.88 1.09...
- Page 54 5808009-YIM-A-0320 Table 19: Airflow performance - bottom duct application ZB078 (6.5 ton) bottom duct Available external static pressure - IWG Air flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied drive Standard 2 HP and drive High static 3 HP and drive...
- Page 55 5808009-YIM-A-0320 ZB120 (10 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Standard 2 HP & Drive Hi Static 3 HP &...
- Page 56 5808009-YIM-A-0320 Table 21: Indoor blower specifications Motor Motor sheave Blower sheave Size Model Belt Datum dia. Datum dia. (tons) Eff. Frame Bore (in.) Model Bore (in.) Model (in.) (in.) 1-1/2 1725 1.15 2.6 - 3.6 1VL40 AK74 (6.5) 1725 1.15 3.6 - 4.6 1VM50 AK74...
- Page 57 5808009-YIM-A-0320 Use an inclined manometer or Magnehelic® to determine After you note the reading, remove the tubes and seal the the pressure drop across the unit. This is the external static holes. pressure (ESP). In order to obtain an accurate Tighten the blower pulley and motor sheave set screws measurement, verify that the air filters are clean.
- Page 58 5808009-YIM-A-0320 Supply air drive adjustment Example A 4 ton unit was selected to deliver 1,700 CFM with a 1.5 HP motor, but the unit is delivering 1,400 CFM. The variable pitch motor sheave is set at 3 turns open. Before you make any blower speed changes, review the Use the equation to determine the required DD for the new installation for any installation errors, leaks, or motor sheave.
- Page 59 5808009-YIM-A-0320 Additional Static Resistance - ZB078-150 Electric Heat kW Size Model Cooling Only Economizer 4” Filter (Tons) 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...
- Page 60 5808009-YIM-A-0320 Operation equipped blower at the second stage speed as set in the Smart Equipment™ control. Cooling operation 2 fan cooling operation • If a Y3 call is present, it is passed to the UCB. The UCB then determines whether the requested operation is •...
- Page 61 5808009-YIM-A-0320 When the thermostat has been satisfied, it de-energizes Y1. If If a high-pressure switch opens three times within two hours of the compressor has satisfied its minimum run time, the operation, the UCB locks out the compressor. compressor and condenser fan are de-energized. Otherwise, the Low-pressure limit switch unit operates the cooling system until the minimum run times for the compressor are completed.
- Page 62 5808009-YIM-A-0320 Safety controls If the temperature limit opens three times within one hour, it locks on the indoor blower. The unit control board monitors the following inputs for each cooling system: Safety controls An evaporator low limit sensor (EC1) to protect against low The UCB monitors the temperature limit switch of electric heat evaporator temperatures due to a low airflow or a low units.
- Page 63 5808009-YIM-A-0320 Recycle operation Table 25: Electric heat anticipator setpoints When a flame is lost after the flame stabilization period, a recy- Setting, Amps cle operation occurs. If the unit fails after five recycle attempts, the furnace is locked out for one hour. 0.13 Gas heating operation errors Gas heating sequence of operations...
- Page 64 5808009-YIM-A-0320 UCB de-energizes the indoor blower following the elapse of the replacement. The ICB remains in this condition until it is fan off delay for heating. replaced. If voltage is sensed at the GV for at least 15 seconds during the Flash codes fan on delay for heating and GV voltage or W1 is lost, the The ICB initiates a flash code associated with errors within the...
- Page 65 5808009-YIM-A-0320 First stage compressors energize after the built-in time Check for the correct manifold gas pressures. See Checking delay of five minutes. gas heat input on page 65. Check the supply gas pressure. It must be within the limits The second stage of the thermostat energizes the second shown on the rating nameplate.
- Page 66 5808009-YIM-A-0320 Even when the thermostat is calling for first stage heat, the To determine rotations per minute, divide 60 by 46 = 1.30. unit lights on second stage and runs on second stage for 1 To calculate rotations per hour, multiply 1.30 60 = 78. minute.
- Page 67 5808009-YIM-A-0320 Reverse the above procedure to replace the assemblies. Table 29: Gas heat limit control settings Verify that burners are level and seated at the rear of the Unit gas orifice. Main limit setting °F Size Option HEAT EXCHANGER TUBE SUPPLY PIPE BURNER...
- Page 68 5808009-YIM-A-0320 Smart Equipment™ unit control board SD-24 Figure 31: Unit control board The following tables describe the details of the UCB, see Figure 31 for the connection locations. Smart Equipment™ UCB - thermostat connection strip Location Label Description Function and comments 1st stage heating request, 24 VAC input switched from R Not effective for cooling-only units Not effective for cooling-only units or units with single-stage heat...
- Page 69 5808009-YIM-A-0320 Smart Equipment™ UCB - limit, 24 VAC power, and shutdown connections Location Label Description Function and comments Monitored 24 VAC input through heat section If voltage is absent, indicating the heat section is over-temperature, the UCB will LIMIT limit switch(es) bring on the indoor blower 24 VAC, 75 VA transformer Common Connects through circuit traces to thermostat connection strip C and indoor...
- Page 70 5808009-YIM-A-0320 Smart Equipment™ UCB - temperature sensor connections (Continued) Location Label Description Function and comments Input required for 2-compressor heat pump units, not required for 2- #2 refrigerant circuit Condenser Coil temperature compressor A/C units, not active for 1-compressor units; 3.625 VDC CC2+ sensor input from 10KΩ...
- Page 71 5808009-YIM-A-0320 Smart Equipment™ UCB - heat section connections Location Label Description Function and comments Not effective for cooling-only units. Output if demand is present and 24 VAC hot output for heat section stage 1 permissions allow one stage or two stages of heat section operation Not effective for cooling-only units or units with single-stage heat sections.
- Page 72 5808009-YIM-A-0320 Smart Equipment™ UCB - refrigerant circuit safety switch and indoor blower overload connections (Continued) Location Label Description Function and comments LPS2 24 VAC hot out for refrigerant circuit 2 Low Not effective for one stage compressor UCBs. Connects through (right pin) Pressure Switch circuit trace to the left HSP2 pin...
- Page 73 5808009-YIM-A-0320 Smart Equipment™ UCB - LEDs Location Label Description Function and comments POWER Green UCB power indicator Lit indicates 24 VAC is present at C and 24V terminals 1/2 second on/off flashing indicates one or more alarm is currently active, Red hard lockout, networking error and firmware 1/10th second on/off flashing indicates a networking error (polarity, FAULT...
- Page 74 5808009-YIM-A-0320 Table 30: Cable for FC buses and SA buses in order of preference Non-plenum applications Plenum applications Bus and cable type Part number O.D. Part number O.D. Anixter: Anixter: CBL-22/3-FC-PLN CBL-22/3-FC-PVC 0.138 in. 0.140 in. FC Bus: 22 AWG Stranded, 3-Wire Twisted Shielded Cable Belden: B6501FE Belden®: B5501FE Anixter:...
- Page 75 5808009-YIM-A-0320 Charging the unit Charge unit by weight using name plate data or use charging tables. Table 32: ZB078 charging table - system 1 Air flow Suction Discharge Entering evap Outdoor DB Suction temp. Liquid temp. Delta T Db Indoor Db/Wb pressure pressure 300 Cfm/Ton 80/62...
- Page 76 5808009-YIM-A-0320 Table 34: ZB090 charging table - system 1 Air flow Suction Discharge Entering evap Outdoor DB Suction temp. Liquid temp. Delta T Db Indoor Db/Wb pressure pressure 300 Cfm/Ton 80/62 300 Cfm/Ton 79.89/67.03 300 Cfm/Ton 80/72 300 Cfm/Ton 75/62 400 Cfm/Ton 80/62 400 Cfm/Ton 79.88/...
- Page 77 5808009-YIM-A-0320 Table 36: ZB102 charging table - system 1 Air flow Suction Discharge Entering evap Outdoor DB Suction temp. Liquid temp. Delta T Db Indoor Db/Wb pressure pressure 300 Cfm/Ton 80/62 300 Cfm/Ton 79.82/66.95 300 Cfm/Ton 80/72 300 Cfm/Ton 75/62 400 Cfm/Ton 80/62 400 Cfm/Ton...
- Page 78 5808009-YIM-A-0320 Table 38: ZB120 charging table - system 1 Air flow Suction Discharge Entering evap Outdoor DB Suction temp. Liquid temp. Delta T Db Indoor Db/Wb pressure pressure 300 Cfm/Ton 10.4 80/62 11.5 300 Cfm/Ton 10.5 79.97/67.09 11.5 300 Cfm/Ton 10.5 80/72 11.5...
- Page 79 5808009-YIM-A-0320 Table 40: ZB150 charging table - system 1 Air flow Suction Discharge Entering evap Outdoor DB Suction temp. Liquid temp. Delta T Db Indoor Db/Wb pressure pressure 10.5 300 Cfm/Ton 11.9 80/62 13.3 10.4 300 Cfm/Ton 11.9 80.01/67.11 13.3 10.4 300 Cfm/Ton 11.8...
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