Table of Contents
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R-410A
ZJ SERIES
6-1/2 - 12-1/2 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . . 36
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1 ZJ078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZJ078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 9
4 ZJ078-150 Unit Physical Dimensions . . . . . . . . . . . . . . . . . . 11
5 ZJ078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 30
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 31
12 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 32
13 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 40
15 Airflow Performance - Side Duct Application . . . . . . . . . . . . . 42
16 Airflow Performance - Bottom Duct Application . . . . . . . . . . 44
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
®
Component Location (ZJ120 Shown) . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZJ078-120 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 9
9 ZJ150 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZJ078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . . . 12
11 ZJ078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . . 13
12 ZJ078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 13
13 ZJ150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . 14
14 ZJ078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . . . . 14
15 ZJ078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZJ078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . 16
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . 18
TABLE OF CONTENTS
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 49
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 53
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 53
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 54
Ignition Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 54
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . . . . . 61
Option Byte Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LIST OF TABLES
17 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 46
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 46
20 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . . 48
21 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 49
22 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
23 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54
24 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 55
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 56
26 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
27 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
28 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 60
29 Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
30 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 62
31 VAV Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . 62
LIST OF FIGURES
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
23 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . . 19
24 Typical Field Wiring 24 Volt Thermostat . . . . . . . . . . . . . . . 19
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
28 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
29 Honeywell Economizer Control W7212 . . . . . . . . . . . . . . . . 38
30 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
31 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 40
32 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
33 Occupied Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
34 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
35 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
36 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
37 Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . 63
38 Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
39 Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
524581-YIM-I-0512
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Table of Contents
Troubleshooting
Related Manuals for York ZJ078
Summary of Contents for York ZJ078
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Page 1: Table Of Contents
34 Typical Flame ........59 15 ZJ078-150 Roof Curb ......15 35 Typical Gas Valve . -
Page 2: General
524581-YIM-I-0512 General ® ® York Predator units are single package air conditioners with optional gas heating designed for outdoor installation on a Before performing service or maintenance operations on rooftop or slab and for non-residential use. These units can be unit, turn off main power switch to unit. - Page 3 Reference Additional information is available in the following reference forms: • Technical Guide - ZJ078-150, 528150 Improper installation may create a condition where the • General Installation - ZJ078-150, 524581 operation of the product could cause personal injury or •...
- Page 4 Simplicity IntelliComfort II Controller w/Simplicity®LINC 120 = 10.0 Ton 150 = 12.5 Ton York Commercial Comfort System (YCCS) Rtu Controller Hot Gas Bypass (Standard on VAV, Optional on CV) Variable Air Volume, VFD (not available with factory installed BAS options) Heat Type and Nominal Heat Capacity Variable Air Volume, VFD with Simplicity®LINC (not available with factory installed BAS options)
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Page 5: Installation
524581-YIM-I-0512 Installation Remove the toolless doorknobs and instruction packet prior to installation. Installation Safety Information Condenser Read these instructions before continuing this appliance Coil External installation. This is an outdoor combination heating and cooling Protective unit. The installer must assure that these instructions are made Covering available to the consumer and with instructions to retain them Barometric... -
Page 6: Predator ® Component Location (Zj120 Shown)
Roof efficient operation curbs for transitioning from Compressor #1 access Side entry power York Sunline™ footprint to Toolless (high-efficiency compressor and control wiring the ZJ Series footprints door latch w/crankcase heater) knockouts... -
Page 7: Location
524581-YIM-I-0512 Table 1: ZJ078-150 Unit Limitations Unit Limitations Size Model Unit Voltage Applied Voltage Outdoor DB Temp (Tons) Max (°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) 575-3-60... -
Page 8: Weights And Dimensions
524581-YIM-I-0512 Before lifting, make sure the unit weight is distributed equally on the rigging cables so it will lift evenly. Units may be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose. LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES. -
Page 9: Zj078-150 Unit Accessory Weights
524581-YIM-I-0512 Table 3: ZJ078-150 Unit Accessory Weights Weight (lbs.) Unit Accessory Shipping Operating Economizer Power Exhaust Electric Heat Gas Heat Variable Frequency Drive 1. Weight given is for the maximum heater size available (54KW). 2. Weight given is for the maximum number of tube heat exchangers available (8 tube). -
Page 10: Zj150 Physical Dimensions
524581-YIM-I-0512 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: ZJ150 Physical Dimensions Johnson Controls Unitary Products... -
Page 11: Zj078-150 Unit Physical Dimensions
524581-YIM-I-0512 Table 4: ZJ078-150 Unit Physical Dimensions Dimension (in.) Unit Model Number ZJ078 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZJ090 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZJ102 50 3/4 30 3/16 24 3/16... -
Page 12: Zj078-150 Unit Bottom Duct Openings
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 0.875 Ø 2.469 Figure 10: ZJ078-150 Unit Bottom Duct Openings Johnson Controls Unitary Products... -
Page 13: Zj078-150 Unit Electrical Entry
D o t P l u g s Return Supply Air 2 - 3 1 /3 2 5 - 5 /3 2 3 1 - 1 1 /1 6 Figure 12: ZJ078-120 Unit Side Duct Openings Johnson Controls Unitary Products... -
Page 14: Side Duct Dimensions
ZJ102 28 1/4 18 1/16 28 1/4 18 1/4 ZJ120 28 1/4 18 1/16 28 1/4 18 1/4 ZJ150 28 1/4 18 1/16 28 1/4 18 1/4 30-3/8 4-5/16 Figure 14: ZJ078-150 Unit Left Duct Opening Johnson Controls Unitary Products... -
Page 15: Ductwork
76-5/8 59-1/4 FRONT RIGHT 64-1/4 Figure 16: ZJ078-150 Transition Roof Curb Ductwork supply and return air duct connections at the unit should be made with flexible joints to minimize noise. Ductwork should be designed and sized according to the The supply and return air duct systems should be designed for methods in Manual D of the Air Conditioning Contractors of the CFM and static pressure requirements of the job. -
Page 16: Condensate Drain
524581-YIM-I-0512 Duct Covers Units are shipped with the side duct openings covered and a covering over the bottom of the unit. For bottom duct application, no duct cover changes are necessary. For side duct application, remove the side duct covers and install over the bottom duct openings. -
Page 17: Filters
Procedures which risk oil leakage include, but are not limited to, disconnects are available. If installing a disconnect (field compressor replacement, repairing refrigerant leaks, replacing ® supplied or York International supplied accessory), refer to refrigerant components such as filter drier, pressure switch, Figure 4 for the recommended mounting location. -
Page 18: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat And All Units With Vfd Option
524581-YIM-I-0512 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. Refer to Electrical Data Table 8 to size power or the basepan inside the curb. wiring, fuses, and disconnect switch. -
Page 19: Control Wire Sizes
524581-YIM-I-0512 Thermostat Wiring (Not applicable to units with VFD) thermostat to the unit. Refer to Table 7 for control wire sizing and maximum length. The thermostat should be located on an inside wall approximately 56 inch above the floor where it will not be Table 7: Control Wire Sizes subject to drafts, sun exposure or heat from electrical fixtures or Wire Size... -
Page 20: Electrical Data
524581-YIM-I-0512 Table 8: Electrical Data ZJ078-150 Standard Motor - Without Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr... - Page 21 524581-YIM-I-0512 ZJ078-150 Standard Motor - Without Powered Convenience Outlet (Continued) OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps) Size...
- Page 22 524581-YIM-I-0512 ZJ078-150 Hi Static Motor - Without Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps) Size...
- Page 23 524581-YIM-I-0512 ZJ078-150 Hi Static Motor - Without Powered Convenience Outlet (Continued) OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps)
- Page 24 524581-YIM-I-0512 ZJ078-150 Standard Motor - With Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps) Size (Amps)
- Page 25 524581-YIM-I-0512 ZJ078-150 Standard Motor - With Powered Convenience Outlet (Continued) OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps) Size...
- Page 26 524581-YIM-I-0512 ZJ078-150 Hi Static Motor - With Powered Convenience Outlet OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps) Size...
- Page 27 524581-YIM-I-0512 ZJ078-150 Hi Static Motor - With Powered Convenience Outlet (Continued) OD Fan Supply Max Fuse Compressors Max Fuse Motors Blower Conv Electric Heat Option Breaker (each) Size w/Pwr Breaker (each) Motor Motor Outlet Volt Size w/ Pwr (Tons) (Amps)
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Page 28: Physical Data
524581-YIM-I-0512 Table 9: Physical Data ZJ078-150 Physical Data Models Component ZJ078 ZJ090 ZJ102 ZJ120 ZJ150 Nominal Tonnage 12.5 AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Btu) 80000 93000 106000 124000 155000 AHRI net capacity (Btu) 78000 90000 102000... - Page 29 524581-YIM-I-0512 ZJ078-150 Physical Data (Continued) Models Component ZJ078 ZJ090 ZJ102 ZJ120 ZJ150 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.
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Page 30: Optional Electric Heat
524581-YIM-I-0512 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. Power supply need only be brought into the single point Fuses are supplied, where required, by the factory. -
Page 31: Optional Gas Heat
524581-YIM-I-0512 Optional Gas Heat These gas-fired heaters have aluminized-steel or optional stainless steel, tubular heat exchangers with spark ignition. OPTIONAL NOTE: On VAV units, individual VAV boxes must be fully open COIL in heating mode to insure airflow falls within specified GUARD Temperature Rise range. -
Page 32: Gas Heat Minimum Supply Air
524581-YIM-I-0512 Table 12: Gas Heat Minimum Supply Air Supply Air (CFM) Size Model Heat Size Cooling Heating (Tons) 1950 3250 1950 3250 (6.5) 1950 3250 1950 3250 2250 3750 2250 3750 (7.5) 2250 3750 2250 3750 2550 4250 2550 4250 (8.5) 2550 4250... -
Page 33: Options/Accessories
524581-YIM-I-0512 For satisfactory operation, LP gas pressure must be 10.5 inch electric heaters are fused and intended for use with single point W.C. at the unit under full load. Maintaining proper gas power supply. pressure depends on three main factors: Smoke Detectors The vaporization rate which depends on the temperature of the liquid and the “wetted surface”... -
Page 34: Optional Variable Air Volume (Vav)
524581-YIM-I-0512 the assembly. Field installed Motorized Outdoor Damper there should be no obstructions, turns or VAV terminal boxes accessories include complete instructions for installation. up- or down-stream of the sensing tube location for at least a distance of 6-10 times the duct diameter. Tubing must also be Economizer run between the 'LOW' pressure tap of the transducer and atmospheric pressure (outside of the unit). - Page 35 524581-YIM-I-0512 call for Differential Demand Ventilation mode for units Factory-installed VFD installed with economizer option. The factory-installed VFD is mounted in the blower access • APS - a 24 VAC binary input provided by a field-installed compartment. The drive comes wired from the factory to include air proving switch which monitors the pressure difference both 3-phase power and control connections (run permit signal, across the indoor blower.
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Page 36: Optional Hot Gas Bypass (Hgbp)
524581-YIM-I-0512 Bas-ready VFD nuts. After removing the wire nuts, connect the wires to the field-installed VFD per the VFD wiring diagram (See Figure 27). Factory-installed VFD is also available with 'BAS-Ready' The VFD should also be grounded per the manufacturer's models. -
Page 37: Standard Economizer And Power Exhaust Set Point
524581-YIM-I-0512 HGBP is standard on all units with VAV and optional with CV the "A", "B", "C" or "D" setting corresponding to the lettered units. curve of the Enthalpy Set Point Adjustment Figure 29. • For a dual enthalpy operation, carefully turn the set point Standard Economizer And Power Exhaust Set Point adjusting screw fully clockwise past the "D"... -
Page 38: Supply Air Limitations
524581-YIM-I-0512 CONTROL POINT CONTROL APPROX. CURVE (29) (32) (35) (38) (41) (43) AT 50% RH 73 (23) 70 (21) (27) 67 (19) 63 (17) (24) (21) (18) (16) (13) (10) (10) (13) (16) (21) (24) (27) (29) (32) (38) (41) (43) (18) (35) -
Page 39: Belt Adjustment
524581-YIM-I-0512 Scroll compressors require proper rotation to operate Procedure for adjusting belt tension: correctly. Units are properly phased at the factory. Do 1. Loosen six nuts (top and bottom) A. not change the internal wiring to make the blower 2. Adjust by turning (B). condenser fans, or compressor rotate correctly. -
Page 40: Altitude/Temperature Correction Factors
524581-YIM-I-0512 Table 14: Altitude/Temperature Correction Factors Altitude (Ft.) 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 0.982... -
Page 41: Airflow Performance
524581-YIM-I-0512 Drive Selection Determine side or bottom supply duct Application. Determine desired airflow. Calculate or measure the amount of external static pressure. Using the operating point determined from steps 1, 2 & 3, locate this point on the appropriate supply air blower performance table. -
Page 42: Airflow Performance - Side Duct Application
524581-YIM-I-0512 Table 15: Airflow Performance - Side Duct Application ZJ078 (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 Standard 1.5 HP &... - Page 43 524581-YIM-I-0512 ZJ120 (10 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 &...
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Page 44: Airflow Performance - Bottom Duct Application
524581-YIM-I-0512 Table 16: Airflow Performance - Bottom Duct Application ZJ078 (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 Standard 1.5 HP &... -
Page 45: Rpm Selection
524581-YIM-I-0512 ZJ120 (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 46: Air Balance
524581-YIM-I-0512 Table 18: 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 47: Dry Coil Delta P
Failure to properly adjust the total system air quantity measurement, be certain that the air filters are clean. can result in extensive blower damage. Determine the number of turns the variable motor sheave is open. ZJ078 ZJ090 0.45 ZJ102 ZJ120 ZJ150 0.35... -
Page 48: Motor Sheave Datum Diameters
524581-YIM-I-0512 Supply Air Drive Adjustment EXAMPLE A 12.5 ton unit was selected to deliver 4,000 CFM with a 3 HP motor, but the unit is delivering 3,800 CFM. The variable pitch motor sheave is set at 2 turns open. Before making any blower speed changes review the Use the equation to determine the required DD for the new installation for any installation errors, leaks or undesirable motor sheave,... -
Page 49: Operation
524581-YIM-I-0512 Table 21: Additional Static Resistance 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 50: No Outdoor Air Options
524581-YIM-I-0512 For units with VFD and VAV control, the unit must first be put The following components are needed to access the control into the Occupied Mode to start operation. The default setting points in the Simplicity® controller. Installation and operation for all VAV units is 'Unoccupied', therefore the installer must guide is located on UPGNET. -
Page 51: Cooling Operation Errors
524581-YIM-I-0512 maintain a constant supply air temperature as monitored by the Control set point plus 5 °F, and the Economizer OAT Enable set point. discharge air sensor. If the outdoor air enthalpy is above the set point, "Y1" energizes compressor #1. •... - Page 52 524581-YIM-I-0512 dampers open; gravity closes the dampers when the exhaust for cooling is still present at the conclusion of the ASCD, the UCB will re-energize the halted compressor. fan is off. Should a freezestat open three times within two hours of Motorized Outdoor Air Dampers operation, the UCB will lock-out the associated compressor and This system operation is the same as the units with no outdoor...
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Page 53: Electric Heating Sequence Of Operations
VOLTAGE SWITCH The following sequence describes the operation of the electric OPENS °F heat section. ZJ078, 090 (6.5, 7.5) 208/230 For units with VFD and electric heat, the speed of the ZJ102, 120, 150 indoor blower motor continues to be controlled by duct (8.5,10, 12.5) -
Page 54: Gas Heating Sequence Of Operations
524581-YIM-I-0512 Electric Heat Anticipator Setpoints second will cause the GV to close and the retry operation to begin. It is important that the anticipator setpoint be correct. Too high of a setting will result in longer heat cycles and a greater At the conclusion of the flame stabilization period, the ICB will temperature swing in the conditioned space. -
Page 55: Gas Heat Limit Control Settings
°F Size Opt. counted as a recycle. ZJ078 Gas Valve ZJ090 The UCB and ICB continuously monitor the GV. If the ICB senses voltage at the GV when not requested, the ZJ102 ICB will energize the draft motor. -
Page 56: Start-Up (Cooling)
524581-YIM-I-0512 Flash Codes Operating Instructions The ICB will initiate a flash code associated with errors within Turn unit electrical power on. the system. Refer to IGNITION CONTROL FLASH CODES NOTE: Prior to each cooling season, the crankcase heaters Table 30. must be energized at least 10 hours before the system is put into operation. -
Page 57: Checking Gas Heat Input
524581-YIM-I-0512 Checking Gas Heat Input Post Start Checklist After the entire control circuit has been energized and the This unit has two stages of gas heat. The first stage is 60% of heating section is operating, make the following checks: the full fire input and is considered the minimum input for the Check for gas leaks in the unit piping as well as the supply furnace. -
Page 58: Gas Rate Cubic Feet Per Hour
524581-YIM-I-0512 Manifold Gas Pressure Adjustment Table 26: Gas Rate Cubic Feet Per Hour Size of Test Dial This gas furnace has two heat stages. Therefore, the gas valve Seconds for One Rev. 1/2 cu. ft. 1 cu. ft. has two adjustment screws located under a plastic protective cover. -
Page 59: Charging The Unit
524581-YIM-I-0512 Adjustment Of Temperature Rise HIGH & LOW GAS ADJUSTMENT The temperature rise (the difference of temperature between the return air and the heated air from the furnace) must lie within the range shown on the CSA rating plate and the data in Table 9. After the temperature rise has been determined, the CFM can be calculated as follows: INLET... -
Page 60: Unit Control Board Flash Codes
524581-YIM-I-0512 ® Predator Flash Codes equates to the number of flashes, and is shown in the table. Pressing and releasing the LAST ERROR button on the UCB Various flash codes are utilized by the unit control board (UCB) can check the alarm history. The UCB will cycle through the last to aid in troubleshooting. -
Page 61: Unit Control Board Option Setup
524581-YIM-I-0512 Check Alarm History Reset All ASCDs for One Cycle Non Alarm Condition Green LED Flashing Current Alarm Flashed Red LED Figure 36: Unit Control Board Unit Control Board Option Setup Heat Delay Setup • Enter the Option Setup mode by pushing the OPTION Option Byte Setup SETUP / STORE button, and holding it for at least 2 seconds. -
Page 62: Heat Delay
524581-YIM-I-0512 Table 29: Heat Delay Table 31: VAV Control Board Flash Codes Heat Heat Flash Codes Description Fan On Fan Off On Steady This is a Control Failure LED 8 LED 4 LED 2 LED 1 Delay Delay 1 Flash Not Applicable 2 Flashes Loss of Communications with UCB... -
Page 63: Basic Troubleshooting Flowchart
524581-YIM-I-0512 Monitored Loss of Call for Systems Programming? Call for Heat Off Heating? Problem? Heating? Program Call for 2nd Unit Call for Trip/Failure Stage Control Heat Cooling Board Energize ID Call for First Monitor Blower Motor Cooling? Stage? Call for 1st Turn off ID Fan on Fan off... -
Page 64: Trip Failure Flow Chart
524581-YIM-I-0512 Figure 39: Trip Failure Flow Chart Johnson Controls Unitary Products... -
Page 65: Yim-I
524581-YIM-I-0512 Cooling Troubleshooting Guide On calls for cooling, the supply air blower motor is operating but compressor #1 is not (the room thermostat fan switch is in the NOTE: For units with optional VFD without manual bypass, the “AUTO” position): M3 contactor has been replaced with an "ice cube"... - Page 66 524581-YIM-I-0512 out, cancel any call for cooling. This will reset any 16. If none of the above correct the error, replace the UCB. compressor lock outs. On calls for the second stage of cooling, the supply air blower NOTE: While the above step will reset any lockouts, motor and compressor #1 are operating but compressor #2 is compressor #1 may be held off for the ASCD.
- Page 67 524581-YIM-I-0512 remove any call for cooling at the thermostat or by If 24 volts is not present at the C1 terminal, check for 24 disconnecting the thermostat wiring at the Y2 UCB volts from the room thermostat at the UCB Y1 terminal. If terminal.
- Page 68 524581-YIM-I-0512 economizer is not providing free cooling. To test the If M3 is not pulled in, check for 24 volts at the M3 coil. If 24 economizer control, disconnect the Mate-N-Locks and volts is present at M3 but M3 is not pulled in, replace the jumper between the WHITE and YELLOW wires of the contactor.
- Page 69 Subject to change without notice. Printed in U.S.A. 524581-YIM-I-0512 Copyright © 2012 by Johnson Controls, Inc. All rights reserved. Supersedes: 524581-YIM-H-0312 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...