York ZR Series Installation Manual
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York ZR Series Installation Manual

York ZR Series Installation Manual

R-410a w/smart equipment, 6-1/2 - 12-1/2 ton, 60 hertz
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R-410A
ZR SERIES W/SMART EQUIPMENT™
6-1/2 - 12-1/2 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dry bulb changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Single enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dual enthalpy changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ZR078-150 unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Weights and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 ZR078-150 unit accessory weights . . . . . . . . . . . . . . . . . . . . 10
5 ZR078-150 unit physical dimensions. . . . . . . . . . . . . . . . . . . 11
6 ZR078-150 unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Side duct dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Roof curb components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
12 ZR078-150 physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
13 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 30
14 Gas application data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 31
16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 31
17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 40
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Unit 4 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Unit 6 point load weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 ZR078-120 physical dimensions . . . . . . . . . . . . . . . . . . . . . 10
9 ZR150 physical dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZR078-150 unit bottom duct openings . . . . . . . . . . . . . . . . . 11
11 ZR078-150 unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . 12
12 ZR078-120 unit side duct openings . . . . . . . . . . . . . . . . . . . 12
13 ZR150 unit side duct openings . . . . . . . . . . . . . . . . . . . . . . . 13
14 ZR078-150 unit/end left duct opening . . . . . . . . . . . . . . . . . 13
15 ZR078-150 roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16 ZR078-150 transition roof curb . . . . . . . . . . . . . . . . . . . . . . . 14
17 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 15
18 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 15

Table of contents

Free cooling operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Power exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 35
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling operation errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Reheat mode sequence of operation . . . . . . . . . . . . . . . . . . . 52
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 53
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 54
Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 54
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 55
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 60
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
List of tables
21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
22 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 46
23 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 46
24 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 48
25 Additional static resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 49
27 Electric heat limit setting 50 in. cabinet . . . . . . . . . . . . . . . . . 54
28 Electric heat limit setting 42 in. cabinet . . . . . . . . . . . . . . . . . 54
29 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 54
30 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 56
31 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . 56
32 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 58
33 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
35 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 66
List of figures
19 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
24 Typical low voltage field wiring . . . . . . . . . . . . . . . . . . . . . . . 19
25 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
26 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
27 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 35
28 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
29 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 40
30 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
33 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
34 Typical gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
35 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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Summary of Contents for York ZR Series

  • Page 1: Table Of Contents

    R-410A ZR SERIES W/SMART EQUIPMENT™ 6-1/2 - 12-1/2 Ton 60 Hertz Table of contents General ..........2 Free cooling operation.

  • Page 2: General

    5167531-YIM-J-1019 General ® York ZR078-150 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 5167531-YIM-J-1019 Nomenclature ® 6.5-12.5 Ton ZR York Model Number Nomenclature Z R 090 C A 2 A 1 Product Generation Product Category 1 = First Generation Z = A/C, Single Pkg., R-410A Cabinet Options A = Std Cabinet Product Identifier...

  • Page 5: Installation

    5167531-YIM-J-1019 Installation Remove the toolless doorknobs and instruction packet, see Figure 3. Installation safety information Read the following instructions before you install this appliance. This is an outdoor combination heating and cooling unit. The installer must assure that these instructions are made available to the consumer.

  • Page 6: Limitations

    5167531-YIM-J-1019 Limitations If components are added to a unit to meet local codes, they are installed at the dealer’s and/or customer’s expense. These units must be installed in accordance with the following: The size of the unit for the proposed installation must be based In the U.S.A.: on a heat loss/heat gain calculation made according to the National Electrical Code, ANSI/NFPA No.

  • Page 7: Unit Components

    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 ZR Series footprints are also available (field-installed accessory). Johnson Controls Ducted Systems...

  • Page 8: Location

    5167531-YIM-J-1019 Table 2: ZR078-150 unit limitations Unit limitations Size Model Unit voltage 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) 575-3-60 width must be at least 6 inches greater than the unit base...

  • Page 9: Weights And Dimensions

    5167531-YIM-J-1019 ® If a unit is installed on a roof curb other than a York roof curb, you must apply gasketing to all surfaces that come in contact with the unit underside. Before lifting the unit, make sure that the unit weight is...

  • Page 10: Zr078-150 Unit Accessory Weights

    5167531-YIM-J-1019 Table 4: ZR078-150 unit accessory weights Weight (lbs.) Unit accessory Shipping Operating Economizer Power Exhaust Electric Heat Gas Heat 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). 29.69 15.25 15.38...

  • Page 11: Zr078-150 Unit Physical Dimensions

    5167531-YIM-J-1019 Table 5: ZR078-150 unit physical dimensions Dimension (in.) Unit model number ZR078 22 1/8 18 3/16 15 3/16 6 3/16 ZR090 22 1/8 18 3/16 15 3/16 6 3/16 ZR102 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZR120 50 3/4 30 3/16...

  • Page 12: Zr078-150 Unit Electrical Entry

    5167531-YIM-J-1019 Item Description Disconnect switch 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 Figure 11: ZR078-150 unit electrical entry 1 8 - 1 /4 D o t P l u g s Return Supply Air 2 - 3 1 /3 2...

  • Page 13: Side Duct Dimensions

    5167531-YIM-J-1019 Dot Plugs 18-1/4 5-5/32 2-7/8 31-5/8 Figure 13: ZR150 unit side duct openings Table 7: Side duct dimensions Dimension (in.) Unit model number ZR078 27 3/4 12 1/16 27 1/2 ZR090 27 3/4 12 1/16 27 1/2 ZR102 28 1/4 18 1/16 28 1/4 18 1/4...

  • Page 14: Roof Curb Components

    5167531-YIM-J-1019 80-5/8 50-1/2 8 or 14 Figure 15: ZR078-150 roof curb 23 4 30-1/2 50-1/2 80-5/8 76-5/8 59-1/4 64-1/4 Figure 16: ZR078-150 transition roof curb Roof curb components Item Description Return air Supply air Right side of the unit Front side of the unit 2 typ.

  • Page 15: Ductwork

    5167531-YIM-J-1019 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 16: Condensate Drain

    5167531-YIM-J-1019 This system uses R-410A refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. The compressor also uses a polyolester (POE oil), Mobil 3MA POE. This oil is extremely hygroscopic, meaning it absorbs water readily.

  • Page 17: Power And Control Wiring

    5167531-YIM-J-1019 coils or safety shutdown. See the physical data tables for the A disconnect must be utilized for these units. Factory-installed number and size of filters needed for the unit. disconnects are available. Do not operate the unit without filters properly installed. Avoid damage to internal components if you drill holes to install a disconnect.

  • Page 18: Typical Field Wiring Disconnect - Cooling Unit With Or Without Electric Heat

    5167531-YIM-J-1019 TERMINAL BLOCK TB1 FACTORY OR FIELD GROUND SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 22: Typical field wiring disconnect - cooling unit with or without electric heat CONTACTOR 1M FACTORY OR FIELD GROUND SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 23: Typical field wiring disconnect - cooling unit with gas heat Johnson Controls Ducted Systems...

  • Page 19: Control Wire Sizes

    5167531-YIM-J-1019 Thermostat wiring insulated wires to connect the thermostat to the unit. See Table 9 for control wire sizing and maximum length. Install the thermostat on an inside wall approximately 56 inches above the floor. The thermostat must not be subject to drafts, Table 9: Control wire sizes sun exposure, or heat from electrical fixtures or appliances.

  • Page 20: Electrical Data

    5167531-YIM-J-1019 Table 10: Electrical data ZR078-150 standard motor - without powered convenience outlet OD fan Supply Max fuse Compressors Pwr exh Max fuse motors blower conv Electric heat option breaker (each) motor Size breaker (each) motor outlet Volt with pwr size with (tons) (amps)
  • Page 21 5167531-YIM-J-1019 ZR078-150 standard motor - without powered convenience outlet (continued) OD fan Supply Max fuse Compressors Pwr exh Max fuse motors blower conv Electric heat option breaker (each) motor Size breaker (each) motor outlet Volt with pwr size with (tons) (amps) size exh (amps)
  • Page 22 5167531-YIM-J-1019 ZR078-150 high static motor - without powered convenience outlet OD fan Supply Max fuse Compressors Pwr exh motors blower conv Electric heat option Max fuse breaker (each) motor Size (each) motor outlet Volt with pwr breaker size with (tons) (amps) exh (amps) size (amps)
  • Page 23 5167531-YIM-J-1019 ZR078-150 high static motor - without powered convenience outlet (continued) OD fan Supply Max fuse Compressors Pwr exh motors blower conv Electric heat option Max fuse breaker (each) motor Size (each) motor outlet Volt with pwr breaker size with (tons) (amps) exh (amps)
  • Page 24 5167531-YIM-J-1019 ZR078-150 standard motor - with powered convenience outlet OD fan Supply Max fuse Compressors Pwr exh motors blower conv Electric heat option Max fuse breaker (each) motor Size (each) motor outlet Volt with pwr breaker size with (tons) (amps) exh (amps) size (amps) pwr exh...
  • Page 25 5167531-YIM-J-1019 ZR078-150 standard motor - with powered convenience outlet (continued) OD fan Supply Max fuse Compressors Pwr exh motors blower conv Electric heat option Max fuse breaker (each) motor Size (each) motor outlet Volt with pwr breaker size with (tons) (amps) exh (amps) size (amps)
  • Page 26 5167531-YIM-J-1019 ZR078-150 high static motor - with powered convenience outlet OD fan Supply Max fuse Compressors Pwr exh motors blower conv Electric heat option Max fuse breaker (each) motor Size (each) motor outlet Volt with pwr breaker size with (tons) (amps) exh (amps) size (amps)
  • Page 27 5167531-YIM-J-1019 ZR078-150 high static motor - with powered convenience outlet (continued) OD fan Supply Max fuse Compressors Pwr exh motors blower conv Electric heat option Max fuse breaker (each) motor Size (each) motor outlet Volt with pwr breaker size with (tons) (amps) exh (amps)

  • Page 28: Zr078-150 Physical Data

    5167531-YIM-J-1019 Table 11: ZR078-150 physical data Models Component ZR078 ZR090 ZR102 ZR120 ZR150 Nominal tonnage 12.5 AHRI cooling performance Gross capacity @ AHRI A point (Mbh) 80000 90000 105000 124000 157000 AHRI net capacity (Mbh) 78000 88000 102000 /100000 118000 150000 11.2 11.2...
  • Page 29 5167531-YIM-J-1019 Table 11: ZR078-150 physical data (continued) Models Component ZR078 ZR090 ZR102 ZR120 ZR150 Nominal tonnage 12.5 Reheat coil data Face area (sq. ft) 6.66 6.66 Rows Fins per inch Tube diameter (in.) Condenser fan data Quantity of fans Fan diameter (inches) Type Prop Prop...

  • Page 30: Optional Electric Heat

    5167531-YIM-J-1019 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 31: Gas Pipe Sizing - Capacity Of Pipe

    5167531-YIM-J-1019 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 32: Options And Accessories

    5167531-YIM-J-1019 • You must install a 1/8-inch NPT plugged tapping, • The pressure drop in the lines between regulators and accessible for test gage connection, immediately between the second stage regulator and the appliance. upstream of the gas supply connection to the unit. The pipe size required depends on the length of the pipe run and the total load of all appliances.

  • Page 33: Economizer Sequences

    5167531-YIM-J-1019 Economizer Dry bulb changeover The economizer can be a factory-installed option or a field- For dry bulb economizer operation, the outside air is suitable for installed accessory. If factory installed, refer to the instructions free cooling if the outside air temperature is 1°F below the included with the economizer to complete the assembly.

  • Page 34: Power Exhaust

    5167531-YIM-J-1019 If the supply air temperature cannot be maintained within 5°F of Power exhaust the economizer setpoint, the first stage compressor (C1) will be turned on. Second stage compressor (C2) will be added as Setpoints needed to keep the supply air temperature within the 5°F of the •...

  • Page 35: Smart Equipment™ Economizer Board

    5167531-YIM-J-1019 Smart Equipment™ economizer board Figure 27: SE-ECO1001-0 economizer controller The following tables describe the details of the economizer board. See Figure 27 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 36 5167531-YIM-J-1019 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 37 5167531-YIM-J-1019 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 38 5167531-YIM-J-1019 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 39: Supply Air Limitations

    5167531-YIM-J-1019 Phasing Re-tighten the belt nuts. ZR078-150 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 40: Altitude/Temperature Correction Factors

    5167531-YIM-J-1019 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 41 5167531-YIM-J-1019 Drive selection Determine side or bottom supply duct application. Determine the required 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 42: Airflow Performance

    5167531-YIM-J-1019 Airflow performance Table 18: Airflow performance - side duct application ZR078 (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 1.5 HP and field supplied drive Standard 1.5 HP and drive High static 2 HP and drive...
  • Page 43 5167531-YIM-J-1019 ZR120 (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 2 HP and field supplied drive Standard 2 HP and drive High static 3 HP and drive 2600...

  • Page 44: Airflow Performance - Bottom Duct Application

    5167531-YIM-J-1019 Table 19: Airflow performance - bottom duct application ZR078 (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 1.5 HP and field supplied drive Standard 1.5 HP and drive High static 2 HP and drive...

  • Page 45: Rpm Selection

    5167531-YIM-J-1019 ZR120 (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 2 HP and field Standard 2 HP and drive High static 3 HP and drive supplied drive 2600...

  • Page 46: Air Balance

    5167531-YIM-J-1019 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 3.4 - 4.4 1VM50 AK74 (6.5) 1725 1.15 3.4 - 4.4 1VM50 AK64...

  • Page 47: Dry Coil Delta P

    5167531-YIM-J-1019 Using the hole drilled in step 1, insert eight inches of 1/4 To adjust measured CFM to required CFM, see Supply air inch metal tubing into the airflow of the return and supply drive adjustment on page 48. air ducts of the unit. After you note the reading, remove the tubes and seal the Note: You must insert the tubes and hold them in a position holes.

  • Page 48: Motor Sheave Datum Diameters

    5167531-YIM-J-1019 Supply air drive adjustment You must adjust the belt drive blower systems to the specific static and CFM requirements for the application. Before you make any blower speed changes, review the The belt drive blowers are not set at the factory for any installation for any installation errors, leaks, or specific static or CFM.

  • Page 49: Additional Static Resistance

    5167531-YIM-J-1019 Table 24: Additional static resistance Electric heat kW Size Model Cooling only Economizer 4 in. filter (tons) 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...

  • Page 50: Operation

    5167531-YIM-J-1019 Operation #1 is energized. If compressor #1 is active for first stage cooling or the first compressor is locked-out, compressor #2 is Cooling sequence of operation energized. In free-cooling mode, if the call for the second stage of cooling continues for 20 minutes, compressor #2 is NOTE: For more in-depth sequence of operation of the Smart energized, provided it has not been locked-out.

  • Page 51: Cooling Operation Errors

    5167531-YIM-J-1019 Economizer with power exhaust the associated compressor, initiates the ASCD, and, if the other compressor is idle, stops the condenser fans. A unit equipped with an economizer (single or dual enthalpy) and a power exhaust operates as specified above with one If the call for cooling is still present at the conclusion of the addition.

  • Page 52: Reheat Mode Sequence Of Operation

    5167531-YIM-J-1019 A low-pressure switch to protect against loss of refrigerant Controller menu. Those modes consist of a Normal, Alternate charge, (opens at 50 ± 5 psig). and, Aux each mode is described below. The above pressure switches are hard-soldered to the unit. The Normal cooling mode refrigeration systems are independently monitored and controlled.

  • Page 53: Electric Heating Sequence Of Operations

    5167531-YIM-J-1019 Evaporator Airflow Coil Condenser Coil Check Valve Check Valve Reheat Coil Airflow Refrigerant Flow Closed Solenoid Valve (SOL 1) Reheat Valve (SOL 3) Compressor Accumulator Open Solenoid Valve (SOL 2) Figure 32: Reheat operation piping schematic - circuit #1 shown Alternate mode Table 25: Dehumidification sequence in normal and When the Unit Control Board (UCB) detects a need for...

  • Page 54: Electric Heat Operation Errors

    5167531-YIM-J-1019 Two-stage heating: Table 27: Electric heat limit setting 42 in. cabinet a. When there is a call for first stage heat by the thermostat, Heater Limit switch Unit (tons) Voltage the heater relay (RA) is energized. After completing the opens °F specified fan on delay for heating, the UCB energizes the blower motor.

  • Page 55: Gas Heating Operation Errors

    5167531-YIM-J-1019 During the flame stabilization period, a loss of the flame for 2 Flame sense seconds causes the GV to close and the retry operation to Flame sensing occurs at all times. If W1 is not present and a begin. After the flame stabilization period, a loss of flame for 3/4 flame is sensed for 2 seconds, the draft motor is energized and second causes the GV to close and the retry operation to begin.

  • Page 56: Cooling Start-Up

    5167531-YIM-J-1019 condition, caused by inadequate supply air flow occurs. This Resets shuts down the heater and energizes the blower. Resets remove the call for heating by lowering the thermostat The auxiliary limit switch (ALS) is wired in series with the limit setting lower than the conditioned space temperature.

  • Page 57: Gas Heat Start-Up

    5167531-YIM-J-1019 Measure the temperature drop across the evaporator coil. Check the supply gas pressure. It must be within the limits shown on the rating nameplate. Gas heat start-up Note: You must check the supply pressure with all gas appliances in the building at full fire. The standby gas Pre-start checklist pressure must never exceed 10.5 in.

  • Page 58: Gas Rate Cubic Feet Per Hour

    5167531-YIM-J-1019 Multiply 189.6  1 (0.5 if using a 1/2 cubic foot dial) = 189.6. Measure the time needed for one revolution of the hand on the smallest dial on the meter. A typical gas meter has a 1/ Multiply 78  (the BTU rating of the gas). For this example, 2 or a 1 cubic foot test dial.

  • Page 59: Charging The Unit

    5167531-YIM-J-1019 After about 20 minutes of operation, determine the furnace temperature rise. Take readings of both the return air and the heated air in the ducts (about 6 feet from the furnace) where they are not affected by radiant heat. After you determine the temperature rise, calculate the CFM according to the following formula.

  • Page 60: Smart Equipment™ Unit Control Board

    5167531-YIM-J-1019 Smart Equipment™ unit control board SD-24 Figure 35: Unit control board The following tables describe the details of the UCB, see Figure 35 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 61 5167531-YIM-J-1019 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 62 5167531-YIM-J-1019 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 63 5167531-YIM-J-1019 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 64 5167531-YIM-J-1019 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 65 5167531-YIM-J-1019 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 66: Cable For Fc Buses And Sa Buses In Order Of Preference

    5167531-YIM-J-1019 Table 33: 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 67: Start-Up Sheet

    5167531-YIM-J-1019 Start-up sheet Johnson Controls Ducted Systems...
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  • Page 72: 5167531-Yim-J-1019

    Subject to change without notice. Printed in U.S.A. 5167531-YIM-J-1019 Copyright © 2019 by Johnson Controls, Inc. All rights reserved. Supersedes: 5167531-YIM-I-1118 York International Corporation 5005 York Drive Norman, OK 73069...

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