York ZF078-150 Instruction Manual
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York ZF078-150 Instruction Manual

York ZF078-150 Instruction Manual

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R-410A
ZF SERIES W/SMART EQUIPMENT™
6-1/2 - 12-1/2 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . . 35
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . . . 37
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Dry Bulb Changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 ZF078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZF078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 9
4 ZF078-150 Unit Physical Dimensions . . . . . . . . . . . . . . . . . . 11
5 ZF078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 ZF078-150 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . . 33
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
16 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . . 44
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
®
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZF078-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZF150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZF078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . . 12
11 ZF078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . 13
12 ZF078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . . 13
13 ZF150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . . 14
14 ZF078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . . . . 14
15 ZF078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZF078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . . 16

TABLE OF CONTENTS

Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Air Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 53
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Electric Heating Sequence Of Operations . . . . . . . . . . . . . . . . 56
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 56
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 57
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 58
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control Board Navigation Components . . . . . . . . . . . . . . . . . . . . 62
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
LIST OF TABLES
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
20 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 50
22 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . . . 52
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 53
24 Electric Heat Limit Setting 50" Cabinet . . . . . . . . . . . . . . . . . 57
25 Electric Heat Limit Setting 42" Cabinet . . . . . . . . . . . . . . . . . 57
26 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 57
27 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 59
28 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 59
29 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 61
30 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
31 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 63
33 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 69
LIST OF FIGURES
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . . . 18
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
28 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 39
29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
30 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 44
31 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
32 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
33 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5464597-YIM-B-0518

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Summary of Contents for York ZF078-150

  • Page 1: Table Of Contents

    30 Altitude/Temperature Correction Factors ....44 15 ZF078-150 Roof Curb ......15 31 Dry Coil Delta P .

  • Page 2: General

    5464597-YIM-B-0518 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 Additional information is available in the following reference forms: • Technical Guide - ZF078-150, 5167798 • General Installation - ZF078-150, 5167512 Improper installation may create a condition where the • Smart Equipment™ Control Quick Start Guide 1136326 operation of the product could cause personal injury or •...
  • Page 4 5464597-YIM-B-0518 Nomenclature ® 6.5-12.5 Ton York Model Number Nomenclature Z F 090 C A 2 A 1 Product Generation Product Category 1 = First Generation 2 = Second Generation Z = A/C, Single Pkg., R-410A Cabinet Options Product Identifier A = Std Cabinet...

  • Page 5: Installation

    5464597-YIM-B-0518 Remove the condenser coil external protective covering Installation prior to operation. Installation Safety Information Remove the toolless doorknobs and instruction packet prior to installation. Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling unit.

  • Page 6: Limitations

    Roof curbs in eight- and board for safe and fourteen-inch heights. 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 ZF Series footprints door latch knockouts...

  • Page 7: Location

    5464597-YIM-B-0518 Table 1: ZF078-150 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

    5464597-YIM-B-0518 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: Zf078-150 Unit Accessory Weights

    5464597-YIM-B-0518 Table 3: ZF078-150 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: Zf150

    5464597-YIM-B-0518 45.64 14.92 4X Ø 24.38 14.92 58.09 14.92 29.95 30.11 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 9: ZF150 Johnson Controls Ducted Systems...

  • Page 11: Zf078-150 Unit Physical Dimensions

    5464597-YIM-B-0518 Table 4: ZF078-150 Unit Physical Dimensions Dimension (in.) Unit Model Number ZF078 22 1/8 18 3/16 15 3/16 6 3/16 ZF090 22 1/8 18 3/16 15 3/16 6 3/16 ZF102 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16...

  • Page 12: Zf078-150 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: ZF078-150 Unit Bottom Duct Openings Johnson Controls Ducted Systems...

  • Page 13: Zf078-150 Unit Electrical Entry

    Power Entry Ø 2-1/2 Convenience Outlet Cover Convenience Outlet Power Entry Ø 7/8 FRONT Figure 11: ZF078-150 Unit Electrical Entry 1 8 - 1 /4 D o t P l u g s Return Supply Air 2 - 3 1 /3 2...

  • Page 14: Side Duct Dimensions

    28 1/4 18 1/16 28 1/4 18 1/4 ZF150 28 1/4 18 1/16 28 1/4 18 1/4 4-5/16 Figure 14: ZF078-150 Unit Left Duct Opening Left/End Duct Dimensions Dimension (in.) Unit Model Number 30.357 13.365 22.516 30.357 13.365 22.516 30.358 22.580...

  • Page 15: Ductwork

    76-5/8 59-1/4 FRONT RIGHT 64-1/4 Figure 16: ZF078-150 Transition Roof Curb supply and return air duct connections at the unit should be Ductwork 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: Side Panels

    5464597-YIM-B-0518 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: Compressors

    A disconnect must be utilized for these units. Factory installed to protect roofing. disconnects are available. If installing a disconnect (field ® supplied or York International supplied accessory), refer to Procedures which risk oil leakage include, but are not limited to, Figure 4 for the recommended mounting location.

  • Page 18: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat And All Units With Vfd Option

    5464597-YIM-B-0518 Avoid damage to internal components if drilling holes for When connecting electrical power and control wiring to disconnect mounting. the unit, water-proof connectors must be used so that water or moisture cannot be drawn into the unit during normal operation. The above water-proofing conditions NOTE: Since not all local codes allow the mounting of a will also apply when installing a field supplied disconnect disconnect on the unit, please confirm compliance with...

  • Page 19: Field Wiring Disconnect - Cooling Unit With Gas Heat Without Vfd Option

    5464597-YIM-B-0518 CONTACTOR 1M FACTORY OR FIELD GROUND SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 23: Field Wiring Disconnect - Cooling Unit With Gas Heat Without VFD Option Johnson Controls Ducted Systems...

  • Page 20: Control Wire Sizes

    5464597-YIM-B-0518 unit. Refer to Table 7 for control wire sizing and maximum Thermostat Wiring (Not applicable to units with VFD) 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 appliances.

  • Page 21: Electrical Data

    5464597-YIM-B-0518 Table 8: Electrical Data ZF078-150 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/ (Tons)
  • Page 22 5464597-YIM-B-0518 ZF078-150 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/ (Tons) (Amps) Size Pwr Exh...
  • Page 23 5464597-YIM-B-0518 ZF078-150 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 24 5464597-YIM-B-0518 ZF078-150 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 25 5464597-YIM-B-0518 ZF078-150 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 26 5464597-YIM-B-0518 ZF078-150 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 27 5464597-YIM-B-0518 ZF078-150 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 28 5464597-YIM-B-0518 ZF078-150 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)

  • Page 29: Zf078-150 Physical Data

    5464597-YIM-B-0518 Table 9: ZF078-150 Physical Data Models Component ZF078 ZF090 ZF102 ZF120 ZF150 Nominal Tonnage 12.5 AHRI COOLING PERFORMANCE Gross Capacity @ AHRI A point (Mbh) 81000 90000 104000 126000 148000 AHRI net capacity (Mbh) 78000 84000 101000 118000 145000 11.2...
  • Page 30 5464597-YIM-B-0518 Table 9: ZF078-150 Physical Data (Continued) Models Component ZF078 ZF090 ZF102 ZF120 ZF150 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 31: Optional Electric Heat

    5464597-YIM-B-0518 These CSA approved heaters are located within the central Optional Electric Heat 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 32: Optional Gas Heat

    5464597-YIM-B-0518 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 Temperature Rise range.

  • Page 33: Gas Heat Minimum Supply Air

    5464597-YIM-B-0518 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 34: Options/Accessories

    5464597-YIM-B-0518 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 35: Optional Variable Air Volume (Vav)

    5464597-YIM-B-0518 the assembly. Field installed Motorized Outdoor Damper plastic tubing (1/4" diameter) must be field supplied and accessories include complete instructions for installation. installed from the transducer to both the ductwork and to the atmosphere. Connect the tubing from the 'HIGH' pressure tap of Economizer the transducer to a static pressure tap (field supplied) in the supply duct located at a point where constant pressure is...

  • Page 36: Simplified Vfd Wiring

    5464597-YIM-B-0518 vary greatly among manufacturers, horsepower ratings and voltage requirements. Keep in mind that drive manufacturers also require various minimum clearances to allow for adequate internal cooling of the drive during operation. If the unit is operated with the manual bypass switch in the LINE (BYPASS) position and there are VAV boxes The unit comes with a mounting bracket installed in the Blower present in the duct system, then boxes must be driven to...

  • Page 37: Optional Hot Gas Bypass (Hgbp)

    5464597-YIM-B-0518 A terminal block located in the control box is provided for field If the outside air temperature rises above the RAT plus 10°F, connection of the VFD speed reference signal (2-10 VDC) and free cooling is no longer available. The outside air temperature to the normally-open, run-permit auxiliary contact.

  • Page 38: Power Exhaust

    5464597-YIM-B-0518 If at any time the economizer output drops below 100% the b. Power Exhaust Enable timer stops and resets when the economizer output returns to c. Modulating Power Exhaust 100%. d. Exhaust VFD Installed Once a compressor output is turned ON, the economizer e.

  • Page 39: Smart Equipment™ Economizer Board Details

    5464597-YIM-B-0518 Figure 28: SE-ECO1001-0 Economizer Controller Table 13: Smart Equipment™ Economizer Board Details Board Cover Description Function & Comments Label Label Directional orientation: viewed with the center text of the cover label upright ANALOG INPUTS Terminal at left on upper edge of economizer board 24 VAC common/0-10 VDC negative for Connects through circuit trace to 24V~ IN pin COM economizer actuator position feedback...
  • Page 40 5464597-YIM-B-0518 Table 13: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label EconCtrlr parameter reports UCB-to-economizer board SA BUS communication status. Positive of the VDC (typically, a fluctuating 1.5 to 3.5 volts reading to C; at least 0.25 volts lower –...
  • Page 41 5464597-YIM-B-0518 Table 13: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label 24 VAC hot connection to power the economizer board. 24 VAC transformer HOT Connects through circuit traces to R/24V~ terminals and pins distributed on the economizer board. ANALOG INPUTS Terminal on lower edge of economizer board 24 VAC hot supplied for the outdoor air 24V~...

  • Page 42: Supply Air Limitations

    5464597-YIM-B-0518 Table 13: Smart Equipment™ Economizer Board Details (Continued) Board Cover Description Function & Comments Label Label BldgPres parameter reports input status (-.250-.250”/w/-.062- BLDG 0-5 VDC positive input from the Building .062kPa). Used for modulating power exhaust functions when PRES Pressure sensor ExFType selection is Modulating Damper or Variable Frequency Fan.

  • Page 43: Belt Adjustment

    5464597-YIM-B-0518 Belt Tension The tension on the belt should be adjusted as shown in Figure 29. Procedure for adjusting belt tension: 1. Loosen six nuts (top and bottom) A. 2. Adjust by turning (B). 3. Never loosen nuts (C). 4. Use belt tension checker to apply a perpendicular force to one belt at the midpoint of the span as shown.

  • Page 44: Altitude/Temperature Correction Factors

    5464597-YIM-B-0518 Table 15: 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 45 5464597-YIM-B-0518 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 46: Airflow Performance - Side Duct Application

    5464597-YIM-B-0518 Airflow Performance Table 16: Airflow Performance - Side Duct Application ZF078 (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 &...
  • Page 47 5464597-YIM-B-0518 ZF120 (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 &...

  • Page 48: Airflow Performance - Bottom Duct Application

    5464597-YIM-B-0518 Table 17: Airflow Performance - Bottom Duct Application ZF078 (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 1.5 HP &...

  • Page 49: Rpm Selection

    5464597-YIM-B-0518 ZF120 (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 Drive Standard 2 HP & Drive Hi Static 3 HP &...

  • Page 50: Air Balance

    5464597-YIM-B-0518 Table 19: Indoor Blower Specifications Motor Motor Sheave Blower Sheave Size Model Datum Dia. Datum Dia. Belt (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 51: Dry Coil Delta P

    5464597-YIM-B-0518 Select the correct blower performance table for the unit from Tables 16 and 17. Tables are presented for side and down flow configuration. Determine the unit Measured CFM from the Blower Failure to properly adjust the total system air quantity Performance Table, External Static Pressure and the can result in extensive blower damage.

  • Page 52: Motor Sheave Datum Diameters

    5464597-YIM-B-0518 EXAMPLE Supply Air Drive Adjustment 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 53: Operation

    5464597-YIM-B-0518 Table 22: Additional Static Resistance Electric Heat kW Size Model Cooling Only Economizer 4” 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 0.10...
  • Page 54 5464597-YIM-B-0518 "Y2" call for first stage cooling the UCB will determine if a VAV Cooling Supply Air Temp Lower Set point second stage cooling output is valid as long as all safeties and (default 55° F) time-delays allow a C2 output for cooling. The C2 relay on the VAV Supply Air Temp Reset Set point (default 72°...

  • Page 55: Cooling Operation Errors

    5464597-YIM-B-0518 of the enthalpy controller (previously determined), "Y1" energizes the economizer. The dampers will modulate to Mobile Access Portal (MAP) Gateway (Portable). maintain a constant supply air temperature as monitored by the discharge air sensor. If the outdoor air enthalpy is above the set •...

  • Page 56: Electric Heating Sequence Of Operations

    5464597-YIM-B-0518 The ASCD is initiated on unit start-up and on any compressor Low Ambient Cooling reset or lock-out. To determine when to operate in low ambient mode, the UCB has an Outdoor Air Temperature Sensor (OAT) with a low Electric Heating Sequence Of Operations ambient setpoint at 45ºF (default).

  • Page 57: Gas Heating Sequence Of Operations

    5464597-YIM-B-0518 Gas Heating Sequence Of Operations Table 23: Electric Heat Limit Setting 50” Cabinet LIMIT HEATER UNIT (TONS) VOLTAGE SWITCH OPENS °F For units with VFD and gas heat, the speed of the indoor ZF102, 120, 150 208/230 (8.5, 10, 12.5) blower motor continues to be controlled by duct static pressure via the VAV control board.

  • Page 58: Gas Heating Operation Errors

    5464597-YIM-B-0518 this failure should occur during an ignition cycle the failure is Retry Operation counted as a recycle. When a flame is lost or is not detected during an attempt to achieve ignition, a retry operation occurs. A 30-second purge is Gas Valve performed between ignition attempts.

  • Page 59: Start-Up (Cooling)

    5464597-YIM-B-0518 Gas Heat Anticipator Setpoints Table 26: Gas Heat Limit Control Settings It is important that the anticipator setpoint be correct. Too high Unit Main Limit Setting of a setting will result in longer heat cycles and a greater °F Size Opt.

  • Page 60: Start-Up (Gas Heat)

    5464597-YIM-B-0518 Start-Up (Gas Heat) Shut Down Set the thermostat to the lowest temperature setting. Pre-Start Check List Turn “OFF” all electric power to unit. Complete the following checks before starting the unit. Open gas heat access panel. Check the type of gas being supplied. Be sure that it is the same as listed on the unit nameplate.

  • Page 61: Gas Rate Cubic Feet Per Hour

    5464597-YIM-B-0518 Manifold Gas Pressure Adjustment Table 28: Gas Rate Cubic Feet Per Hour This gas furnace has two heat stages. Therefore, the gas valve Size of Test Dial Seconds for has two adjustment screws located under a plastic protective One Rev. 1/2 cu.

  • Page 62: Charging The Unit

    5464597-YIM-B-0518 Adjustment Of Temperature Rise MATE-N-LOCK HIGH & LOW GAS ADJUSTMENT CONNECTORS 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 INLET be calculated as follows:...

  • Page 63: Smart Equipment™ Ucb Details

    5464597-YIM-B-0518 THERMOSTAT WIRED HERE SD-24 Figure 34: Unit Control Board Table 30: Smart Equipment™ UCB Details Description Function & Comments Terminal Directional orientation: viewed with silkscreen labels upright Limit, 24 VAC power and shutdown connections from unit wiring harness at left on upper edge of UCB Monitored 24 VAC input through heat section limit If voltage is absent, indicating the heat section is over- LIMIT...
  • Page 64 5464597-YIM-B-0518 Table 30: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal Thermostat connection strip on left edge of UCB 1st stage heating request, 24 VAC input switched Not effective for cooling-only units from R 2nd stage heating request, 24 VAC input switched Not effective for cooling-only units or units with single-stage from R heat sections...
  • Page 65 5464597-YIM-B-0518 Table 30: Smart Equipment™ UCB Details (Continued) Description Function & Comments Input required for operation; 3.625 VDC reading RAT+ to RAT– Return Air Temperature sensor input from 10KΩ with open circuit. Used in return air enthalpy calculation. RAT+ @ 77°F, Type III negative temperature coefficient Substitutes for space temperature if no other space thermistor temperature input is present.
  • Page 66 5464597-YIM-B-0518 Table 30: Smart Equipment™ UCB Details (Continued) Description Function & Comments Terminal at lower right corner of UCB Output relay circuitry is isolated from other UCB components 24 VAC hot for H1, H2, CN-FAN, AUX HGR, FAN 24V FOR OUTPUTS and the 24 VAC hot source may be from a second transformer C1 and C2 output relay contact switching in the unit...
  • Page 67 5464597-YIM-B-0518 Table 30: Smart Equipment™ UCB Details (Continued) Description Function & Comments Not effective for one stage compressor UCBs. Input is only considered if C2 output is needed; input must be present to 24 VAC hot return from refrigerant circuit 2 High allow C1 output.
  • Page 68 5464597-YIM-B-0518 Table 30: Smart Equipment™ UCB Details (Continued) Description Function & Comments Item USB connector at right of UCB Used for backup, restoration, & copying of board parameters as Type A female Universal Serial Bus connector well as board software updating through a flash drive Factory wired SA Bus connector Optional communication sub-board at center of UCB Terminal FC BUS...

  • Page 69: Cable For Fc Buses And Sa Buses In Order Of Preference . 69 33 Ignition Control Flash Codes

    5464597-YIM-B-0518 Table 31: 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 70: Start-Up Sheet

    5464597-YIM-B-0518 Start-Up Sheet Johnson Controls Ducted Systems...
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  • Page 74 5464597-YIM-B-0518 Johnson Controls Ducted Systems...
  • Page 75 Subject to change without notice. Printed in U.S.A. 5464597-YIM-B-0518 Copyright © 2018 by Johnson Controls, Inc. All rights reserved. Supersedes: 5464597-YIM-A-0118 York International Corporation 5005 York Drive Norman, OK 73069...

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