Table of Contents
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R-410A
ZF SERIES
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
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 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 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 ZF078-150 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
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Component Location (ZF120 Shown) . . . . . . . . . . 6
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
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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 . . . . . . . . . . . . . . . . . . . . . . . 55
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 50" Cabinet . . . . . . . . . . . . . . . . . 53
23 Electric Heat Limit Setting 42" Cabinet . . . . . . . . . . . . . . . . . 54
24 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 54
25 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 56
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
29 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 60
30 Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . . . 62
32 VAV Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . 62
LIST OF FIGURES
Electric Heat and All Units With VFD Option . . . . . . . . . . . . 18
Gas Heat Without 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 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
28 Honeywell Economizer Control W7212 . . . . . . . . . . . . . . . . 38
29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
30 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 40
31 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
32 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
33 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
35 Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . 63
36 Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
37 Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
518674-YIM-C-0610
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Table of Contents
Troubleshooting
Related Manuals for York ZF150
Summary of Contents for York ZF150
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Page 1: Table Of Contents
9 ZF150 ........ -
Page 2: General
518674-YIM-C-0610 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 A separate Renewal Parts request for inspection by the carrier’s agent should be made in ® writing. Contact your local York parts distribution center for authorized replacement parts. Approvals Design certified by CSA as follows:...
- Page 4 Simplicity IntelliComfort 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
518674-YIM-C-0610 Installation Turn each bracket toward the ground and the protective plywood covering will drop to the ground. Installation Safety Information Remove the condenser coil external protective covering prior to operation. Read these instructions before continuing this appliance installation. This is an outdoor combination heating and cooling Remove the toolless doorknobs and instruction packet unit. -
Page 6: Limitations
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 w/crankcase heater) knockouts... -
Page 7: Location
If a unit is to be installed on a roof curb other than a ® varnishes, hydrochloric acid, cements and glues, York roof curb, gasketing must be applied to all antistatic fabric softeners for clothes dryers, masonry surfaces that come in contact with the unit underside. -
Page 8: Weights And Dimensions
518674-YIM-C-0610 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
518674-YIM-C-0610 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 30.11 45.64 14.92 14.92 58.09 14.92 Ø 24.47 TYP. 4 PL. See detail A for gas inlet 11 3/8 See detail B for drain location LEFT 4 3/16 21 3/16 FRONT 27 5/16 Figure 9: ZF150 Johnson Controls Unitary Products...
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Page 11: Zf078-150 Unit Physical Dimensions
50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZF120 50 3/4 30 3/16 24 3/16 17 3/16 6 3/16 ZF150 50 3/4 119 1/2 30 3/16 24 3/16 17 3/16 6 3/16 Detail A 3.184 3.184 Gas Pipe Inlet Gas Pipe Inlet Ø... -
Page 12: Zf078-150 Unit Bottom Duct Openings
518674-YIM-C-0610 32 11/16 6 13/16 RETURN SUPPLY 6 13/16 27 1/2 Bottom power, control and convenience outlet LEFT RIGHT wiring entry 20 1/8 19 1/8 17 1/8 12 5/16 Bottom condensate drain 14 1/2 25 9/16 Bottom gas supply entry 16 3/8 18 1/16 FRONT... -
Page 13: Zf078-150 Unit Electrical Entry
518674-YIM-C-0610 Disconnect Swith Cover Power Entry Ø 2-1/2 Control Entry Ø 7/8 Power Entry Ø 2-1/2 Convenience Outlet Cover Convenience Outlet Power Entry Ø 7/8 FRONT Figure 11: ZF078-150 Unit Electrical Entry 18-1/4 Dot Plugs Return Supply 2-31/32 5-5/32 31-11/16 Figure 12: ZF078-120 Unit Side Duct Openings Johnson Controls Unitary Products... -
Page 14: Side Duct Dimensions
518674-YIM-C-0610 Dot Plugs 18-1/4 5-5/32 2-7/8 31-5/8 Figure 13: ZF150 Unit Side Duct Openings Table 6: Side Duct Dimensions Dimension (in.) Unit Model Number ZF078 27 3/4 12 1/16 27 1/2 ZF090 27 3/4 12 1/16 27 1/2 ZF102 28 1/4... -
Page 15: Ductwork
518674-YIM-C-0610 RIGHT 80-5/8 INSULATED DECK UNDER CONDENSER SECTION SUPPLY RETURN 2 TYP. 50-1/2 INSULATED DECK UNDER COMPRESSOR SECTION FRONT 8 or 14 Figure 15: ZF078-150 Roof Curb 2 TYP 23 4 30-1/2 50-1/2 80-5/8 RETURN SUPPLY 76-5/8 59-1/4 FRONT RIGHT 64-1/4 Figure 16: ZF078-150 Transition Roof Curb Ductwork... -
Page 16: Condensate Drain
518674-YIM-C-0610 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
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
518674-YIM-C-0610 Power wiring is brought into the unit through the side of the unit or the basepan inside the curb. TERMINAL BLOCK TB1 FACTORY OR FIELD GROUND SUPPLIED DISCONNECT THREE PHASE POWER SUPPLY Figure 21: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat and All Units With VFD Option CONTACTOR 1M FACTORY OR FIELD GROUND... -
Page 19: Control Wire Sizes
518674-YIM-C-0610 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
518674-YIM-C-0610 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) (Amps) Size Pwr Exh... - Page 21 518674-YIM-C-0610 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 (Amps) (Amps) RLA LRA...
- Page 22 518674-YIM-C-0610 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 (Amps) (Amps) RLA LRA...
- Page 23 518674-YIM-C-0610 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) Size (Amps) (Amps)
- Page 24 518674-YIM-C-0610 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) (Amps) RLA LRA Model...
- Page 25 518674-YIM-C-0610 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 (Amps) (Amps) RLA LRA...
- Page 26 518674-YIM-C-0610 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 (Amps) (Amps) RLA LRA...
- Page 27 518674-YIM-C-0610 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) Size (Amps) (Amps)
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Page 28: Zf078-150 Physical Data
518674-YIM-C-0610 Table 9: ZF078-150 Physical Data Models Component ZF078 ZF090 ZF102 ZF120 ZF150 Nominal Tonnage 12.5 ARI COOLING PERFORMANCE Gross Capacity @ ARI A point (Mbh) 81000 90000 104000 126000 156000 ARI net capacity (Mbh) 78000 88000 101000 120000 150000 11.2... - Page 29 518674-YIM-C-0610 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.
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Page 30: Optional Electric Heat
518674-YIM-C-0610 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
518674-YIM-C-0610 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
518674-YIM-C-0610 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
518674-YIM-C-0610 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)
518674-YIM-C-0610 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 518674-YIM-C-0610 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)
518674-YIM-C-0610 Bas-ready VFD Factory-installed VFD is also available with 'BAS-Ready' models. Terminal blocks are provided in the control box (in place of the VAV control board) for field wiring of a customer- Do not connect AC power to the T1, T2, T3 drive installed BAS to receive 24 VAC power and to connect to the terminals to prevent damage to the VFD. -
Page 37: Enthalpy Set Point Chart
518674-YIM-C-0610 Enthalpy Set Point Adjustment the economizer damper at which the power exhaust is needed. It can be set from 0 to 100% damper open. • The enthalpy set point may now be set by selecting the desired set point shown in the Enthalpy Set Point Indoor Air Quality AQ Adjustment Figure 27. -
Page 38: Supply Air Limitations
518674-YIM-C-0610 Exhaust Air Adjustment Screw Exhaust Air LED Damper Min. Position Screw Indoor Air Quality Max. Adjustment Screw Indoor Air Quality Indoor Air Quality Min. Adjustment Screw Free Cool Free Cooling LED Economizer Enthalpy Set Point Adjustment Screw Figure 28: Honeywell Economizer Control W7212 Phasing Belt Tension ®... - Page 39 518674-YIM-C-0610 CFM Static Pressure and Power-Altitude and Temperature Corrections The information below should be used to assist in application of Procedure for adjusting belt tension: product when being applied at altitudes at or exceeding 1000 feet above sea level. 1. Loosen six nuts (top and bottom) A. 2.
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Page 40: Altitude/Temperature Correction Factors
518674-YIM-C-0610 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
518674-YIM-C-0610 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
518674-YIM-C-0610 Table 15: 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 43: Zf150
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. ZF150 (12.5 Ton) Side Duct Available External Static Pressure - IWG Air Flow... -
Page 44: Airflow Performance - Bottom Duct Application
518674-YIM-C-0610 Table 16: 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 45: Rpm Selection
1. Blower performance includes gas heat exchangers and 2” filters. See STATIC RESISTANCE table for additional applications. 2. See RPM SELECTION table to determine desired motor sheave setting and to determine the maximum continuous BHP. 3. kW = BHP x 0.932. ZF150 (12.5 Ton) Bottom Duct Available External Static Pressure - IWG Air Flow... -
Page 46: Air Balance
518674-YIM-C-0610 Table 18: 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 47: Dry Coil Delta P
Determine the number of turns the variable motor sheave is open. ZF078 0.45 ZF102 ZF090 ZF120 ZF150 0.35 0.25 0.15 0.05 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 Airflow (CFM) Figure 31: Dry Coil Delta P... -
Page 48: Motor Sheave Datum Diameters
518674-YIM-C-0610 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
518674-YIM-C-0610 Table 21: 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 50: No Outdoor Air Options
518674-YIM-C-0610 Continuous Blower When the Return Air Temp (RAT) is above the "VAV Supply Air Temp Reset Set point" the SAT will be maintained at +/- 5 By setting the room thermostat fan switch to "ON," the supply degrees of the "VAV Cooling Supply Air Temp Lower Set point". air blower will operate continuously. - Page 51 518674-YIM-C-0610 * To be available, a compressor must not be locked-out due to a Economizer With Optional VAV OR Intelli-Comfort™ high or low-pressure switch or freezestat trip and the Anti- Control Short Cycle Delay (ASCD) must have elapsed. The position of the outside air and return air dampers are controlled through a 2-10 VDC signal from the VAV or Intelli- Economizer With Single Enthalpy Sensor Comfort™...
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Page 52: Cooling Operation Errors
518674-YIM-C-0610 Economizer With Optional VAV Blower With Power Once the low-pressure switch has been proven (closed during Exhaust the 30-second monitor period described above), the UCB will monitor the low-pressure limit switch for any openings. If the The power exhaust motor is energized via the controller's EXH~ low-pressure switch opens for greater than 5 seconds, the UCB terminal and the M5 contactor, based on the position of the will de-energize the associated compressor, initiate the ASCD,... -
Page 53: Electric Heating Sequence Of Operations
518674-YIM-C-0610 A high-pressure switch to protect against excessive Two-stage heating: discharge pressures due to a blocked condenser coil or a a. Upon a call for first stage heat by the thermostat, the condenser motor failure, (opens at 625 ± 25 psig). heater relay (RA) will be energized. -
Page 54: Gas Heating Sequence Of Operations
518674-YIM-C-0610 When the thermostat calls for the first stage of heating, the low- Table 23: Electric Heat Limit Setting 42” Cabinet voltage control circuit from “R” to “W1” is completed. A call for LIMIT heat passes through the UCB to the Ignition Control Board HEATER UNIT (TONS) VOLTAGE... -
Page 55: Gas Heating Operation Errors
GV. The draft motor is stopped when voltage is not sensed at the GV. ZF150 Any time the UCB senses voltage at the GV without a call for 1. Rollout = 300°F, Auxiliary Limit = 200°F. -
Page 56: Start-Up (Cooling)
518674-YIM-C-0610 Start-Up (Cooling) The ICB monitors the Pressure and Rollout switches of gas heat units. Prestart Check List The control circuit includes the following safety controls: After installation has been completed: Pressure Switch (PS) Check the electrical supply voltage being supplied. Be sure that it is the same as listed on the unit nameplate. -
Page 57: Checking Gas Heat Input
518674-YIM-C-0610 Operating Instructions Open gas heat access panel. Turn gas valve clockwise to “OFF” position (See Figure 33). Checking Gas Heat Input This furnace is equipped with an automatic re-ignition This unit has two stages of gas heat. The first stage is 60% of system. -
Page 58: Gas Rate Cubic Feet Per Hour
518674-YIM-C-0610 Manifold Gas Pressure Adjustment Table 27: 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
518674-YIM-C-0610 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
518674-YIM-C-0610 ® 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
518674-YIM-C-0610 Check Alarm History Reset All ASCDs for One Cycle Non Alarm Condition Green LED Flashing Current Alarm Flashed Red LED Figure 34: 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
518674-YIM-C-0610 Table 30: Heat Delay Table 32: 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
518674-YIM-C-0610 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
518674-YIM-C-0610 Figure 37: Trip Failure Flow Chart Johnson Controls Unitary Products... - Page 65 518674-YIM-C-0610 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, the M3 contactor has been “AUTO” position): replaced with an "ice cube"...
- Page 66 518674-YIM-C-0610 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 518674-YIM-C-0610 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 518674-YIM-C-0610 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 518674-YIM-C-0610 With the draft motor running, check for 24 volts at the Check to ensure gas is being supplied to the unit. Confirm pressure switch terminal on the ICB. If not present, check that the gas pressure to the unit is within the proper limits for 24 volts on the terminal from the pressure switch.
- Page 70 Subject to change without notice. Printed in U.S.A. 518674-YIM-C-0610 Copyright © 2010 by Johnson Controls, Inc. All rights reserved. Supersedes: 518674-YIM-B-1109 Johnson Controls Unitary Products 5005 York Drive Norman, OK 73069...
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