1. Manuals
  2. Brands
  3. York Manuals
  4. Fan
  5. ZT078-102
  6. Installation manual

York ZT078-102 Installation Manual

R-410a
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
R-410A
ZT SERIES W/SMART EQUIPMENT™
6.5 - 12.5 Ton
60 Hertz
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 44
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ZT078-150 unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZT078-150 unit accessory weights . . . . . . . . . . . . . . . . . . . . 11
6 ZT078-150 unit physical dimensions . . . . . . . . . . . . . . . . . . . 13
7 ZT078-150 unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 ZT078-102 side duct dimensions . . . . . . . . . . . . . . . . . . . . . 17
9 ZT120-150 side duct dimensions . . . . . . . . . . . . . . . . . . . . . 17
10 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13 Physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 35
15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 36
16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 36
17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 49
19 Airflow performance - side duct application . . . . . . . . . . . . . . 51
21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
22 Indoor blower specifications . . . . . . . . . . . . . . . . . . . . . . . . . 56
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Barometric relief hood - shipping location . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 4 point and 6 point load weight for W units . . . . . . . . . . . . . . 10
6 4 point and 6 point load weight for V units . . . . . . . . . . . . . . 10
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZT078-102 physical dimensions . . . . . . . . . . . . . . . . . . . . . . 12
9 ZT120-150 physical dimensions . . . . . . . . . . . . . . . . . . . . . . 13
10 ZT078-150 unit bottom duct openings . . . . . . . . . . . . . . . . . 15
11 ZT078-150 unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . 16
12 ZT078-150 unit left/end duct opening . . . . . . . . . . . . . . . . . . 18
13 ZT078-150 roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14 ZT078-150 transition roof curb . . . . . . . . . . . . . . . . . . . . . . . 19
15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 20
16 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 20
17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table of contents

Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Reheat mode sequence of operation . . . . . . . . . . . . . . . . . . . 62
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 64
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 64
Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 65
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 70
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
List of tables
23 Power exhaust specifications . . . . . . . . . . . . . . . . . . . . . . . . 56
24 Motor sheave datum diameters . . . . . . . . . . . . . . . . . . . . . . 58
mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
26 Electric heat limit setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
27 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 64
28 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . 66
29 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 68
30 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
31 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 68
33 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 76
34 ZT078 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 77
35 ZT078 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 77
36 ZT090 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 78
37 ZT090 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 78
38 ZT102 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 79
39 ZT102 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 79
40 ZT120 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 80
41 ZT120 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 80
42 ZT150 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 81
43 ZT150 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 81
List of figures
18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 21
19 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
20 Field wiring disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
21 Typical control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
22 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
23 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
24 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 44
26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 49
28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
31 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
32 Typical two stage gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 69
33 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6021980-UIM-A-1120

Advertisement

Table of Contents
loading

Related Manuals for York ZT078-102

Summary of Contents for York ZT078-102

  • Page 1: Table Of Contents

    28 Gas heat anticipator setpoints ......66 8 ZT078-102 side duct dimensions ..... 17 29 Gas rate cubic feet per hour .

  • Page 2: General

    6021980-UIM-A-1120 General ZT078-150 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. equipped with factory or field-installed electric heaters for Electrical shock could cause personal injury.
  • Page 3 6021980-UIM-A-1120 Inspection Renewal parts As soon as you receive a unit, you must inspect it for possible Contact your local Ducted Systems parts distribution center for damage during transit. If damage is evident, note the extent of authorized replacement parts. the damage on the carrier’s freight bill.
  • Page 4 6021980-UIM-A-1120 Nomenclature 6.5-12.5 Ton Model Number Nomenclature Z T 078 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 T = Pkg AC Ultra High Eff E = SSD (SST Drain Pan) R = Reverse Drain Pan...

  • Page 5: Installation

    6021980-UIM-A-1120 Installation Installation safety information FIRE OR EXPLOSION HAZARD Read the following instructions before you install this appliance. This is an outdoor combination heating and cooling unit. The Failure to follow the safety warning exactly could result installer must assure that these instructions are made available in serious injury, death, or property damage.

  • Page 6: Limitations

    6021980-UIM-A-1120 National Fuel Gas Code, ANSI Z223.1 - Latest Edition Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edition Local building codes, and Local gas utility requirements In Canada: Toolless Doorknobs Canadian Electrical Code, CSA C22.1 Installation Codes, CSA - B149.1. Local plumbing and waste water codes, and Other applicable local codes.

  • Page 7: Component Location Table

    6021980-UIM-A-1120 Figure 4: Component location Figure 4 shows the ZT078-102 model. Table 1 lists the components of the unit. Table 1: Component location table Item Description Item Description Smart Equipment™ supply fan controls with IntelliSpeed™. Includes Power ventor motor screw connectors for thermostat wiring and network connections...

  • Page 8: Zt078-150 Unit Limitations

    6021980-UIM-A-1120 Table 2: ZT078-150 unit limitations Unit limitations Size Model Unit voltage Applied voltage Outdoor DB temp (tons) Minimum Maximum Maximum (°F) 208/230-3-60 (6.5) 460-3-60 208/230-3-60 (7.5) 460-3-60 208/230-3-60 (8.5) 460-3-60 208/230-3-60 (10.0) 460-3-60 208/230-3-60 (12.5) 460-3-60 Johnson Controls Ducted Systems...

  • Page 9: Location

    6021980-UIM-A-1120 Air for Combustion and Ventilation of the National Fuel Gas Location Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2, Use the following guidelines to select a suitable location for 7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) - these units: Latest Edition, and/or applicable provisions of the local building codes.

  • Page 10: 4 Point And 6 Point Load Weight For W Units

    6021980-UIM-A-1120 LEFT LEFT FRONT FRONT Figure 5: 4 point and 6 point load weight for W units FRONT FRONT LEFT LEFT Figure 6: 4 point and 6 point load weight for V units FRONT LEFT Figure 7: Center of gravity Johnson Controls Ducted Systems...

  • Page 11: Zt078-150 Standard Unit Weights And Dimensions

    6021980-UIM-A-1120 Table 3: ZT078-150 standard unit weights and dimensions Weight (lbs.) Center of gravity 4 point load location (lbs.) 6 point load location (lbs.) Size Model (tons) Shipping Operating 1287 1282 47.25 24.00 (6.5) 1288 1283 48.25 25.34 (7.5) 1289 1284 47.25 24.75...

  • Page 12: Zt078-102 Physical Dimensions

    6021980-UIM-A-1120 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 27.31 LEFT 21.19 89.00 FRONT Figure 8: ZT078-102 physical dimensions Johnson Controls Ducted Systems...

  • Page 13: Zt078-150 Unit Physical Dimensions

    6021980-UIM-A-1120 28.86 29.66 44.09 15.23 14.85 29.03 29.03 14.85 Ø 24.58 TYP. 4 PL. 15.23 See detail A for gas inlet 11 3/8 See detail B for drain location 21 3/16 LEFT 4 3/16 FRONT 27 5/16 Figure 9: ZT120-150 physical dimensions Table 6: ZT078-150 unit physical dimensions Dimension (in.) Unit model number...

  • Page 14: Zt078-150 Unit Clearances

    6021980-UIM-A-1120 Detail A Detail B 3.184 Gas Pipe Inlet Ø 2.000 Gas Exhaust Vent 5-3/8 Ø 3.126 14.594 1” FPT 7.705 4.727 42” CABINET Table 7: ZT078-150 unit clearances Direction Distance (in.) Direction Distance (in.) Right Front Left Rear Bottom 1.

  • Page 15: Zt078-150 Unit Bottom Duct Openings

    6021980-UIM-A-1120 32 11/16 6 13/16 6 13/16 SUPPLY RETURN 27 1/2 LEFT RIGHT 20 1/8 19 1/8 17 1/8 12 5/16 Bottom condensate drain 14 1/2 25 9/16 Bottom gas supply entry 16 3/8 18 1/16 FRONT Top view Bottom power, control and convenience outlet wiring entry 3X Ø...

  • Page 16: Zt078-150 Unit Electrical Entry

    6021980-UIM-A-1120 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: ZT078-150 unit electrical entry Johnson Controls Ducted Systems...

  • Page 17: Zt078-102 Side Duct Dimensions

    6021980-UIM-A-1120 ZT078-102 unit side duct openings Dot Plugs 18-1/4 5-5/32 2-7/8 31-5/8 Table 8: ZT078-102 side duct dimensions Dimension (in.) Unit model number ZT078, 090, 102 28 1/4 18 1/16 28 1/4 18 1/4 ZT120-150 unit side duct openings Dot Plugs...

  • Page 18: Left/End Duct Dimensions

    6021980-UIM-A-1120 4-5/16 Figure 12: ZT078-150 unit left/end duct opening Table 10: Left/end duct dimensions Dimension (in.) Unit model number ZT078, 090, 102 30.358 22.580 22.330 ZT120, 150 30.358 22.580 22.330 RIGHT 80-5/8 INSULATED DECK UNDER CONDENSER SECTION SUPPLY RETURN 2 TYP. 50-1/2 INSULATED DECK UNDER COMPRESSOR SECTION...

  • Page 19: Zt078-150 Transition Roof Curb

    6021980-UIM-A-1120 2 TYP 23 4 30-1/2 50-1/2 80-5/8 RETURN SUPPLY 76-5/8 59-1/4 FRONT RIGHT 64-1/4 Figure 14: ZT078-150 transition roof curb Johnson Controls Ducted Systems...

  • Page 20: Ductwork

    6021980-UIM-A-1120 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 21: Condensate Drain

    6021980-UIM-A-1120 Compressors The scroll compressor used in this product is specifically designed to operate with R-410A refrigerant and cannot be interchanged. This system uses R-410A refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. The compressor also uses a polyolester (POE oil), Mobil 3MA POE.

  • Page 22: Filters

    6021980-UIM-A-1120 The internal wiring harnesses furnished with this unit are an Filters integral part of the design certified unit. Field alteration to Two-inch filters are supplied with each unit. One-inch filters may comply with electrical codes is not required. be used with no modification to the filter racks. If any of the wire supplied with the unit must be replaced, Always install filters ahead of evaporator coil.

  • Page 23: Field Wiring Disconnect

    6021980-UIM-A-1120 Power wiring detail Units are factory wired for the voltage shown on the unit Power wiring is brought into the unit through the side of the unit nameplate. See Table 12, Electrical data, on page 25 to size or the basepan inside the curb. power wiring, fuses, and the disconnect switch.

  • Page 24: Control Wire Sizes

    6021980-UIM-A-1120 Thermostat wiring Table 11: Control wire sizes Install the thermostat on an inside wall approximately 56 inches Wire size Maximum length above the floor. The thermostat must not be subject to drafts, 20 AWG < 150 feet sun exposure, or heat from electrical fixtures or appliances. 18 AWG 150-250 feet Follow the manufacturer's instructions enclosed with thermostat...

  • Page 25: Electrical Data

    6021980-UIM-A-1120 Table 12: Electrical data ZT078-150 standard indoor blower - without powered convenience outlet Compressors (each) OD fan Supply Max fuse Max fuse motors blower exh. conv. Electric heat option breaker Size with pwr breaker Volt (each) motor motor outlet size with (tons) (amps)
  • Page 26 6021980-UIM-A-1120 ZT078-150 standard indoor blower - without powered convenience outlet (Continued) Compressors (each) OD fan Supply Max fuse Max fuse motors blower exh. conv. Electric heat option breaker Size with pwr breaker Volt (each) motor motor outlet size with (tons) (amps) exhaust size...
  • Page 27 6021980-UIM-A-1120 ZT078-150 high static indoor blower - without powered convenience outlet Compressors (each) OD fan Supply Max fuse Max fuse motors blower exh. conv. Electric heat option breaker Size with pwr breaker Volt (each) motor motor outlet size with (tons) (amps) exhaust size...
  • Page 28 6021980-UIM-A-1120 ZT078-150 high static indoor blower - without powered convenience outlet (Continued) Compressors (each) OD fan Supply Max fuse Max fuse motors blower exh. conv. Electric heat option breaker Size with pwr breaker Volt (each) motor motor outlet size with (tons) (amps) exhaust...
  • Page 29 6021980-UIM-A-1120 ZT078-150 standard indoor blower - with powered convenience outlet Compressors (each) OD fan Supply Max fuse motors blower exh. conv. Electric heat option fuse breaker Size with pwr Volt (each) motor motor outlet breaker size with (tons) (amps) exhaust size pwr exh.
  • Page 30 6021980-UIM-A-1120 ZT078-150 standard indoor blower - with powered convenience outlet (Continued) Compressors (each) OD fan Supply Max fuse motors blower exh. conv. Electric heat option fuse breaker Size with pwr Volt (each) motor motor outlet breaker size with (tons) (amps) exhaust size pwr exh.
  • Page 31 6021980-UIM-A-1120 ZT078-150 high static indoor blower - with powered convenience outlet Compressors (each) OD fan Supply Max fuse Max fuse motors blower exh. conv. Electric heat option breaker Size with pwr breaker Volt (each) motor motor outlet size with (tons) (amps) exhaust size...
  • Page 32 6021980-UIM-A-1120 ZT078-150 high static indoor blower - with powered convenience outlet (Continued) Compressors (each) OD fan Supply Max fuse Max fuse motors blower exh. conv. Electric heat option breaker Size with pwr breaker Volt (each) motor motor outlet size with (tons) (amps) exhaust...

  • Page 33: Physical Data

    6021980-UIM-A-1120 Table 13: Physical data ZT078-150 Models Component ZT078 ZT090 ZT102 ZT120 ZT150 Nominal tonnage 12.5 AHRI cooling performance Gross capacity @ AHRI A point (Mbh) 76000 91500 104000 121000 147500 AHRI net capacity (Mbh) 74000 89000 101000 117000 142000 12.4 /12.6 13.1...
  • Page 34 6021980-UIM-A-1120 ZT078-150 (Continued) Models Component ZT078 ZT090 ZT102 ZT120 ZT150 Nominal tonnage 12.5 Evaporator coil data Face area (sq. ft.) 47.5 47.5 Rows Fins per inch Tube diameter 0.375 0.375 0.375 0.375 0.375 Circuitry type Intertwined Intertwined Intertwined Intertwined Intertwined Refrigerant control Reheat option coil data Face area (sq.

  • Page 35: Optional Electric Heat

    6021980-UIM-A-1120 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. You only need to bring the power supply into the single Fuses are supplied, where required, by the factory.

  • Page 36: Gas Pipe Sizing - Capacity Of Pipe

    6021980-UIM-A-1120 Table 15: 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 37: Options And Accessories

    6021980-UIM-A-1120 • You must install a 1/8-inch NPT plugged tapping, • The proper pressure regulation. Two-stage regulation is accessible for test gage connection, immediately recommended. upstream of the gas supply connection to the unit. • The pressure drop in the lines between regulators and •...
  • Page 38 6021980-UIM-A-1120 assembly. Field-installed motorized outdoor damper Smoke detectors accessories include complete instructions for installation. Economizer The economizer can be a factory-installed option or a field- The use of duct smoke detectors have specific limitations installed accessory. If factory installed, refer to the instructions as established by the National Fire Protection included with the economizer to complete the assembly.

  • Page 39: Economizer Sequences

    6021980-UIM-A-1120 Manual bypass Economizer sequences An optional, factory-installed manual bypass switch is available Several functions can drive the economizer, including: minimum with factory-installed VFD. The manual bypass switch is located position, free cooling, economizer loading, and minimum in the blower motor access compartment. The manual bypass outdoor air supply.
  • Page 40 6021980-UIM-A-1120 Note: The exception to this rule occurs when hydronic heat Low ambient minimum position enable and SAT tempering with hydronic heat enable The low ambient economizer minimum position overrides all (40°F default) are both on. Hydronic heat is used to other minimum position functions.
  • Page 41 6021980-UIM-A-1120 Dry bulb Cooling stages set to one for single compressor unit The control determines the type of free cooling changeover With a stage 1 cooling demand (Y1 input), the economizer based on which sensors are present and reliable. Conditions modulates to get SAT to VAV cooling supply air temperature include the following items: upper setpoint +/-5°F.
  • Page 42 6021980-UIM-A-1120 minutes, and the SAT is greater than the upper SAT setpoint + cooling setpoint, the staged percent command holds the current 5°F, the compressor output energizes. value. With a stage 2 cooling demand (Y2 input), the economizer If the operating space temperature drops 0.6°F or more below modulates to get the SAT to the lower SAT setpoint +/-5°F.

  • Page 43: Power Exhaust

    6021980-UIM-A-1120 If all compressor outputs de-engerize, the economizer VAV unit sensor option A modulates to control to operating VAV SAT Setpoint +/-0.5°F. The operating VAV SAT setpoint is determined by the reset function not by the number of compressors operating. When the cooling demand ends the compressors de-energize immediately and the dampers return to operating minimum When free cooling available and the SAT is above the operating...

  • Page 44: Smart Equipment™ Economizer Board

    6021980-UIM-A-1120 Smart Equipment™ economizer board Figure 25: SE-ECO1001-0 economizer controller The following tables describe the details of the economizer board. See Figure 25 for connection locations. Smart Equipment™ economizer board - analog inputs Board Cover Location Description Function and comments label label 24 VAC common/0-10 VDC negative for...
  • Page 45 6021980-UIM-A-1120 Smart Equipment™ economizer board - analog inputs (Continued) Board Cover Location Description Function and comments label label 24 VAC common/0-10 VDC negative for the Connects through circuit trace to 24V~ IN pin COM supply air humidity sensor 24 VAC hot supplied for the indoor air quality 24V~ Connects through circuit trace to 24V~ IN pin HOT sensor...
  • Page 46 6021980-UIM-A-1120 Smart Equipment™ economizer board - SA bus details Board Cover Location Description Function and comments label label EconCtrlr parameter reports UCB-to-economizer board SA bus communication status. Negative of the SA BUS communication Common for SA BUS power and circuit to the UCB. Through the unit wiring harness, may continue on communication circuits to the 4-stage board and/or fault detection &...
  • Page 47 6021980-UIM-A-1120 Smart Equipment™ economizer board - binary outputs Board Cover Location Description Function and comments label label 24 VAC hot supplied for an incremental 24V~ Connects through circuit trace to 24V~ IN pin HOT (floating control) economizer actuator 24 VAC hot outputs to position an incremental ACT-A Unused in current control revision (floating control) economizer actuator...

  • Page 48: Supply Air Limitations

    6021980-UIM-A-1120 Phasing ZT078-150 units are properly phased at the factory. Check for proper compressor rotation. If the blower or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the phasing of the field line connection at the factory or field supplied disconnect to obtain proper rotation.

  • Page 49: Altitude/Temperature Correction Factors

    6021980-UIM-A-1120 Table 18: Altitude/temperature correction factors Altitude (ft.) Air temp. 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 1.060 1.022 0.986 0.950 0.916 0.882 0.849 0.818 0.788 0.758 0.729 1.039 1.002 0.966 0.931 0.898 0.864 0.832 0.802 0.772 0.743 0.715 1.019...
  • Page 50 6021980-UIM-A-1120 Drive selection Determine side or bottom supply duct application. Determine desired airflow. Calculate or measure the amount of external static pressure. With the operating point determined from steps 1, 2, and 3, locate this point on the appropriate supply air blower performance table.

  • Page 51: Airflow Performance

    6021980-UIM-A-1120 Airflow performance Table 19: Airflow performance - side duct application ZT078 (6.5 Ton) side duct Available external static pressure - IWG Air flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied drive Standard 1.5 HP and drive High static 2 HP and drive...
  • Page 52 6021980-UIM-A-1120 ZT102 (8.5 Ton) side duct Available external static pressure - IWG Air flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied drive Standard 2 HP and drive High static 3 HP and drive 2200 0.39...
  • Page 53 6021980-UIM-A-1120 ZT150 (12.5 Ton) side duct Available external static pressure - IWG Air flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied drive Standard 3 HP and drive 3200 0.44 0.79...

  • Page 54: Airflow Performance - Bottom Duct Application

    6021980-UIM-A-1120 Table 20: Airflow performance - bottom duct application ZT078 (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 and drive High static 2 HP and drive...
  • Page 55 6021980-UIM-A-1120 ZT120 (10 Ton) bottom duct Available external static pressure - IWG Air flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field supplied Standard 2 HP and drive High static 3 HP and drive drive 2600...

  • Page 56: Rpm Selection

    6021980-UIM-A-1120 Table 21: RPM selection Size Motor Blower 6 turns 5 turns 4 turns 3 turns 2 turns 1 turn Fully Model Airflow option (tons) sheave sheave open open open open open open closed Standard 1.725 1VL40 AK74 (6.5) High static 1VM50 AK74 1025...

  • Page 57: Dry Coil Delta P

    6021980-UIM-A-1120 Use the pressure drop indicated by the manometer and the Use an inclined manometer or Magnehelic® to determine graph in Figure 28 to determine the unit CFM. In order to the pressure drop across the unit. This is the external static obtain an accurate measurement, verify that the air filters pressure (ESP).

  • Page 58: Motor Sheave Datum Diameters

    6021980-UIM-A-1120 Supply air drive adjustment Example A 4 ton unit was selected to deliver 1,700 CFM with a 1.5 HP motor, but the unit is delivering 1,400 CFM. The variable pitch motor sheave is set at 3 turns open. Before you make any blower speed changes, review the Use the equation to determine the required DD for the new installation for any installation errors, leaks, or motor sheave.
  • Page 59 6021980-UIM-A-1120 Additional static resistance - ZT078 through 150 Electric heat kW Size (tons) Model Cooling only Reheat coil Economizer 4 in. Filter 1900 0.03 0.07 0.04 0.12 0.05 0.06 0.07 0.08 0.10 2100 0.04 0.08 0.10 0.13 0.06 0.07 0.08 0.09 0.11 2300...

  • Page 60: Operation

    6021980-UIM-A-1120 SAT lower setpoint. If the output to the economizer Operation actuator is at 10 VDC and the supply air temperature cannot be controlled to within 5 degrees of the cooling Cooling operation SAT lower setpoint, compressor stage 2 is energized. The economizer is then modulated to maintain supply air •...

  • Page 61: Cooling Operation Errors

    6021980-UIM-A-1120 Cooling Operation Errors Low ambient cooling Each cooling system is monitored for operation outside of the To determine when to operate in low ambient mode, the UCB intended parameters. Errors are handled as described below. All has an outdoor air temperature sensor (OAT) with a low system errors override minimum run times for compressors.

  • Page 62: Reheat Mode Sequence Of Operation

    6021980-UIM-A-1120 Reheat mode sequence of operation Alternate mode If the return humidity is greater than or equal to the hot gas The MagnaDRY reheat mode of operation is designed to reheat humidity setpoint, and there is no demand for cooling, remove latent heat (humidity) from a space when there are low C1 and AUX-HGR outputs energize, and C2 energizes.

  • Page 63: Cooling Operation Piping Schematic - Circuit No. 1

    6021980-UIM-A-1120 Evaporator Airflow Coil Condenser Coil Check Valve Check Valve Reheat Coil Airflow Refrigerant Flow Open Solenoid Valve Reheat Valve (SOL 1) (SOL 3) Compressor Accumulator Closed Solenoid Valve (SOL 2) Figure 29: Cooling operation piping schematic - circuit no. 1 Evaporator Airflow Coil...

  • Page 64: Electric Heating Sequence Of Operations

    6021980-UIM-A-1120 If there is a call for dehumidification and no call for cooling, the Table 26: Electric heat limit setting unit automatically reverts back to the normal hot gas reheat Heater Limit switch mode only allowing refrigerant stage one to run in reheat mode Unit (tons) Voltage opens °F...

  • Page 65: Gas Heating Operation Errors

    6021980-UIM-A-1120 a 30-second purge is initiated. At the end of the purge, the GV This limit is monitored regardless of unit operation status, that is opened and the spark igniter is energized for 10 seconds. is, this limit is monitored at all times. The ICB then checks for the presence of flame.

  • Page 66: Cooling Start-Up

    6021980-UIM-A-1120 Auxiliary limit switch Table 28: Gas heat anticipator setpoints The auxiliary limit switch (ALS) is wired in series with the limit Setting, amps switch. As such, the UCB cannot distinguish the auxiliary limit and the gas heat limit switch operation except the auxiliary is 0.65 manual reset.

  • Page 67: Checking Gas Heat Input

    6021980-UIM-A-1120 Operating instructions Checking gas heat input This unit has two stages of gas heat. The first stage is 60% of the full fire input and is considered the minimum input for the furnace. The intended input for each furnace is shown in Table 30.

  • Page 68: Gas Rate Cubic Feet Per Hour

    6021980-UIM-A-1120 Turn off electrical power to the unit. Table 29: Gas rate cubic feet per hour Using the outlet pressure port on the gas valve, connect a Size of Test Dial Seconds for manometer to monitor the manifold pressure. One Rev. 1/2 cu.

  • Page 69: Navigation Components For The Smart Equipment™ Control Board

    6021980-UIM-A-1120 After you determine the temperature rise, calculate the MATE-N-LOCK HIGH & LOW GAS ADJUSTMENT CFM according to the following formula. CONNECTORS Increase the blower CFM to decrease the temperature rise. INLET PRESSURE Decrease the blower CFM to increase the rise (see Supply OUTLET PRESSURE air drive adjustment on page 58).

  • Page 70: Smart Equipment™ Unit Control Board

    6021980-UIM-A-1120 Smart Equipment™ unit control board SD-24 Figure 33: Unit control board The following tables describe the details of the UCB, see Figure 33 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 71 6021980-UIM-A-1120 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 72 6021980-UIM-A-1120 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 73 6021980-UIM-A-1120 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 74 6021980-UIM-A-1120 Smart Equipment™ UCB - refrigerant circuit safety switch and indoor blower overload connections (Continued) Location Label Description Function and comments 24 VAC hot out for refrigerant circuit 2 Low Not effective for one stage compressor UCBs. Connects through LPS2 (right pin) Pressure Switch circuit trace to the left HSP2 pin...
  • Page 75 6021980-UIM-A-1120 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 76: Cable For Fc Buses And Sa Buses In Order Of Preference

    6021980-UIM-A-1120 Table 32: 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 77: Charging The Unit

    6021980-UIM-A-1120 Charging the unit Charge unit by weight using name plate data or use charging tables. Table 34: ZT078 charging table - system 1 Air flow Suction Suction Discharge Entering evap Leaving evap Outdoor DB Liquid temp. Delta T Db Indoor Db/Wb pressure temp.

  • Page 78: Zt090 Charging Table - System 1

    6021980-UIM-A-1120 Table 36: ZT090 charging table - system 1 Air flow Suction Suction Discharge Entering evap Leaving evap Outdoor DB Liquid temp. Delta T Db Indoor Db/Wb pressure temp. pressure 300 CFM/ton 80/62 300 CFM/ton 80/67 300 CFM/ton 80/72 300 CFM/ton 75/62 400 CFM/ton 80/62...

  • Page 79: Zt102 Charging Table - System 1

    6021980-UIM-A-1120 Table 38: ZT102 charging table - system 1 Air flow Suction Suction Discharge Entering evap Leaving evap Outdoor DB Liquid temp. Delta T Db Indoor Db/Wb pressure temp. pressure 300 CFM/ton 80/62 300 CFM/ton 80/67 300 CFM/ton 80/72 300 CFM/ton 75/62 400 CFM/ton 80/62...

  • Page 80: Zt120 Charging Table - System 1

    6021980-UIM-A-1120 Table 40: ZT120 charging table - system 1 Air flow Suction Suction Discharge Entering evap Leaving evap Outdoor DB Liquid temp. Delta T Db Indoor Db/Wb pressure temp. pressure 300 CFM/ton 80/62 300 CFM/ton 80/67 300 CFM/ton 80/72 300 CFM/ton 75/62 400 CFM/ton 80/62...

  • Page 81: Zt150 Charging Table - System 1

    6021980-UIM-A-1120 Table 42: ZT150 charging table - system 1 Air flow Suction Suction Discharge Entering evap Leaving evap Outdoor DB Liquid temp. Delta T Db Indoor Db/Wb pressure temp. pressure 300 CFM/ton 80/62 300 CFM/ton 80/67 300 CFM/ton 80/72 300 CFM/ton 75/62 400 CFM/ton 80/62...

  • Page 82: Start-Up Sheet

    6021980-UIM-A-1120 Start-up sheet Johnson Controls Ducted Systems...
  • Page 83 6021980-UIM-A-1120 Johnson Controls Ducted Systems...
  • Page 84 6021980-UIM-A-1120 Johnson Controls Ducted Systems...
  • Page 85 6021980-UIM-A-1120 Johnson Controls Ducted Systems...
  • Page 86 6021980-UIM-A-1120 Johnson Controls Ducted Systems...
  • Page 87 Subject to change without notice. Printed in U.S.A. 6021980-UIM-A-1120 Copyright © 2020 by Johnson Controls, Inc. All rights reserved. York International Corporation 5005 York Drive Norman, OK 73069...

This manual is also suitable for:

Zt seriesZt120-150Zt078-150Zt078Zt090Zt102 ... Show all

Table of Contents