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© 2025
WARNING
Improper installation, adjustment, alteration, ser vice
or maintenance can cause property damage, personal
injury or loss of life. Installation and ser vice must be
performed by a licensed professional HVAC installer or
equivalent, service agency, or the supplier.
Table of Contents
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
INSTALLATION
INSTRUCTIONS
ZHD092
ZHD102
ZHD120
HEAT PUMP PACKAGED UNITS
508730-01
4
2/2025
5
6
6
6
8
8
9
To prevent serious injury or death:
9
1- Lock-out/tag-out before performing maintenance.
10
11
2- If system power is required (e.g., smoke detector
11
maintenance), disable power to blower, remove fan
16
belt where applicable, and ensure all controllers and
16
thermostats are set to the OFF position before per-
19
forming maintenance.
19
3- Always keep hands, hair, clothing, jewelery, tools,
22
etc., away from moving parts.
7-1/2 Ton
8-1/2 Ton
10 Ton
R-454B
WARNING
23
29
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Summary of Contents for Lennox ZHD092
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Page 1: Table Of Contents
INSTALLATION © 2025 INSTRUCTIONS WARNING ZHD092 Improper installation, adjustment, alteration, ser vice 7-1/2 Ton or maintenance can cause property damage, personal ZHD102 8-1/2 Ton injury or loss of life. Installation and ser vice must be ZHD120 performed by a licensed professional HVAC installer or 10 Ton equivalent, service agency, or the supplier. - Page 2 CAUTION WARNING As with any mechanical equipment, contact with sharp •This appliance must be installed in accordance with sheet metal edges can result in personal in jury. Take local and national wiring regulations. care while handling this equipment and wear gloves and •If the appliance is not fitted with an option for full protective clothing.
- Page 3 A2L Refrigerant Considerations When breaking into the refrigerant circuit to make repairs or for any other purpose – conventional procedures shall Ensure that the work area is adequately ventilated before be used. However, for flammable refrigerants it is important breaking into the system or conducting any hot work. that best practices be followed since flammability is a A degree of ventilation shall continue during the period consideration.
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Page 4: Parts Arrangement
ZHD092-120 Parts Arrangement UNIT FUSE BLOCK FUSE ELECTRIC HEAT Page 4... -
Page 5: Dimensions
ZHD 092, 102, & 120 Dimensions BOTTOM POWER ENTRY Holes required for Optional Bottom Power Entry Kit Threaded Hole Diameter Wire Conduit Fittings Required in (Provided in Kit) Unit Base (Max.) ACC. 7/8 (23) 7/8 (23) 1-1/4 POWER 1-3/4 (44) 10-1/2 (991) (267) -
Page 6: Shipping And Packing List
CAUTION WARNING As with any mechanical equipment, contact with sharp Electric shock hazard and danger of sheet metal edges can result in personal in jury. Take explosion. Can cause injury, death or product care while handling this equipment and wear gloves and or property damage. - Page 7 “Halt” rows and then multiply the value needed from the tables above by the altitude factor number. Example: For the minimum airflow in CFM for an ZHD092 at 1000 ft. above see level, multiply 394 by 1.05 to get 413.7 CFM as the new Q...
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Page 8: Unit Support
If this unit has been used for heating or cooling of buildings Installer’s Roof Mounting Frame or structures under construction, the following conditions Many types of roof frames can be used to install the unit must be met or the warranty will be void: depending upon different roof structures. -
Page 9: Rigging Unit For Lifting
UNIT ALIGNMENT BRACKETS Rigging Unit for Lifting NEW ROOF CURBS (89-3/8” IN LENGTH): Rig unit for lifting by attaching four cables to holes in unit Remove all three brackets. base rail. See FIGURE 2. EXISTING ROOF CURBS (81-3/4” LONG): Set unit on roof curb positioning alignment brackets as shown. 1 - Detach wooden base protection before rigging. -
Page 10: Control Wiring
CONTROL WIRING Electrical Connections Connect either a thermostat, room/zone sensor, or direct POWER SUPPLY digital controller; one of the three are required for unit A-Wiring function. Refer to the literature provided with each device and the following information. Do not apply power or close disconnect switch until installation is complete. -
Page 11: Unit Power-Up
Three phase scroll compressors must be phased sequentially to ensure correct compressor and blower ZHD092/102 Units are equipped with two-stage blowers. rotation and operation. Compressor and blower are wired The blower will operate at high speed with a Y3 thermostat in phase at the factory. - Page 12 LOCATION OF STATIC PRESSURE READINGS INSTALLATIONS WITH DUCTWORK INSTALLATIONS WITH CEILING DIFFUSERS ROOFTOP UNIT ROOFTOP UNIT RETURN AIR READING LOCATION RETURN AIR READING LOCATION SUPPLY SUPPLY TURN TURN FIRST BRANCH OFF OF MAIN RUN MAIN DUCT RUN SUPPLY AIR SUPPLY AIR READING READING DIFFUSER...
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Page 13: Pulley Alignment
STANDARD BLOWER ASSEMBLY SIDE VIEW TO INCREASE BELT TENSION 1- Loosen four bolts securing motor mounting base to frame. MOTOR ALLEN SCREW 2- Turn adjusting bolt to the right, or clockwise, to move the motor away from the blower housing. PULLEY IMPORTANT - Gap between end of frame and motor BLOWER... -
Page 14: Blower Data
BLOWER DATA 092S, 102S, 120S STANDARD EFFICIENCY BELT DRIVE BLOWER − BASE UNIT BLOWER TABLE INCLUDES RESISTANCE FOR BASE UNIT ONLY (NO HEAT SECTION) WITH DRY INDOOR COIL AND AIR FILTERS IN PLACE. FOR ALL UNITS ADD: 1− Wet indoor coil air resistance of selected unit. 2−... - Page 15 BLOWER DATA FACTORY INSTALLED BELT DRIVE KIT SPECIFICATIONS Nominal hp Maximum hp Drive Kit Number RPM Range 590 - 890 800 - 1105 795 - 1195 3.45 730 - 970 3.45 940 - 1200 3.45 1015 - 1300 5.75 900 - 1135 5.75 1040 - 1315 5.75...
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Page 16: Heating Start-Up
TABLE 3 MANUFACTURER’S NUMBERS DRIVE COMPONENTS DRIVE NO. ADJUSTABLE SHEAVE FIXED SHEAVE BELT BROWNING NO. OEM PART NO. BROWNING NO. OEM PART NO. BROWNING NO. OEM PART NO. 1VP34x7/8 31K6901 AK61x1 100244-20 44L5501 1VP40x7/8 79J0301 AK59x1 31K6801 AX45 100245-23 1VP34x7/8 31K6901 AK46x1 100244-17... -
Page 17: Refrigerant Charge And Check
Do Refrigerant Charge R-454B not mix refrigerants in recovery units and especially Unit (lbs) (kg) not in cylinders. ZHD092 13.56 • If compressors or compressor oils are to be re- ZHD102 13.94 moved, ensure that they have been evacuated to ZHD120 16.13... - Page 18 AHRI TESTING TABLE 4 581375-01 1 - Using the same thermometer, compare liquid tem- ZHD092 NORMAL OPERATION PRESSURES perature to outdoor ambient temperature. CIRCUIT 1 CIRCUIT 2 2 - Approach Temperature = Liquid temperature (at con- Outdoor Appr.
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Page 19: Modes Of Operation
4 - Compressor Monitoring and Defrost Controls (CMC1 MODES OF OPERATION & CMC2) Initializing The unit is equipped with two CMC control boards The RDS Non-Communicating Blower Control Board is (CMC1 & CMC2 for compressors B1 and B2 establishing connection with the refrigerant detection respectively) which has the combined function of a sensor and sensor is “warming up”. - Page 20 TABLE 8 LED Operational Modes / Troubleshooting Operating Mode LED Status Action Initializing Flashing green None Monitoring Solid green* None Check coil tubes for leak. Mitigation Flashing blue (Leak Detected) Repair the issue and restart the equipment. Fault / Service Solid blue, interrupted by red flash code Refer to table for troubleshooting guidance.
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Page 21: Sensor Maintenance
FIGURE 11 SENSOR MAINTENANCE It is recommended to check the state of the sensor every 6 months, at the beginning of each cooling and heating season. • Check that the sensor cable is in good condition. • Ensure that the sensor opening is clear and free of debris. -
Page 22: Defrost Control Board
When the jumper is placed across the TEST pins for Defrost Control Board two seconds, the control will enter the defrost mode. If The defrost thermostat, defrost pressure switch and the the jumper is removed before an additional 5-second defrost control board work together to ensure that the period has elapsed (7 seconds total), the unit will remain heat pump outdoor coil does not ice excessively during in defrost mode until the defrost pressure switch opens... -
Page 23: Preventative Maintenance / Repair
– that no live electrical components and wiring are exposed Preventative Maintenance / Repair while charging, recovering or purging the system IMPORTANT MAINTENANCE / REPAIR SAFETY – that there is continuity of earth bonding INSTRUCTIONS The following checks shall be applied to installations using Prior beginning work... -
Page 24: Back Of Unit
Approved filters should be checked monthly and replaced B-Lubrication when necessary. Take note of air flow direction marking on All motors are lubricated at the factory. No further filter frame when reinstalling filters. See FIGURE 15. lubrication is required. NOTE - Filters must be U.L.C. certified or equivalent for C-Indoor Coil use in Canada. -
Page 25: Top View
CLEAN OUTDOOR COIL ENDPLATE IS SECURED TO MULLION 1- Remove screws securing coil end plate to mullion. 2- Remove wire ties connecting coils slabs and separate TOP VIEW slabs 3-4” (76-102mm). SUPPLY 3- Clean coils with detergent or commercial coil cleaner. 4- Rinse thoroughly with water and reassemble 5- Secure coil slabs together using field-provided wire RETURN... - Page 26 TABLE 14 ZHD 092 Electric Heat Size 7.5 KW 15 KW Unit Voltage 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph W / O W / O W / O W / O...
- Page 27 TABLE 18 ZHD 102 continued Electric Heat Size 22.5 KW 30 KW Unit Voltage 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph 208/230V - 3 Ph 460V - 3 Ph 575V - 3 Ph W / O W / O W / O W / O...
- Page 28 ZHD 120 continued Electric Heat Size 45 KW 60 KW Unit Voltage 208/230V - 3 Ph 460V - 3Ph 575V - 3Ph 208/230V - 3 Ph 460V - 3Ph 575V - 3Ph W / O W / O W / O W / O W / O W / O...
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Page 29: Decommissioning
f) Make sure that cylinder is situated on the scales before Decommissioning recovery takes place. Before carrying out this procedure, it is essential that g) Start the recovery machine and operate in accordance the technician is completely familiar with the equipment with instructions. -
Page 30: Start-Up Report
START-UP REPORT Job Name:___________________________________ Inspections and Checks Store No.___________Start-Up Date:______________ Damage? R454B If yes, reported to:____________________________ Address:_____________________________________ City:______________________________State:______ Verify factory and field-installed accessories. Start-Up Contractor:____________________________ Check electrical connections. Tighten if necessary. Technician:___________________________________ Supply voltage: L1-L2______L1-L3_____L2-L3_____ Model No.:___________________________________ If unit contains a 208-230/240 volt transformer: Serial No.:____________________________________ Check primary transformer tap Transformer secondary voltage: __________...
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