York ZT078-102, Installation Manual

Page 1: ...r specifications 56 23 Power exhaust specifications 56 24 Motor sheave datum diameters 58 25 3 stage dehumidification sequence in normal and alternate mode 62 26 Electric heat limit setting 64 27 Elec...

Page 2: ...edition Wear safety glasses and work gloves Use quenching cloth and have a fire extinguisher available during brazing operations Improper installation may create a condition where the operation of th...

Page 3: ...ooring or in the U S on wood flooring or Class A Class B or Class C roof covering materials For use with natural gas The unit can be converted to LP with a kit This product must be installed in strict...

Page 4: ...n A No Economizer B Economizer w Barometric RLF D Economizer w Power EXH H Motorized Damper Outdoor Air Option 1 No Service Options 2 DSC Disconnect Switch 3 NCO Non PWR Conv Outlet 4 PCO Powered Conv...

Page 5: ...t air and combustion air intake hoods The unit must be operated under thermostatic control Return and supply air ducts must be sealed to the unit Air filters in place The unit furnace input rate and t...

Page 6: ...ain a temperature rise within the range specified on the unit rating plate If components are added to a unit to meet local codes they are installed at the dealer s and or customer s expense The size o...

Page 7: ...ng life Stainless steel option D High efficiency sine wave fin evaporator coil N Intelligent control board for safe and efficient operation E ECM outdoor fan motor O Slide out drain pan with 1 inch NP...

Page 8: ...ed voltage Outdoor DB temp Minimum Maximum Maximum F 078 6 5 ZT 208 230 3 60 187 252 125 460 3 60 432 504 125 090 7 5 ZT 208 230 3 60 187 252 125 460 3 60 432 504 125 102 8 5 ZT 208 230 3 60 187 252 1...

Page 9: ...dling Exercise care when you move the unit Do not remove any packaging until the unit is near the place of installation To rig the unit attach chain or cable slings to the lifting holes provided in th...

Page 10: ...ed Systems Figure 5 4 point and 6 point load weight for W units Figure 6 4 point and 6 point load weight for V units Figure 7 Center of gravity A LEFT D C FRONT B A LEFT B C D FRONT E F A D C B LEFT F...

Page 11: ...with the Magna Dry option Size tons Model Weight lbs Center of gravity 4 point load location lbs 6 point load location lbs Shipping Operating X Y A B C D A B C D E F 078 6 5 ZT 1293 1288 47 25 24 00...

Page 12: ...Controls Ducted Systems Figure 8 ZT078 102 physical dimensions LEFT 59 00 A C D E F 4 19 27 31 89 00 21 19 FRONT SEE DETAIL B FOR DRAIN LOCATION 11 38 SEE DETAIL A FOR GAS INLET B 29 95 30 11 14 92 58...

Page 13: ...t model number Dimension in A B C D E F ZT078 ZT090 ZT102 42 89 22 1 8 18 3 16 15 3 16 6 3 16 ZT120 ZT150 50 3 4 119 1 2 30 3 16 24 3 16 17 3 16 6 3 16 15 23 29 03 14 85 29 03 14 85 15 23 28 86 29 66...

Page 14: ...able 7 ZT078 150 unit clearances Direction Distance in Direction Distance in Top1 1 Units must be installed outdoors Make sure that overhanging structures or shrubs do not obscure the condenser air di...

Page 15: ...it bottom duct openings Bottom condensate drain Bottom gas supply entry FRONT RETURN AIR SUPPLY AIR RIGHT LEFT 20 1 8 19 1 8 17 1 8 6 13 16 6 13 16 32 11 16 14 1 2 16 3 8 18 1 16 25 9 16 12 5 16 27 1...

Page 16: ...16 Johnson Controls Ducted Systems Figure 11 ZT078 150 unit electrical entry Disconnect Swith Cover Power Entry 2 1 2 Control Entry 7 8 Power Entry 2 1 2 Convenience Outlet Cover Convenience Outlet Po...

Page 17: ...le 8 ZT078 102 side duct dimensions Unit model number Dimension in A B C D ZT078 090 102 28 1 4 18 1 16 28 1 4 18 1 4 Table 9 ZT120 150 side duct dimensions Unit model number Dimension in A B C D ZT12...

Page 18: ...T078 150 roof curb Table 10 Left end duct dimensions Unit model number Dimension in A B C ZT078 090 102 30 358 22 580 22 330 ZT120 150 30 358 22 580 22 330 4 5 16 A C B 8 or 14 50 1 2 30 20 20 80 5 8...

Page 19: ...6021980 UIM A 1120 Johnson Controls Ducted Systems 19 Figure 14 ZT078 150 transition roof curb 76 5 8 94 50 1 2 30 1 2 64 1 4 59 1 4 10 23 4 26 80 5 8 2 TYP FRONT RIGHT SUPPLY RETURN...

Page 20: ...he following steps 1 Remove the side duct covers 2 Orient the supply panel with the painted surface up 3 Slide the supply panel between the heat exchanger and the unit bottom The painted surface must...

Page 21: ...imes as much water as other oils designed for HCFC and CFC refrigerants Take all the necessary precautions to avoid exposure of the oil to the atmosphere POE polyolester compressor lubricants are know...

Page 22: ...must be replaced replacement wire must be of the type shown on the wiring diagram and the same minimum gauge as the replaced wire A disconnect must be used for these units Factory installed disconnect...

Page 23: ...it nameplate See Table 12 Electrical data on page 25 to size power wiring fuses and the disconnect switch Power wiring is brought into the unit through the side of the unit or the basepan inside the c...

Page 24: ...NAL BLOCK TERMINALS ON A LIMITED NUMBER OF THERMOSTATS 1 4 3 1 2 4 Second stage heating not required on single stage he g units Jumper is required if there is no Smoke Detector circuit Jumper is requi...

Page 25: ...8 3 53 8 60 60 E09 9 1 21 7 48 3 53 8 60 60 E18 18 2 43 3 60 6 67 5 70 70 E24 24 2 57 7 78 6 85 5 80 90 E36 34 2 81 8 108 8 115 6 110 125 460 5 7 6 4 38 41 9 10 1 6 2 6 2 2 None 22 7 24 9 25 30 E09 9...

Page 26: ...175 175 460 8 5 8 5 66 1 66 1 13 13 1 6 4 7 2 2 None 30 2 32 4 35 40 E18 18 2 21 7 33 35 8 35 40 E24 24 2 28 9 42 44 8 45 45 E36 34 2 40 9 57 59 8 60 60 E54 54 2 65 70 9 73 6 80 80 1 Minimum Circuit...

Page 27: ...e 52 7 58 2 60 70 E09 9 1 21 7 52 7 58 2 60 70 E18 18 2 43 3 66 1 73 70 80 E24 24 2 57 7 84 1 91 90 100 E36 34 2 81 8 114 3 121 1 125 125 460 5 7 6 4 38 41 9 10 1 6 4 7 2 2 None 24 8 27 30 30 E09 9 1...

Page 28: ...175 460 8 5 8 5 66 1 66 1 13 13 1 6 6 6 2 2 None 32 1 34 3 40 40 E18 18 2 21 7 35 4 38 1 40 40 E24 24 2 28 9 44 4 47 1 45 50 E36 34 2 40 9 59 4 62 1 60 70 E54 54 2 65 73 3 76 80 90 1 Minimum Circuit...

Page 29: ...9 1 21 7 58 3 63 8 70 70 E18 18 2 43 3 73 1 80 80 80 E24 24 2 57 7 91 1 98 100 100 E36 34 2 81 8 121 3 128 1 125 150 460 5 7 6 4 38 41 9 10 1 6 2 6 2 2 20 None 27 7 29 9 30 35 E09 9 1 10 8 27 7 29 9...

Page 30: ...161 3 175 175 460 8 5 8 5 66 1 66 1 13 13 1 6 4 7 2 2 20 None 35 2 37 4 40 45 E18 18 2 21 7 39 3 42 40 45 E24 24 2 28 9 48 3 51 50 60 E36 34 2 40 9 63 3 66 70 70 E54 54 2 65 77 1 79 9 90 90 1 Minimum...

Page 31: ...2 70 80 E09 9 1 21 7 62 7 68 2 70 80 E18 18 2 43 3 78 6 85 5 80 90 E24 24 2 57 7 96 6 103 5 100 110 E36 34 2 81 8 126 8 133 6 150 150 460 5 7 6 4 38 41 9 10 1 6 4 7 2 2 20 None 29 8 32 35 35 E09 9 1 1...

Page 32: ...8 175 175 460 8 5 8 5 66 1 66 1 13 13 1 6 6 6 2 2 20 None 37 1 39 3 45 45 E18 18 2 21 7 41 6 44 4 45 45 E24 24 2 28 9 50 6 53 4 60 60 E36 34 2 40 9 65 6 68 4 70 70 E54 54 2 65 79 5 82 3 90 90 1 Minim...

Page 33: ...at output K Btu 96 144 96 144 96 144 144 192 144 192 AFUE Steady state efficiency 80 80 80 80 80 80 80 80 80 80 No burners 4 6 4 6 4 6 6 8 6 8 No stages 23 23 23 23 23 23 23 23 23 23 Temperature rise...

Page 34: ...t drive evap fan data Quantity 1 1 1 1 1 Fan size inches 15 x 15 15 x 15 15 x 15 15 x 15 15 x 15 Type Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Motor sheave 1VL40 1VM50 1VL40 1VM50 1...

Page 35: ...f gas flow required specific gravity of the gas and the length of run Follow the National Fuel Gas Code Z223 1 in U S A or the current Gas Installation Codes CSA B149 1 in Canada in all cases unless t...

Page 36: ...dope sparingly to male threads only Clean all piping of dirt and scale Hammer on the outside of the pipe and blow out loose particles Before initial start up make sure that all gas lines external to t...

Page 37: ...eat Electric heaters are available as factory installed options or field installed accessories Refer to the electric heat instructions for installation These heaters mount in the heat compartment with...

Page 38: ...e are two field installed power exhaust accessories 1 Down flow application 2 Horizontal flow application that requires the purchase of a barometric relief hood Rain hood For factory installed options...

Page 39: ...r minimum position low speed fan When the VFD output is between the fan high speed and fan low speed settings the economizer damper is position proportionally between the economizer minimum position s...

Page 40: ...economizer outside air dampers close until the supply air temperature rises above 49 F but does not go below the current economizer operating minimum position The economizer then modulates to control...

Page 41: ...e number of cooling stages demanded Cooling stages set to one for single compressor unit With a stage 1 cooling demand Y1 input the economizer modulates to get SAT to VAV cooling supply air temperatur...

Page 42: ...ure drops to less than 0 6 F above the operating cooling setpoint the staged percent command holds the current value If the operating space temperature drops 0 6 F or more below the operating cooling...

Page 43: ...remains at 100 for 5 minutes and the SAT is greater than the operating VAV SAT setpoint 5 F the next available compressor energizes If the economizer position remains at 100 the process repeats every...

Page 44: ...cts through circuit trace to 24V IN pin HOT C COM Mixed air temperature sensor input from 10K 77 F Type III negative temperature coefficient thermistor The MAT parameter reports input status F C 3 65...

Page 45: ...tation sensor MOA Range parameter sets the cubic feet per minute liters per second measured by the air monitoring station sensor when it outputs 10 VDC Fr Air parameter reports input status 0 50000CFM...

Page 46: ...o the 4 stage board and or fault detection diagnostics board 1 When wiring the unit and other devices using the SA Bus and FC Bus see Table 32 Smart Equipment economizer board analog outputs Location...

Page 47: ...economizer actuator Connects through circuit trace to 24V IN pin COM EX FAN 24 VAC hot output to energize power exhaust fan contactor coil VFD enable relay coil ExFan parameter reports output status O...

Page 48: ...ection force recommended for the belt section 5 Re tighten the belt nuts Figure 26 Belt adjustment CFM static pressure and power altitude and temperature corrections Use the information below to assis...

Page 49: ...given is at an elevation of 5 000 ft The first step is to convert this static pressure to equivalent sea level conditions Sea level static pressure 0 6 832 0 72 in Enter the blower table at 1 400 sCF...

Page 50: ...5 1 62 BHP exceeds the maximum continuous BHP rating of the 1 5 HP motor The 2 HP motor is required 6 1230 RPM is within the range of the 2 HP drives 7 Using the 2 HP motor and drive 5 turns open achi...

Page 51: ...88 1 28 757 1 54 817 1 76 873 1 94 932 2 11 998 2 26 1078 2 41 1176 2 57 2 HP and field supplied drive ZT090 7 5 Ton side duct Air flow CFM Available external static pressure IWG1 1 Blower performance...

Page 52: ...2 63 1049 2 77 1106 2 91 1167 3 07 1232 3 25 4200 794 2 03 852 2 29 909 2 51 964 2 69 1019 2 85 1075 2 99 1133 3 13 1193 3 29 3 HP field supplied drive ZT120 10 Ton side duct Air flow CFM Available e...

Page 53: ...867 1 79 913 2 09 961 2 35 1011 2 60 1063 2 83 1116 3 04 1169 3 25 1222 3 45 4000 808 1 38 846 1 74 888 2 06 933 2 35 982 2 62 1032 2 86 1084 3 09 1137 3 31 1190 3 51 1242 3 71 4200 830 1 67 868 2 03...

Page 54: ...2 23 2400 675 0 76 730 0 95 788 1 12 847 1 26 907 1 41 967 1 55 1025 1 71 1081 1 90 1132 2 11 1179 2 37 2600 694 0 91 749 1 10 807 1 27 866 1 41 926 1 56 986 1 70 1044 1 86 1100 2 05 1151 2 26 1198 2...

Page 55: ...pplied drive ZT150 12 5 Ton bottom duct Air flow CFM Available external static pressure IWG1 1 Blower performance includes gas heat exchangers and 2 in filters See the static resistance table for addi...

Page 56: ...1VM50 AK74 N A 903 943 985 1028 1071 1113 120 10 ZT Standard 2 2 3 1VM50 AK84 N A 781 819 859 897 932 969 High static 3 3 45 1VM50 AK74 N A 903 943 985 1028 1076 1113 150 12 5 ZT Standard 3 3 45 1VM5...

Page 57: ...oss the unit This is the external static pressure ESP In order to obtain an accurate measurement verify that the air filters are clean 4 Determine the number of turns the variable motor sheave is open...

Page 58: ...in blower speed can result in substantial changes in static pressure and BHP BHP and AMP draw of the blower motor increase by the cube of the blower speed Static pressure increases by the square of th...

Page 59: ...07 0 08 0 09 0 10 0 13 2500 0 08 0 10 0 23 0 16 0 08 0 09 0 10 0 11 0 14 2700 0 10 0 11 0 29 0 17 0 09 0 10 0 12 0 13 0 16 2900 0 12 0 12 0 34 0 19 0 10 0 11 0 13 0 14 0 18 3100 0 15 0 13 0 40 0 20 0...

Page 60: ...ressors that are energized remain energized and the economizer dampers are modulated to maintain supply air temperature to within 1 degree of the cooling SAT lower setpoint If the output to the econom...

Page 61: ...es within two hours of operation the UCB locks out the compressor Low ambient cooling To determine when to operate in low ambient mode the UCB has an outdoor air temperature sensor OAT with a low ambi...

Page 62: ...and there is not a call for cooling the UCB energizes solenoids SOL 3 HGRH SOL 2 and the reheat relay RHR which de energizes SOL 1 The unit then operates with refrigerant flow in the evaporator reheat...

Page 63: ...reduces the amount of over cooling while maintaining humidity control in the space The aux mode is only applicable when the unit is set up in the alternate reheat mode Evaporator Coil TXV Check Valve...

Page 64: ...c heat limit setting on page 64 It resets automatically The limit switch operates when a high temperature condition caused by inadequate supply air flow occurs This shuts down the heater and energizes...

Page 65: ...ed following the elapse of the fan off delay for heating This limit is monitored regardless of unit operation status that is this limit is monitored at all times If the temperature limit opens three t...

Page 66: ...cipator setpoints The anticipator setpoint must be correct Too high of a setting results in longer heat cycles and a greater temperature swing in the conditioned space Reducing the value below the cor...

Page 67: ...calling for second stage 100 input heat 3 Measure the time needed for one revolution of the hand on the smallest dial on the meter A typical gas meter has a 1 2 or a 1 cubic foot test dial 4 Using th...

Page 68: ...ifold pressure or counterclockwise to decrease manifold pressure Note Do not to over fire the unit on second stage 7 After you check the high manifold pressure adjust the thermostat to call for first...

Page 69: ...l flame Figure 32 Typical two stage gas valve Navigation components for the Smart Equipment control board The following components are needed to access the control points in the Smart Equipment contro...

Page 70: ...e also effective for economizer free cooling supply air temperature reset when the ClgStgs parameter is set for 1 or more G Continuous indoor blower request 24 VAC input switched from R OCC Occupancy...

Page 71: ...erminate temporary occupancy COM Common for ST and SSO inputs Negative of VDC circuit for ST and SSO inputs SSO Space Sensor Offset input from 0 to 20K potentiometer Positive of VDC circuit 3 625 VDC...

Page 72: ...hot return from Air Proving Switch When this optional input is enabled the air proving switch must close within 30 seconds of initiation of indoor blower operation and not open for greater than 10 se...

Page 73: ...ntilation cooling reheat or heat pump heating demands C2 24 VAC hot output for compressor 2 Not effective for one stage compressor UCBs If demand is present and permissions allow compressor 2 operatio...

Page 74: ...f the 15 VDC reading to C circuit for powering an optional netstat and or Multi Touch gateway C Common for SA BUS power and communication circuits Also incorporated in the J8 6 pin phone jack connecto...

Page 75: ...than FC bus BACnet MSTP communication circuit FC FC Field Connected BUS BACnet MSTP communication Positive of the VDC typically a fluctuating 1 5 to 3 5 volts reading to COM at least 0 25 volts lower...

Page 76: ...2 AWG stranded shielded cable A 22 gauge cable offers the best performance for various baud rates cable distances and number of trunk devices primarily due to lower conductor to conductor capacitance...

Page 77: ...355 97 19 80 61 400 CFM ton 80 72 75 155 70 271 77 17 80 63 85 161 69 305 86 16 80 64 95 164 68 354 97 15 80 65 400 CFM ton 75 62 75 134 57 264 77 22 75 53 85 135 57 308 86 21 75 54 95 137 57 353 96...

Page 78: ...71 263 78 17 80 63 85 166 70 304 88 17 80 64 95 169 70 350 97 16 80 64 400 CFM ton 75 62 75 139 58 255 80 22 75 53 85 142 57 296 90 21 75 54 95 144 57 342 98 21 75 54 Air flow Indoor Db Wb Outdoor DB...

Page 79: ...2 279 75 17 80 63 85 159 71 319 85 16 80 64 95 162 70 364 95 16 80 64 400 CFM ton 75 62 75 135 57 268 75 22 75 53 85 138 56 308 85 21 75 54 95 140 56 354 95 21 75 54 Air flow Indoor Db Wb Outdoor DB S...

Page 80: ...0 267 77 17 80 63 85 160 69 310 87 16 80 64 95 165 68 358 98 15 80 65 400 CFM ton 75 62 75 132 55 259 77 22 75 53 85 135 54 304 86 21 75 54 95 138 53 349 96 20 75 55 Air flow Indoor Db Wb Outdoor DB S...

Page 81: ...9 279 76 16 80 64 85 160 67 322 86 16 80 64 95 165 66 370 96 15 80 65 400 CFM ton 75 62 75 133 54 271 76 22 75 53 85 136 54 314 86 21 75 54 95 140 54 363 96 20 75 55 Air flow Indoor Db Wb Outdoor DB S...

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