York ZR SERIES Specifications download pdf

R-410A

ZR SERIES

6-1/2 - 12-1/2 Ton

60 Hertz

567040-YIM-B-1210

TABLE OF CONTENTS

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Power And Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 15

Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Optional Gas Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Economizer And Power Exhaust Set Point Adjustments . 32

Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 45

No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . 45

Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . 46

Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . 47

Electric Heating Sequence Of Operations . . . . . . . . . . . . 49

Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . 49

Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . 50

Ignition Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . 51

Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Unit Control Board Option Setup . . . . . . . . . . . . . . . . . . . . . . 57

Option Byte Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Heat Delay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

LIST OF TABLES

1 ZR078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . .7

2 Weights and Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 ZR078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . 9

4 ZR078-150 Unit Physical Dimensions . . . . . . . . . . . . . . .10

5 ZR078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . .10

6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .12

7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

9 ZR078-150 Physical Data . . . . . . . . . . . . . . . . . . . . . . . .26

10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . .28

11 Gas Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

12 Gas Pipe Sizing - CapacIty of Pipe . . . . . . . . . . . . . . . . .29

13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . .30

14 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

15 Altitude/Temperature Correction Factors . . . . . . . . . . . . .35

16 Air Flow Performance - Side Duct Application . . . . . . . .37

17 Air Flow Performance - Bottom Duct Application . . . . . . .39

18 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

19 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . .41

20 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . .41

21 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . .43

22 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . .44

23 Electric Heat Limit Setting 50” Cabinet . . . . . . . . . . . . . .50

24 Electric Heat Limit Setting 42” Cabinet . . . . . . . . . . . . . .50

25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . .50

26 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . .52

27 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . .52

28 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . .54

29 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

30 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . .56

31 Heat Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

32 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . .57

33 Reheat Control Board Flash Codes . . . . . . . . . . . . . . . . .57

LIST OF FIGURES

1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Predator

Component Location (ZR120 Shown) . . . . . . 6

5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . 8

7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8 ZR078-120 Physical Dimensions . . . . . . . . . . . . . . . . . . 9

9 ZR150 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . 9

10 ZR078-150 Unit Bottom Duct Openings . . . . . . . . . . . . 10

11 ZR078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . 11

12 ZR078-120 Unit Side Duct Openings . . . . . . . . . . . . . . 11

13 ZR150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 12

14 ZR078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . 12

15 ZR078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 13

16 ZR078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . 13

17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . 14

18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . 14

19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . 14

20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

21 Typical Field Wiring Disconnect - Cooling Unit With/Without

Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

22 Typical Field Wiring Disconnect - Cooling Unit With Gas

Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

23 Typical Low Voltage Field Wiring . . . . . . . . . . . . . . . . . 17

24 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 29

25 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 29

26 Enthalpy Set Point Chart . . . . . . . . . . . . . . . . . . . . . . . . 33

27 Honeywell Economizer Control W7212 . . . . . . . . . . . . . 33

28 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

29 Altitude/Temperature Correction Factors . . . . . . . . . . . 35

30 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

31 Reheat Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 48

32 System Piping Schematic . . . . . . . . . . . . . . . . . . . . . . . 49

33 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

34 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

35 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

36 Basic Troubleshooting Flowchart . . . . . . . . . . . . . . . . . 58

37 Power On Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 58

38 Trip Failure Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . 59

1 2 3 4 5 6 ... 63 64

Summary of Contents

Page 1 - ZR SERIES

R-410AZR SERIES 6-1/2 - 12-1/2 Ton60 Hertz 567040-YIM-B-1210TABLE OF CONTENTSGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 2

567040-YIM-B-121010 Johnson Controls Unitary ProductsDetail A Detail BFigure 10: ZR078-150 Unit Bottom Duct OpeningsTable 4: ZR078-150 Unit Physical D

Page 3

567040-YIM-B-1210Johnson Controls Unitary Products 11Figure 11: ZR078-150 Unit Electrical EntryFigure 12: ZR078-120 Unit Side Duct OpeningsDisconnect

Page 4 - Model Number Nomenclature

567040-YIM-B-121012 Johnson Controls Unitary ProductsFigure 13: ZR150 Unit Side Duct OpeningsFigure 14: ZR078-150 Unit Left Duct OpeningDot Plugs2-7/8

Page 5 - Installation

567040-YIM-B-1210Johnson Controls Unitary Products 13Figure 15: ZR078-150 Roof CurbFigure 16: ZR078-150 Transition Roof CurbDuctworkDuctwork should be

Page 6

567040-YIM-B-121014 Johnson Controls Unitary ProductsDuct CoversUnits are shipped with the side duct openings covered and a covering over the bottom o

Page 7 - Rigging And Handling

567040-YIM-B-1210Johnson Controls Unitary Products 15designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the o

Page 8

567040-YIM-B-121016 Johnson Controls Unitary ProductsPower Wiring DetailUnits are factory wired for the voltage shown on the unit nameplate. Refer to

Page 9 - See detail A for gas inlet

567040-YIM-B-1210Johnson Controls Unitary Products 17Thermostat WiringThe thermostat should be located on an inside wall approximately 56 inch above t

Page 10

567040-YIM-B-121018 Johnson Controls Unitary ProductsTable 8: Electrical Data ZR078-150 Standard Motor - Without Powered Convenience Outlet Size(Tons

Page 11

567040-YIM-B-1210Johnson Controls Unitary Products 19120(10)208 17.9 120 28.0 1.5 8.2 5.5 0.0None---51.557.060 70E18 13.5 2 37.5 57.1 64.0 60 70E24 18

Page 12 - Table 6: Side Duct Dimensions

567040-YIM-B-12102 Johnson Controls Unitary ProductsGeneralYork® Predator® units are single package air conditioners with optional gas heating designe

Page 13 - Ductwork

567040-YIM-B-121020 Johnson Controls Unitary ProductsZR078-150 Hi Static Motor - Without Powered Convenience Outlet Size(Tons)VoltCompressors(each)OD

Page 14 - 3" Minimum

567040-YIM-B-1210Johnson Controls Unitary Products 21120(10)208 17.9 120 28.0 1.5 10.9 5.5 0.0None - - - 54.2 59.7 70 70E18 13.5 2 37.5 60.5 67.3 70 7

Page 15 - Power And Control Wiring

567040-YIM-B-121022 Johnson Controls Unitary ProductsZR078-150 Standard Motor - With Powered Convenience Outlet Size(Tons)VoltCompressors(each)OD FanM

Page 16

567040-YIM-B-1210Johnson Controls Unitary Products 23120(10)208 17.9 120 28.0 1.5 8.2 5.5 10.0None - - - 61.5 67.0 70 80E18 13.5 2 37.5 69.6 76.5 70 8

Page 17 - 18 AWG 150 Feet

567040-YIM-B-121024 Johnson Controls Unitary ProductsZR078-150 Hi Static Motor - With Powered Convenience Outlet Size(Tons)VoltCompressors(each)OD Fa

Page 18 - Table 8: Electrical Data

567040-YIM-B-1210Johnson Controls Unitary Products 25120(10)208 17.9 120 28.0 1.5 10.9 5.5 10.0None - - - 64.2 69.7 80 80E18 13.5 2 37.5 73.0 79.8 80

Page 19

567040-YIM-B-121026 Johnson Controls Unitary ProductsTable 9: ZR078-150 Physical Data ComponentModelsZR078 ZR090 ZR102 ZR120 ZR150Nominal Tonnage 6.5

Page 20

567040-YIM-B-1210Johnson Controls Unitary Products 27REHEAT COIL DATAFace area (Sq. Ft.) 6.66 6.66 10 10 10Rows 22222Fins per inch 13 13 13 13 13Tube

Page 21

567040-YIM-B-121028 Johnson Controls Unitary ProductsOptional Electric HeatThe factory-installed heaters are wired for single point power supply. Powe

Page 22

567040-YIM-B-1210Johnson Controls Unitary Products 29Optional Gas HeatThese gas-fired heaters have aluminized-steel or optional stainless steel, tubul

Page 23

567040-YIM-B-1210Johnson Controls Unitary Products 3Wear safety glasses and work gloves. Use quenching cloth and have a fire extinguisher available du

Page 24

567040-YIM-B-121030 Johnson Controls Unitary ProductsGas ConnectionThe gas supply line can be routed within the space and roof curb, exiting through t

Page 25

567040-YIM-B-1210Johnson Controls Unitary Products 31Lp Units, Tanks And PipingAll gas heat units are shipped from the factory equipped for natural ga

Page 26

567040-YIM-B-121032 Johnson Controls Unitary ProductsPower ExhaustThe Power Exhaust can be a factory installed option or a field installed accessory.

Page 27 - Stage 60% of Full Capacity

567040-YIM-B-1210Johnson Controls Unitary Products 33Figure 26: Enthalpy Set Point ChartFigure 27: Honeywell Economizer Control W7212PhasingPredator®

Page 28 - Optional Electric Heat

567040-YIM-B-121034 Johnson Controls Unitary ProductsBlower RotationCheck for proper supply air blower rotation. If the blower is rotating backwards,

Page 29 - Optional Gas Heat

567040-YIM-B-1210Johnson Controls Unitary Products 35Figure 29: Altitude/Temperature Correction FactorsThe examples below will assist in determining t

Page 30

567040-YIM-B-121036 Johnson Controls Unitary ProductsDrive Selection1. Determine side or bottom supply duct Application.2. Determine desired airflow.3

Page 31 - Options/Accessories

567040-YIM-B-1210Johnson Controls Unitary Products 37Table 16: Air Flow Performance - Side Duct ApplicationZR078 (6.5 Ton) Side DuctAir Flow(CFM)Avai

Page 32 - Adjustments

567040-YIM-B-121038 Johnson Controls Unitary ProductsZR120 (10 Ton) Side DuctAir Flow(CFM)Available External Static Pressure - IWG11. Blower performan

Page 33

567040-YIM-B-1210Johnson Controls Unitary Products 39Table 17: Air Flow Performance - Bottom Duct ApplicationZR078 (6.5 Ton) Bottom DuctAir Flow(CFM)A

Page 34

567040-YIM-B-12104 Johnson Controls Unitary ProductsNomenclatureZ R 090 N10 A 2 A AA 5 0 1 2 4 AProduct CategoryZ = A/C, Single Pkg., R-410AA = Std. M

Page 35 - Correction Factor

567040-YIM-B-121040 Johnson Controls Unitary ProductsZR120 (10 Ton) Bottom DuctAir Flow(CFM)Available External Static Pressure - IWG11. Blower perform

Page 36 - Airflow Performance

567040-YIM-B-1210Johnson Controls Unitary Products 41Air BalanceStart the supply air blower motor. Adjust the resistances in both the supply and the r

Page 37

567040-YIM-B-121042 Johnson Controls Unitary ProductsNOTE: The tubes must be inserted and held in position perpendicular to the airflow so that veloc

Page 38

567040-YIM-B-1210Johnson Controls Unitary Products 43Supply Air Drive AdjustmentAt unit start-up, the measured CFM may be higher or lower than the req

Page 39

567040-YIM-B-121044 Johnson Controls Unitary ProductsTable 22: Additional Static ResistanceSize(Tons)Model CFM Cooling Only11. Add these values to the

Page 40

567040-YIM-B-1210Johnson Controls Unitary Products 45OperationCooling Sequence Of OperationFor the Predator® series of units, the thermostat makes a c

Page 41 - Checking Air Quantity

567040-YIM-B-121046 Johnson Controls Unitary Productsaddition. The power exhaust motor is energized 45 seconds after the actuator position exceeds the

Page 42 - Air Flow Rate (cfm)

567040-YIM-B-1210Johnson Controls Unitary Products 47Compressor ProtectionIn addition to the external pressure switches, the compressors also have inh

Page 43

567040-YIM-B-121048 Johnson Controls Unitary ProductsFigure 31: Reheat Control BoardRY1Y2GW1OCCCW2P4P5P6P3COMHGRRHGRHUMK1K2K4K3`MODESELECTIONJUMPERDEH

Page 44

567040-YIM-B-1210Johnson Controls Unitary Products 49Figure 32: System Piping SchematicElectric Heating Sequence Of OperationsThe following sequence d

Page 45 - Operation

567040-YIM-B-1210Johnson Controls Unitary Products 5InstallationInstallation Safety InformationRead these instructions before continuing this applianc

Page 46

567040-YIM-B-121050 Johnson Controls Unitary ProductsSafety ControlsThe UCB monitors the temperature limit switch of electric heat units.The control c

Page 47

567040-YIM-B-1210Johnson Controls Unitary Products 51When “W1” is satisfied, both valves are closed.Second Stage Of HeatingWhen the ICB receives a cal

Page 48

567040-YIM-B-121052 Johnson Controls Unitary Productsgas heat limit switch operation except the auxiliary is manual reset. Consequently, the control w

Page 49 - Air Flow

567040-YIM-B-1210Johnson Controls Unitary Products 53Start-Up (Gas Heat)Pre-Start Check ListComplete the following checks before starting the unit.1.

Page 50

567040-YIM-B-121054 Johnson Controls Unitary ProductsNOTE: To find the Btu input, multiply the number of cubic feet of gas consumed per hour by the B

Page 51

567040-YIM-B-1210Johnson Controls Unitary Products 55Burners/Orifices Inspection/ServicingBefore checking or changing burners, pilot or orifices, CLOS

Page 52 - Start-Up (Cooling)

567040-YIM-B-121056 Johnson Controls Unitary ProductsFigure 35: Unit Control BoardTable 30: Unit Control Board Flash CodesFlash Code DescriptionGreenL

Page 53 - Checking Gas Heat Input

567040-YIM-B-1210Johnson Controls Unitary Products 57Unit Control Board Option SetupOption Byte Setup• Enter the Option Setup mode by pushing the OPTI

Page 54

567040-YIM-B-121058 Johnson Controls Unitary ProductsFigure 36: Basic Troubleshooting FlowchartFigure 37: Power On Flow ChartMonitorMonitoredSystemsPr

Page 55 - Troubleshooting

567040-YIM-B-1210Johnson Controls Unitary Products 59Figure 38: Trip Failure Flow Chart

Page 56

567040-YIM-B-12106 Johnson Controls Unitary Products3. Gas-Fired Central Furnace Standard, ANSI Z21.47a. - Latest Edition4. Local building codes, and5

Page 57 - Heat Delay Setup

567040-YIM-B-121060 Johnson Controls Unitary ProductsCooling Troubleshooting GuideOn calls for cooling, if the compressors are operating but the suppl

Page 58

567040-YIM-B-1210Johnson Controls Unitary Products 61out, the UCB may have the compressor in an ASCD. Check the LED for an indication of an ASCD cycle

Page 59

567040-YIM-B-121062 Johnson Controls Unitary Products10. If 24 volts is present at the UCB Y2 terminal and none of the switches are open and the compr

Page 60

567040-YIM-B-1210Johnson Controls Unitary Products 63conditions. These options are not enabled by default. They can be checked by local distributors.F

Page 61

Page 62

567040-YIM-B-1210Johnson Controls Unitary Products 7LocationUse the following guidelines to select a suitable location for these units:1. Unit is desi

Page 63

567040-YIM-B-12108 Johnson Controls Unitary ProductsUnits may be moved or lifted with a forklift. Slotted openings in the base rails are provided for

Page 64 - Norman, OK 73069

567040-YIM-B-1210Johnson Controls Unitary Products 9Figure 8: ZR078-120 Physical DimensionsFigure 9: ZR150 Physical DimensionsTable 3: ZR078-150 Unit

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York ZR SERIES Specifications

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Summary of Contents

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