York ZJ102 User Manual

R-410A
ZJ SERIES W/SIMPLICITY SE
6-1/2 - 12-1/2 Ton
60 Hertz
1183875-YIM-A-1014
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Optional Variable Air Volume (VAV). . . . . . . . . . . . . . . . . . . 34
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . 36
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 36
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . 37
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Cooling Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 52
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Electric Heating Sequence Of Operations . . . . . . . . . . . . . . 54
Electric Heat Operation Errors. . . . . . . . . . . . . . . . . . . . . . 55
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . 55
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . 56
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control Board Navigation Components . . . . . . . . . . . . . . . . . . 60
Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic
Unit Control Board Navigation Examples: . . . . . . . . . . . . . . 61
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
LIST OF TABLES
1 ZJ078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZJ078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . 9
4 ZJ078-150 Unit Physical Dimensions . . . . . . . . . . . . . . . . 11
5 ZJ078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . 31
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . 32
12 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . 32
13 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . 38
14 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 43
16 Airflow Performance - Side Duct Application . . . . . . . . . . . 45
17 Airflow Performance - Bottom Duct Application . . . . . . . . . 47
18 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
19 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . 49
20 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . 49
21 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . 51
22 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . 52
23 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . 55
24 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . 55
25 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . 57
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . 57
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . 59
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
29 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . 63
30 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . 68
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Predator
®
Component Location (ZJ120 Shown) . . . . . . . . . 7
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 ZJ078-120 Physical Dimensions . . . . . . . . . . . . . . . . . . . . 10
9 ZJ150 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . 11
10 ZJ078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . 13
11 ZJ078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . 14
12 ZJ078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . . 14
13 ZJ150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . 15
14 ZJ078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . . . 15
15 ZJ078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
16 ZJ078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . 16
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . 17
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . 17
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . 17
20 Save Side Panels For Economizer Hood Tops . . . . . . . . . 17
21 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Field Wiring Disconnect - Cooling Unit With/Without Electric
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . 19
23 Field Wiring Disconnect - Cooling Unit With Gas Heat Without
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
24 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . 21
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 33
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
28 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . 39
29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
30 Altitude/Temperature Correction Factors . . . . . . . . . . . . . 44
31 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
32 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
33 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
35 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
36 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

York ZJ102 Specifications

General

Brand	York
Model	ZJ102
Category	Air Conditioner
Language	English

Summary

Safety Considerations

Signal Words: DANGER, WARNING, CAUTION

Understand hazard levels indicated by signal words for safety.

Installation and Service Safety

Follow manual instructions to prevent injury or damage from improper installation/service.

R-410A Refrigerant Safety

Use R-410A compatible equipment; system operates at higher pressures.

Fire and Explosion Hazard Warning

Adherence to manual is critical to prevent fire or explosion risks.

Inspection and References

Installation Compliance and Codes

Install in compliance with all applicable local, state, and national codes.

Installation Procedures

Installation Safety Information

Read and follow safety instructions before proceeding with installation.

Preceding Installation Steps

Includes removing shipping brackets and protective coverings.

Unit Limitations and Codes

Units must be installed per codes like NEC and National Fuel Gas Code.

Site Selection and Handling

Location Guidelines

Rigging and Handling Procedures

Compressors, Filters, and Wiring

Compressor Specifications and Handling

Scroll compressors use R-410A and POE oil; avoid atmospheric exposure.

Filter Installation and Maintenance

Power and Control Wiring Requirements

Field wiring must conform to NEC and CEC; use disconnects.

Field Wiring and Disconnects

Disconnect Mounting Caution

Electrical Line Sizing and Circuit Protection

Use copper conductors; wire with a separate, fused branch circuit.

Water-Proof Connector Requirement

Use water-proof connectors for power and control wiring to prevent moisture ingress.

Thermostat Wiring and Control

Thermostat Location and Wiring

Electrical Data Tables

ZJ078-150 Standard Motor Electrical Data

Provides detailed electrical data for standard motor units without convenience outlet.

ZJ078-150 Hi Static Motor Electrical Data

Provides electrical data for Hi Static motor units without convenience outlet.

ZJ078-150 Standard Motor with Powered Convenience Outlet

Electrical data for standard motor units with powered convenience outlet.

ZJ078-150 Hi Static Motor with Powered Convenience Outlet

Electrical data for Hi Static motor units with powered convenience outlet.

Electric Heat, Gas Heat, and Gas Piping

Optional Electric Heat Details

Optional Gas Heat and Piping

Unit Options and Accessories

Smoke Detector Installation and Limitations

Economizer Options and Operation

Factory or field installed; options include Down Flow and Horizontal Flow.

Optional Variable Air Volume (VAV) System

VAV option uses VFD to control blower speed based on duct static pressure.

Variable Air Volume (VAV) and VFD Systems

Factory-Installed VFD System

VFD mounted in blower compartment; parameters pre-programmed.

Manual Bypass Switch Operation

Switch has DRIVE, LINE (BYPASS), and TEST positions for VFD control.

Bas-Ready VFD Connections

Terminal blocks for field wiring customer-installed BAS for control signals.

Economizer Operation and Free Cooling

Economizer Sequences and Minimum Position

Free Cooling Changeover Types

Economizer Free Cooling and Power Exhaust

Auto Changeover and Free Cooling

Power Exhaust Setpoints and Operation

Economizer Controller Board Details

Analog Inputs Terminal Layout

Altitude and Temperature Correction Calculations

Altitude/Temperature Correction Factors Table

Applying Correction Factors Examples

Drive Selection and Performance Tables

Drive Selection Steps

Steps to select motor and drive based on airflow and static pressure.

Supply Air Blower Performance Data

Airflow Performance - Side Duct

ZJ078 (6.5 Ton) Side Duct Performance

ZJ090 (7.5 Ton) Side Duct Performance

ZJ102 (8.5 Ton) Side Duct Performance

Airflow Performance - Side Duct (Continued)

ZJ120 (10 Ton) Side Duct Performance

ZJ150 (12.5 Ton) Side Duct Performance

Airflow Performance - Bottom Duct

ZJ078 (6.5 Ton) Bottom Duct Performance

ZJ090 (7.5 Ton) Bottom Duct Performance

ZJ102 (8.5 Ton) Bottom Duct Performance

Airflow Performance - Bottom Duct (Continued) and RPM Selection

ZJ120 (10 Ton) Bottom Duct Performance

ZJ150 (12.5 Ton) Bottom Duct Performance

Blower and Air Balance Specifications

Air Balance and Quantity Check

Procedures for balancing airflow and checking air quantity using manometer.

Supply Air Drive Adjustment

Adjusting Blower Speed

Adjust variable pitch motor sheave to achieve required CFM.

Motor Sheave Datum Diameter Tables

Static Resistance and Cooling Operation

Cooling Sequence of Operation

Details how compressors and fans operate during cooling stages.

Optional VAV Start-up and Control

Explains VAV mode blower control by duct static pressure.

Economizer and VAV Controls

Single Enthalpy Economizer Operation

Dual Enthalpy Economizer Operation

Cooling Operation Errors and Safety

Cooling Operation Error Conditions

Details errors like high/low pressure limits, evaporator low limit, low ambient.

Safety Controls Monitoring

Monitors freezestat, high-pressure, and low-pressure switches for protection.

Compressor Protection Features

Includes anti-short cycle delay and minimum run time to protect compressors.

Electric and Gas Heat Operation and Safety

Electric Heat Operation and Errors

Describes electric heat sequence, temp limit errors, and safety controls.

Gas Heat Limit Control Settings

Table 25 specifies limit switch settings for gas heat units.

Gas Heating Sequence and Anticipator

Details gas heat sequence, safety controls, and anticipator setpoints.

Gas Heat Operation, Errors, and Controls

Gas Heating Operation Errors

Covers lock-out, temperature limits, flame sensing, and gas valve issues.

Start-Up Procedures (Cooling)

Gas Heat Safety Controls

Monitors limit switches, pressure switches, roll-out switches, and microprocessor.

Gas Heat Anticipator Setpoints

Table 26 provides settings for gas heat anticipators for proper cycling.

Cooling Pre-Start Checklist

Checks electrical supply, thermostat settings, and blower rotation.

Start-Up Procedures (Cooling and Gas Heat)

Cooling System Start-Up and Checks

Includes operating instructions and post-start checks for cooling.

Gas Heat System Start-Up and Checks

Covers pre-start checks, operating instructions, and shut down for gas heat.

Checking Gas Heat Input

Procedure to determine and adjust gas flow rate for heat stages.

Gas Input and Manifold Pressure Adjustment

Gas Rate Calculation

Table 27 helps calculate gas consumption based on meter dial revolutions.

Manifold Gas Pressure Adjustment

Procedure to adjust second and first stage manifold gas pressure.

Gas Heat Stages and Controls

Gas Heat Stages and Temperature Rise

Unit Charging and Control Navigation

Simplicity SE Control Board Navigation

Understanding the Local LCD Display

Navigating the UCB LCD for status, alarms, and settings.

Basic Menu Navigation Examples

Step-by-step guide to viewing status, DVent-Mode, and OprST.

Simplicity SE Control Board Commissioning

Navigating the Commissioning Menu

Accessing and modifying parameters like HVAC zone, cooling, and set points.

Changing Set Points

Unit Control Board (UCB) Details

UCB Terminal Connections - Limit and Power

UCB Terminal Connections - Smoke Detector

UCB Terminal and Sensor Connections

UCB Thermostat Terminal Connections

UCB Temperature Sensor Connections

UCB Refrigerant Safety and Overload Connections

UCB Refrigerant Pressure Switch Connections

UCB Communication and Ignition Codes

Ignition Control Flash Codes

Table 30 lists flash codes indicating fault conditions and checks.

Start-Up and Warranty Information

Start-Up Checklist

Provides a checklist for initial equipment start-up and data recording.

Equipment Start-Up Procedure

Recommends using local LCD or MAP Gateway for start-up completion.

Safety Warnings and Design Application

Start-Up Safety Warnings

Cautions about lethal voltages and moving parts during start-up checks.

Design Application Information

Information required from specifying engineer for system CFM and pressures.

Operating Measurements - Air Flow and Electrical Data

Air Flow Measurements

Electrical Data Measurements

Operating Measurements - Cooling and Gas Heating

Cooling Measurements

Refrigerant Safety Checks

Gas Heating Measurements

Staging Controls, Final Inspection, and Concerns

Verify Staging Control Operation

Ensure heating/cooling stages and economizer stages energize correctly.

Final Inspection Checks

Verify set points, option parameters, and access panel security.