York ZJ150 - 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 ZJ150 Specifications

General

Brand	York
Model	ZJ150
Category	Air Conditioner
Language	English

Summary

General Safety Considerations and Warnings

Safety Considerations

Explains safety alert symbol and signal words DANGER, WARNING, CAUTION.

Installation Warnings

Critical warnings about improper installation, fire, and explosion hazards.

Installation Procedures and Requirements

Unit Inspection and Clearances

Guidelines for inspecting the unit and required installation clearances.

Installation Limitations and Approvals

Specifies installation limitations, codes, and CSA approvals.

Model Nomenclature Breakdown

Nomenclature Components

Details on product category, capacity, heat, airflow, and voltage options.

Installation Safety and Preparation

Installation Safety Information

Crucial safety information before proceeding with unit installation.

Preceding Installation Steps

Steps to perform before the main installation process begins.

Location, Clearances, and Handling

Location Selection and Clearances

Guidelines for choosing a location and required clearances.

Rigging and Handling Precautions

Instructions for safely moving and lifting the unit.

Unit Weights, Dimensions, and Load Points

Load Weight and Center of Gravity Diagrams

Diagrams for unit load weight and center of gravity.

Weights and Dimensions Table

Table detailing unit weights and physical dimensions.

Physical Dimensions and Unit Clearances

Physical Dimensions Table

Table listing physical dimensions for different models.

Unit Clearances Table

Table specifying required clearances for unit operation.

Ductwork Installation Guidelines

Ductwork Design Standards

Standards and recommendations for designing and sizing ductwork.

Duct Covers, Panels, and Condensate Drain

Duct Cover and Panel Usage

Instructions on using duct covers and side panels.

Condensate Drain Installation

Procedures for installing and orienting the condensate drain.

Compressor, Filter, and Wiring Details

Compressor and Filter Precautions

Compressor details, R-410A, POE oil, and filter maintenance.

Power and Control Wiring Requirements

Field wiring, fuses, disconnects, and voltage tolerances.

Electrical Wiring Connections and Precautions

Field Wiring Disconnect Installation

Instructions for installing field wiring disconnects and precautions.

Power and Control Wiring Cautions

Cautions regarding electrical connections and water-proofing.

Thermostat Wiring Procedures

Thermostat Installation and Control Wire Specs

Guidelines for locating, wiring thermostats, and control wire specs.

Electrical Data Tables

Standard Motor Electrical Data

Table detailing electrical data for standard motor configurations.

Physical Data Tables

Unit Physical Data Summary

Table summarizing physical data for different unit models.

Optional Heaters and Gas Piping

Optional Electric Heat Installation

Information on factory-installed electric heat options.

Gas Piping Installation Guidelines

Recommendations and codes for gas piping installation.

Gas Piping and Connections

Gas Pipe Sizing and Supply Air Tables

Tables for sizing gas pipes and minimum supply air.

Gas Supply Line Routing and Safety

Details on routing the gas line and safety warnings.

LP Gas Units, Venting, and Accessories

LP Gas Unit Requirements

Information on LP gas units, tanks, piping, and pressure regulation.

Vent and Combustion Air

Guidelines for venting and combustion air.

Unit Options and Sensors Overview

Smoke Detectors, Dampers, and Economizers

Information on smoke detectors, motorized dampers, and economizers.

Power Exhaust and VAV System Details

Information on power exhaust and variable air volume systems.

VFD Systems and Control Board Integration

Factory-Installed VFD Operation and Safety

Details on factory-installed VFDs, parameters, and safety.

BAS-Ready VFD Connections and Precautions

Information on connecting BAS to VFD-ready units and precautions.

VFD Operation and Economizer Sequences

VFD Wiring, Bypass, and Economizer Sequences

VFD wiring, bypass switch, and economizer sequence explanations.

Free Cooling and Power Exhaust Control

Free Cooling Modes Explained

Description of free cooling options: dry bulb, enthalpy, auto.

Power Exhaust System Operation

Details on power exhaust setpoints, inputs, outputs, and operation.

Economizer Controller and Board Details

SE-ECO1001-0 Economizer Controller Diagram

Diagram of the economizer controller.

Simplicity SE Economizer Board Terminals

Table detailing economizer board terminal connections.

Simplicity SE Economizer Board Details (Continued)

SA BUS, Analog, and Binary Outputs

Details on SA BUS connections, analog, and binary outputs.

Simplicity SE Economizer Board Details (Continued)

24 V IN Connections and Analog Inputs

Details on 24V IN connections and analog inputs for sensors.

Simplicity SE Economizer Board Details (Continued)

Sensor Inputs and Air Quality

Details on sensor inputs and indoor air quality.

Phasing and Blower Rotation Checks

Instructions for checking unit phasing and blower rotation.

Belt Tension and Airflow Altitude Corrections

Belt Tension Adjustment Procedure

Step-by-step guide for adjusting belt tension.

Altitude;Temperature Airflow Corrections

Explains how altitude and temperature affect airflow performance.

Altitude;Temperature Correction Factors

Correction Factor Tables and Examples

Tables and examples for applying altitude and temperature correction factors.

Drive Selection Process and Performance Data

Steps for Drive Selection

A guide to selecting the appropriate drive for the unit.

Blower Performance and RPM Selection Tables

Performance data and RPM selection tables.

Airflow Performance Tables

Side Duct Airflow Performance

Airflow performance data for side duct applications.

Airflow Performance Tables (Continued)

Side Duct Airflow Performance (Continued)

Continued airflow performance data for side duct applications.

Airflow Performance Tables (Continued)

Bottom Duct Airflow Performance

Airflow performance data for bottom duct applications.

Airflow Performance Tables (Continued)

Bottom Duct Airflow Performance (Continued)

Continued airflow performance data for bottom duct applications.

RPM Selection Table

Table for selecting RPM based on drive type.

Blower Specifications and Air Balancing

Blower and Power Exhaust Specs

Tables detailing blower and power exhaust specifications.

Air Balancing and Quantity Checks

Methods for balancing airflow and checking air quantity.

Air Balancing Procedures (Continued)

Method Two for Air Quantity

Second method for checking air quantity and static pressure.

Dry Coil Delta P Chart

Chart showing dry coil delta P versus airflow.

Supply Air Drive Adjustment

Adjusting Supply Air Drive Speed

Procedure for adjusting the supply air drive speed.

Motor Sheave Datum Diameters Table

Table for adjusting motor sheave datum diameters.

Operation Modes and VAV Control

Static Resistance and Cooling Sequences

Static resistance table and cooling sequences of operation.

Blower Operation and VAV Start-up

Blower modes and VAV system start-up procedures.

Cooling Operation and Economizer Modes

Cooling Sequence Details

Further details on the cooling sequence of operations.

Economizer Modes Explained

Explanations of economizer operation with single, dual enthalpy, and power exhaust.

Cooling Errors, Safety Controls, and Electric Heat Sequence

Cooling System Error Conditions

Description of cooling operation errors like high/low pressure limits.

Safety Controls Monitoring

Overview of safety controls monitored by the unit control board.

Electric Heating Operation Sequence

Description of the electric heating sequence of operations.

Electric Heat Errors and Gas Heat Sequence

Electric Heat Errors and Safety Controls

Details on electric heat errors, temperature limits, and safety controls.

Gas Heating Operation Sequence

Description of the gas heating sequence of operations.

Gas Heating Operation Errors and Safety

Gas Heating Sequence Steps

Steps for first and second stage heating ignition and operation.

Gas Heating Error Conditions

Explanation of gas heating errors like lock-out, temperature limits, and flame sense.

Gas Heating Safety and Start-Up Procedures

Gas Heating Safety Controls

Details on gas heat safety controls including limit, pressure, and roll-out switches.

Gas Heat Anticipator Setpoints

Recommendations for setting gas heat anticipators.

Cooling Start-Up Checklist

Pre-start and post-start checklists for cooling system startup.

Start-Up Procedures for Cooling and Gas Heat

Cooling Start-Up Checks

Post start checks for cooling system operation.

Gas Heat Start-Up and Input Check

Procedures for starting gas heat and checking input.

Gas Heat Input Adjustment Procedures

Determining Gas Flow Rate and Manifold Pressure

Procedures for determining gas flow and adjusting manifold pressure.

Gas Heat Stages, Temperature Rise, and Control Board Navigation

Gas Heat Stages and Temperature Rise

Table of gas heat stages and how to adjust temperature rise.

Burner Servicing and Unit Charging

Procedures for servicing burners and charging the unit.

Control Board Navigation Components

Components needed to access the Simplicity SE control board.

Simplicity SE Control Board Navigation Examples

Understanding the LCD Display

Explanation of the unit's LCD display and navigation.

Basic Menu Navigation Steps

Step-by-step examples of navigating basic menus.

Simplicity SE Control Board Navigation Examples (Continued)

Commissioning Menu Navigation

Demonstrates navigating the commissioning menu to change settings.

Setpoint Adjustment Guidance

Notes on adjusting setpoints and thermostat interaction.

Unit Control Board Terminal Details

Unit Control Board Diagram

Diagram of the unit control board and its connections.

UCB Terminal Connections Table

Table detailing UCB terminal connections and functions.

Simplicity SE UCB Terminal Details (Continued)

Thermostat Connections and UCB LEDs

Details on thermostat terminals and UCB LED indicators.

Sensor Connections and Air Quality

Details on connecting sensors and indoor air quality.

Simplicity SE UCB Terminal Details (Continued)

Pin Temperature Sensor Connections

Details on connecting temperature sensors to the UCB.

Simplicity SE UCB Terminal Details (Continued)

Refrigerant Circuit Safety Switches

Details on refrigerant circuit safety switches and their connections.

Simplicity SE UCB Terminal Details (Continued)

SA BUS Connections and USB Connector

Details on SA BUS connections and USB connector.

Simplicity SE UCB Terminal Details (Continued)

Ignition Control Flash Codes Table

Table listing ignition control flash codes and their meanings.

Start-Up and Service Data Instruction

Start-Up Checklist

A comprehensive checklist for equipment startup.

Warranty Statement and Startup Procedures

Warranty info and guidance for equipment startup.

Safety Warnings and Design Information

General Safety Warnings for Startup

Critical safety warnings for technicians during startup procedures.

Design Application Information Requirements

Information required from the specifying engineer for design application.

Reference and Inspection Checklists

General and Air Moving Inspection Checklists

Checklists for general unit inspection and air moving components.

Economizer and Exhaust Inspection Checklists

Checklists for inspecting economizer and exhaust components.

Operating Measurements - Air Flow

Airflow Measurement Procedures

Steps for measuring airflow, static pressure, and blower parameters.

Electrical Data Measurement Table

Table for recording electrical data measurements.

Operating Measurements - Cooling and Gas Heating

Cooling Measurement Parameters

Parameters to measure during cooling operation.

Refrigerant Safety Checks

Procedures for proving refrigerant safety controls.

Gas Heating Measurement Parameters

Parameters to measure during gas heating operation.

Operational Measurements - Staging Controls and Final Inspection

Verifying Staging Controls and VFD

Procedures for verifying staging controls and VFD operation.

Final Inspection Checklist

Final inspection items to ensure proper installation and configuration.

Observed Product Deficiencies

Section for documenting any observed product deficiencies or concerns.