York ZT078-102 - User Manual

R-410A
ZT SERIES W/SMART EQUIPMENT™
6.5 - 12.5 Ton
60 Hertz
6021980-UIM-A-1120
Table of contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rigging and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Side panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Power and control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Optional electric heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Optional gas heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Economizer sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Smart Equipment™ economizer board . . . . . . . . . . . . . . . . . . 44
Airflow performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Air balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking air quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Reheat mode sequence of operation . . . . . . . . . . . . . . . . . . . 62
Electric heating sequence of operations . . . . . . . . . . . . . . . . . 64
Electric heat operation errors . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heating sequence of operations. . . . . . . . . . . . . . . . . . . . 64
Ignition control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Gas heating operation errors . . . . . . . . . . . . . . . . . . . . . . . . 65
Cooling start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Gas heat start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking gas heat input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Navigation components for the Smart Equipment™ control board . . 69
Smart Equipment™ unit control board . . . . . . . . . . . . . . . . . . . . . 70
Charging the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Start-up sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
List of tables
1 Component location table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ZT078-150 unit limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZT078-150 standard unit weights and dimensions . . . . . . . . 11
4 ZT078-150 unit weights with the Magna Dry option . . . . . . . 11
5 ZT078-150 unit accessory weights . . . . . . . . . . . . . . . . . . . . 11
6 ZT078-150 unit physical dimensions . . . . . . . . . . . . . . . . . . . 13
7 ZT078-150 unit clearances . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 ZT078-102 side duct dimensions . . . . . . . . . . . . . . . . . . . . . 17
9 ZT120-150 side duct dimensions . . . . . . . . . . . . . . . . . . . . . 17
10 Left/end duct dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11 Control wire sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
12 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13 Physical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14 Electric heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . 35
15 Gas pipe sizing - capacity of pipe . . . . . . . . . . . . . . . . . . . . . 36
16 Gas heat minimum supply air . . . . . . . . . . . . . . . . . . . . . . . . 36
17 Supply air limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Altitude/temperature correction factors . . . . . . . . . . . . . . . . . 49
19 Airflow performance - side duct application . . . . . . . . . . . . . . 51
20 Airflow performance - bottom duct application . . . . . . . . . . . 54
21 RPM selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
22 Indoor blower 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 Electric heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . 64
28 Gas heat anticipator setpoints . . . . . . . . . . . . . . . . . . . . . . . . 66
29 Gas rate cubic feet per hour . . . . . . . . . . . . . . . . . . . . . . . . . 68
30 Gas heat stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
31 Gas heat limit control settings . . . . . . . . . . . . . . . . . . . . . . . . 68
32 Cable for FC buses and SA buses in order of preference . . 76
33 Ignition control flash codes . . . . . . . . . . . . . . . . . . . . . . . . . . 76
34 ZT078 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 77
35 ZT078 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 77
36 ZT090 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 78
37 ZT090 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 78
38 ZT102 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 79
39 ZT102 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 79
40 ZT120 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 80
41 ZT120 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 80
42 ZT150 charging table - system 1 . . . . . . . . . . . . . . . . . . . . . 81
43 ZT150 charging table - system 2 . . . . . . . . . . . . . . . . . . . . . 81
List of figures
1 Unit shipping bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Barometric relief hood - shipping location . . . . . . . . . . . . . . . 5
3 Compressor section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 4 point and 6 point load weight for W units . . . . . . . . . . . . . . 10
6 4 point and 6 point load weight for V units . . . . . . . . . . . . . . 10
7 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZT078-102 physical dimensions . . . . . . . . . . . . . . . . . . . . . . 12
9 ZT120-150 physical dimensions . . . . . . . . . . . . . . . . . . . . . . 13
10 ZT078-150 unit bottom duct openings . . . . . . . . . . . . . . . . . 15
11 ZT078-150 unit electrical entry . . . . . . . . . . . . . . . . . . . . . . . 16
12 ZT078-150 unit left/end duct opening . . . . . . . . . . . . . . . . . . 18
13 ZT078-150 roof curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
14 ZT078-150 transition roof curb . . . . . . . . . . . . . . . . . . . . . . . 19
15 Side panels with hole plugs . . . . . . . . . . . . . . . . . . . . . . . . . 20
16 Return down flow plenum with panel . . . . . . . . . . . . . . . . . . 20
17 Discharge panel in place . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
18 Side panels for economizer hood tops . . . . . . . . . . . . . . . . . 21
19 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
20 Field wiring disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
21 Typical control wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
22 Side entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
23 Bottom entry gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
24 Simplified VFD wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
25 SE-ECO1001-0 economizer controller . . . . . . . . . . . . . . . . . 44
26 Belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
27 Altitude/temperature correction factors . . . . . . . . . . . . . . . . 49
28 Dry coil delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Cooling operation piping schematic - circuit no. 1 . . . . . . . . 63
30 Reheat operation piping schematic - circuit no. 1 . . . . . . . . 63
31 Typical flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
32 Typical two stage gas valve . . . . . . . . . . . . . . . . . . . . . . . . . 69
33 Unit control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Summary

General Information

Safety Considerations

Discusses safety alerts and hazard types like DANGER, WARNING, CAUTION.

Inspection, Reference, and Approvals

Inspection

Procedures for checking unit for damage during transit.

Reference

Lists available related technical documents and guides.

Approvals

Lists CSA certifications for the unit.

Nomenclature

Installation Safety and Preceding Installation

Installation Safety Information

General safety rules to follow before installation.

Preceding Installation

Initial steps to prepare the unit for installation.

Limitations

Location, Rigging, and Clearances

Location

Guidelines for selecting a suitable installation site for the unit.

Rigging and Handling

Procedures and precautions for moving and lifting the unit.

Unit Weights and Dimensions

Physical Dimensions

Unit Physical Dimensions

Unit Clearances

Bottom Duct Openings

Electrical Entry

Side Duct Openings

Duct Openings and Roof Curb

Left;End Duct Opening

Diagram of left/end duct connection dimensions.

Roof Curb

Diagram of the unit's roof curb dimensions.

Transition Roof Curb

Ductwork and Side Panels

Ductwork

Design and sizing recommendations for ductwork.

Side Panels

Information on using side panels for economizer hoods.

Condensate Drain and Compressors

Condensate Drain

Instructions for installing the condensate drain connection.

Compressors

Information on compressor type and oil requirements.

Filters and Power;Control Wiring

Filters

Details on filter installation and maintenance.

Power and Control Wiring

Guidelines for field wiring and electrical safety.

Power Wiring Detail

Thermostat Wiring and Control Wiring

Thermostat Wiring

Recommendations for thermostat installation and wiring.

Typical Control Wiring Detail

Diagram showing typical control wiring connections.

Electrical Data

Electrical Data Continued

Electrical Data Continued

Electrical Data Continued

Electrical Data with Powered Convenience Outlet

Electrical Data Continued

Electrical Data Continued

Electrical Data Continued

Physical Data

Physical Data Continued

Optional Heat and Gas Piping

Optional Electric Heat

Information on factory-installed electric heaters.

Optional Gas Heat

Details on gas-fired heating systems.

Gas Piping

Guidelines for proper gas pipe sizing.

Gas Heat Minimum Supply Air and Gas Connection

Gas Heat Minimum Supply Air

Table of minimum supply air for gas heating.

Gas Connection

Procedures for routing and connecting the gas supply line.

Gas Piping Recommendations and LP Units

Gas Piping Recommendations

Specific recommendations for gas piping installation.

LP Units, Tanks and Piping

Requirements for LP gas systems.

Unit Options and Features

Smoke Detectors

Details on factory-installed smoke detector operation and limitations.

Motorized Outdoor Damper

Information on factory or field-installed outdoor dampers.

Economizer

Details on economizer options and installation.

Power Exhaust

Information on power exhaust options.

Factory-installed VFD (standard)

Details on VFD installation and parameter configuration.

Manual Bypass and Economizer Sequences

Manual Bypass

Explains the operation of the manual bypass switch for VFD.

Economizer Sequences

Overview of economizer operational modes.

Economizer Minimum Position Sequences

Describes various minimum position sequences.

Economizer Minimum Position and Free Cooling Options

Low Ambient Minimum Position

How low ambient conditions affect economizer operation.

Air Monitoring Station Reset

How air monitoring affects economizer reset.

Demand Ventilation

Details on demand ventilation operation.

Free Cooling Changeover Options

Discusses different free cooling selection methods.

Free Cooling Options and Thermostat Sequences

CV Option A Thermostat Sequence

Describes thermostat sequences for CV option A.

Single Enthalpy Changeover

Details single enthalpy economizer operation.

Dual Enthalpy Changeover

Details dual enthalpy economizer operation.

CV Option B Thermostat Sequence and Sensor Operation

CV Option B Thermostat Sequence

Describes thermostat sequences for CV option B.

Sensor CV Option A Occupied

Operation for CV option A in occupied mode.

Sensor CV Option B Occupied

Operation for CV option B in occupied mode.

Sensor CV Option A and B Unoccupied

Operation for unoccupied modes.

VAV Unit Sensor Options and Economizer;Power Exhaust

VAV Unit Sensor Option A

Operation details for VAV unit sensor option A.

VAV Unit Sensor Option B

Operation details for VAV unit sensor option B.

Economizer Loading

How economizer loading functions.

Power Exhaust

Setpoints, inputs, and outputs for power exhaust.

Smart Equipment Economizer Board

Analog Inputs

Description of analog inputs on the economizer board.

Economizer Board Details

Analog Inputs (Continued)

Further description of analog inputs.

LED Details

Description of LEDs on the economizer board.

Economizer Board Connections

SA Bus Details

Description of SA Bus connections.

Analog Outputs

Description of analog outputs on the economizer board.

Economizer Board Outputs, Inputs, and Indoor Air Quality

Binary Outputs

Description of binary outputs.

24 V~ IN Connections

Description of 24V IN connections.

Binary Inputs

Description of binary inputs.

Indoor Air Quality

Details on indoor air quality sensing.

Phasing, Blower Rotation, and Drive Adjustment

Phasing

Instructions for checking compressor and blower rotation.

Blower Rotation

How to check blower rotation.

Adjusting the Belt Tension

Steps for adjusting belt tension.

CFM Static Pressure and Altitude;Temperature Corrections

Explains corrections for altitude and temperature.

Altitude;Temperature Correction Factors

Drive Selection and RPM Selection

Drive Selection

Steps to select the correct drive.

RPM Selection

Table for RPM selection.

Airflow Performance

Airflow Performance

Airflow Performance

Airflow Performance

Airflow Performance

Blower Specifications and Power Exhaust

Indoor Blower Specifications

Details on motor, sheaves, and belts for blower.

Power Exhaust Specifications

Table of power exhaust motor specs.

Air Balance and Checking Air Quantity

Air Balance

Balancing supply and return air in conditioned space.

Checking Air Quantity

Methods to measure airflow.

Supply Air Drive Adjustment

Additional Static Resistance

Operation and Cooling Operation

Operation

General overview of unit operation.

Cooling Operation

Step-by-step process for cooling operation.

Free Cooling Operation with Economizer

How economizer provides free cooling.

Cooling Operation Errors, Low Ambient Cooling, and Safety Controls

Cooling Operation Errors

Describes errors related to cooling system operation.

Low Ambient Cooling

How the unit operates in low ambient conditions.

Safety Controls

Monitors safety inputs like limit switches and pressure sensors.

Compressor Protection

Inherent protection features for compressors.

Reheat Mode Sequence of Operation and Alternate Mode

Reheat Mode Sequence of Operation

Details the MagnaDRY reheat mode sequence.

Normal Cooling Mode

Step-by-step process for normal cooling mode.

Alternate Mode

Describes alternate mode operation.

Reheat Operation Schematics and Aux Mode

Cooling Operation Piping Schematic

Diagram for cooling operation circuit.

Reheat Operation Piping Schematic

Diagram for reheat operation circuit.

Optional Aux Mode

Details on the optional aux mode for reheat.

Electric Heating Sequence, Errors, and Safety Controls

Electric Heating Sequence of Operations

Describes how electric heat operates.

Electric Heat Operation Errors

Details errors related to electric heat.

Temperature Limit

How the temperature limit affects blower operation.

Safety Controls

Safety controls for electric heat units.

Electric Heat Safety Controls and Gas Heating Sequence

Auxiliary Limit Switch

Function of the auxiliary limit switch.

Gas Heating Sequence of Operations

Step-by-step for gas heating ignition.

Flame Sense

How flame sensing works.

Gas Valve

Monitoring of the gas valve.

Safety Controls

Safety controls for gas heat units.

Gas Heating Sequence, Anticipator Setpoints, and Start-up Checks

Gas Heat Anticipator Setpoints

Settings for gas heat anticipators.

Cooling Start-up

Checklist before and after cooling start-up.

Gas Heat Start-up

Checklist before gas heating start-up.

Lighting Main Burners and Checking Gas Heat Input

Lighting the Main Burners

Procedure for lighting the main burners.

Post-Start Checklist

Checks after heating section operation.

Checking Gas Heat Input

How to check gas heat input.

Checking Gas Heat Input and Gas Heat Stages

Determining the Rate of Gas Flow (Second Stage)

Procedure to measure gas flow for second stage.

Determining the Rate of Gas Flow (First Stage)

Procedure to measure gas flow for first stage.

Adjusting the Manifold Gas Pressure

How to adjust gas manifold pressure.

Gas Heat Stages

Table of gas heat stages and input.

Adjusting Temperature Rise and Burner Servicing

Adjusting the Temperature Rise

How to adjust temperature rise.

Inspecting and Servicing Burners and Orifices

Procedures for inspecting and servicing burners and orifices.

Smart Equipment Unit Control Board

UCB - Thermostat Connection Strip

Details on thermostat connection points.

UCB Connections

UCB - Limit, 24 VAC Power, and Shutdown Connections

Details on limit, power, and shutdown connections.

UCB - Space Temperature Sensor Connections

Details on space temperature sensor connections.

UCB - Temperature Sensor Connections

Details on temperature sensor connections.

UCB Connections Continued

UCB - Temperature Sensor Connections (Continued)

Further details on temperature sensor connections.

UCB - Pinned Connections

Details on pinned connections.

UCB Connections Continued

UCB - Heat Section Connections

Details on heat section connections.

UCB - Pin Cooling and Fan Output

Details on cooling and fan output pins.

UCB - Refrigerant Circuit Safety Switch and Indoor Blower Overload Connections

Details on safety switches and overloads.

UCB Connections Continued

UCB - SA BUS Connections

Details on SA BUS connections.

UCB - User Interface

Information on the unit's user interface.

UCB LEDs and Optional Communication Sub-board

UCB - LEDs

Description of UCB LEDs.

UCB - Optional Communication Sub-board

Details on optional communication sub-boards.

Cable for FC Buses and SA Buses, and Ignition Control Flash Codes

Cable for FC Buses and SA Buses

Recommended cables for FC and SA buses.

Ignition Control Flash Codes

Table of ignition control flash codes and their meanings.

Charging the Unit and Charging Tables

Charging the Unit

Instructions for charging the unit by weight or table.

ZT078 Charging Table - System 1

Charging data for ZT078 system 1.

Charging Tables Continued

ZT090 Charging Table - System 1

Charging data for ZT090 system 1.

ZT090 Charging Table - System 2

Charging data for ZT090 system 2.

Charging Tables Continued

ZT102 Charging Table - System 1

Charging data for ZT102 system 1.

ZT102 Charging Table - System 2

Charging data for ZT102 system 2.

Charging Tables Continued

ZT120 Charging Table - System 1

Charging data for ZT120 system 1.

ZT120 Charging Table - System 2

Charging data for ZT120 system 2.

Charging Tables Continued

ZT150 Charging Table - System 1

Charging data for ZT150 system 1.

ZT150 Charging Table - System 2

Charging data for ZT150 system 2.

Start-up Sheet

Safety Warnings and Design Application Information

Safety Warnings

General safety precautions for start-up procedures.

Design Application Information

Fields for specifying engineering application data.

Reference

Operating Measurements - Air Flow and Electrical Data

Operating Measurements - Air Flow

Section for recording air flow measurements.

Electrical Data

Section for recording electrical data.

Operating Measurements - Cooling and Gas Heating

Operating Measurements - Cooling

Section for recording cooling measurements.

Refrigerant Safeties

Checks for refrigerant system safety.

Operating Measurements - Gas Heating

Section for recording gas heating measurements.

Operational Measurements - Staging Controls and Final Inspection

Operational Measurements - Staging Controls

Verifying staging control operations.

Final - Inspection

Final checks before concluding the start-up process.

Observed Product Deficiencies & Concerns

Area to document any issues found.

York ZT078-102 Specifications

General

Brand	York
Model	ZT078-102
Category	Fan
Language	English