York ZJ078 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 ZJ078 Specifications

General

Brand	York
Model	ZJ078
Category	Air Conditioner
Language	English

Summary

General Unit Information

Safety Considerations and Warnings

Signal Words: DANGER, WARNING, CAUTION

Explains the meaning of safety signal words used in the manual.

Improper Installation Warning

Warning about improper installation causing injury or property damage.

R-410A Refrigerant Caution

Caution about R-410A refrigerant and system requirements.

Fire and Explosion Hazard Warning

Warning about fire or explosion hazard if manual is not followed.

Installation Code Compliance Caution

Caution about product installation compliance with codes.

Inspection, Reference and Approvals

Unit Inspection Procedure

Procedure for inspecting the unit for damage during transit.

Reference and Approvals

Lists related documents, parts, and unit certifications.

Nomenclature

Installation Guidelines

Installation Safety Information

General safety instructions for installing the unit.

Preceding Installation Steps

Steps to take before the main installation begins.

Installation Limitations and Codes

Specifies installation requirements and applicable codes.

Installation Location and Clearances

Location Guidelines

Guidelines for selecting a suitable installation location for the unit.

Required Clearances

Required clearances for unit operation, servicing, and construction.

Rigging and Handling

Weights and Dimensions

Unit Accessory Weights

Physical Dimensions Overview

Unit Physical Dimensions and Clearances

Unit Physical Dimensions Table

Details the physical dimensions of the unit models in a table.

Unit Clearances Table

Specifies required clearances for unit operation and servicing.

Unit Bottom Duct Openings

Unit Entry Points

Unit Electrical Entry

Illustrates the locations of electrical entry points on the unit.

Unit Side Duct Openings

Shows the location and dimensions of side duct openings.

Duct Opening Dimensions

Side Duct Opening Dimensions

Details the dimensions of side duct openings for various models.

Left Duct Opening Dimensions

Shows the location and dimensions of the left duct opening.

Roof Curb Information

Standard Roof Curb

Provides diagrams and dimensions for standard roof curbs.

Transition Roof Curb

Provides diagrams and dimensions for transition roof curbs.

Ductwork Design Guidelines

Ductwork Covers and Side Panels

Duct Cover Instructions

Instructions on handling and reusing duct covers.

Side Panel Usage

Information on saving and using side panels for economizer hoods.

Condensate Drain System

Compressors and Filters

Compressor Information

Information about the scroll compressors and their oil.

Filter Details

Details about the unit filters and their maintenance.

Power and Control Wiring

Field Wiring Disconnect

Field Wiring Disconnect (Gas Heat)

Thermostat Wiring

Electrical Data - Standard Motor

Electrical Data - Standard Motor (Continued)

Electrical Data - Hi Static Motor

Electrical Data - Hi Static Motor (Continued)

Electrical Data - Standard Motor with PCO

Electrical Data - Standard Motor with PCO (Continued)

Electrical Data - Hi Static Motor with PCO

Electrical Data - Hi Static Motor with PCO (Continued)

Physical Data - Unit Specifications

Physical Data - Fan and Filter Specs

Optional Heating Features

Optional Electric Heat

Information on factory-installed electric heaters.

Optional Gas Heat

Details on gas-fired heaters and their features.

Gas Piping Installation

Gas Pipe Sizing and Supply Air

Gas Pipe Sizing Table

Table for sizing gas pipes based on length and capacity.

Gas Heat Minimum Supply Air Table

Table showing minimum supply air requirements for gas heat.

Gas Connection Recommendations

LP Gas Units and Piping

Vent and Combustion Air

Options and Accessories Overview

Unit Options and Features

Smoke Detectors

Limitations and installation notes for duct smoke detectors.

Motorized Outdoor Damper

Information on factory or field installed motorized outdoor dampers.

Economizer System

Details on factory or field installed economizer options.

Power Exhaust System

Information on factory or field installed power exhaust options.

Rain Hood Component Details

Information on hood components and their packaging.

Optional Variable Air Volume (VAV)

Explanation of VAV option and its function.

Duct Static Pressure Transducer

Details about the duct static pressure transducer used in VAV systems.

Variable Frequency Drive (VFD) Details

Factory-Installed VFD

Information on the factory-installed Variable Frequency Drive.

Manual Bypass Switch

Explains the manual bypass switch for VFD units.

BAS-Ready VFD Integration

Details on VFD options compatible with BAS integration.

Optional Hot Gas Bypass and Economizer Sequences

Optional Hot Gas Bypass (HGBP)

Information on the optional hot gas bypass system.

Economizer Sequences Overview

Describes how the economizer sequences function.

Economizer Minimum Position

Details the economizer minimum position setting.

Free Cooling Options

Economizer Cooling Sequences

Dual Enthalpy Changeover

Details the operation of dual enthalpy economizer control.

Auto Mode for Free Cooling

Explains the auto mode for free cooling changeover control.

Free Cooling Operation

Describes how free cooling operates based on thermostat and sensor inputs.

Thermostat Interaction

How the thermostat interacts with free cooling mode.

Sensor Functionality

How sensors are used in free cooling operation.

Power Exhaust Operation

Simplicity SE Economizer Controller Details

Simplicity SE Economizer Board Details (Continued)

Simplicity SE Economizer Board Details (Continued)

Simplicity SE Economizer Board Details (Continued)

Indoor Air Quality (AQ) Sensor Input

Explanation of indoor air quality sensor inputs and operation.

Motor Phasing Check

Instructions for checking and correcting motor phasing.

Blower Belt Tension Adjustment

Altitude and Temperature Corrections

Altitude/Temperature Correction Factors

Drive Selection Procedure

Supply Air Blower Performance Tables

RPM Selection Tables

Airflow Performance - Side Duct Application

Airflow Performance - Side Duct Application (Continued)

Airflow Performance - Bottom Duct Application

Airflow Performance - Bottom Duct Application (Continued)

RPM Selection Table

Blower and Power Exhaust Specifications

Indoor Blower Specifications

Specifications for indoor blower motors and sheaves.

Power Exhaust Specifications

Specifications for power exhaust units.

Air Balance and Quantity Checking

Air Balance Procedure

Procedures for balancing airflow in the unit.

Checking Air Quantity Methods

Methods for measuring and adjusting air quantity.

Dry Coil Delta P Analysis

Supply Air Drive Adjustment Procedure

Motor Sheave Datum Diameter Adjustment

Additional Static Resistance and Operation Overview

Additional Static Resistance Table

Table showing additional static resistance values for components.

General Operation Overview

General overview of unit operation modes.

Cooling Sequence of Operation

Continuous and Intermittent Blower Modes

Continuous Blower Mode

How to set the unit for continuous blower operation.

Intermittent Blower Mode

How the blower operates in intermittent mode.

Optional VAV Start-up and Control

Economizer Cooling Sequences

Single Enthalpy Economizer Operation

Operation sequence for economizer with single enthalpy sensor.

Dual Enthalpy Economizer Operation

Operation sequence for economizer with dual enthalpy sensors.

Economizer with Power Exhaust

How power exhaust integrates with economizer operation.

Motorized Outdoor Air Dampers Operation

Operation of motorized outdoor air dampers.

Cooling Operation Errors and Safety Controls

Cooling Operation Errors

Details common cooling system errors and their handling.

Error Types and Safety Controls

Covers pressure limits, evaporator limits, ambient cooling, and compressor protection.

Electric Heating Sequence of Operations

Describes the sequence of operations for electric heating.

Electric Heat Operation Errors and Controls

Electric Heat Operation Errors

Explains errors related to electric heat operation.

Temperature Limit Monitoring

How the temperature limit switch affects electric heat operation.

Electric Heat Safety Controls

Safety controls monitored by the UCB for electric heat.

Limit Switch (Ls) Function

Location and function of the limit switch in gas heat.

Gas Heating Sequence of Operations

Describes the sequence of operations during gas heating.

Gas Heating Operation Errors

Gas Heating Operation Errors

Details errors related to gas heating operation.

Unit Lock-Out Conditions

Conditions that cause the unit to lock out.

Temperature Limit in Heating

How the temperature limit switch affects heating operation.

Flame Sense Operation

How flame sensing works and its role in operation.

Gas Valve Monitoring

Monitoring and control of the gas valve.

Gas Heat Limit Controls and Anticipator Setpoints

Limit Switch (LS) and Auxiliary Limit Switch (ALS)

Location and function of the limit and auxiliary limit switches.

Gas Heat Limit Control Settings Table

Table of limit settings for gas heat.

Gas Heat Anticipator Setpoints Table

Settings for gas heat anticipators.

Start-Up (Cooling) Checklist

Start-Up (Gas Heat) Procedures

Checking Gas Heat Input

Gas Flow Rate Calculation and Manifold Pressure Adjustment

Gas Rate Calculation (Cubic Feet Per Hour)

Table for calculating gas rate based on time.

Manifold Gas Pressure Adjustment

Procedure for adjusting manifold gas pressure.

Gas Heat Stages, Adjustment, and Servicing

Gas Heat Stages Table

Table showing gas heat stages and input ratings.

Temperature Rise Adjustment

How to adjust and calculate temperature rise.

Burner and Orifice Servicing

Procedures for inspecting and servicing burners and orifices.

Unit Charging and Control Board Navigation

Charging the Unit Procedure

Instructions for charging the unit with refrigerant.

Control Board Navigation Components

Components needed to navigate the Simplicity SE control board.

Simplicity SE Control Board Navigation Examples

Simplicity SE Control Board Navigation Examples (Continued)

Unit Control Board (UCB) Details

UCB Terminal Connections Diagram

Diagram and details of the Simplicity SE Unit Control Board (UCB).

Simplicity SE UCB Terminal Details

Table detailing terminal connections and functions on the UCB.

Simplicity SE UCB Details (Continued)

UCB Thermostat Connections

Details thermostat connection terminals on the UCB.

UCB LEDs Indicators

Explanation of the UCB's LED indicators.

Space Temperature Sensor Connections

Details connections for space temperature sensors.

Simplicity SE UCB Details (Continued)

Pin Temperature Sensor Connections

Details pin connections for temperature sensors.

VFD Connection to UCB

Details the connection for the VFD to the UCB.

Simplicity SE UCB Details (Continued)

Refrigerant Circuit Safety Switches

Details connections for refrigerant circuit safety switches.

Indoor Blower Overload Connections

Details connections for indoor blower overload relays.

Simplicity SE UCB Details (Continued)

SA BUS Connections

Details SA BUS connections on the UCB.

User Interface Controls

Describes the UCB's display, buttons, and joystick.

Simplicity SE UCB Details (Continued)

USB Connector Functionality

Details the function of the USB connector on the UCB.

Communication Board Details

Details the communication board components and LEDs.

Ignition Control Flash Codes

Start-Up and Service Data Instruction

Safety Warnings for Start-Up

Design Application Information

Inspection Checklists

General Inspection Checklist

Checklist items for general unit inspection.

Air Moving Inspection Checklist

Checklist items for air moving component inspection.

Economizer Inspection Checklist

Checklist items for economizer inspection.

Operating Measurements - Air Flow and Electrical Data

Air Flow Measurements Recording

Fields for recording air flow measurements and blower data.

Electrical Data Recording

Fields for recording electrical data measurements.

Operating Measurements - Cooling and Gas Heating

Cooling Operating Measurements

Fields for recording cooling operating measurements.

Refrigerant Safeties Checklist

Checklist for refrigerant safety verifications.

Gas Heating Operating Measurements

Fields for recording gas heating operating measurements.

Final Inspection and Product Concerns

Staging Controls Verification

Verifying proper operation of heating/cooling staging controls.

Final Inspection Checklist

Final inspection checklist items.

Observed Product Deficiencies

Section to record any observed product issues.