Broan ZB80ML1, ZB110ML1 Installation Manual

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ZB80ML1 n ZB110ML1

X2 | Multi-Speed Ventilation
Fan with Dimmable Light

and Motion Sensor

INSTALLATION GUIDE

Easy installation in both
new construction and retrofit

© 2017 Broan

Table of Contents

Warnings and Cautions 2
Typical Installation 2
New Construction Installation 3
Retrofit Installation 7
Operation 12
Cleaning and Maintenance 13
Troubleshooting 13
Service Parts 14
Warranty 14

Page 2

ZB80ML1 n ZB110ML1 Installation Guide

WARNING

TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR
INJURY TO PERSONS, OBSERVE THE FOLLOWING:

1. Use this unit only in the manner intended by the manufacturer.
If you have questions, contact the manufacturer at the address
or telephone number listed in the warranty.

2. Before servicing or cleaning unit, switch power off at service
panel and lock the service disconnecting means to prevent
power from being switched on accidentally. When the service
disconnecting means cannot be locked, securely fasten a
prominent warning device, such as a tag, to the service panel.

3. Installation work and electrical wiring must be done by a
qualified person(s) in accordance with all applicable codes
and standards, including fire-rated construction codes and
standards.

4. Sufficient air is needed for proper combustion and exhausting
of gases through the flue (chimney) of fuel burning equipment
to prevent backdrafting. Follow the heating equipment
manufacturer’s guideline and safety standards such as those
published by the National Fire Protection Association (NFPA),
and the American Society for Heating, Refrigeration and
Air Conditioning Engineers (ASHRAE), and the local code
authorities.

5. When cutting or drilling into wall or ceiling, do not damage
electrical wiring and other hidden utilities.

6. Ducted fans must always be vented to the outdoors.

7. Use only ON/OFF switch, mechanical timer or relay-switched

control.

8. Acceptable for use over a tub or shower when connected to
a GFCI (Ground Fault Circuit Interrupter) - protected branch
circuit.

9. This unit must be grounded.

CAUTION

1. For general ventilating use only. Do not use to exhaust

hazardous or explosive materials and vapors.

2. This product is designed for installation in flat ceilings. Sensor
will not function reliably if product is not installed in flat ceiling.
DO NOT MOUNT THIS PRODUCT IN A WALL.

3. To avoid motor bearing damage and noisy and/or unbalanced
impellers, keep drywall spray, construction dust, etc. off power
unit.

4. Please read specification label on product for further
information and requirements.

NOT FOR USE IN A COOKING AREA

Do not install above or inside this area

45° 45°

Cooking
Equipment

Floor

Typical Installation

• Installation is the same for:

Joists I-Joists Trusses

• Fits in 2" x 8" ceiling construction.

• Infinitely adjust the fan position
between joists from 14" to 24"
on center.

The ducting from this fan to the outside of the building has a strong effect on the air flow, noise and en­ergy use of the fan. Use the shortest, straighest duct routing possible for best performance, and avoid
installing the fan with smaller ducts than recommended. Insulation around the ducts can reduce en­ergy loss and inhibit mold growth. Fans installed with existing ducts may not achieve their rated airflow.

6-inch round rigid metal duct is recommended for best performance.

HOUSING

POWER
CABLE*

Seal gaps

around

Housing.

*Purchase
separately.

INSULATION*

(Place around and

over Fan Housing.)

FAN

ROUND

DUCT*

Seal duct

joints with

tape.

OR

ROUND

ELBOWS*

ROOF CAP*

(with built-in

damper)

Keep duct

runs short.

WALL CAP*

(with built-in

damper)

Page 3

New Construction Installation

ZB80ML1 n ZB110ML1 Installation Guide

Tools needed

• Power screwdriver with a Phillips bit

• Phillips screwdriver

• Flathead screwdriver

• Pliers

• Wire insulation stripper

• Wire cutter

Remove Packaging

1

Parts Bag holds
Knockout Plate
and six (6)
screws

Materials needed

• 6" round metal ducting recommended for best performance.
Use of other ducting is acceptable but may impact performance.

• Roof cap or wall cap (built-in damper recommended)

• Tape to seal duct connections

• Electrical wiring and supplies per local code requirements

Punch out Mask from

Remove
Instruction
Sheet

packaging. See Step 6.

Install

2

Mounting
Frame

2

1

4

3

Page 4

3

1

4

2

New Construction Installation

Snap-in and

3

Secure Housing

2

ZB80ML1 n ZB110ML1 Installation Guide

1

Attach Duct Connector and Ducting

snap!

4

Top and bottom flanges
go outside Housing

Insert tab into slot
inside Housing

1

Screws from Parts Bag

3

4

Position Housing
between joists and
crimp channel on both
sides of Mounting Frame
to lock Housing in place.

Do not crimp Housing.

Screw from

2

Parts Bag

6" Ducting

Tape

3

4" Ducting

6" to 4" Reducer (for Model ZB80ML only)

Tape

Tape

Page 5

New Construction Installation

Connect Wires and Install Knockout Plate

5

• Run 120VAC electrical wiring to the installation location.

• Use proper UL-approved connectors to secure wiring to the Knockout Plate provided in Parts Bag.

• Connect wires as shown in wiring diagram.

1

Attach cable clamps to Knockout

Plate. Knockout Plate mounts to

outside of Housing and may be

oriented as desired.

Light

Fan

LINE

MANUAL

ON

SENSOR/

CONTROL

MASTER

BLK

LINE

WHT

IN

GRD

LIGHT

SWITCH

BLK
WHT

IN

GRD

Connect wires

2

LIGHT WITH ON/OFF SWITCH

14/2

BLK BLU

WHT

FAN

MANUAL

ON

FAN

MASTER &

SENSOR/

CONTROL

RED

BLK
WHT
GRD

14/3

LIGHT WITH DIMMER SWITCH

DIMMER
SWITCH

SWITCH BOX

14/2

14/4

ORG

BLK

WHT

RED

BLU
BLK

WHT

GRD

BRN

RED

BLK

LIGHT

SENSOR

CONTROL

BLK

FAN

UNITSWITCH BOX

BLU

ORG

BRN

RED

BLK

3

WHT

WHT

LIGHT

SENSOR

CONTROL

BLK

FAN

UNIT

ZB80ML1 n ZB110ML1 Installation Guide

4

Screw from

Parts Bag

• See OPERATION
section on page 12 for
details.

• MASTER switch
turns fan system
on and shuts it off
for fan cleaning
and maintenance
purposes.

• SENSOR/CONTROL
switch turns motion
control automatic
operation on/off.

• MANUAL-ON switch
directly increases fan
operation to certified
airflow rate.

• MASTER and
SENSOR/CONTROL
switches can be
combined (see page

10).

• Motion sensor can be
wired to control light

WHT

WHT

(see page 10).

• MASTER switch along
with or separate from
SENSOR/CONTROL
switch may be located
where they are not
easily accessed for
everyday usage;
they may need to be
labeled and located
where they can’t be
turned on without
being seen from fan to
comply with local and
national codes.

Page 6

New Construction Installation

Insert Mask and

6

Finish Ceiling

• Install ceiling material.

• Cut out around Housing.

CAUTION

IN ORDER TO PREVENT
MOTOR/CONTROL DAMAGE:

If the blower was unplugged, power must
be disconnected (see page 2, WARNING
item 2) before inserting motor plugs into
control assembly.

Install Grille

7

ZB80ML1 n ZB110ML1 Installation Guide

Mask protects unit

during construction.

Remove before
installing Grille.

Plug in
Sensor

1

2

Plug in
Light

3

4

Page 7

Retrofit Installation

ZB80ML1 n ZB110ML1 Installation Guide

Tools needed

• Power screwdriver with a Phillips bit

• Phillips screwdriver

• Flathead screwdriver

• Pliers

• Wire insulation stripper

• Wire cutter

• Ruler

• Pencil

• Drywall saw

• Claw hammer or pry bar

• Utility knife

Materials needed

• Tape to seal duct connections

• Existing rigid duct will require the
addition of a short length of flexible duct

• Electrical wiring and supplies per
local code requirements

Remove Packaging

1

Remove
Instruction
Sheet

Parts Bag holds
Knockout Plate
and six (6)
screws

Punch out Mask from

packaging. See Step 12.

Switch Off Power

2

WARNING

Before removing existing fan, switch power off at service panel and lock the service disconnecting
means to prevent power from being switched on accidentally. When the service disconnecting means
cannot be locked, securely fasten a prominent warning device, such as a tag, to the service panel.

Enlarge Ceiling Opening and Remove Existing Fan

3

12" (30.5 cm)

11" (27.9 cm)
parallel with joists

1

Examine Wiring

4

Examine the existing wiring to make sure it is not damaged. If any damage is found,
DO NOT CONTINUE INSTALLATION of this product. Contact a qualified person(s) for repair.

Existing ductwork and
wiring left in place

2

Page 8

Retrofit Installation

Remove Blower Assembly

5

2

ZB80ML1 n ZB110ML1 Installation Guide

1

Set aside
Blower
Assembly

Both sides

Remove Wiring Panel

6

1

Set aside
screw

3

Set aside
Wiring Panel

2

3

Insert

7

Mounting
Frame

4

3

1

Remove screws from
Mounting Frame
and set aside

5

2

Bend up
four tabs

Page 9

Retrofit Installation

Secure

8

Mounting
Frame

Snap-in Housing

9

ZB80ML1 n ZB110ML1 Installation Guide

Screws set

aside

in Step 7

2

10

Pull existing
ductwork
into Housing

1

Pull existing wiring into
Housing as it is inserted
into Mounting Frame

snap!

Attach Ducting and Duct Connector

1

2

6" Ducting

Tape

4" Ducting

Tape

Tape

4

Screw from

Parts Bag

3

Insert tab into
slot inside
Housing

6" to 4" Reducer (for Model ZB80ML only)