Lennox ZHA036, ZHA048, ZHA060 Installation Instructions Manual

Litho U.S.A.

2015

INSTALLATION
INSTRUCTIONS

WARNING

Improper installation, adjustment, alteration, ser
vice or maintenance can cause property damage,
personal injury or loss of life. Installation and ser
vice must be performed by a licensed professional
HVAC installer or equivalent or service agency.

CAUTION

Danger of sharp metallic edges. Can cause injury.
Take care and wear protective clothing when
servicing unit to avoid accidental contact with
sharp edges.

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

Table Of Contents

Dimensions Page 2.................................

Shipping and Packing List Page 3....................

General Page 3....................................

Requirements Page 3...............................

Unit Support Page 4................................

Duct Connection Page 4............................

ZHA036 (3 TON)
ZHB036 (3 TON)
ZHA048 (4 TON)
ZHB048 (4 TON)
ZHA060 (5 TON)
ZHB060 (5 TON)

HEAT PUMP PACKAGED UNITS

507111-02
2/2015
Supersedes 507111-01

Rigging Unit For Lifting Page 4.......................

Horizontal Air Discharge Page 5......................

Condensate Drains Page 5..........................

Electrical Connections Page 6.......................

Blower Operation and Adjustments Page 7............

Start-Up Page 16....................................

Defrost Control Board Page 22........................

Service Page 23....................................

ZH 036, 048, 060 PARTS ARRANGEMENT

CONTROL

PANEL

OUTDOOR

COIL FAN

COMPRESSOR

OUTDOOR

COIL

SIDE POWER

ENTRY

EVAPORATOR

COIL

BLOWER

MOTOR

BLOWER

HOUSING

ELECTRIC HEAT

(OPTIONAL)

TB2 UNIT

TERMINAL

STRIP

UNIT FUSE

BOTTOM POWER

ENTRY

ZH 036, 048, 060, DIMENSIONS in (mm)

Holes required for Optional Bottom Power Entry Kit

BOTTOM POWER ENTRY

Conduit Fittings
(Provided in Kit)

A
B
C

Threaded

1/2

1/2
3/4

Wire

Use

ACC.

24V

POWER

47-1/4
(1200)
BASE

Hole Diameter

Required in

Unit Base (Max.)

7/8 (23)

7/8 (23)

1-1/8 (29)

16-1/8

(410)

13-5/8

(346)

11-1/8

(283)

24-9/16

(624)

BOTTOM
RETURN

AIR OPENING

A
B
C

BOTTOM

POWER

ENTRY

(See Table)

75-7/8
(1927)

12-1/8

(308)

TOP VIEW (Base)

25-5/8

(651)

BOTTOM

SUPPLY

OPENING

AIR

5-1/8
(130)

17-3/4

(451)

5-3/4

(146)

5-1/8
(130)

10-7/8

(276)

29

(737)

45-1/4
(1149)

44-7/8 (1140) ZH 060

ZHB036, 048

36-7/8 (937) ZHA036, 046

1

(25)

47-1/4
(1200)

(25)

BASE

POWER

ENTRY

1

(25)

Either

side

3-1/2

(89)

1

END VIEW

ZH 036, 048, 060

LIFTING HOLES

(For rigging)

73-3/4
(1873)

FRONT VIEW

Page 2

3-1/2 (89)

TYP.

11-7/8

(302)

5-3/4
(146)

6-1/2
(165)

CONDENSATE

OUTLET

HORIZONTAL

SUPPLY

17-3/8

(441)

27

(686)

31

(787)

END VIEW

6-1/4
(159)

RETURN

HORIZONTAL

5-9/16

(141)

8-3/8

(213)

10-7/8

(276)

25-3/4

(654)

5-3/4
(146)

Shipping and Packing List

Package 1 of 1 contains:

1 - Assembled unit

Check unit for shipping damage. Receiving party should
contact last carrier immediately if shipping damage is
found.

General

These instructions are intended as a general guide and
do not supersede local codes in any way. Authorities
having jurisdiction should be consulted before
installation.

Availability of units and options varies by brand.

Requirements

NOTICE

Roof Damage!
This system contains both refrigerant and oil.
Some rubber roofing material may absorb oil,
causing the rubber to swell. Bubbles in the rubber
roofing material can cause leaks. Protect the roof
surface to avoid exposure to refrigerant and oil
during service and installation. Failure to follow
this notice could result in damage to roof surface.

The National Electric Code (ANSI/NFPA No. 70-1984) is
available from:

National Fire Protection Association
1 Batterymarch Park
PO Box 9101
Quincy, MA 02269-9101

The ZH unit is CSA certified as a heat pump with cooling
and with or without auxiliary electric heat for
non-residential use only at the clearances to combustible
materials as listed on the unit nameplate and in figure 1.

Installation of ZH heat pumps must conform with standards
in National Fire Protection Association (NFPA) “Standard
for Installation of Air Conditioning and Ventilating Systems
NFPA No. 90A,” “Standard for Installation of Residence
Type Warm Air Heating and Air conditioning Systems NFPA
No. 90B,” local municipal building codes and
manufacturer's installation instructions.

UNIT CLEARANCES

HORIZONTAL

OUTDOOR
AIR HOOD

C

D

A

OUTDOOR
AIR HOOD

B

Installation of CSA certified units must also conform with
current standard C273.5 “Installation Requirements for
Heat Pumps” and applicable local codes. Authorities
having jurisdiction should be consulted before
installation.

Use of this unit as a construction heater or air conditioner
is not recommended during any phase of construction.
Very low return air temperatures, harmful vapors and
operation of the unit with clogged or misplaced filters will
damage the unit.

If this unit has been used for heating or cooling of
buildings or structures under construction, the following
conditions must be met or the warranty will be void:

 A room thermostat must control the unit. The use of

fixed jumpers that will provide continuous heating or
cooling is not allowed.

 A pre-filter must be installed at the entry to the return

air duct.

 The return air duct must be provided and sealed to

the unit.

FIGURE 1

1

Unit

Clearance

Service

Clearance

Minimum Opera

tion Clearance36(914)36(914)

*Clearance is 60 in. (1524mm) in horizontal air flow applications.
Note - Entire perimeter of unit base requires support when elevated above
mounting surface.

1

Service Clearance - Required for removal of serviceable parts.
Minimum Operation Clearance - Required clearance for proper unit operation.

A

in.(mm)Bin.(mm

36

(914)36(914)

C

in.(mm)Din.(mm)

)

36*

(914)36(914)

36*

(914)36(914)

To p

Clearance

Unob

structed

Unob

structed

 Return air temperature range between 55°F (13°C)

and 80°F (27°C) must be maintained.

 Air filters must be replaced and pre-filter must be

removed upon construction completion.

 The unit components, duct system, air filters and

evaporator coil must be thoroughly cleaned following
final construction clean-up.

 The unit operating conditions (including airflow,

cooling operation, and heating operation) must be
verified according to these installation instructions.

Page 3

507111-02 2/2015

WARNING

Electric shock hazard and danger of
explosion. Can cause injury, death or
product or property damage. Turn off
electrical power to unit before
performing any maintenance or
servicing operations on the unit.

IMPORTANT

The Clean Air Act of 1990 bans the intentional vent
ing of refrigerant (CFC's and HCFC's) as of July 1,

1992. Approved methods of recovery, recycling or
reclaiming must be followed. Fines and/or incar
ceration may be levied for non-compliance.

Unit Support

NOTE - Securely fasten roof frame to roof per local codes.

NOTE-When installing unit on a combustible surface for
downflow discharge applications, the Z1CURB roof
mounting frame is required.

B - Horizontal Discharge Applications

1- Specified installation clearances must be maintained

when installing units. Refer to figure 1.

2- Top of support slab should be at least 4” (102mm)

above the finished grade and located so no run-off
water from higher ground can collect around the unit.

3- Units require support along all four sides of unit base.

Supports must be constructed of steel or suitably
treated wood materials.

Duct Connection

All exterior ducts, joints, and openings in roof or building
walls must be insulated and weatherproofed with flashing
and sealing compounds in accordance with applicable
codes. Any duct passing through an unconditioned space
must be insulated.

ZH 036, 048, 060 units are installed on Z1CURB frames.

A - Downflow Discharge Application

Roof Mounting with Z1CURB

1- The Z1CURB roof mounting frame must be installed,

flashed and sealed in accordance with the
instructions provided with the frame.

2- The Z1CURB roof mounting frame should be square

and level to 1/16” per linear foot (5mm per linear
meter) in any direction.

3- Duct must be attached to the roof mounting frame

and not to the unit; supply and return plenums must
be installed before setting the unit.

Installer's Roof Mounting Frame

Many types of roof frames can be used to install the unit,
depending upon different roof structures. Items to keep
in mind when using the building frame or supports are:

1- The unit base is fully enclosed and not insulated, so

an enclosed, insulated frame is required.

2- The frames or supports must be constructed with

non-combustible materials and should be square and
level to 1/16” per linear foot (5mm per linear meter)
in any direction.

3- Frame or supports must be high enough to prevent

any form of moisture from entering unit.
Recommended minimum frame height is 14”
(356mm).

4- Duct must be attached to the roof mounting frame

and not to the unit. Supply and return plenums must
be installed before setting the unit.

5- Units require support along all four sides of unit base.

Supports must be constructed of steel or suitably
treated wood materials.

ZH 036, 048, 060

Page 4

!

CAUTION

In downflow applications, do not drill or punch
holes in base of unit. Leaking in roof may occur if
unit base is punctured.

Rigging Unit For Lifting

1- Connect rigging to the unit base using both holes in

each corner. See figure 2.

2- All panels must be in place for rigging.

3- Place field‐provided H‐style pick in place just above

top edge of unit. Frame must be of adequate
strength and length. (H-style pick prevents damage
to unit.)

UNIT

ZH

*Maximum weight with all available
installed accessories.

CAUTION: DO NOT

WALK ON UNIT.

WEIGHT*

LBS. KG.

664 301

Lifting Point Should

Be Directly Above
Center Of Gravity.

FIGURE 2

Horizontal Air Discharge

Unit is shipped with panels covering the horizontal supply
and return air openings. See figure 3.

UNIT SUPPLY AND RETURN AIR OPENINGS

HORIZONTAL

HORIZONTAL

SUPPLY AIR

OPENING

RETURN AIR

OPENING

4- Install return air duct on the intake air side of the

horizontal economizer. See figure 5.

5- Horizontal economizer and return air duct must be

field-supported.

HORIZONTAL RETURN AIR DUCTWORK

WITH ECONOMIZER

HOOD

PROVIDED

WITH

ECONOMIZER

This opening not used

in horizontal applica

tions with economizer

OPTIONAL

HORIZONTAL

ECONOMIZER

UNIT

DOWNFLOW

SUPPLY AIR

OPENING

DOWNFLOW

RETURN AIR

OPENING

FIGURE 3

1- Remove horizontal covers and place a bead of silicone

sealant on the underside of the duct cover flanges. See
figure 4.

2- Position covers over downflow openings. Secure

covers with self-drilling screws in at least two places on
each cover. Drill through duct cover side into flange of
base pan.

3- Place a bead of silicone between insulation and duct

cover to seal in insulation edges. Let silicone dry before
running gas or electric heat.

Units Equipped With An Optional Horizontal Economizer

1- Install the horizontal supply air cover over the down

flow supply air opening as described above.

2- Leave the horizontal return air cover in place.

3- Locate the extra horizontal return cover that is

included with the horizontal economizer kit. Install as
described in previous section.

INSTALL DUCT COVERS - SIDE VIEW

APPLY SILICONE

SEALANT TO

FLANGES

NOT TO

SCALE

FLANGE AND UNIT INSULATION

DUCT COVER

FLANGES

UNIT BASE

FLANGES

APPLY SILICONE SEALANT

BETWEEN DUCT COVER

INSULATION

HORIZONTAL

SUPPLY AIR DUCT

(FIELD-PROVIDED)

HORIZONTAL
RETURN AIR DUCT
(FIELD-PROVIDED)

FIGURE 5

Condensate Drains

Make drain connection to the drain coupling provided
on unit.

Note - The drain pan is made with a glass reinforced
engineered plastic capable of withstanding typical joint
torque but can be damaged with excessive force. Tighten
pipe nipple hand tight and turn an additional quarter turn.

A trap must be installed between drain connection and an
open vent for proper condensate removal. See figure 6. It is
sometimes acceptable to drain condensate onto the roof or
grade; however, a tee should be fitted to the trap to direct
condensate downward. The condensate line must be
vented. Check local codes concerning condensate disposal.
Refer to pages 1 and 2 for condensate drain location.

CONDENSATE SIDE DRAIN CONNECTION

CAULK AROUND CONDENSATE COUPLING

NOTE - Allow clearance to
open doors when installing
condensate piping.

Minimum Pitch
1” (25 mm) per
10' (3 m) of line

OPEN VENT

UNIT

MOUNTING

FRAME

FIGURE 4

FIGURE 6

Page 5

507111-02 2/2015

Electrical Connections

POWER SUPPLY

Do not apply power or close disconnect switch until
installation is complete. Refer to start-up directions. Refer
closely to unit wiring diagram.

Refer to unit nameplate for minimum circuit ampacity
and maximum fuse size.

1- Units are factory-wired for 240, 460, or 575 volt supply.

For 208V supply

from the 208V terminal on the control transformer. Move
the wire from the transformer 240V terminal to the 208V
terminal. Place the insulated terminal cover on the
unused 240V terminal.

2- Route power through the side or bottom power

entry area. For bottom power entry, a bottom
power entry kit must be used. Connect power
wiring to K1/K3 contactors in control box. See
figure 7. On units equipped with electric heat, route
power wiring to TB2; see parts arrangement for
location. See unit wiring diagram.

, remove the insulated terminal cover

POWER WIRING

IMPORTANT - Unless field thermostat wires are rated
for maximum unit voltage, they must be routed away
from line voltage wiring.

B - Control Wiring

1- Route thermostat cable or wires from subbase to

control panel (refer to unit dimensions to locate
bottom and side power entry).

Use18 AWG wire for all applications using remotely
installed electro-mechanical and electronic
thermostats.

2- Install thermostat assembly in accordance with

instructions provided with thermostat.

3- Connect thermostat wiring to low voltage leads in

control box. Wire as shown in figure 8 for
electro-mechanical and electronic thermostats. If
using other temperature control devices or energy
management systems see instructions and wiring
diagram provided by manufacturer.

IMPORTANT-Terminal connections at the wall plate or
subbase must be made securely. Loose control wire
connections may allow unit to operate but not with proper
response to room demand.

Y, G, J, M

VOLT ONLY

K1

CONNECT FIELD-

SUPPLIED WIRING

TO K1/K3

K3

FIGURE 7

CONTROL WIRING

A - Thermostat Location

Room thermostat mounts vertically on a standard 2” X 4”
handy box or on any non-conductive flat surface.

Locate thermostat approximately 5 feet (1524 mm)
above the floor in an area with good air circulation at
average temperature. Avoid locating the room
thermostat where it might be affected by:

-drafts or dead spots behind doors and in corners

-hot or cold air from ducts

-radiant heat from sun or appliances

-concealed pipes and chimneys

ZH 036, 048, 060

Page 6

24 VOLT FIELD WIRING WITH ELECTRONIC AND

ELECTRO-MECHANICAL THERMOSTATS

UNIT CONTROL AREA

A2 THERMOSTAT

Note - On electro-mechanical thermo
stats set anticipator at 0.1 amps.

TO CMC1; DO NOT

REMOVE FACTORY

INSTALLED WIRES

NOT ALL TERMINALS

ARE FOUND ON ALL

THERMOSTATS

Jumper terminals R and
OC when thermostat has
no night setback terminals.

FIGURE 8

Blower Operation and Adjustments

Units are equipped with belt drive blowers; available
drive varies by model.

Blower performance data is based on static pressure
readings taken in locations shown in figure 9.

Note - Static pressure readings can vary if not taken
where shown.

IMPORTANT

Three phase scroll compressors must be phased
sequentially for correct compressor and blower
rotation. Follow “COOLING START-UP” section of
installation instructions to ensure proper compres
sor and blower operation.

A - Blower Operation

Initiate blower demand at thermostat according to
instructions provided with thermostat. Unit will cycle on
thermostat demand. The following steps apply to
applications using a typical electro-mechanical
thermostat.

1- Set thermostat or temperature control device fan

switch to AUTO or ON. With fan switch in ON position,
blower will operate continuously. With fan switch in
AUTO position, the blower will cycle with demand.

2- Blower and entire unit will be off when thermostat or

temperature control device system switch is in OFF
position.

B - Determining Unit CFM

1- The following measurements must be made with air

filters in place.

2- With all access panels in place, measure static

pressure external to unit (from supply to return).

3- Measure the indoor blower wheel RPM.

4- Referring to pages 9-14, use static pressure and

RPM readings to determine unit CFM. Use
option/accessory air resistance table on page 15
when installing units with any of the options or
accessories listed. Refer to table 3 for minimum
airflow when electric heat is installed.

5- The blower RPM can be adjusted at the motor pulley.

Loosen Allen screw and turn adjustable pulley
clockwise to increase CFM. Turn counterclockwise to
decrease CFM. See figure 10. Do not exceed
minimum and maximum number of pulley turns as
shown in table 1.

TABLE 1

MINIMUM AND MAXIMUM PULLEY ADJUSTMENT

Belt Min. Turns Open Maxi. Turns Open

A Section No minimum 5

C - Blower Belt Adjustment

Maximum life and wear can be obtained from belts only if
proper pulley alignment and belt tension are maintained.
Tension new belts after a 24-48 hour period of operation.
This will allow belt to stretch and seat grooves. Make sure
blower and motor pulley are aligned as shown in figure 11.

INSTALLATIONS WITH DUCTWORK

ROOFTOP UNIT

READING LOCATION

SUPPLY

MAIN

RE

TURN

OFF OF MAIN RUN

DUCT RUN

LOCATION OF STATIC PRESSURE READINGS

INSTALLATIONS WITH CEILING DIFFUSERS

ROOFTOP UNIT

RETURN AIR

SUPPLY

FIRST BRANCH

SUPPLY AIR

READING

LOCATION

SUPPLY AIR

READING

LOCATION

DIFFUSER

FIGURE 9

Page 7

RETURN AIR

READING

RE

TURN

LOCATION

507111-02 2/2015

BLOWER ASSEMBLY

TO INCREASE BELT TENSION

1-Loosen four bolts securing motor base to mounting frame.

2-Slide the motor downward to tighten the belt.

3-Tighten four bolts on motor base.

LOOSEN FOUR BOLTS

AND SLIDE BLOWER
MOTOR DOWNWARD

SIDE VIEW

TO TIGHTEN BELT

MOTOR

TO INCREASE CFM

LOOSEN ALLEN SCREW &

TURN PULLEY CLOCKWISE

ALLEN

SCREW

PULLEY

TO DECREASE CFM

TURN PULLEY

COUNTERCLOCKWISE

FIGURE 10

PULLEY ALIGNMENT

ALIGNED

MOTOR

PULLEY

BELT

NOT ALIGNED

BLOWER

PULLEY

FIGURE 11

1- Loosen four bolts securing motor base to mounting

frame. See figure 10.

2- Apply perpendicular force to center of span (X) with

enough pressure to deflect belt 1/64” for every inch
of span length or 1.5mm per 100mm of span length.

Example: Deflection distance of a 40” span would be
40/64” or 5/8”.

Example: Deflection distance of a 400mm span
would be 6mm.

3- Measure belt deflection force. For a used belt, the

deflection force should be 5 lbs. (35kPa). A new belt
deflection force should be 7 lbs. (48kPa).

A force below these values indicates an
undertensioned belt. A force above these values
indicates an overtensioned belt.

MEASURE BELT TENSION

2- To increase belt tension -

Slide blower motor downward to tighten the belt. This
increases the distance between the blower motor and
the blower housing.

To loosen belt tension -

Slide blower motor upward to loosen the belt. This
decreases the distance between the blower motor
and the blower housing.

3- Tighten four bolts securing motor base to the

mounting frame.

D - Check Belt Tension

Overtensioning belts shortens belt and bearing life.
Check belt tension as follows:

1- Measure span length X. See figure 12.

ZH 036, 048, 060

FORCE

DEFLECTION 1/64” PER INCH OF SPAN

OR 1.5mm PER 100mm OF SPAN

FIGURE 12

E-Field-Furnished Blower Drives

For field-furnished blower drives, use pages 9-14 to
determine BHP and RPM required. Reference page 15
for additional air resistance and drive kit numbers. See
table 2 for drive component manufacturer's numbers.

Page 8