Lennox ZHA092, ZHA120, ZHA102 Installation Instructions Manual
Litho U.S.A.
2014
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.
Table Of Contents
Dimensions Page 2.................................
Shipping and Packing List Page 3....................
General Page 3....................................
Safety Page 3.....................................
Unit Support Page 4................................
Duct Connection Page 4............................
Rigging Unit For Lifting Page 5.......................
Condensate Drains Page 5..........................
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
ZHA092
ZHA102
ZHA120
HEAT PUMP PACKAGED UNITS
507257-01
7/2014
Electrical Connections Page 6.......................
Unit Power-Up Page 6..............................
Blower Operation and Adjustments Page 7............
Heating Start-Up Page 13............................
Cooling Start-Up Page 13............................
Electric Heat Start-Up Page 17........................
Defrost Control Board Page 18........................
Service Page 19....................................
(7.5- Ton)
(8.5 -Ton)
(10 -Ton)
TB1 LOW VOLTAGE
TERMINAL STRIP
CONDENSER
FANS
TB13 HIGH VOLTAGE
TERMINAL STRIP
CONDENSER
COIL
EVAPORATOR
COIL
COMPRESSORS
F4 FUSE
BLOCK
(OPTIONAL)
TB2 TERMINAL
BLOCK (OPTIONAL)
20 x 24 x 2”
FILTERS
(BEHIND COIL)
ELECTRIC HEAT
CONTROLS
INVERTER
(OPTIONAL)
BLOWER
HOUSING
BLOWER
MOTOR
ELECTRIC HEAT
(OPTIONAL)
ZH 092, 102 & 120 DIMENSIONS
POWER ENTRY
18
(457)
BOTTOM
(See Table)
16
(406)
(356)
Holes required for Optional Bottom Power Entry Kit
BOTTOM POWER ENTRY
Threaded
Conduit Fittings
(Provided in Kit)
A
B
C
A
B
14
28-1/4
(718)
C
BASE
95-3/8
(2423)
1/2
1/2
1-1/4
39
(991)
BOTTOM RETURN
AIR OPENING
BOTTOM
SUPPLY
AIR
OPENING
15
(381)
Wire
Use
ACC.
24V
POWER
10-1/2
(267)
10-1/2
(267)
TOP VIEW
Hole Diameter
Required in
Unit Base (Max.)
7/8 (23)
7/8 (23)
1-3/4 (44)
14-1/2
(368)
39-3/8
(1000)
28-1/4
(718)
5 (127)
60-1/8
(1527)
BASE
(25)
58-1/8
93-3/8
(2372)
48-7/8
(1241)
HORIZONTAL
42-5/8
(1083)
3-3/8
(86)
14-1/2
(368)
6 (152)
1
FORKLIFT SLOTS
(BOTH SIDES)
95-3/8
(2423)
BASE
3-1/2 (89)
TYP.
LIFTING HOLES
(FOR RIGGING)
FRONT VIEW
(1476)
CONDENSATE
OUTLET
SUPPLY
30-1/4
(768)
37-3/4
(959)
60-1/8
(1527)
8-3/4
(222)
HORIZONTAL
6-7/8
(175)
RETURN
5-3/16
(132)
6 (152)
14-5/8
(371)
38-3/4
(984)
48-7/8
(1241)
END VIEW
3-3/8
(86)
POWER
ENTRY
38-5/8
(981)
26-5/8
(676)
END VIEW
Page 2
CAUTION
Danger of sharp metallic edges. Can cause injury.
Take care when servicing unit to avoid accidental
contact with sharp edges.
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.
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. Follow
lighting instructions attached to unit
when putting unit back into operation
and after service or maintenance.
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.
The ZH packaged rooftop units are available in 7-1/2,
8‐1/2 and 10 ton cooling capacities. Optional electric
heat is available.
Units are available with an optional supply air inverter.
During cooling, the blower will operate at lower speeds
when demand is low and increase to higher speeds
when demand is high. During a blower only demand, the
blower will operate at low speed. During a heating
demand, the blower will operate at high speed.
Availability of units and options varies by brand.
Safety
See figure 1 for unit clearances.
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.
UNIT CLEARANCES
OUTDOOR AIR
C
D
A
HOOD
B
FIGURE 1
1
Unit
Clearance
Service
Clearance
Minimum Opera
tion Clearance36(914)36(914)60(1524)36(914)
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)Cin.(mm)Din.(mm)
36
(914)36(914)60(1524)36(914)
To p
Clearance
Unob
structed
Unob
structed
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.
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.
Page 3
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.
Return air temperature range between 55°F (13°C)
and 80°F (27°C) must be maintained.
Air filters must be replaced and pre-filters must be
removed upon construction completion.
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 base is fully enclosed and insulated, so an
enclosed frame is not 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).
The input rate and temperature rise must be set per
the unit rating plate.
The heat exchanger, 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, ignition, input rate, temperature
rise and venting) must be verified according to these
installation instructions.
Unit Support
In downflow discharge installations, install the unit on a
non-combustible surface only. Unit may be installed on
combustible surfaces when used in horizontal discharge
applications or in downflow discharge applications when
installed on an Z1CURB roof mounting frame.
NOTE - Securely fasten roof frame to roof per local codes.
A-Downflow Discharge Application
Roof Mounting with Z1CURB
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.
NOTE-When installing a unit on a combustible surface for
downflow discharge applications, an 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 approximately 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.
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.
Duct Connection
All exterior ducts, joints and openings in roof or building
walls must be insulated and weather-proofed with
flashing and sealing compounds in accordance with
applicable codes. Any duct passing through an
unconditioned space must be insulated.
CAUTION
In downflow applications, do not drill or punch
holes in base of unit. Leaking in roof may occur if
unit base is punctured.
Page 4
Rigging Unit For Lifting
UNIT ALIGNMENT BRACKETS
Rig unit for lifting by attaching four cables to holes in unit
base rail. See figure 2.
1- Detach wooden base protection before rigging.
2- Connect rigging to the unit base using both holes in
each corner.
3- All panels must be in place for rigging.
4- 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.)
5- All Units -
Partially lift unit and remove five (5) L-brackets which
secure the protective base board. See figure 2.
Important - Protective wooden base board
must be removed before setting unit.
6- New roof curbs (89-3/8” in length) -
Remove the three alignment brackets shown in figure 3.
7- Existing roof curbs (81-3/4” in length) -
Set unit on roof curb positioning alignment brackets
as shown in figure 3.
RIGGING - ALL UNITS
Unit
*Maximum weight with all avail
able installed accessories.
IMPORTANT - ALL
PANELS MUST BE IN
PLACE FOR RIGGING.
*Weight
Lbs. Kg.
1270ZH576
LIFTING POINT SHOULD
BE DIRECTLY ABOVE
CENTER OF GRAVITY
NEW ROOF CURBS (89-3/8” IN LENGTH):
Remove all three brackets.
EXISTING ROOF CURBS (81-3/4” LONG):
Set unit on roof curb positioning alignment brackets as shown.
THREE (3) UNIT
ALIGNMENT
BRACKETS
ROOF CURB
FIGURE 3
Condensate Drains
Make drain connection to the 1” N.P.T. 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 4. 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 page 2 for condensate drain location.
Units are shipped with the drain coupling facing the right
side of the unit. The unit can be installed in either
downflow or horizontal air discharge regardless of
condensate drain location.
CAUTION - Do not
walk on unit.
REMOVE FIVE (5)
L-BRACKETS AND BASE
PROTECTION BOARD
FIGURE 2
Page 5
CONDENSATE DRAIN CONNECTION
CAULK AROUND CONDENSATE COUPLING
Minimum Pitch
1” (25 mm) per
10' (3 m) of line
OPEN VENT
FIGURE 4
UNIT
MOUNTING
FRAME
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- 230/460/575 volt units are factory wired. For 208V
supply, disconnect the pink wire (230V) at all control
power transformer(s). Reconnect the pink wire
(208V). Tape the exposed end of the 230V pink wire.
2- Route power through the bottom power entry area
and connect to L1, L2, and L3 on the bottom of
TB13 in control box. Route power to S48
disconnect switch when the option is
factory-installed. See unit wiring diagram.
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 (1524mm)
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
B-Control Wiring
1- Route thermostat cable or wires from subbase to
control box (refer to unit dimensions to locate bottom
and side power entry).
IMPORTANT - Unless field thermostat wires are rated
for maximum unit voltage, they must be routed away
from line voltage wiring. Use wire ties located near the
lower left corner of the controls hat section to secure
thermostat cable.
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 TB1 terminal board on
the left side of the controls area. Wire as shown in
figure 5 for electro-mechanical and electronic
thermostats. If using other temperature control
devices or energy management systems see
instructions and wiring diagram provided by
manufacturer.
24 VOLT FIELD WIRING WITH ELECTRONIC AND
ELECTRO-MECHANICAL THERMOSTATS
NOT ALL TERMINALS
ARE FOUND ON ALL
THERMOSTATS
Jumper terminals R and
OC when thermostat has
no night setback terminals
A2 THERMOSTAT
Note - On electro-mechanical thermo
stats set anticipator at 0.1 amps.
on units equipped with an
economizer.
FIGURE 5
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.
Unit Power-Up
A-General
1- Make sure that unit is installed in accordance with the
installation instructions and applicable codes.
2- Inspect all electrical wiring, both field‐ and
factory‐installed, for loose connections. Tighten as
required.
3- Check to ensure that refrigerant lines do not rub
against the cabinet or against other refrigerant lines.
4- Check voltage at main unit power connection.
Voltage must be within range listed on nameplate. If
not, consult power company and have voltage
condition corrected before starting unit.
5- Make sure filters are in place before start‐up.
6- Make sure there is no heating, cooling, or blower
demand from thermostat. Apply power to unit.
Page 6
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