Reznor ZQYRA-8 Installation Manual

Form I-ZQYRA (5-16)

CQS

Obsoletes Form I-ZQYRA (12-15)

Installation / Operation / Maintenance

Applies to: Z Series Model ZQYRA

Ventilation Unit

CQS

R-410A Refrigerant

DANGER

This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death. Installation, maintenance, and service should

only be performed by an HVAC technician qualied in R-410A refrigerant and

using proper tools and equipment. Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for R22 refrigerant.

IMPORTANT: Do not release refrigerant to the atmosphere! If required service procedures include the adding or removing of refrigerant, the service technician must comply with all federal, state and local laws. The procedures discussed

in this manual should only be performed by a qualied HVAC technician.

IMPORTANT: Failure to maintain, misuse of the unit, use of replacement parts not factory approved or wrong startup procedures will void the warranty.

Form I-ZQYRA P/N 260414R8, Page 1

Table of Contents

1.0 General .......................................................................... 2

1.1 Hazard Labels and Notices ....................................... 2

1.2 General Information .................................................... 3

1.3 Warranty ...................................................................... 3

1.4 Installation Codes ....................................................... 3

2.0 Location ......................................................................... 3

3.0 Receiving, Moving, and Uncrating .............................. 3

3.1 Receiving .................................................................... 3

3.2 Storage and Moving .................................................... 3

3.3 Uncrating and Preparation ......................................... 4

4.0 Dimensions and Clearances ........................................ 4

4.1 Dimensions .................................................................. 4

4.2 Clearances ................................................................... 5

5.0 Mounting ........................................................................ 5

5.1 Weights ........................................................................ 5

5.2 Rigging and Lifting ..................................................... 5

5.3 Curb Cap Base and Mounting .................................... 6

5.3.1 Mounting without a Roof Curb .............................. 6

5.3.2 Mounting on a Roof Curb ...................................... 6

6.0 Mechanical .................................................................... 9

6.1 Identity of Mechanical Procedure Locations ............ 9

6.2 Inlet Air and Exhaust Air Openings .......................... 9

6.2.1 Field-Installed Inlet Air and Exhaust Hoods ........ 9

6.2.2 Exhaust Air Hood ................................................. 10

6.2.3 Inlet Air Hood ........................................................ 10

6.2.4 Inlet and Exhaust Dampers, Option AR2Y .........12

6.3 Duct Connections and Ductwork ............................ 12

6.4 Condensate Drain ..................................................... 13

7.0 Electrical Connections and Wiring ........................... 14

7.1 Supply Voltage ..........................................................14

7.2 Supply Wiring ............................................................ 15

7.3 Electrical Compartment ............................................ 16

7.4 Electrical Components ............................................. 16

7.4.1 Fan Motors ............................................................ 16

7.4.2 Energy Recovery (enthalpy) Wheel ................... 17

7.4.3 Heat Pump (R-410A Refrigerant) ........................ 17

7.4.4 Optional Electric Preheat, PH1A (5kW) and PH2A (10kW) .....

7.5 Control Wiring (eld-installed) ................................. 18

7.5.1 Control Wiring General Requirements ............... 18

7.5.2 Instructions for Installing Discharge Air Sensor in the

Ductwork ........................................................... 19

8.0 Controls ....................................................................... 26

8.1 Main Control Module and Unit Mounted Display ... 26

8.2 Sequence of Operation ............................................. 27

8.3 Safeties, Alarms, and Lockouts .............................. 31

8.3.1 Service Alarms ...................................................... 32

8.3.2 Maintenance Alarms ............................................ 34

8.4 Supplemental Heating Mode .................................... 34

8.4.1 PreHeat Outside Air Temp Control ..................... 36

8.5 Controller Points ....................................................... 36

8.5.1 Controller Display Menus .................................... 36

8.6 Setting Schedule ....................................................... 54

8.7 Optional Communication Cards .............................. 55

8.7.1 BACnet® MSTP (Option BHB8) Communication 55

8.7.2 LONworks® (Option BHB7) Communication ...... 58

8.8 Dirty Filter Alarm, Option BE18 (outside air lters only) 61

9.0 Startup ......................................................................... 61

9.1 Preparation and Startup Requirements .................. 61

9.2 Test Mode Control ..................................................... 61

9.3 Setting Fans to Test and Balance Airow .............. 63

9.3.1 Setting Fan Speeds Using the TAB Menu ..........63

9.3.2 Measure Supply and Exhaust Airow Pressure Drops ..........

9.3 Setting Fans to Test and Balance Airow (cont’d) 66

10.0 Maintenance and Service ......................................... 67

10.1 Maintenance Schedule ........................................... 67

10.2 Maintenance Procedures ........................................ 67

10.2.1 Inlet and Exhaust Hoods.................................... 67

10.2.2 Inlet and Exhaust Fans ...................................... 67

10.2.3 Inlet and Return Air Filters ................................ 67

10.2.4 Energy Recovery Wheel..................................... 67

10.2.5 Heat Pump Maintenance ................................... 70

10.3 Troubleshooting ...................................................... 72

10.3.1 General Troubleshooting ................................... 72

10.3.2 Compressor Digital Controller Troubleshooting 74

APPENDIX ......................................................................... 75

Wiring Diagram Option Identication ............................ 75

DAT, OAT, and Wheel DAT Sensor

Resistance vs. Temperature ................................... 75

Startup Form .................................................................... 76

INDEX ................................................................................. 77

INSTALLATION RECORD - to be completed by the

installer:........................................................................ 78

1.0 General

Form I-ZQYRA P/N 260414R8, Page 2

1.1 Hazard Labels and Notices

There are warning labels on the condensing unit and throughout this manual. For

your safety, read the denitions below and comply with all boxes labeled CAUTION, WARNING, and DANGER during installation, operation, maintenance, and service of

this system.

Denitions of Hazard Intensity Levels in this Manual

HAZARD INTENSITY LEVELS

DANGER: Failure to comply will result in severe personal injury

or death and/or property damage.

WARNING: Failure to comply could result in severe personal

injury or death and/or property damage.

CAUTION: Failure to comply could result in minor personal

injury and/or property damage.

WARNING

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury, or

death. A qualied installer or service agency must perform

installation and service.

DANGER

The heat pump in this ventilation unit is designed to use R-410A high pressure refrigerant only. Hazards exist that could result in personal injury or death. Installation, maintenance, and service should only be performed by an HVAC

technician qualied in R-410A refrigerant and using proper tools and equipment.

Due to much higher pressure of R-410A refrigerant, DO NOT USE service equipment or tools designed for R22 refrigerant.

DANGER

Never use oxygen to pressurize a refrigeration system. Oxygen can explode on contact with oil and result in personal injury or death. When using high pressure gas such as nitrogen for pressurizing a refrigeration system, ALWAYS USE A PRESSURE REGULATOR that can control the pressure down to 1 or 2 psig.

SAFETY WARNINGS

For your safety, wear eye protection, gloves, and protective clothing when handling

R-410A refrigerant or POE oil and when brazing. Have a re extinguisher nearby

when brazing.

DANGER

Before installing or servicing, always turn off the main power to the system and install a lock out on the disconnect switch.

1.2 General Information

1.3 Warranty

1.4 Installation Codes

2.0 Location

This booklet includes installation, operation, maintenance, and service information. Before beginning any procedure, carefully review the information, paying particular attention to the warnings. All installations must be in compliance with all codes and requirements of authorities having jurisdiction.

Refer to limited warranty information on the Warranty Form in the “Literature Bag” shipped with this system.

All installations must be in compliance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or, in Canada, the Canadian Electrical Code, Part I-C.S.A. Standard C 22.1. Check any local ordinances or utility company requirements that apply. The installation must be in compliance with all authorities having jurisdiction. Local code requirements supersede national requirements.

This ventilation unit is designed to be mounted outdoors on a level surface but could be mounted indoors. The supporting structure must be able to support the operating weight of the unit and maintain a level plane during continued operation. Water should drain away from the unit. Location must comply with free space clearances for

unrestricted airow

3.0 Receiving,

Moving, and Uncrating

3.2 Storage and

Moving

3.1 Receiving

Check for any damage that may have happened during shipment. If damage is found, document the damage with the transporting agency and immediately contact your distributor. If you are an authorized Distributor, follow the FOB freight policy procedures.

With the shipping skid attached, the unit may be moved with a fork lift or an overhead crane. After the shipping skid has been removed, the unit must be lifted from overhead. The heavy gauge base of the ventilation unit has a lifting lug on each corner. Always use spreader bars when rigging to prevent damage to the cabinet.

Form I-ZQYRA P/N 260414R8, Page 3

(610)

Exhaust

Air

Opening

15-3/8

(391)

Inlet Air

Filter

Access

Panel

REAR VIEW

(Exhaust End)

3-3/8

(86)

3-3/8

(86)

19-1/2

(495)

Inlet Air

Opening

Exhaust

Hood

27 (686)

Wheel

Access

Panel

Supply Fan Access

Panel

Inlet Side Post

Cover

3/4” SCH 40

Condensate Drain

Socket Adapter Fitting

22-1/8

(562)

3-7/8

(98)

70-1/2 (1791)

*Horizontal (Discharge)

Supply Air

Opening

*Horizontal

Return Air

(559)

(229)

14-1/4 (362)

15 (381)

7-9/16

(141)

(381)

Electrical

Compartment

- Controls and

Compressors

Return Air Filter

Access Panel

Non-fused

Optional

Disconnect

Switch

High Voltage Entrance

Low Voltage Entrance

(76)

52-11/32

(1330)

(lifting hole

centerline)

64-1/2 (1638)

(lifting lug centerline)

Exhaust

Hood

24-1/2

(622)

6-1/2 (165)

Inlet Hood

22-15/16

(583)

(254)

22 (559)

14-3/8 (365)

*Vertical Return

Air Opening

*Optional

Supply Air

Opening

9 (229)

(533)

3-3/8 (86)

3-5/16 (84)

1-1/2 (38)

4 Lifting Holes

CONTROL SIDE

(Partial view)

8-1/2 (216)

(508)

50-3/8 (1280)

Inlet Air Hoods Size 8 - 2 Hoods Size 12 - 3 Hoods

BOTTOM VIEW

(from underneath)

3-5/16

(84)

SIDE VIEW

(Side Opposite Controls)

FRONT VIEW

(Horizontal Supply and

Return Air Connections)

(Reheat

Pump

Coil)

3.0 Receiving, Moving, and Uncrating

(cont’d)

3.2 Storage and Moving (cont’d)

If the unit is going to be stored, take precautions to prevent condensation inside the electrical compartment and motors. To prevent damage to the unit, do not store sitting on the ground.

3.3 Uncrating and Preparation

Immediately upon uncrating, check the electrical characteristics to verify that the unit is suitable for the installation site.

Shipped-with and Shipped-separate Items - A carton shipped inside the unit contains the vertical supply air opening cover and parts to assemble and install the

inlet and exhaust hoods. The hoods will be attached after the unit is in the installed

location. Before beginning installation, be sure that all shipped-separate options ordered are

available at the site. Shipped-separate options could include a roof curb, a wallmounted control, and/or a disconnect switch.

Supply Air (Discharge) and Return Air Openings - To enable the installer to adapt to either vertical or horizontal ductwork, the cabinet has both vertical and horizontal supply and return air openings. Both the horizontal supply air and return air openings are capped during shipping.

NOTE: There are no vertical duct connections on the unit; duct ange connections are

part of the roof curb. The curb is designed to slide the ductwork into the vertical duct openings from the roof before the unit is lifted to the curb.

4.0 Dimensions and Clearances

4.1 Dimensions

FIGURE 1 - Dimensions - inches (mm)

Size A B C D E F G H J K

inches

9-1/4 14-5/16 32-15/16 24 39-1/2 9-3/4 6-1/4 34-7/8 27-3/8 22-3/8

235 364 837 610 1003 248 159 886 695 568

inches

12-1/4 21-3/8 36-5/16 30 45-1/2 12-3/4 9-1/4 37-7/8 30-3/8 25-3/8

311 543 922 762 1156 324 235 962 772 645

Dimensions - inches and mm

* Conguration of

Supply (Discharge) Air and Return Air Ductwork can be either Vertical or Horizontal

Follow the instructions in Paragraph 6.2 that apply.

NOTE: Vertical duct connections are on the roof curb. There are no vertical

duct anges on the unit.

The curb is designed for ductwork to be installed from the top before the unit is set on the curb.

Form I-ZQYRA P/N 260414R8, Page 4

RETURN

AIR

DISCHARGE

AIR

TOP VIEW

SIDE VIEW

INLET AIR

HOODS

EXHAUST

AIR

EXHAUST

AIR

INLET AIR

HOOD

4.2 Clearances

Unit Top -

Minimum

Clearance =

6” (15cm)

Inlet Air

4 ft (1.2M) -

Required to slide

out energy

recovery wheel.

3 ft (.9M) -

Required to the

disconnect switch.

Return Air

Supply

Air

12”

(30cm)

Energy Recovery Wheel

Exhaust

Air

Control Side

Disconnect Switch, Option BA6

FIGURE 2 - Minimum Unit Clearances

NOTE: For indoor installation, see Paragraph 6.3 for special ductwork requirement.

Minimum Service Clearances

5.0 Mounting

Before installing, check the supporting structure to

be sure that it has sufcient load-bearing capacity to

5.1 Weights

support the operating weight of the unit. Mounting is the responsibility of the installer. Corner weights are provided for lifting and operation.

FIGURE 3 - Corner Weights and Center of Gravity

Approximate Corner Weights and

Center of Gravity Dimensions

ZQYRA Size 8 Size 12

Corner lbs (kg) lbs kg

A 210 (95) 239 (108) B 197 (89) 233 (106) C 219 (99) 262 (119) D 232 (105) 269 (122)

Total 858 (389) 1003 (455)

Length (L) 70-1/2” (1791mm)

Width (W) 50-3/8” (1278mm)

Dimension inches (mm) inches (mm)

5.2 Rigging and Lifting

X 26-1/2 (673) 26-11/16 (678) Y 34-3/16 (868) 34-13/16 (884) Z 16 (407) 18-13/16 (479)

Overall Dimensions

Center of Gravity Location

On each corner, the heavy gauge base of the ventilation unit has a lifting lug with a 1-1/2” diameter hole for rigging. When attaching rigging, insert a clevis in each lifting lug. Use spreader bars in the rigging. Lift the unit straight up with vertical force.

Test lift the unit to be sure that it is secure. Adjust cables so that the unit will remain horizontal throughout the lift. Lift slowly, following safe lifting procedures.

Rigging and lifting are the responsibility of the installer.

Approximate Operating

Weight

“Z” Size 8 12

Weight

Form I-ZQYRA P/N 260414R8, Page 5

858 lbs 1003 lbs 389 kg 455 kg

SIDE VIEW

of Unit

After test lift, adjust cable

length as needed so that the

unit will remain horizontal

throughout the lift.

To prevent damage to the cabinet, spreader bars are REQUIRED.

FRONT VIEW

of Unit

To prevent damage to the cabinet, spreader bars are REQUIRED.

Lifting Lug with 1-1/2” ( 38mm) diameter hole (4) one on each corner

5.0 Mounting

(cont’d)

5.2 Rigging and

Lifting (cont’d)

FIGURE 4 Rigging and Lifting

5.3 Curb Cap Base and Mounting

IMPORTANT NOTE: Unit must be level.

5.3.1 Mounting

without a Roof Curb

This unit is equipped with a load-bearing curb cap. The curb cap has bolted seams and is designed so that it may be set on perpendicular supports or over a roof curb. A curb is required if the application uses vertical (down) discharge and or vertical (down) return air.

Because of condensate drain requirements, setting this unit directly on a at surface

(cement slab) is not recommended. Be sure to comply with clearances in FIGURE 2, page 5. It is recommended that this

ventilation unit be positioned so that the outside air inlet hood is not facing into the prevailing wind.

Prior to installation, be sure that the method of support is in agreement with all local building codes and is suited to the climate. If considering an installation without a roof curb in snow areas, it is recommended that the support under the system be at least 12” (305mm) higher than the roof surface.

If setting cross supports on the roof surface and not decking, be sure to have sufcient

tread material under the supports to adequately spread the load and prevent “sinking”

into the roong material. The eld-supplied, weather resistant, cross-support structure

must be secure and adequate for the weight of the unit (Refer to Paragraph 5.1).

FIGURE 5 - Locations for Field-Supplied Rail Cross Supports

5.3.2 Mounting on a

Roof Curb

Form I-ZQYRA P/N 260414R8, Page 6

The curb, Option CJ3C, is a 16” (406mm) high, fully enclosed, insulated curb. If the

application is sound sensitive, consider installing a eld-supplied vibration isolation

curb or specialty sound attenuation curb. Whether using the optional roof curb available

with the system or a eld-supplied curb, the curb must be secure, square, and level. When using a eld-supplied curb with vertical ductwork, eld-fabricated custom duct

connections will be required as there are no duct anges on the unit. The top surface of the roof curb must be caulked with 1/4” x 1-1/4” sealant tape or two

1/4” beads of suitable sealant. The unit must be sealed to the curb to minimize sound transmission, prevent air leakage, and to prevent water leakage into the curb area due to wind blown rain and capillary action.

Roof Curb,

(Right End)

(Center

Support)

(Left End)

Top View (showing supply and return airflow)

(Front Side)

(Rear Side)

Use 3/4” Cap Screw, P/N 16247, with Lockwasher, P/N 1333, and Nut, P/N 1035, in bottom two holes in each corner.

Use 1-1/4” Lag Screw, P/N 16243, with Lockwasher, P/N 1333, in all attachmentsmade into the wood nailer around the top of the curb.

Use sheetmetal screws, P/N 11813, for attaching duct support parts to each other and to the insulated portion of the curb rails.

Assembled Views

Slide vertical ductwork down from the top and attach to duct flanges at bottom of curb. See dimensions on page 8.

Bottom View (from inside the building showing flanges for ductwork on the openings on the bottom of the curb)

Return Air Duct Flange

Supply Air Duct Flange

Return Air

Supply Air

Option CJ3C

Roof curb Option CJ3C, is shipped separately for eld installation. The roof curb

designed for this system includes integral duct connections for supply air and return air

making it very important to know the orientation of the unit when installing the curb. See the illustrations in FIGURE 6 and the component list below. See dimensions

in FIGURE 8, page 8 and orientation in FIGURE 9, page 9. The roof curb is designed for ductwork to be installed from the top prior to setting the

Components in Option CJ3C, Pkg P/N 260418

unit. If ductwork is installed after the unit, eld-fabricated custom connections will be required as the unit does not have duct anges.

Item Qty P/N Description

Roof Curb Rail and Cross Support Parts, Items A, B, C, D, and E are ALWAYS used:

A 1 260215 Roof Curb Front Side B 1 260216 Roof Curb Right End C 1 260217 Roof Curb Left End D 1 260218 Roof Curb Rear Side E 1 259636 Roof Curb Center Support

Vertical Duct Support Parts (Items F-M) are required if the application has vertical supply and return air. Installation of these parts is optional if installing a unit using the horizontal supply and return air openings.

F 1 259637 Roof Curb Cross Support (return air)

G 1 259638 Roof Curb Cross Support (discharge air)

H 1 259639 Roof Curb Cross Support (return air) J 1 259640 Roof Curb Center Support (discharge air) K 1 259641 Duct Angle Support (discharge air right end) L 1 259642 Duct Angle Support (discharge air front side)

M 1 259643 Duct Angle Support (return air right end)

FIGURE 6 - Layout of Roof Curb Components listed above

Instructions and Requirements for Assembling and Installing Roof Curb Option CJ3C

The option package includes the following hardware:

Roof Curb

Hardware

Bag

includes:

1. Verify that the roof curb parts match those listed in the package component table and the hardware bag component table above. Verify that the location has adequate support for the weight (Paragraph 5.1).

Qty P/N Description

10 16243 Hex Hd Lag Bolt 5/16 X 1-1/4” lg 18 1333 Lockwasher 5/16 In.

8 16247 Cap Screw 5/16 X 3/4” lg 8 1035 Hex Nuts

31 11813 S/M Screw #10-16x1/2 Ab Stalgd

1 66302 Roll of Sealant Tape, 1/4” x 1-1/4”

2. Position the roof curb end and side assemblies as shown in FIGURE 6. Fasten each corner using lag screws with lockwashers in the top holes and cap screws with lockwashers and nuts in each of the other holes. Install the center support.

Before continuing to Step 3, verify that the airow orientation is correct.

Form I-ZQYRA P/N 260414R8, Page 7

5.0 Mounting

Roofing Felts (by others)

Cant Strip

(by installer)

Counter Flashing

(by installer)

MUST be sealed between curb cap and roof curb.

2 x 6 Wood Nailer

Insulation

Weld, bolt, or lag screw curb to deck structure.

Roof Curb

44-1/8”

(1121mm)

- inside of curb

47-7/16”

(1205mm)

- outside of rails

Rail Width 1-21/32” (42mm)

Outside Air Inlet Location (on side of unit)

TOP VIEW of Assembled

ROOF CURB

Exhaust Air Outlet Location (on side of unit)

Supply Air Opening

18-7/32” x 8-11/64”

(463mm x 208mm)

64-5/32” (1629mm) - inside of curb

67-15/32” (1713mm) - outside of rails

21-1/2”

(546mm)

Return Air Opening 19-51/64” x 8-11/64”

(503mm x 208mm)

22-1/4” (565mm)

Horizontal Return Air Opening Location on Side of Unit

Supply Air Opening Location on Side of Unit

(cont’d)

5.3 Curb Cap Base and Mounting

(cont’d)

5.3.2 Mounting on a

Roof Curb (cont’d)

FIGURE 7 - Crosssection of Roof Curb showing Construction Detail

Instructions and Requirements for Assembling and Installing Roof Curb

Option CJ3C (cont’d)

3. Identify the duct supports that create the integral supply and return air ductwork.

NOTE: If the system is not using the vertical duct openings, the duct support parts are not required but may be installed. Position the duct support parts as shown in FIGURE 6 and attach. Use 1-1/4” lag screws with lockwashers when attaching supports to the top portion of the curb rails with the wood nailer. Use sheetmetal screws in all other locations.

4. Check the roof curb for squareness. The curb must be adjusted so that the diagonal measurements are equal within a tolerance of ±1/8" (3mm).

5. Level the roof curb. To ensure a good weatherproof seal between the cabinet curb cap and the roof curb, the curb must be leveled in both directions with no twist end

to end. Shim as required and secure curb to the roof deck before installing ashing

(See Curb Detail in FIGURE 7).

6. Install eld-supplied ashing.

Form I-ZQYRA P/N 260414R8, Page 8

FIGURE 8 Option CJ3C Roof Curb and Duct Opening Dimensions

Slide return air and supply ductwork down from the top and attach to

duct anges.

Apply sealant tape to top of all curb rails.

7. Before lifting and placing the unit on the curb, check the following:

□The curb is designed for ductwork to be installed from the top BEFORE the unit

is in place. Slide the ductwork down into the discharge and return air openings. See dimensions in FIGURE 8. Ductwork should be sized slightly smaller with a

minimum 3/4" duct ange that will attach to all sides of the duct connection in the

curb. See Paragraph 6.2 for connecting ductwork.

□Apply 1/4" x 1-1/4" foam sealant tape to both the top surface of the curb rails and

the top surface of the duct connection supports, being sure to make good butt joints at all corners. The sealant tape must be applied to the rails to prevent water leakage into the curb area due to blown rain and capillary action.

□The unit has eld convertible (either vertical or horizontal) supply and return air

opening locations. Depending on whether the ductwork is vertical or horizontal,

Inlet

Air

Drain

Electrical

Entrance

Installed Option CJ3 Curb

Model ZQYRA

Return Air

Supply Air

Inlet Air Hoods with Filters (Size 8 - 2 hoods; Size 12 - 3 hoods) See assembly and installation instructions in Paragraph 6.2.3.

Condensate Drain Connection; see Paragraph 6.4.

Vertical Discharge Air

Opening (In the bottom)

Vertical Return Air Opening (in the bottom)

Inlet Side Post

Supply Fan Access

Inlet Hoods

Exhaust Hood See assembly and installation instructions in Paragraph 6.2.2.

Disconnect Switch (Optional)

Controls

Compressor

Electric Heat (Optional)

High

Voltage

Entrance

Low

Voltage

Entrance

Exhaust Fan Acccess

Horizontal

Supply Air

Horizontal Return Air Opening

(Control Side)

Return Air Filter Access

Inlet Air

Filter Access

Enthalpy Wheel Access

Control

Side

Post

Remove the inlet air filter access panel to find 1) the carton that contains the inlet hood components and the cover for the vertical supply duct opening; and 2) the bundle of exhaust hood parts.

verify that the discharge and return air openings being used are uncovered and the openings not being used are covered.

□When it is time to lift the unit onto the prepared curb (See Rigging and Lifting,

Paragraph 5.2), be sure that all of the above preparations have been made. IMPORTANT: Verify that the unit is being placed on the curb in the correct

airow orientation. See FIGURE 9 for required orientation when installing a

unit with vertical ductwork.

FIGURE 9 - Correct Orientation of Unit to Roof Curb when using Vertical Ductwork

Reminder NOTES: Curb is

designed for ductwork to be installed from the top prior to setting unit on the curb. Always apply sealant tape to top of curb rails before placing unit.

6.0 Mechanical

FIGURE 10 - Identication of Locations referenced

in Paragraphs 6.2 - 6.4

6.2 Inlet Air and Exhaust Air Openings

6.1 Identity of Mechanical Procedure Locations

6.2.1 Field-Installed Inlet Air and Exhaust Hoods

All Model ZQYRA ventilation units require eld installation of the inlet air hood and the exhaust hood. All hood components plus the vertical supply duct cover are shipped inside the cabinet. Remove the inlet lter access panel (see FIGURE 10); a carton and

a bundle of parts are visible. First, slide out the carton and then remove the bundle of parts that is attached to brackets. DO NOT remove the brackets or the carton stop.

The bundled parts are for the exhaust hood. Use screws from the hardware bag in the carton and follow the instructions In Paragraph 6.2.2 below to install the exhaust hood.

Follow the instructions in Paragraph 6.2.3 to install the inlet air hood.

Form I-ZQYRA P/N 260414R8, Page 9

Right

Side

Left

Side

Top

Cover

Screws

(26 required)

6.0 Mechanical

(cont’d)

6.2 Inlet Air and Exhaust Air Openings (cont’d)

Use of the vertical supply air cover will be determined in Paragraph 6.3.

6.2.2 Exhaust Air Hood

Exhaust Hood Components and Installation

FIGURE 11 - Components and Assembly of the Exhaust Hood

Code Qty

1 1 260210 Hood Left Side 2 1 260211 Hood Right Side 3 1 261138 261855 Hood Top Cover 4 26 11813 Screws*

* Screws are shipped in is in the carton with the inlet hood parts. The bag includes

enough screws for both the inlet and exhaust hoods.

P/N

Size 8 Size 12

hardware bag, P/N 260354, that

Description

Exhaust Hood Assembly and Installation Instructions

1. Undo the exhaust hood component bundle and identify the three parts illustrated above.

2. If the exhaust opening has a shipping cover, remove it.

If the exhaust opening has a factory-installed damper, check damper blade operation.

3. Position one of the hood side panels with the ange out as illustrated. Line the holes up with the holes in the cabinet. Attach the side panel to the cabinet with the screws provided. Repeat with the opposite side.

4. Position the hood top UNDER the edge of the cabinet top and OVER the installed side panels.

Using six screws, attach the hood top to the cabinet. Attach the top to both sides as illustrated.

6.2.3 Inlet Air Hood

Inlet Air Hood Components

Components of the Inlet Air Hood - (qty) and P/N by Model ZQYRA Size

CODE (See FIG 13B-D)

A (2) Strips of P/N 103604 Gasket strips are for across top and bottom; length of each is 23” (584mm) . B (2) Strips of P/N 103604 Gasket strips are for sides - Size 8, 28-1/2” (724mm) length; Size 12, 32” (812mm) length C (1) 262662 (1) 262662 D (1) 262663 (2) 262663 For Middle and Bottom Hoods E (2) 262665 (3) 262664 Inlet Hood Right Side Panel F (2) 262667 (3) 262666 Inlet Hood Left Side Panel

G (2) 262668 (3) 262668 Front Hood Cross Brackets - Length 21-15/16” (557mm) & Width 1-1/16” (27mm)

H (2) 262669 (3) 262669 Rear Hood Cross Brackets - Length 22-13/16” (579mm) & Width 2-1/16” (52mm) J (4) 262671 (6) 262671 Side Filter Bracket K (2) 262670 (3) 262670 Filter Access Panel

M (2) 262673 (3) 262673 Permanent Aluminum Filter, 1x14-1/2x22-1/2

N N/A (1) 262672 Front Filler Plate

(Qty) & P/N by Size

Size 8 Size 12

Inlet Hood Top

(107) 11813 Screws (in hardware bag, P/N 260354, for both the inlet hoods and the exhaust hood)

For Top Hood (top with wider ange across the back)

Description

Outside Inlet Air Hood Assembly and Installation Instructions

- Steps apply to both sizes unless noted.

Form I-ZQYRA P/N 260414R8, Page 10

1. Identify the hood components from the list above and the assembly illustrations.

2. Prepare the Cabinet Inlet

a) Remove the shipping cover. b) If the inlet has a factory-installed damper, check the damper for any damage.

(For additional information on the damper, see Paragraph 6.2.4.) If damper blades are operating properly, remove the screws (listed in table below) holding the damper frame.

Facing the Inlet Opening Size 8 Size 12

Across the Top 4 screws 4 screws Right Side 5 screws 8 screws Left Side 1 screw 2 screws (in oblong holes)

If the inlet does not have a damper, there are no screws to remove.

c) Determine gasket strip location, clean the surface, and carefully attach each

gasket strip in the order listed. 1st - BOTTOM Gasket Strip (A) - At the corner, measure up from the bottom of the cabinet:

- Size 8 - 7-1/2” (191mm)

Refer to FIGURE 10,

Top for Bottom & Middle Hood

Right Side Panel

Front Cross Bracket - 21-15/16” (557mm) long

Filter

Front Filler Plate (Size 8 only)

Filter Access

Rear Cross

Bracket -

22-13/16”

(579mm) long

Left Side

Panel

Side Filter Bracket (2)

page 9, and FIGURE 12 below for appearance of installed hoods.

FIGURE 12 - View of installed hoods showing that the assembled inlet air hoods attach to the outside of the cabinet corner post.

- Size 12 - 10” (254mm) At that point starting at the corner, mark a straight horizontal line. Position one of the 23” (584mm)

FIGURE 13A - Attach Gasket Strips

Top

gasket strips with the bottom edge on the line. Adhere the gasket.

2nd - SIDE Gasket Strips (B) - Left Side - Starting even with the

bottom of the horizontal gasket strip,

Left Side

Right Side

position the side strip on the edge of the corner post (around the corner from the opening). Clean the surface. Starting at the bottom, adhere the gasket strip.

Measure up from the cabinet bottom.

Size 8 - 7-1/2” (191mm)

Size 12 - 10” (254mm)

Bottom

Right Side - On the post or damper frame on the right of the opening, starting at the bottom, adhere the gasket strip vertically up the side of the opening. 3rd - TOP Gasket Strip (A) - Position the top strip horizontally across the top connecting the two side strips. Clean the surface and adhere the gasket.

3. Assemble and Install the Bottom Hood Using Screws from the Hardware Bag a) Assemble the hood as illustrated in FIGURE 13B, except for installing the lter

(M) and the lter access panel (K).

FIGURE 13B - Assemble Bottom Hood

FIGURE 13C Attach Bottom Hood

NOTE: Size 12 is illustrated. Size 12 does not have a filler plate (N). Procedure is the same for both sizes.

b) Attach the assembled hood; refer to FIGURE 13C. Position the hood so

that the rear cross bracket is on the bottom gasket strip, the left side is on the gasket strip on the corner post, and the right side on the other gasket strip. On the right side, match the holes under the gasket strip with the holes in the hood side panel. Adjust hood location slightly as needed and attach with screws. Being sure the holes match, attach the left side of the hood to the corner post.

c) Slide the lter (M) in place and attach the lter access panel (K).

4. Size 12 only - Repeat the procedure in Step 3a (FIGURE 13B) to

assemble the middle hood. Position it above the bottom hood. Line up the holes on the right side and attach the hood. Attach the left side to the corner post.

Slide the lter in place and attach the lter access panel.

5. Using the hood top with the longer ange, repeat the procedure in

Step 3a (FIGURE 13B) to assemble the last hood. When positioning the hood on the cabinet (FIGURE 13D), slide the

Top was

already attached

to the hood sides

in Step 3a.

Filter

FIGURE 13D - Attach Top Hood

NOTE: Size 8 is illustrated. Procedure is the same for Size 12.

Form I-ZQYRA P/N 260414R8, Page 11

Filter Access

When attaching the top hood, slide the hood flange under the edge of the cabinet top.

6.0 Mechanical

(cont’d)

6.2 Inlet Air and Exhaust Air Openings (cont’d)

6.2.3 Inlet Air Hood (cont’d)

hood top ange under the edge of the cabinet top. (If needed, loosen the screw

in the cabinet top.) Matching holes, attach the hood on both sides and across the top.

To complete the installation, slide the lter (M) in place and attach the lter access

panel (K).

6.2.4 Inlet and Exhaust Dampers, Option AR2Y

6.3 Duct Connections and Ductwork

Indoor Installation NOTE: If installing this ventilation unit indoors, exhaust and

supply airow will be

double. Ductwork and louvers must be sized accordingly.

(Size 8 - CFM Range is 500-1100; Size 12 - CFM Range is 900-1500)

Example: A Model ZQYRA 12 installed indoors operating at 1500 cfm will require supply and exhaust ductwork sized for 3000 cfm.

If equipped with optional intake and exhaust dampers, the intake damper has a motorized actuator and the exhaust damper has a barometric control.

The intake damper has a 24volt, two-position, spring return actuator directly interlocked with the supply fan. The actuator opens the damper whenever the supply fan is commanded to operate. When the supply fan is off, the actuator’s spring drives the damper closed.

The exhaust hood features a low leak gravity operated back draft damper. The exhaust

damper starts to open at 0.03” w.c and is fully opened at 0.10” w.c.

Duct Connection Conguration

This unit has both vertical and horizontal supply and return air duct opening locations so ductwork connection openings being used depend on the installation.

Installation using Horizontal Ductwork - See locations of the horizontal duct openings in FIGURE 10, page 9, and dimensions in FIGURE 1, page 4. Remove the cover from the horizontal return air opening and re-locate it to cover the vertical return air opening in the bottom of the cabinet. Remove and discard the cover from the horizontal supply (discharge) air opening. Shipped in the carton with the hood parts

(see Paragraph 6.2), nd the cover for the vertical supply air opening. Install the cover

to close the vertical supply air opening.

Installation using Vertical Ductwork - Vertical ductwork connection anges are in the roof curb; see dimensions in FIGURE 8, page 8. If vertical ductwork was not installed

from the top or a eld-supplied curb is used, a transition may be required for attaching

ductwork. When using vertical ductwork, the horizontal duct opening covers should not be removed and the vertical supply duct cover shipped in the hood carton will not be used.

Requirements and Suggestions for Ductwork Design and Installation

Before operating the unit, be sure that the unused supply and return air openings are closed with the covers provided.

CAUTION: An external duct system static pressure not within the limits shown on the rating plate may overload the motors. See Hazard Levels, page 2.

• Type of Ductwork - The type of duct installation to be used depends in part on

the construction of the roof (whether wood joist, steel bar joist, steel truss, pre-cast

concrete) and the ceiling (whether hung, ush, etc.).

• Ductwork Material - Rectangular duct should be constructed of not lighter than

No. 26 U.S. gauge galvanized iron or No. 24 B & S gauge aluminum.

• Ductwork Structure - All duct sections 24 inches (610mm) or wider, and over 48

inches (1219mm) in length, should be cross broken on top and bottom and should have standing seams or angle-iron braces. Joints should be S and drive strip, or locked.

• Through Masonry Walls - No supply air duct should come in contact with

masonry walls. Insulate around all air ducts through masonry walls with not less than 1/2" (13mm) of insulation. 1" (25mm) is recommended.

• Through Uncooled/Unheated Space - Insulate all exposed supply air ducts

passing through an uncooled or unheated space with at least 1/2" (1" is recommended) of insulation.

• Duct Supports - Suspend all ducts securely from buildings members. Do not

support ducts solely by the unit duct connections.

Form I-ZQYRA P/N 260414R8, Page 12

6.4 Condensate Drain

NOTE: Do not reduce

   





the diameter of the condensate drain piping. 3/4” PVC is required for attaching to the drain connection. See FIGURE 10, page 9, for drain location.

Condensate Drain Trap

• Duct Sizing - Proper sizing of the supply air ductwork is necessary to ensure a

satisfactory installation. The recognized authority for such information is the Air Conditioning Contractors Association, 2800 Shirlington Road, Suite 300, Arlington, VA 22206 (www.acca.org). A manual covering duct sizing in detail may be purchased directly from them.

• Duct Connections - To minimize sound and vibration transmission, use

exible duct connections. Ducts must be attached and sealed to provide airtight

connections.

• Return Air Duct/Grill Size - Make certain that return air ducting or grill has a free

area equal to the return duct size connection.

All systems require a condensate drain. A non-corrosive drain pan with a 3/4 Schedule

40 PVC socket adapter tting is located on the non-control side of the cabinet. When

connecting the drain line, provide a means of disconnecting the line at or near the cabinet connection to allow for cleaning.

Ensure the system is level before connecting the drain line. Do not reduce the drain diameter.

Follow the instructions below to install a trap in the drain. Pitch the drain line at least 1/2" (13mm) for every 10 feet (3M) of horizontal run. Drain lines must not interfere with drain pan or access panels.

An obstruction in the drain or a poorly designed drain can cause the condensate pan

to over ow. Do not reduce the drain piping diameter. Overow could result in damage

to the unit and/or the building. If the installation or local code requires, run drain into a waste water system.

The design of the drain trap is important. The trap height must account for this static

pressure difference. Maximum negative static can be determined by reading the negative pressure at the blower inlet and adding .2” w.c. to allow for dirty lters.

If dimension "B" in FIGURE 14A is not tall enough, the water seal will not hold, and air will be drawn through the drain pipe into the system. If the outlet leg of the trap is too tall, water will back up into the drain pan. As condensate forms during normal

operation, the water level in the trap rises until there is a constant outow. FIGURE 14A illustrates the appropriate dimensions for trapping a negative pressure system.

Improper trap design accounts for some condensate drainage system failures, but incorrect use and maintenance of condensate drain trap can also cause problems. The combination of airborne particles and moisture in the air handler can result in algae formation in the drain pan and trap. The trap must be cleaned regularly to avoid

blockage that can slow or stop water ow, resulting in backup into the system.

If drain has a cleanout opening (FIGURE 14B), be sure to close the opening after cleaning.

FIGURE 14A Condensate Drain Trap Dimensions

A = 1" (25mm) for each 1"

(25mm) of maximum static pressure plus 1" (25mm)

B = A + A/2

Condensate Drain Use





















FIGURE 14B - Drain Trap with Cleanout





At the beginning of the cooling and heating season, inspect and clean the condensate drain pan and line. Thoroughly clean dirt, algae, grease, and other contaminants.

Inspect condensate drain pan, trap, and piping; ll trap with water to ensure proper

operation. Since the heat pump operates year round, more frequent inspections of the condensate

drain may be required. Freeze protection of the trap will be required when the outside temperature is below freezing.

Form I-ZQYRA P/N 260414R8, Page 13

7.0 Electrical Connections and Wiring

All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition). In addition, the installer should be aware of any local ordinances or electric company requirements that might apply.

See FIGURE 1, page 4, to show the entrance locations for the high voltage and low voltage wiring.

7.1 Supply Voltage

CAUTION: If this unit is allowed to operate on an electric supply that is not within

the specied

tolerances, the product warranty shall be void. See Hazard Levels, page 2.

CAUTION: Check compressor rotation to verify correct phasing. DO NOT use fan rotation to check phasing. ECM fans cannot run backwards.

Disconnect Switch

The system may be factory equipped with a built-in non-fusible, lockable disconnect switch (See location in FIGURE 1, page 4). The built-in disconnect switch (Option BA6)

requires copper wiring with ampere rating based on 75°C maximum temperature rating

at the line side terminals.

If the system does not have a built-in disconnect switch, a eld-provided or optional

shipped-separate, wall-mounted disconnect switch is required. It is recommended that there is at least four feet (1.2M) of service room between the wall-mounted switch and

unit access panels. All external wiring must be within approved conduit and have a

minimum temperature rise rating of 60°C. Run conduit so that it does not interfere with unit access panels. When providing or replacing fuses in a fusible disconnect, use dual element time delay fuses and size according to the rating plate. Check the rating plate for the supply voltage and current requirements. The electric supply to the unit must meet stringent requirements for the system to operate properly.

Voltage supply should be within ±10% or as stated on the rating plate. Maximum

imbalance on a 3-phase system is 2%. Follow instructions below to check.

If the power supply is not within these tolerances, contact the power company prior to operating the system.

Check Voltage Supply - See voltage use range on the rating plate. Measure (and record) each supply leg voltage at all line disconnect switches. Readings must fall within the allowable range.

Check Voltage Imbalance - In a 3-phase system, excessive voltage imbalance

between phases will cause compressor motors to overheat and eventually fail.

Maximum allowable imbalance is 2%. To determine voltage imbalance, use recorded

voltage measurements taken above in the following formula.

Key:

Formula:

3-Phase Wiring Connection - There is a chance of unknowingly connecting 3-phase power in such a way as to cause compressor rotation in reverse. To prevent damage to the components, it is important to check this on startup.

Checking the rotation of the compressor requires connecting pressure gauges BEFORE startup. Connect refrigerant manifold pressure gauges rated for use with

R410-A refrigerant to the compressor suction and discharge lines. At startup, observe the gauges. If the suction pressure rises and discharge pressure

drops, the compressor is operating in reverse and should be shut down. (After several minutes of operation in reverse, the compressor’s internal protector will trip. If compressors are repeatedly allowed to restart and run in reverse, the compressors will be permanently damaged.)

To correct, shut down the unit and turn off the power. At the incoming power connection, switch the 3-phase line voltage wiring connections before restarting the unit. Recheck the pressure gauges.

V1, V2, V3 = line voltages as measured

VA (average) =

VD = line voltage (V1, V2, or V3) that deviates farthest from average (VA)

% Line Voltage Imbalance =

(V1 + V2 + V3)

[100 x (VA - VD)]

CAUTION: Connect pressure gauges to the suction and discharge lines BEFORE startup so that compressor rotation can be checked immediately. Scroll compressors will be destroyed if operated in the wrong direction. See Hazard Levels, page 2.

Form I-ZQYRA P/N 260414R8, Page 14

and C in the electrical compartment.)

7.2 Supply Wiring

FIGURE 15A illustrates supply wiring connections with or without Option BA6

disconnect switch.

Option BA6

60A LOCKABLE ON/OFF

DISCONNECT SWITCH

#6 BK

#6 Y

#6 R

Field installed wiring (If there is no Option BA disconnect switch, connect field wires at A, B,

Supply Wiring Connections

FIGURE 15A - Supply Wiring Connections for Options AK5, AK6 and AK7

OPTIONAL FUSIBLE

DISCONNECT SWITCH

460/3/60

208 or 230/3/60

GND

Depending on option selection, the unit is wired for:

• 208v /3ph / 60Hz - Option AK5

• 230v / 3ph / 60Hz - Option AK6

• 460v / 3ph / 60Hz - Option AK7

Supply Voltage Supply Fan Motor Exhaust Fan Motor Supply Wiring and Connection (See FIGURE 15A)

Option AK5 (208v/3ph/60Hz)

Option AK6 (230v/3ph/60Hz)

Option AK7 (460v/3ph/60Hz)

Direct drive ECM

(3ph)

Direct drive ECM

(3ph)

Direct drive ECM

(3ph)

Direct drive ECM

(3ph)

Direct drive ECM

(3ph)

Direct drive ECM

(3ph)

Standard 3ph/60Hz

Distribution Blocks in the Electrical Compartment

MCA and MOP

ECM

Model ZQYRA

Voltage Size FLA FLA MCC LRA RLA FLA VA FLA kW FLA FLA MCA MOP Opt kW FLA FLA MCA MOP

208/3/60

(Option AK5)

230/3/60

(Option AK6)

460/3/60

(Option AK7)

NOTE: Where 240/3 and 480/3 rated electric coils are used, kW is derated to the nameplate voltage of 208, 230 or 460. Where 208/3 rated coils

are used, there is no kW derate on 208/3 units.

Supply

8 3.0 5.2 18.2 88 11.7 0.7 150 0.7 10 27.8 37.4 46.7 50

12 3.0 9.7 25.1 110 16.1 0.6 150 0.7 10 27.8 41.9 52.4 60

8 3.0 5.2 18.2 88 11.7 0.7 150 0.7 9.2 23.1 32.7 40.9 45

12 3.0 9.7 25.1 110 16.1 0.6 150 0.7 9.2 23.1 37.2 46.5 50

8 1.7 2.6 9.6 44 6.2 0.35 150 0.3 9.2 11.5 16.9 21.1 25

12 1.7 4.6 12.1 52 7.8 0.35 150 0.3 9.2 11.5 18.9 23.6 25

Fan

ECM

Exhaust

Fan

Compressor

Energy

Wheel

Control

Transformer

Supplemental

Electric Heat

(Standard)

Standard Model Z (without Optional

Electric PreHeat)

Optional Electric

PreHeat

PH1A 3.8 10.4 47.8 59.8 60 PH2A 7.5 20.9 58.3 72.9 80 PH1A 3.8 10.4 52.3 65.4 70 PH2A 7.5 20.9 62.8 78.5 80 PH1A 4.6 11.5 44.2 55.3 60 PH2A 9.2 23.1 55.8 69.8 70 PH1A 4.6 11.5 48.7 60.9 70 PH2A 9.2 23.1 60.3 75.4 80 PH1A 4.6 5.8 22.7 28.3 30 PH2A 9.2 11.5 28.4 35.4 40 PH1A 4.6 5.8 24.7 30.8 35 PH2A 9.2 11.5 30.4 37.9 40

Model Z unit with Optional Electric

PreHeat

WARNING

To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open. See Hazard Levels, page 2.

Form I-ZQYRA P/N 260414R8, Page 15

7.0 Electrical Connections and Wiring (cont’d)

7.3 Electrical

Compartment

Locations of Components

Remove the electrical compartment access panel to view the controls and compressor as illustrated in FIGURE 16. Some components in the electrical compartment are common and some vary by options selected.

FIGURE 16 - Control Locations

Electrical

Panel

Contactor (fans)

Multi Voltage

Relay Module

(time

schedule

clock,

Opt CN7A)

Distribution

Blocks -

A, B, and C

Grounding

Lug

Contactor

(wheel)

Contactor (heat pump)

Digital Controller (Compressor)

Contactor (optional electric preheat)

Terminal Blocks

Control Transformers

Control Transformer

Control Compartment

with Access Panel

Removed

Transformer (Size 8, 460V)

Supply & Exhaust Fan Overload Relays

Contactor (supplemental heating element)

Relay

(damper motor)

Field

(damper motor)

Connection

Terminal

Blocks

Unit Controller (NOTE: If ordered with a BACnet® or LONworks® communication card, it is located on the controller; see Paragraph 8.7.)

Controls on either the side or

back wall of the Control

Compartment

Display Module

Air Proving Switch (supply side), P/N 197031 set at 0.35” w.c.

Air Proving Switch (exhaust side), P/N 197031 set at 0.35” w.c.

Option BE18

Dirty Filter

Switch

7.4 Electrical Components

7.4.1 Fan Motors

The supply and exhaust fans are centrifugal, backward curve fans with integral

electronically commutated motors (ECM) that are directly controlled by the unit interface

control. The unit uses a portion of the outside intake air as part of the return airow as

shown in FIGURE 17. At startup, the speed of each fan must be set. See the instructions in Paragraph 9.3

FIGURE 17 - Diagram showing Airow through the Unit

NOTE: If installing this ventilation unit

indoors, exhaust and supply airow will be

double. Ductwork and louvers must be sized accordingly.

(Size 8 - CFM Range is 500-1100; Size 12 - CFM Range is 900-1500)

Example: A Model ZQYRA installed indoors operating at 1500 cfm will require supply and exhaust ductwork sized for 3000 cfm.

Form I-ZQYRA P/N 260414R8, Page 16

Outside Air Inlet

Exhaust Air

WHEEL

Supply Air

Return

Air

7.4.2 Energy Recovery

Power Light (Green LED)

Compressor Modulating Solenoid Valve Energized Light (Yellow LED)

Alarm Light (Red LED) - See Paragraph 10.3.2.

Compressor Digital

Controller for

Modulating Operation

VAC

COM

560K OHM Resistor between T1 & T2

is on the suction line

for heat, the valve reverses

(enthalpy) Wheel

7.4.3 Heat Pump (R-410A Refrigerant)

The energy recovery wheel is equipped with a motor and belt drive. When the unit controller requires energy recovery, the wheel motor responds and rotates the wheel through both the inlet and return airstreams.

Compressor - The heat pump has a digital scroll compressor providing quieter, more

efcient operation. The compressor has high and low pressure switches, a crankcase

heater, a thermistor to protect against too high temperature, and a modulating solenoid valve for operation. The digital controller in the electrical compartment (See FIGURES 18A and 19.) is the electronic interface between the compressor and the system controller. The compressor controller is connected to the unit control to provide protection and diagnostics for compressor operation.

After a compressor shutdown, a two-minute anti-short cycle timer in the compressor

controller delays the compressor restart. The unit controller has a ve-minute compressor on/off time. The delay times are concurrent so total delay time is ve

minutes.

FIGURE 18A - Compressor Digital Controller located in the control compartment interfaces the compressor with the unit controller.

LED

Color

Green Solid

Green Flashing

LED

State

Indicates

Power (24VAC present at power terminals) Anti-short cycle timer is active Unloader (Solenoid valve

Yellow Solid

is energized; compressor

capacity is 0.) Red Not lit No abnormal operation alerts Red Flashing See Paragraph 10.3.2.

The heat pump compressor and refrigerant piping with reversing valve shown in FIGURE 18B are located directly under the control compartment and are accessed through the same removable side panel.

FIGURE 18B - Heat Pump Compressor and Piping

Compressor Modulating Solenoid Valve

High Pressure Switch (manual reset)

is on the discharge line

Reversing Valve

(enlarged view below)

When the controller calls

refrigerant flow.

Compressor

Thermistor

Crankcase Heater

CAUTION: Crankcase heater must be allowed to warm up for at least 24 hours prior to startup or after a power outage of eight or more hours. Either turn the unit off with a CN option switch if available or remove the jumper to break contact between Terminals 3 and 8, BEFORE turning on power to warm up the crankcase heater.

The scroll compressor also has a belly band crankcase heater which straps around the bottom half of the compressor. The crankcase heater must be allowed to warm up for at least 24 hours prior to startup or after an 8-hour power outage.

Charge Compensator

Low Pressure Switch (auto reset)

Form I-ZQYRA P/N 260414R8, Page 17

Accumulator

7.0 Electrical and

Wiring (cont’d)

Coils

7.4 Electrical Components (cont’d)

7.4.3 Heat Pump (cont’d)

The heat pump has highly efcient evaporator and condenser coils and a cleanable

condensate drain pan. When the heat pump is in a defrost state, electric heat coils (5kW Size 8; 10kW Size 10) are activated to ensure the discharge air stays at a comfortable temperature.

FIGURE 19 shows the locations of the evaporator and condenser coils and their

thermostatic expansion and check valves. The system is factory charged with

environmentally friendly R-410A refrigerant (Size 8 - 6.5 lbs and Size 12 - 13 lbs).

FIGURE 19 - TXV Valves on Heat Pump Coils

Compressor

Control Side View

7.4.4 Optional Electric Preheat, PH1A (5kW) and PH2A (10kW)

Condenser Coil

Check Valve

Flow Direction

TXV Bulb Location

Thermostatic

Expansion

Valve

Thermostatic Expansion Valve

Flow Direction

Expansion Valve

Evaporator Coil

Flow Direction

Expansion Valve

Check Valve

TXV Bulb Location

Flow Direction

Condensate Drain

Side Opposite Controls View

(partial view)

If ordered with optional electric preheat, electric elements will be installed in the cabinet between the inlet hood and the energy recovery wheel. Optional electric preheat

provides frost protection for the wheel in extremely cold temperatures. For more

detailed information on controls, see “Optional Preheat Control” in Paragraph 8.2. Check the unit rating plate for the MCA and MOP of a unit with optional electric preheat.

FIGURE 20 - Location of Optional Electric Heating Elements

Model ZQYRA Size 12 with Option PH2A

Model ZQYRA Size 8 with Option PH1A (one heating element)

NOTES: Both Model Sizes 8 and 12 could have either Option PH1A (5kW) or PH2A (10kW). If it is determined after

installation that electric preheat is needed, contact your distributor about eld installing heating elements.

7.5 Control Wiring

(eld-installed)

7.5.1 Control Wiring General Requirements

There are ve wall-mounted control options & one duct mounted temperature sensor that require eld installation and wiring. Follow the manufacturer’s instructions for instal-

lation. Refer to Paragraph 7.5.2 for more detailed information about wiring and operation for each control option.

Form I-ZQYRA P/N 260414R8, Page 18

(two heating elements)

Digital Control

4 x 12 x 24

3.14

4 x 305 x 610

3.14

Signal Wiring Recommendations and Requirements

24V Field Control Wiring Length and Size Requirements

Total Wire Length Minimum Recommended Wire Size

150 ft #18 gauge shielded wire 250 ft #18 gauge shielded wire 350 ft #14 gauge shielded wire

The manufacturer recommends for optimum temperature control performance that the analog and digital inputs (CO2 and air quality sensors) that are connected to the main controller have a <3% wattage drop and be routed to the unit in one of the following manners:

1) In separate conduits, isolated from 24 VAC controls and line voltage power to the

unit, OR

2) If the digital sensor wires are to be run in the same conduit as the 24 VAC control

wiring, the CO2, VOC, and display sensor wiring in Options CN7B, CN7C, and RB5 must be completed using shielded cable and bundled separately from the 24 VAC control wiring. The shield must be drained at the unit and taped on the opposite end.

Comply with the digital control sensor wire gauge and length requirements in the table below.

Maximum

Sensor Wire Length for less than 1°F Signal

Error

Wire Gauge

AWG

14 800 244 16 500 152

18 310 94

Maximum Sensor Wire Length (Digital Control)

Feet Meters

7.5.2 Instructions for Installing Discharge Air Sensor in the Ductwork

FIGURE 20A- Discharge Air Temperature Sensor Probe and Weatherproof Box, P/N 222753

The discharge air temperature sensor (See FIGURE 20A.) is shipped with every unit

and must be eld installed in the ductwork. The location and position of the sensor are

important. Follow the instructions below.

1. Determine the appropriate distance from the unit. Be sure there is sufcient

distance from the outlet to have a good mixture of discharge air temperature.

According to the latest edition of AMCA Standard 201, in straight ducts, the air

is typically well mixed a minimum of ve equivalent duct diameters from the discharge of the unit with equivalent duct diameter dened as equal to the square

root of 4AB/3.14. "A" and "B" are the duct cross-sectional dimensions.

Example: Supply ductwork cross-sectional dimension is 24" x 12" (610mm x 305mm).

5 x

= 96" 5 x

= 2435mm

Locate the sensor a minimum of 96" (2435mm) from the

outlet of the unit.

NOTE: If the length of the discharge duct is less than 8 ft (2.4M), a mixing vane is

recommended for mixing the discharge air.

Do not mount the sensor in the ductwork after a split in the supply as that will

cause loss of control in the duct that does not house the sensor.

2. Determine the location and orientation of the sensor. The position of the sen-

sor in the duct is also important. In horizontal ductwork, locate the sensor assem-

bly in the top, middle of the duct with the sensor probe extending vertically down

into the center of the airstream.

In vertical ductwork, locate the sensor assembly in the middle of the side of the

duct that corresponds with the top middle of the discharge outlet.

3. Attach the sensor. Mark the selected location and drill a 7/16" hole. Insert the

probe into the hole. Be sure that the blue plastic tting holding the probe is centered in the hole. Attach with two No. 8 sheetmetal screws (do not overtighten). Check to be certain that the hole is sealed.

4. Run the sensor wire to the unit. Use eld-supplied 2 to 3 pair of 16 to 22 ga

wire. Digital control inputs are low-current, resistance-based signals.

Form I-ZQYRA P/N 260414R8, Page 19

Multi-Voltage Relay Module, P/N 260189, used with Option CN7A is mounted in the electrical compartment at the factory; see FIGURE 16, page 16.

Time ClockWall Switch,

Leviton Model VPT24-1P,

P/N 260188

Y/R

G/Y

(HOT) BK

(NEUT) W

}

115/1/60

LINE

PAM-1

TIMER

SWITCH

Multi-voltage

relay

(see below)

= field wiring

= field connection terminal block

7.0 Electrical and

Wiring (cont’d)

7.5 Control Wiring

(eld-installed) (cont’d)

7.5.2 Specic

Wiring by Control

Option (cont’d)

Depending on which eld-installed control option was ordered, the unit will operate

whenever there is a call for fresh air (ventilation) from that control. Otherwise, the unit is OFF.

• Option CN5 - Wall-mounted, Manual Start/Stop Switch

• Option CN7A - Time Schedule Clock with Manual On/Off Override Switch

• Option CN7B - CO

Sensor with Unit Control Hand/Off/Auto Switch

• Option CN7C - Indoor Air Quality (VOC & CO) with Hand/Off/Auto Switch

• Option CN7D - Occupancy Motion Switch with Manual On/Off Override

Switch

Wall Start/Stop Switch, Option CN5

FIGURE 21 - Option CN5, Start/Stop Wall Switch and Wiring Connections

Time Clock Wall Switch, Option CN7A

The wall-mounted, manual two-position key switch in Option CN5 will start or stop

the unit. Mount the 2-wire, 24V switch in a eld-supplied, standard 2 x 4 electrical box. Install the cover plate. Follow the wiring diagram to run the wires and make the

connections. Mount the start/stop switch on the wall.

Components and wiring information for Option CN5.

START

STOP

Cover, P/N 260229 Label, P/N 260228

2-Position (start/stop) Key Switch, P/N 260227

2 Key Positions

START

STOP

Reference

CN5

KEY LOCK

POWER SWITCH

= field wiring

= field connection terminal block in the

electrical compartment of the unit

The compact wall-mounted time clock with manual ON/OFF override will start or stop the unit. The

24-hour time clock schedule allows exible weekday

and weekend start/stop times with a convenient daylight savings update. A rechargeable battery maintains the programming in a temporary power outage. The unit requires a 2-wire, 120V power supply, external of the ventilation unit. As shown in the wiring diagram, a switch relay converts the time clock 120V output to a set of dry contacts. Two

FIGURE 22 Option CN7A, Time Clock Wall Switch and Wiring Connections

Form I-ZQYRA P/N 260414R8, Page 20

Time Clock Wall Switch, Option CN7A (cont’d)

dry contact wires are terminated to controller terminals 3 and 8 which activate the unit when closed.

Install the time clock in a standard, eld-supplied 2 x 4 electrical box to be mounted in

the wall. Provide power to the time clock. Follow the wiring diagram to run the control wires and make the connections. Add the supplied cover plate. For programming, see the instruction sheet provided by the manufacturer. Follow the instructions for programming Leviton Model VPT24-1P.

CO2 Sensor, Option

VOC and CO Sensor, P/N 260192

Keyed, 3-Position Wall Switch, P/N 260230

Cover, P/N 260229 Label, P/N 260231

3 Key Positions

HAND

OFF

AUTO

HAND

AUTO

OFF

Reference

SW2

AUTO & HAND

AUTOSW1

SHIELD

GROUND

SIGNAL

IAQ SENSOR

SHIELD

(OPT. CN7C)

POWER

GROUND

SWITCH

KEYED

= field wiring

CN7B

The CO2 sensor with manual HAND/OFF override will start or stop the unit. The infrared beam technology provides reliable and accurate sensing of the CO2 level (±50 ppm). When in AUTO, the CO2 sensor will activate the unit whenever the carbon

dioxide rises above the factory default value of 1000 ppm (0-2000 ppm range).

The manual key switch will allow the unit to be directly commanded HAND or OFF, bypassing the sensor.

FIGURE 23 - Option CN7B, CO2 Sensor Switch and Wiring Connections

(OPT. CN7B)

SHIELD

= field connection terminal block in the electrical compartment of the ventilation unit

= field wiring

KEYED

SWITCH

AUTO & HAND

SW2

AUTOSW1

SHIELD

Follow the sensor manufacturer-provided instructions for mounting the sensor. Install the switch in a eld-supplied, standard 2 x 4 electrical box to be mounted in the wall.

The sensor is powered from the control module 24VAC transformer. Follow the wiring diagram to run the wires and make the connections. Use shielded 2/c cable for the 0-10V digital signal.

Attach the “HAND/OFF/AUTO” cover plate.

CO2 SENSOR

GROUND

SIGNAL

GROUND

POWER

HAND

OFF

AUTO

Cover, P/N 260229 Label, P/N 260231

CO2 Sensor,

P/N 234820

Keyed, 3-Position Wall Switch, P/N 260230

3 Key Positions

HAND

Reference

OFF

AUTO

Indoor Air Quality (VOC and CO) Sensor, Option CN7C

The volatile organic compound (VOC & CO) sensor with manual HAND/OFF override will start or stop the unit. When in AUTO, the unit will start whenever the air quality in

the space environment exceeds the VOC level of the setpoint.

This option also provides a three-position keyed, manual switch that is wired to the digital input. The three position switch provides “auto”, “hand (manual on)” and “off” modes.

• When the switch is in the AUTO mode, the sensor is powered, the digital start/stop input is open, and the system monitors the VOC levels.

• When the switch is in HAND mode, the contact is closed and the sensor is disabled. When the input is closed, the unit is on.

FIGURE 24 - Option CN7C, Air Quality Sensor Switch and Wiring Connections

• When the switch is in the manual OFF mode, the contact is open and the sensor is disabled. When the input is open, the unit is off

Follow the sensor manufacturer-provided instructions for adjusting the setpoint and for

mounting the sensor. Install the switch in a eld-supplied, standard 2 x 4 electrical box

to be mounted in the wall. The sensor is powered from the control module 24VAC transformer. Follow the unit

wiring diagram to run wires and make connections. Use shielded 2/c cable for the 0-10V digital signal.

Attach the “HAND/OFF/AUTO” cover plate.

Form I-ZQYRA P/N 260414R8, Page 21

COM

RELAY

OUTPUT

COMM

INPUT

POWER

24V IN

N.O.

OCCUPANCY SENSOR

PW-100-24

OPT. CN7D

= field wiring

7.0 Electrical and Wiring (cont’d)

7.5 Control Wiring (eld-installed) (cont’d)

Space Mounted Occupancy Switch, Option CN7D

The space-mounted occupancy switch is well suited for small enclosed spaces with clear line of sight of the occupants. In “Auto-On” mode, the unit will start or stop based on occupancy. The passive infrared sensor features an adjustable 5 to 30 minute sensing window to prevent nuisance switching. The sensor has a manual on/off override feature providing manual on/off control.

Refer to the manufacturer’s instructions for mounting and operation. The sensor

requires a separate power supply, external of the ventilation unit.

Four wires are required from the ventilation unit control panel to the wall sensor. Follow the wiring diagram provided with the ventilation unit to run the wires and make the necessary connections.

FIGURE 25 - Option CN7D, Occupancy Sensor Switch and Wiring Connections

Occupancy Sensor, P/N 260195

Form I-ZQYRA P/N 260414R8, Page 22

Field-Installed, Remote

.91”

(23mm)

(2) Cable Splitter and Signal Booster Modules, P/N 260735

(2) 6-pin Connection Cables, P/N 260175

Front and Side Views with Dimensions

Plug

Screw Terminals

Plug

5 432

1.125” (29mm)

2.75” (70mm)

1.56” (40mm)

3.13” (80mm)

Ø.219 (6mm)

Mounted Unit Display, Option RB5

FIGURE 26 Components of Option RB5, Field-Installed Remote Display

The factory-installed display (Paragraph 8.1) allows complete access to unit test features, schedules, discharge air setpoints, fan control, alarms, and other unit operational setpoints. Option RB5 is a second, remote-mounted display that can be

eld-installed up to 1500 ft (457M) from the unit allowing the same unit access. To

install the remote-mounted display, follow the illustrated instructions below.

Component List

P/N Qty Description 260178 1 Unit Display 260175 2 6-pin Connection Cable

260735 2

Cable Splitter and Signal Booster Module

Unit Display, P/N 260178

FIGURE 27A - Install one of the cable splitter and signal booster modules on the wall of the electrical compartment.

Instructions to eld install Option RB5, Remote Mounted Display

Option RB5 is a remote unit interface display that provides the same access as the unit interface module described in Paragraph 8.1. The remote unit interface module

is shipped separately or loose for eld mounting. Field-supplied 22 AWG to 18 AWG twisted pair wire (EIA 485) and an electrical junction box are required. Follow the

instructions below for setup and installation.

1. Turn power off to the unit (lock the disconnect switch open).

2. Install one Cable Splitter and Signal Booster Module inside the Cabinet a) Remove the electrical compartment access panel. Position one of the cable

splitter/signal booster modules (P/N 260735) on the wall of the electrical compartment as illustrated. Attach it with the screws provided.

Main Controller

Unit Display

Attach cable splitter/cable booster module for Option RB5 to the wall of the control compartment

Control

Compartment

(Control Side)

Form I-ZQYRA P/N 260414R8, Page 23

Remote-Mounted Cable Splitter/ Signal Booster Module

(field-

installed in STEP 3b)

6-pin Wire Connection Cable

(factory-installed, moved in STEP 2b)

6-pin Wire Connection Cable

(field-installed, STEP 2C)

Maximum Length - 1500 ft (457M)

6-Pin Connection on Main Controller

(factory-installed)

6-pin Wire Connection Cable

(field-installed, STEPS 3c, 4a, and 4b)

Field-supplied - 2 sets shielded twisted pair wire, EIA485, 22 AWG to 18 AWG

Shield

Unit-Mounted Display

(factory-installed in the electrical compartment)

Remote-Mounted Display in Option RB5

(field-installed,

STEP 4)

Unit-Mounted Cable Splitter/ Signal Booster

(field-installed in STEP 2a)

7.0 Electrical and

Wiring (cont’d)

7.5 Control Wiring

(eld-installed) (cont’d)

b) In the electrical compartment, nd the unit display and the main controller (See

FIGURE 27A). At the main controller, locate and unplug the 6-pin connection

cable (the cable that connects from the unit display to the controller). Move the disconnected end of the cable to the module installed in Step 2a) and connect it to plug “A” (see illustration below).

c) Install one of the new 6-pin connection cables (P/N 260175), connecting one

end to the main controller and the other to plug “S” (see below) on the module installed in Step 2a).

3. Install the second Cable Splitter/Signal Booster Module at the Remote

FIGURE 27B - Wiring Connections on Cable Splitter in Option RB5

Wiring Connections on Cable Splitter and Signal Booster Module, P/N 260735

5 432

Plug

Screw Terminals

Plug

Location a) Determine the desired location for the remote display unit. It can be located up

to 656 feet (200M) from the unit.

Terminal Screw

Connection

Plug

0 = Earth 1 1 +VRL=30 Vdc 2 2 GND 3 3 Rx-/Tx-

4 4 Rx+/Tx+ 5 (not used) 5 (not used) GND 6 (not used) 6 (not used) +VRL=30 Vdc

FIGURE 28 - Wiring Connections for Installing Option RB5

Pin Telephone

Connection

Meaning

Using eld-supplied 22 AWG to 18 AWG shielded twisted pair wire (EIA 485), run dedicated wires

from that location to the unit. Two sets of twisted pair wire are required -- one for the power and one for communication. The communication wire should be shielded to prevent noise.

On the cable splitter/signal booster module installed in Step 2a), connect the shield to screw terminal 0. Connect the power wires to screw terminals 1 and

2. Connect the communication wires to terminals 3 and 4.

On the cable splitter/signal booster module installed in Step 2a), connect the power wires to screw terminals 1 and 2. Connect the communication wires to terminals 3 and 4.

Form I-ZQYRA P/N 260414R8, Page 24

b) Install the second cable splitter/signal booster

module (P/N 260735) in a eld-supplied junction box to be recessed behind the remote display.

Connect the shield to screw terminal 0. Connect the power wires to terminals 1 and 2 and communication wires to terminals 3 and 4, making sure that power and communication polarity is maintained.

CAUTION: Improper wiring can damage the remote unit interface display as well as the main system controller.

c) Attach the second 6-pin connection cable (P/N

260175) in the kit to plug “A” on the remote cable

splitter/signal booster module.

+ 56 hidden pages

Reznor ZQYRA-8 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual