Broan ZB80ML User manual

ZB80ML nZB110ML
X2 | Multi-Speed Ventilation
Fan with Light, Night Light
and Motion Sensor
INSTALLATION GUIDE
READ AND SAVE THESE
INSTRUCTIONS
Easy installation in both
new construction and retrofit
2
2
3
7
12
13
13
14
Table of Contents
Warnings and Cautions
Typical Installation
New Construction Installation
Retrofit Installation
Operation
Cleaning and Maintenance
Troubleshooting
Service Parts
© 2017 Broan

ZB80ML nZB110ML Installation Guide
Page 2
WARNING
TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR
INJURY TO PERSONS, OBSERVE THE FOLLOWING:
1. Use this unit only in the manner intended by the manufacturer.
If you have questions, contact the manufacturer at the address
or telephone number listed in the warranty.
2. Before servicing or cleaning unit, switch power off at service
panel and lock the service disconnecting means to prevent
power from being switched on accidentally. When the service
disconnecting means cannot be locked, securely fasten a
prominent warning device, such as a tag, to the service panel.
3. Installation work and electrical wiring must be done by a
qualified person(s) in accordance with all applicable codes
and standards, including fire-rated construction codes and
standards.
4. Sufficient air is needed for proper combustion and exhausting
of gases through the flue (chimney) of fuel burning equipment
to prevent backdrafting. Follow the heating equipment
manufacturer’s guideline and safety standards such as those
published by the National Fire Protection Association (NFPA),
and the American Society for Heating, Refrigeration and
Air Conditioning Engineers (ASHRAE), and the local code
authorities.
5. When cutting or drilling into wall or ceiling, do not damage
electrical wiring and other hidden utilities.
6. Ducted fans must always be vented to the outdoors.
7. Use only ON/OFF switch, mechanical timer or relay-switched
control.
8. Acceptable for use over a tub or shower when connected to
a GFCI (Ground Fault Circuit Interrupter) - protected branch
circuit.
9. This unit must be grounded.
Typical Installation
CAUTION
1. For general ventilating use only. Do not use to exhaust
hazardous or explosive materials and vapors.
2. This product is designed for installation in flat ceilings. Sensor
will not function reliably if product is not installed in flat ceiling.
DO NOT MOUNT THIS PRODUCT IN A WALL.
3. To avoid motor bearing damage and noisy and/or unbalanced
impellers, keep drywall spray, construction dust, etc. off power
unit.
4. Please read specification label on product for further
information and requirements.
45° 45°
• Installation is the same for:
• Fits in 2" x 8" ceiling construction.
• Infinitely adjust the fan position
between joists from 14" to 24"
on center.
*Purchase
separately.
INSULATION*
(Place around and
over Fan Housing.)
ROOF CAP*
(with built-in
damper)
FAN
HOUSING
POWER
CABLE*
ROUND
DUCT*
ROUND
ELBOWS*
Seal gaps
around
Housing.
Seal duct
joints with
tape.
OR
Keep duct
runs short.
WALL CAP*
(with built-in
damper)
NOT FOR USE IN A COOKING AREA
Do not install above or inside this area
Floor
Cooking
Equipment
Joists I-Joists Trusses
The ducting from this fan to the outside of the building has a strong effect on the air flow, noise and en-
ergy use of the fan. Use the shortest, straighest duct routing possible for best performance, and avoid
installing the fan with smaller ducts than recommended. Insulation around the ducts can reduce en-
ergy loss and inhibit mold growth. Fans installed with existing ducts may not achieve their rated airflow.
6-inch round rigid metal duct is recommended for best performance.

ZB80ML nZB110ML Installation Guide
Page 3
1
2
3
4
Parts Bag holds
Knockout Plate
and six (6)
screws
Remove
Instruction
Sheet
Remove CFL Bulbs
from protective packaging Punch out Mask from packaging. See Step 6.
New Construction Installation
Tools needed
• Power screwdriver with a Phillips bit
• Phillips screwdriver
• Flathead screwdriver
• Pliers
• Wire insulation stripper
• Wire cutter
Materials needed
• 6" round metal ducting recommended for best performance.
Use of other ducting is acceptable but may impact performance.
• Roof cap or wall cap (built-in damper recommended)
• Tape to seal duct connections
• Electrical wiring and supplies per local code requirements
• 4W (max.) C7-type night light bulb
1Remove Packaging
2Install
Mounting
Frame

ZB80ML nZB110ML Installation Guide
Page 4
3
1
4
2
1
2
3
New Construction Installation
3Snap-in and
Secure Housing
4Attach Duct Connector and Ducting
Position Housing
between joists and
crimp channel on both
sides of Mounting Frame
to lock Housing in place.
Do not crimp Housing.
Screws from Parts Bag
Top and bottom flanges
go outside Housing
Insert tab into slot
inside Housing
Screw from
Parts Bag
6" to 4" Reducer (for Model ZB80ML only)
Tape
Tape
Tape
6" Ducting 4" Ducting
snap!

ZB80ML nZB110ML Installation Guide
Page 5
3
4
1
2
New Construction Installation
5Connect Wires and Install Knockout Plate
• Run 120VAC electrical wiring to the installation location.
• Use proper UL-approved connectors to secure wiring to the Knockout Plate provided in Parts Bag.
• Connect wires as shown in wiring diagram.
• Do not use a dimmer switch to operate the light.
Screw from
Parts Bag
Attach cable clamps to Knockout
Plate. Knockout Plate mounts to
outside of Housing and may be
oriented as desired.
Connect wires
Fan Light
LIGHT
WHT
MANUAL-ON
GRD
WHT
BLK
GRD
WHT
BLK
RED
120 VAC
LINE IN MULTI-FUNCTION
WALL SWITCHES
SENSOR/CONTROL
MASTER
LIGHT
NIGHT
LIGHT
FAN
SENSOR/
CONTROL
BLK
WHT
BLK
BRN
BLU
NIGHT
LIGHT
RED
ORG
WHT
BLK
RED
BLU
RED
14/4
(IF ALL
WALL SWITCH
OPTIONS
ARE USED)
14/3
KNOCKOUT
PLATE
LIGHT RECEPTACLE WIRES
FAN RECEPTACLE
WIRES
MULTI-FUNCTION
WALL CONTROLS
(purchase separately) 120 VAC
LINE IN
MANUAL - ON
MASTER
SWITCH
BOX
LIGHT
NIGHT
LIGHT
SENSOR / CONTROL
BLACK
WHITE
ORANGE
RED
BLUE
GROUND
(green or bare)
BROWN RECEPTACLES
• See OPERATION
section on page 12 for
details.
• MASTER switch
turns fan system
on and shuts it off
for fan cleaning
and maintenance
purposes.
• SENSOR/CONTROL
switch turns motion
control automatic
operation on/off.
• MANUAL-ON switch
directly increases fan
operation to certified
airflow rate.
• MASTER and
SENSOR/CONTROL
switches can be
combined (see page
10).
• Motion sensor can be
wired to control light
(see page 10).
• MASTER switch along
with or separate from
SENSOR/CONTROL
switch may be located
where they are not
easily accessed for
everyday usage;
they may need to be
labeled and located
where they can’t be
turned on without
being seen from fan to
comply with local and
national codes.

ZB80ML nZB110ML Installation Guide
Page 6
2
3
4
2
3
4
1
1
New Construction Installation
6Insert Mask and
Finish Ceiling
7Install Grille
8Install Bulbs
See Page 12 for Operations, Cleaning
and Maintenance, and Troubleshooting.
Mask protects unit
during construction.
Remove before
installing Grille.
Night Light
(purchase
separately)
• Install ceiling material.
• Cut out around Housing.
Plug in
Sensor
Plug in
Light
CAUTION
If the blower was unplugged, power must
be disconnected (see page 2, WARNING
item 2) before inserting motor plugs into
control assembly.
IN ORDER TO PREVENT
MOTOR/CONTROL DAMAGE:

ZB80ML nZB110ML Installation Guide
Page 7
12" (30.5 cm)
1
2
Retrofit Installation
Parts Bag holds
Knockout Plate
and six (6)
screws
Existing ductwork and
wiring left in place
11" (27.9 cm)
parallel with joists
WARNING
Before removing existing fan, switch power off at service panel and lock the service disconnecting
means to prevent power from being switched on accidentally. When the service disconnecting means
cannot be locked, securely fasten a prominent warning device, such as a tag, to the service panel.
Examine the existing wiring to make sure it is not damaged. If any damage is found,
DO NOT CONTINUE INSTALLATION of this product. Contact a qualified person(s) for repair.
Remove
Instruction
Sheet
Remove CFL Bulbs
from protective packaging Punch out Mask from packaging. See Step 12.
1Remove Packaging
2Switch Off Power
4Examine Wiring
3Enlarge Ceiling Opening and Remove Existing Fan
• Ruler
• Pencil
• Drywall saw
• Claw hammer or pry bar
• Utility knife
Materials needed
• Tape to seal duct connections
• Existing rigid duct will require the
addition of a short length of flexible duct
• Electrical wiring and supplies per
local code requirements
• 4W (max.) C7-type night light bulb
Tools needed
• Power screwdriver with a Phillips bit
• Phillips screwdriver
• Flathead screwdriver
• Pliers
• Wire insulation stripper
• Wire cutter

ZB80ML nZB110ML Installation Guide
Page 8
2
1
2
3
45
1
1
2
3
3
Retrofit Installation
5Remove Blower Assembly
6Remove Wiring Panel
7Insert
Mounting
Frame
Both sides
Set aside
Blower
Assembly
Set aside
Wiring Panel
Set aside
screw
Bend up
four tabs
Remove screws from
Mounting Frame
and set aside

ZB80ML nZB110ML Installation Guide
Page 9
1
2
2
1
3
4
Retrofit Installation
Screw from
Parts Bag
Screws set
aside
in Step 7
Pull existing wiring into
Housing as it is inserted
into Mounting Frame
Pull existing
ductwork
into Housing
Insert tab into
slot inside
Housing
10 Attach Ducting and Duct Connector
8Secure
Mounting
Frame
9Snap-in Housing
snap!
6" to 4" Reducer (for Model ZB80ML only)
Tape
Tape
Tape
6" Ducting 4" Ducting

ZB80ML nZB110ML Installation Guide
Page 10
2
1
4
5
6
3
Retrofit Installation
11 Install Knockout Plate, Connect Wires and Reinstall Wiring Panel
Screw from
Parts Bag
Connect wires
Fan
Light
Screw set
aside in
Step 6
• Use proper UL-approved connectors to secure wiring to the Knockout Plate provided in Parts Bag.
• Connect wires as shown in wiring diagram.
• Do not use a dimmer switch to operate the light.
Attach cable
clamps to
Knockout Plate.
Knockout Plate
mounts to inside of
Housing and may
be oriented
as desired.
LIGHT
WHT
BLU
NIGHT
LIGHT
RED
MASTER NIGHT
LIGHT
GRD
WHT
BLK
GRD
120 VAC
LINE IN
STANDARD OR
MULTI-FUNCTION
WALL SWITCHES
WHT
BLK
RED
FAN
SENSOR/
CONTROL
RED
WHT
BLK
ORG
WHT
BLK
BRN
LIGHT
BLK
14/3
14/2
KNOCKOUT
PLATE
LIGHT RECEPTACLE WIRES
FAN RECEPTACLE
WIRES
STANDARD OR
MULTI-FUNCTION
WALL CONTROLS
(purchase separately)
120 VAC
LINE IN
MASTER SWITCH
BOX
LIGHT NIGHT
LIGHT RECEPTACLES
BLACK
WHITE
ORANGE
RED
BLUE
GROUND
(green or bare)
BROWN
• See OPERATION section on page
12 for details.
• MASTER switch turns fan system on
along with motion control and shuts
them off for cleaning and maintenance
purposes.
• MASTER switch may be located where it
is not easily accessed for everyday usage;
it may need to be labeled and located
where it can’t be turned on without being
seen from fan to comply with local and
national codes.

ZB80ML nZB110ML Installation Guide
Page 11
12 3
1
2
2
3
4
2
3
4
1
1
12 3
Retrofit Installation
12 Reinsert and Secure Blower Assembly
13 Install Grille
If ceiling repairs are needed, place Mask in Housing after Blower
Assembly is secured. See New Construction Installation Step 6.
Remove Mask before installing Grille.
Screws from Parts Bag
Plug in
Sensor
Plug in
Light
CAUTION
Power must be disconnected (see page 2, WARNING item 2) before inserting motor plugs into control assembly.
IN ORDER TO PREVENT MOTOR/CONTROL DAMAGE:
LIGHT
WHT
BLU
NIGHT
LIGHT
RED
MASTER NIGHT
LIGHT
GRD
WHT
BLK
GRD
120 VAC
LINE IN
STANDARD OR
MULTI-FUNCTION
WALL SWITCHES
RED
FAN
SENSOR/
CONTROL
RED
WHT
BLK
ORG
WHT
BLK BRN
BLK
14/3
Motion Controlled Light along with Fan

ZB80ML nZB110ML Installation Guide
Page 12
ZB80ML User-adjustable controls
ZB110ML User-adjustable controls
WARNING Before servicing or cleaning unit,
switch power off at service panel and lock the service
disconnecting means to prevent power from being
switched on accidentally. When the service disconnecting
means cannot be locked, securely fasten a prominent
warning device, such as a tag, to the service panel.
Operation
It is normal for this ventilation fan to take approximately 5 seconds
to start running after it is turned on.
Modes
(For reference, wiring diagrams are on pages 5, 10 and 11.)
Continuous ventilation:
1. Turn master wall switch on.
2. Fan operates at user-adjustable airflow rate.
Motion sensing:
1. If master wall switch is not already on, turn it on.
2. Turn sensor/control wall switch on. Some installations may not
have a separate sensor/control wall switch; where it is com-
bined with master wall switch.
3. Fan operates at certified airflow rate and sensor detects motion.
4. When no more motion is detected, fan enters time delay mode.
(See below.)
Manual-on (optional manual-on wall switch must be installed):
1. Turn master and manual-on wall switches on (sensor/control wall
switch can be on or off).
2. Fan operates at certified airflow rate.
3. When manual-on wall switch is turned off, fan enters timed-off
mode. (See below.)
Time Delay:
Fan operates at certified airflow rate until user-adjustable TIME
delay has passed, then fan reverts to user-adjustable airflow rate.
To Set the User-Adjustable Airflow Rate*
Using a small, flat-blade screwdriver, carefully rotate the CFM
adjustment until the arrow points to the desired airflow rate.
To Set the User-Adjustable Time Delay*
Using a small, flat-blade screwdriver, carefully rotate TIME
adjustment until the arrow points to the desired minutes of time
delay.
To Set the User-Adjustable Motion Light Timed-Off**
1. This adjustment should only be made if, during installation, light
was wired to motion sensor along with the fan.
2. Using a small, flat-blade screwdrive, carefully rotate the TIME**
adjustment until the arrow points to the desired minutes light
should remain on after no more motion is detected.
3. Adjust fan Time Delay* for desire time (minutes) fan operates at
certified airflow rate after Timed-off** turns off the light. The total
certified airflow rate fan on-time is the combination of the Time
Delay* and Timed-Off** time settings.
* The user-adjustable controls are located in one corner of the
Fan Housing, behind the Grille.
** Motion Light Timed-Off adjustment is located in a different
corner of Fan Housing, behind the Grille, than the Airflow Rate*
and Time Delay* adjustments.
To Turn Fan OFF
Turn the master switch OFF.
Light Timed-Off control
2
3
4
2
3
4
1
1
12 3
14 Install Bulbs
Night Light
(purchase
separately)

ZB80ML nZB110ML Installation Guide
Page 13
Troubleshooting
Before continuing, turn off power as previously noted in
WARNING on previous page and CAUTION section on this
page.
Symptom: Fan does not run.
• Check for an open fuse or circuit breaker in building’s
service panel.
• Check two (2) plug-in connections for Motor and its
Control are seated firmly in place.
• Check two (2) plug-in connections for Sensor and its
Control are seated firmly in place.
• Check that Blower Wheel spins freely.
Symptom: Motion mode does not operate fan at
certified air flow rate.
• Check two (2) plug-in connections for Sensor and its
Control are seated firmly in place.
Symptom: Fan runs erratically.
• Check that Blower Wheel is firmly attached to Motor shaft
and both spin freely.
Symptom: Fan seems noisy.
• Check that back draft damper in fan’s Duct Connector
pivots freely. Screws used to attach duct to Duct Connector
may prevent damper from opening.
• Check that back draft damper in wall or roof cap pivots
freely. Dampers are sometimes mistakenly painted shut or
obstructed by bird or insect debris.
Symptom: Fan does not properly ventilate room.
• For spot ventilation, turn both master switch and sensor/
control wall switch ON, so sensor/control operates fan at
certified airflow rate.
• For spot ventilation followed by continuous ventilation,
increase the “TIME” setting of user-adjustable time delay.
• For continuous ventilation, increase “CFM” setting of user-
adjustable airflow rate.
Cleaning and Maintenance
To Clean
For quiet and efficient operation, long life and attractive ap-
pearance, remove Grille and vacuum interior of unit with a
dusting brush attachment.
Do not use cleaning sprays, solvents or water on, or near,
the sensor.
Motor is permanently lubricated and never needs oiling.
If motor is making excessive or unusual noises, replace
Control Assembly and Motor.
To Change Bulbs
Refer to Retrofit Installation Step
14 (page 11).
1. Carefully insert a small
flathead screwdriver between
the Grille and Lens, then twist
to remove Lens.
2. Purchase two (2) 18W (max.)
type GU24 fluorescent lamps
with Maximum Overall Length
(MOL) of 3.9” (100 mm).
Purchase a 4W (max.) C7-
type incandescent night light bulb.
3. Insert bulbs into their sockets. Replace Lens.
M.O.L.
3.9" (100 mm)
CAUTION
IN ORDER TO PREVENT MOTOR/CONTROL DAMAGE:
DO NOT remove motor plug to stop spinning motor.
Power must be disconnected (see WARNING on previous
page) before motor plug is removed or inserted into control
assembly.

ZB80ML nZB110ML Installation Guide
Page 14
8
7
11
1
3
9
10
12
14
2
13
4
6
5
Service Parts
Order replacement
parts by Part No.,
not by Key No.
Key No. Part No. Description
1 97018349 Mounting Frame
2 97018721 Knockout Plate & Screws
3 97018382 Housing
4 97018474 Wiring Panel/Harness Assembly
5 97019369 Motion Control Assembly
6 97020846 Control Assembly & Motor (ZB80ML)
97020845 Control Assembly & Motor (ZB110ML)
7 97018331 Duct Connector - 6"
8 99111513 6” to 4” Reducer (ZB80ML only)
9 99020301 Blower Wheel
10 97019371 Scroll Assembly (ZB80ML)
97018768 Scroll Assembly (ZB110ML)
11 97018776 Grille Assembly (includes 12, 13)
12 99140208 Grille Spring (2 req’d)
13 99111542 Lens
14 99271381 Bulb, GU24 18W 3500K Fluorescent (2 req’d)
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