Johnson Controls ZF078 User manual

R-410A
ZF SERIES W/SIMPLICITY SE
6-1/2 - 12-1/2 Ton
60 Hertz
1183755-YIM-A-1014
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preceding Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condensate Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Optional Variable Air Volume (VAV) . . . . . . . . . . . . . . . . . . . 35
Optional Hot Gas Bypass (HGBP) . . . . . . . . . . . . . . . . . . . . 37
Economizer Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . 37
Dual Enthalpy Changeover. . . . . . . . . . . . . . . . . . . . . . . . . . 37
Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Free Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cooling Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . 53
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Electric Heating Sequence Of Operations . . . . . . . . . . . . . . 56
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . 56
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . 57
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . 58
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control Board Navigation Components. . . . . . . . . . . . . . . . . . . 62
Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic
Unit Control Board Navigation Examples:. . . . . . . . . . . . . . . 63
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TABLE OF CONTENTS
1 ZF078-150 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZF078-150 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . 9
4 ZF078-150 Unit Physical Dimensions . . . . . . . . . . . . . . . . 11
5 ZF078-150 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 ZF078-150 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . 31
11 Gas Pipe Sizing - Capacity of Pipe. . . . . . . . . . . . . . . . . . . 32
12 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . 33
13 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . 39
14 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
15 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 44
16 Airflow Performance - Side Duct Application . . . . . . . . . . . 46
17 Airflow Performance - Bottom Duct Application . . . . . . . . . 48
18 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
19 Indoor Blower Specifications . . . . . . . . . . . . . . . . . . . . . . . 50
20 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . 50
21 Motor Sheave Datum Diameters . . . . . . . . . . . . . . . . . . . . 52
22 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . 53
23 Electric Heat Limit Setting 50” Cabinet . . . . . . . . . . . . . . . . 57
24 Electric Heat Limit Setting 42” Cabinet . . . . . . . . . . . . . . . . 57
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . 57
26 Gas Heat Limit Control Settings . . . . . . . . . . . . . . . . . . . . . 59
27 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . 59
28 Gas Rate Cubic Feet Per Hour. . . . . . . . . . . . . . . . . . . . . . 61
29 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
30 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . 65
31 Ignition Control Flash Codes . . . . . . . . . . . . . . . . . . . . . . . 70
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Predator®Component Location (ZF120 Shown) . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZF078-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZF150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 ZF078-150 Unit Bottom Duct Openings . . . . . . . . . . . . . . 12
11 ZF078-150 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . 13
12 ZF078-120 Unit Side Duct Openings . . . . . . . . . . . . . . . . 13
13 ZF150 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . . . 14
14 ZF078-150 Unit Left Duct Opening . . . . . . . . . . . . . . . . . . 14
15 ZF078-150 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
16 ZF078-150 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . 15
17 Side Panels With Hole Plugs . . . . . . . . . . . . . . . . . . . . . . . 16
18 Return Downflow Plenum With Panel . . . . . . . . . . . . . . . . 16
19 Discharge Panel In Place . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 Save Side Panels For Economizer Hood Tops . . . . . . . . . 16
21 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
22 Field Wiring Disconnect - Cooling Unit With/Without Electric
Heat and All Units With VFD Option . . . . . . . . . . . . . . . . . 18
23 Field Wiring Disconnect - Cooling Unit With Gas Heat Without
VFD Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
24 Typical Electronic Thermostat Field Wiring . . . . . . . . . . . . 20
25 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
26 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 32
27 Simplified VFD Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
28 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . 39
29 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
30 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . 44
31 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
32 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
33 Typical Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

1183755-YIM-A-1014
2Johnson Controls Unitary Products
General
York® Predator®units are single package air conditioners with
optional gas heating designed for outdoor installation on a
rooftop or slab and for non-residential use. These units can be
equipped with factory or field installed electric heaters for
heating applications.
These units are completely assembled on rigid, permanently
attached base rails. All piping, refrigerant charge, and electrical
wiring is factory installed and tested. The units require electric
power, gas supply (where applicable), and duct connections.
The electric heaters have nickel-chrome elements and utilize
single-point power connection.
Safety Considerations
This is a safety alert symbol. When you see this symbol
on labels or in manuals, be alert to the potential for
personal injury.
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal injury.
Understand and pay particular attention the signal words
DANGER, WARNING or CAUTION.
DANGER indicates an imminently hazardous situation, which,
if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation, which,
if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if
not avoided may result in minor or moderate injury.It is also
used to alert against unsafe practices and hazards involving
only property damage.
Due to system pressure, moving parts, and electrical
components, installation and servicing of air conditioning
equipment can be hazardous. Only qualified, trained service
personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions
of cleaning coils and filters and replacing filters.
Observe all precautions in the literature, labels, and tags
accompanying the equipment whenever working on air
conditioning equipment. Be sure to follow all other applicable
safety precautions and codes including ANSI Z223.1 or CSA-
B149.1- latest edition.
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage. Improper installation, adjustment,
alteration, service or maintenance can cause injury or
property damage. Refer to this manual for assistance or
for additional information, consult a qualified contractor,
installer or service agency.
This product must be installed in strict compliance with
the installation instructions and any applicable local,
state and national codes including, but not limited to
building, electrical, and mechanical codes.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury. Improper installation,
adjustment, alteration, service or maintenance can
cause injury or property damage. Refer to this manual.
For assistance or additional information consult a
qualified installer, service agency or the gas supplier.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system. Gage sets, hoses, refrigerant
containers and recovery systems must be designed to
handle R-410A. If you are unsure, consult the equipment
manufacturer. Failure to use R-410A compatible servicing
equipment may result in property damage or injury.
If the information in this manual is not followed exactly, a
fire or explosion may result causing property damage,
personal injury or loss of life.
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
a. Do not try to light any appliance.
b. Do not touch any electrical switch; do not use any
phone in your building.
c. Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
d. If you cannot reach your gas supplier, call the fire
department.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.

1183755-YIM-A-1014
Johnson Controls Unitary Products 3
Wear safety glasses and work gloves. Use quenching cloth and
have a fire extinguisher available during brazing operations.
Inspection
As soon as a unit is received, it should be inspected for possible
damage during transit. If damage is evident, the extent of the
damage should be noted on the carrier’s freight bill. A separate
request for inspection by the carrier’s agent should be made in
writing.
Reference
Additional information is available in the following reference
forms:
• Technical Guide - ZF078-150, 528194
• General Installation - ZF078-150, 1183755
• SSE Control Quick Start Guide 1136326
• Economizer Accessory -
Downflow Factory Installed
Downflow Field Installed
Horizontal Field Installed
• Motorized Outdoor Air Damper
• Manual Outdoor Air Damper (0-100%)
• Manual Outdoor Air Damper (0-35%)
• Gas Heat Propane Conversion Kit
• Gas Heat High Altitude Kit (Natural Gas)
• Gas Heat High Altitude Kit (Propane)
• –60F Gas Heat Kit
• Electric Heater Accessory 50” cabinet
• Electric Heater Accessory 42” cabinet
Renewal Parts
Contact your local York® parts distribution center for authorized
replacement parts.
Approvals
Design certified by CSA as follows:
1. For use as a cooling only unit, cooling unit with
supplemental electric heat or a forced air furnace.
2. For outdoor installation only.
3. For installation on combustible material and may be
installed directly on combustible flooring or, in the U.S., on
wood flooring or Class A, Class B or Class C roof covering
materials.
4. For use with natural gas (convertible to LP with kit).
This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state and national codes including, but not limited
to, building, electrical, and mechanical codes.
The furnace and its individual shut-off valve must be
disconnected from the gas supply piping system during
any pressure testing at pressures in excess of 1/2 PSIG.
Pressures greater than 1/2 PSIG will cause gas valve
damage resulting in a hazardous condition. If it is
subjected to a pressure greater than 1/2 PSIG, the gas
valve must be replaced.
The furnace must be isolated from the gas supply piping
system by closing its individual manual shut-off valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state, and national codes including, but not limited
to, building, electrical, and mechanical codes.
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.

1183755-YIM-A-1014
4Johnson Controls Unitary Products
Nomenclature
Z F 090 N10 A 2 A AA 7 0 1 2 4 A
Product Category
Z = A/C, Single Pkg., R-410A
C00 = Cooling Only. No heat installed
Heat Type and Nominal Heat Capacity
N10 = 100 MBH Output Aluminized Steel
N15 = 150 MBH Output Aluminized Steel
N20 = 200 MBH Output Aluminized Steel
S10 = 100 MBH Output Stainless Steel
S15 = 150 MBH Output Stainless Steel
S20 = 200 MBH Output Stainless Steel
E09 = 9 KW
E18 = 18 KW
E24 = 24 KW
E36 = 36 KW
E54 = 54 KW
Gas Heat Options
Electric Heat Options
078 = 6.5 Ton
Nominal Cooling Capacity
090 = 7.5 Ton
102 = 8.5 Ton
120 = 10.0 Ton
150 = 12.5 Ton
Product Identifier
F = 11.2 + EER A/C
Voltage
2 = 208/230-3-60
4 = 460-3-60
5 = 575-3-60
Product Style
A = Style A
B = Style B
C = Style C
A = No Options Installed
Installation Options
B = Option 1
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
Options
6.5-12.5 Ton York
®
Model Number Nomenclature
Product Generation
7 = Seventh Generation
SS Drain Pan
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
CPC Controller, DFS, APS
Honeywell Controller, DFS, APS
Novar Controller, DFS, APS
2" Pleated Filters, MERV 7
BAS Ready Economizer (2-10 V.D.C. Actuator without a Controller)
Shipping Bag
York Commercial Comfort System (YCCS) Rtu Controller
Hot Gas Bypass (Standard on VAV, Optional on CV)
Variable Air Volume, VFD (not available with factory installed BAS options)
Variable Air Volume, VFD Ready (for customer-provided, field-installed drive)
Variable Air Volume, VFD and Manual Bypass
(not available with factory installed BAS options)
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
AA = None
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
Additional Options
RC = Coil Guard, Shipping Bag & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
4" Pleated Filters, MERV 13
EA = E-Coat Condenser Coil
EJ = E-Coat Evaporator Coil
ES = E-Coat Cond & Evap Coils
IntelliSpeed with VFD
IntelliSpeed, VFD and Manual Bypass
IntelliSpeed, VFD Ready (for customer-provided, field-installed drive)
Airow
Simplicity®Smart Equipment w/Comm Card (BACnet, N2, Mod-Bus)
A = Std. Motor
D = Std. Motor/Motorized Damper (Downow Only)
H = Std Motor/Low Leak Econ/Barometric Relief (Downow
& Horizontal End Return Only)
J = Std Motor/Low Leak Econ/Power Exhaust (Downow
& Horizontal End Return Only)
N = Hi Static
R = Hi Static/Motorized Damper (Downow Only)
V = Hi Static Mtr/Low Leak Econ/Barometric Relief
(Downow & Horizontal End Return Only)
W = Hi Static Mtr/Low Leak Econ/Power Exhaust
(Downow & Horizontal End Return Only)

1183755-YIM-A-1014
Johnson Controls Unitary Products 5
Installation
Installation Safety Information
Read these instructions before continuing this appliance
installation. This is an outdoor combination heating and cooling
unit. The installer must assure that these instructions are made
available to the consumer and with instructions to retain them
for future reference.
1. Refer to the unit rating plate for the approved type of gas
for this product.
2. Install this unit only in a location and position as specified
on Page 7 of these instructions.
3. Never test for gas leaks with an open flame. Use
commercially available soap solution made specifically for
the detection of leaks when checking all connections, as
specified on Pages 5, 33, 34 and 60 of these instructions.
4. Always install furnace to operate within the furnace's
intended temperature-rise range with the duct system and
within the allowable external static pressure range, as
specified on the unit name/rating plate, specified on
Page 62 of these instructions.
5. This equipment is not to be used for temporary heating of
buildings or structures under construction.
Preceding Installation
1. Remove the two screws holding the brackets in the front,
rear and compressor side fork-lift slots.
Figure 1: Unit Shipping Bracket
2. Turn each bracket toward the ground and the protective
plywood covering will drop to the ground.
3. Remove the condenser coil external protective covering
prior to operation.
4. Remove the toolless doorknobs and instruction packet
prior to installation.
Figure 2: Condenser Covering
Figure 3: Compressor Section
5. If a factory option convenience outlet is installed, the
weatherproof outlet cover must be field installed. The cover
shall be located behind the filter access panel. To install
the cover, remove the shipping label covering the
convenience outlet, follow the instructions on the back of
the weatherproof cover box, and attach the cover to the
unit using the (4) screws provided.
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warning exactly could result
in serious injury, death or property damage.
Never test for gas leaks with an open flame. use a
commercially available soap solution made specifically
for the detection of leaks to check all connections. A fire
or explosion may result causing property damage,
personal injury or loss of life.
Bracket
Screws Turn down
208/230-3-60 and 380/415-3-50 units with factory
installed Powered Convenience Outlet Option are wired
for 230v and 415v power supply respectively. Change
Tap on transformer for 208-3-60 or 380-3-50 operation.
See unit wiring diagram.
Condenser
Coil External
Protective
Covering
Barometric
Relief Hood
in Shipping
Location
(if Included)
Toolless
Doorknobs
Installation
Instruction
Packet

1183755-YIM-A-1014
6Johnson Controls Unitary Products
Limitations
These units must be installed in accordance with the following:
In U.S.A.:
1. National Electrical Code, ANSI/NFPA No. 70 - Latest
Edition
2. National Fuel Gas Code, ANSI Z223.1 - Latest Edition
3. Gas-Fired Central Furnace Standard, ANSI Z21.47a. -
Latest Edition
4. Local building codes, and
5. Local gas utility requirements
In Canada:
1. Canadian Electrical Code, CSA C22.1
2. Installation Codes, CSA - B149.1.
3. Local plumbing and waste water codes, and
4. Other applicable local codes.
Refer to unit application data found in this document.
After installation, gas fired units must be adjusted to obtain a
temperature rise within the range specified on the unit rating
plate.
If components are to be added to a unit to meet local codes,
they are to be installed at the dealer’s and/or customer’s
expense.
Size of unit for proposed installation should be based on heat
loss/heat gain calculation made according to the methods of Air
Conditioning Contractors of America (ACCA).
This furnace is not to be used for temporary heating of buildings
or structures under construction.
Figure 4: Predator®Component Location (ZF120 Shown)
The Simplicity ® SE control board used in this product
will effectively operate the cooling system down to 0°F
when this product is applied in a comfort cooling
application for people. An economizer is typically
included in this type of application. When applying this
product for process cooling applications (computer
rooms, switchgear, etc.), please reference applications
bulletin AE-011-07 or call the applications department
for Unitary Products @ 1-877-UPG-SERV for guidance.
Additional accessories may be needed for stable
operation at temperatures below 30° F.
Roof curbs in eight- and
fourteen-inch heights. Roof
curbs for transitioning from
York Sunline™ footprint to
the ZF Series footprints
are also available (field
installed accessory)
Base rails w/forklift
slots (three sides)
and lifting holes
Compressor #2
access (high-
efficiency
compressor
w/crankcase
heater)
Dual stage
cooling for
maximum
comfort
Second model
nameplate
inside hinged
access panel
Terminal block for
hi-voltage connection
Simplicity® SE control board
w/screw connector for T-stat
wiring and network connections
Disconnect location
(optional disconnect switch)
Filter Access
(2” or 4” filter options) Filter drier
(solid core)
Slide-out motor and
blower assembly for
easy adjustment
and service
Belt-drive
blower motor
Power ventor motor
20-guage aluminized
steel tubular heat
exchanger for long
life (stainless steel
option)
Two-stage gas
heating to maintain
warm, comfortable
temperature
Intelligent control
board for safe and
efficient operation
Compressor #1 access
(high-efficiency compressor
w/crankcase heater)
Toolless
door latch
Side entry power
and control wiring
knockouts
VFD Location (optional)
Slide-out drain pan
with 3/4” NPT,
female connection
ZF Series utilize Micro-Channel
Aluminum Tube/Aluminum Fin
Condenser

1183755-YIM-A-1014
Johnson Controls Unitary Products 7
Location
Use the following guidelines to select a suitable location for
these units:
1. Unit is designed for outdoor installation only.
2. Condenser coils must have an unlimited supply of air.
Where a choice of location is possible, position the unit on
either north or east side of building.
3. Suitable for mounting on roof curb.
4. For ground level installation, use a level concrete slab with
a minimum thickness of 4 inches. The length and width
should be at least 6 inches greater than the unit base rails.
Do not tie slab to the building foundation.
5. Roof structures must be able to support the weight of the
unit and its options/accessories. Unit must be installed on a
solid, level roof curb or appropriate angle iron frame.
6. Maintain level tolerance to 1/2” across the entire width and
length of unit.
Clearances
All units require particular clearances for proper operation and
service. Installer must make provisions for adequate
combustion and ventilation air in accordance with section 5.3 of
Air for Combustion and Ventilation of the National Fuel Gas
Code, ANSI Z223.1 – Latest Edition (in U.S.A.), or Sections 7.2,
7.3, or 7.4 of Gas Installation Codes, CSA-B149.1 (in Canada) -
Latest Edition, and/or applicable provisions of the local building
codes. Refer to Table 5 for clearances required for combustible
construction, servicing, and proper unit operation.
Rigging And Handling
Exercise care when moving the unit. Do not remove any
packaging until the unit is near the place of installation. Rig the
unit by attaching chain or cable slings to the lifting holes
provided in the base rails. Spreader bars, whose length
exceeds the largest dimension across the unit, MUST be used
across the top of the unit.
Table 1: ZF078-150 Unit Limitations
Size
(Tons) Model Unit Voltage
Unit Limitations
Applied Voltage Outdoor DB Temp
Min Max Max (°F)
078
(6.5) ZF
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
090
(7.5) ZF
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
102
(8.5) ZF
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
120
(10) ZF
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
150
(12.5) ZF
208/230-3-60 187 252 125
460-3-60 432 504 125
575-3-60 540 630 125
Excessive exposure of this furnace to contaminated
combustion air may result in equipment damage or
personal injury. Typical contaminates include:
permanent wave solution, chlorinated waxes and
cleaners, chlorine based swimming pool chemicals,
water softening chemicals, carbon tetrachloride,
Halogen type refrigerants, cleaning solvents (e.g.
perchloroethylene), printing inks, paint removers,
varnishes, hydrochloric acid, cements and glues,
antistatic fabric softeners for clothes dryers, masonry
acid washing materials.
Do not permit overhanging structures or shrubs to
obstruct condenser air discharge outlet, combustion air
inlet or vent outlets.
If a unit is to be installed on a roof curb other than a
Yor k®roof curb, gasketing must be applied to all
surfaces that come in contact with the unit underside.

1183755-YIM-A-1014
8Johnson Controls Unitary Products
Units may be moved or lifted with a forklift. Slotted openings in
the base rails are provided for this purpose.
LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES.
Figure 5: Unit 4 Point Load Weight
Figure 6: Unit 6 Point Load Weight
Figure 7: Center of Gravity
Before lifting, make sure the unit weight is distributed
equally on the rigging cables so it will lift evenly.
All panels must be secured in place when the unit is
lifted.
The condenser coils should be protected from rigging
cable damage with plywood or other suitable material.
D
A
CB
LEFT
FRONT
D
A
C
B
E
F
LEFT
FRONT
XY
LEFT FRONT
Table 2: Weights and Dimensions
Size
(Tons) Model Weight (lbs.) Center of Gravity 4 Point Load Location (lbs.) 6 Point Load Location (lbs.)
ShippingOperatingX Y ABCDABCDEF
078
(6.5) ZF 865 860 38 24 200 149 218 292 140 114 95 138 167 205
090
(7.5) ZF 885 860 38 24 205 153 223 299 144 117 97 142 171 210
102
(8.5) ZF 1012 1007 38 24 235 175 255 342 164 134 111 162 195 240
120
(10) ZF 1065 1060 38 24 247 184 268 360 173 141 117 171 206 253
150
(12.5) ZF 1258 1253 47 25 251 280 381 341 164 176 190 259 240 223

1183755-YIM-A-1014
Johnson Controls Unitary Products 9
Figure 8: ZF078-120
Table 3: ZF078-150 Unit Accessory Weights
Unit Accessory Weight (lbs.)
Shipping Operating
Economizer 90 85
Power Exhaust 40 35
Electric Heat1
1. Weight given is for the maximum heater size available
(54KW).
49 49
Gas Heat2
2. Weight given is for the maximum number of tube heat
exchangers available (8 tube).
110 110
Variable Frequency Drive3
3. Weight includes mounting hardware, controls and manual
bypass option.
30 30
LEFT
A
59.00
C
D
E
F
4.19
27.31
89.00
21.19
11.38
15.38
59.00
15.38
29.69
15.25
FRONT
SEE DETAIL B
FOR DRAIN LOCATION
SEE DETAIL A FOR GAS INLET
B
2X Ø 24.38

1183755-YIM-A-1014
10 Johnson Controls Unitary Products
Figure 9: ZF150
LEFT
59.00
A
C
D
E
F
4.19
27.31
89.00
21.19
FRONT
SEE DETAIL B
FOR DRAIN LOCATION
11.38
SEE DETAIL A FOR GAS INLET
B
29.95 30.11
14.92
58.09
14.92
14.92
45.64
4X Ø 24.38

1183755-YIM-A-1014
Johnson Controls Unitary Products 11
Detail A
Detail B
Table 4: ZF078-150 Unit Physical Dimensions
Unit Model Number Dimension (in.)
ABCDEF
ZF078 42 89 22 1/8 18 3/16 15 3/16 6 3/16
ZF090 42 89 22 1/8 18 3/16 15 3/16 6 3/16
ZF102 50 3/4 89 30 3/16 24 3/16 17 3/16 6 3/16
ZF120 50 3/4 89 30 3/16 24 3/16 17 3/16 6 3/16
ZF150 50 3/4 119 1/2 30 3/16 24 3/16 17 3/16 6 3/16
42” CABINET
Ø 3.126
Ø 2.000
3.184
4.727
7.705
14.594
Gas Pipe Inlet
Gas Exhaust Vent
50 3/4” CABINET
Ø 3.126
Ø 2.000
3.184
4.737
7.715
17.541
Gas Pipe Inlet
Gas Exhaust Vent
5-3/8
3/4” FPT
Table 5: ZF078-150 Unit Clearances
Direction Distance (in.) Direction Distance (in.)
Top1
1. Units must be installed outdoors. Over hanging structure or shrubs should not obscure condenser air discharge outlet.
72 Right 12
Front 36 Left 36
Rear 36 Bottom2
2. Units may be installed on combustable floors made from wood or class A, B or C roof covering materials.
0

1183755-YIM-A-1014
12 Johnson Controls Unitary Products
TOP VIEW
Figure 10: ZF078-150 Unit Bottom Duct Openings
Bottom condensate drain
Bottom gas
supply entry
FRONT
RETURN
AIR
SUPPLY
AIR
RIGHT
LEFT
20 1/8 19 1/8 17 1/8
6 13/16
6 13/16
32 11/16
14 1/2
16 3/8
18 1/16
25 9/16
12 5/16
27 1/2 24
21
18
89
Ø 2.469
3X Ø 0.875
Bottom power, control
and convenience outlet
wiring entry

1183755-YIM-A-1014
Johnson Controls Unitary Products 13
Figure 11: ZF078-150 Unit Electrical Entry
Figure 12: ZF078-120 Unit Side Duct Openings
Disconnect Swith Cover
Power Entry Ø 2-1/2
Control Entry Ø 7/8
Power Entry Ø 2-1/2
Convenience Outlet Cover
Convenience Outlet
Power Entry Ø 7/8 FRONT
Dot Plugs
5-5/32
31-11/16
2-31/32
18-1/4
Return
Air
Supply Air
A
B
C
D

1183755-YIM-A-1014
14 Johnson Controls Unitary Products
Figure 13: ZF150 Unit Side Duct Openings
Figure 14: ZF078-150 Unit Left Duct Opening
Dot Plugs
2-7/8
5-5/32
D
C31-5/8
18-1/4
B
A
Table 6: Side Duct Dimensions
Unit Model Number Dimension (in.)
ABCD
ZF078 27 3/4 12 1/16 27 1/2 16
ZF090 27 3/4 12 1/16 27 1/2 16
ZF102 28 1/4 18 1/16 28 1/4 18 1/4
ZF120 28 1/4 18 1/16 28 1/4 18 1/4
ZF150 28 1/4 18 1/16 28 1/4 18 1/4
4-5/16
30-3/8

1183755-YIM-A-1014
Johnson Controls Unitary Products 15
Figure 15: ZF078-150 Roof Curb
Figure 16: ZF078-150 Transition Roof Curb
Ductwork
Ductwork should be designed and sized according to the
methods in Manual D of the Air Conditioning Contractors of
America (ACCA) or as recommended by any other recognized
authority such as ASHRAE or SMACNA.
A closed return duct system should be used. This will not
preclude use of economizers or outdoor fresh air intake. The
supply and return air duct connections at the unit should be
made with flexible joints to minimize noise.
The supply and return air duct systems should be designed for
the CFM and static pressure requirements of the job. They
should NOT be sized to match the dimensions of the duct
connections on the unit.
Refer to Figure 10 for bottom air duct openings. Refer to
Figures 12, 13 and Table 6 for side air duct openings.
8 or 14
50-1/2
30
20
20
80-5/8
6
2TYP.
INSULATED DECK UNDER
COMPRESSOR SECTION
INSULATED DECK UNDER
CONDENSER SECTION
FRONT
RIGHT
SUPPLY
RETURN
76-5/8
94
50-1/2 30-1/2
64-1/4
59-1/4
10
23 4
26 80-5/8
2TYP
FRONT RIGHT
SUPPLY
RETURN

1183755-YIM-A-1014
16 Johnson Controls Unitary Products
Duct Covers
Units are shipped with the side duct openings covered and a
covering over the bottom of the unit. For bottom duct
application, no duct cover changes are necessary. For side
duct application, remove the side duct covers and install over
the bottom duct openings. The panels removed from the side
duct connections are designed to be reused by securing each
panel to its respective down flow opening. But keep in mind that
the supply panel is installed with the painted surface UP, facing
the heat exchanger, while the return panel is installed with the
painted surface DOWN, facing the down flow duct opening. The
supply panel is secured with the bracket (already in place from
the factory) and two screws. It’s a snug fit for the panel when
sliding it between the heat exchanger and unit bottom, but there
is room. The return panel is secured with four screws.
Figure 17: Side Panels With Hole Plugs
NOTE: Orientation. Panel is “insulation” side up.
Figure 18: Return Downflow Plenum With Panel
Figure 19: Discharge Panel In Place
Side Panels
Units are shipped with side panels to cover the area where an
economizer or motorized damper may be installed. These
panels must be saved and used as tops for the Economizer rain
hoods (See Figure 19)
Figure 20: Save Side Panels For Economizer Hood Tops
Condensate Drain
The side condensate drain is reversible and maybe re-oriented to
the rear of the cabinet to facilitate condensate piping. A
condensate drain connection is available through the base pan
for piping inside the roof curb. Trap the connection per Figure 21.
The trap and drain lines should be protected from freezing.
Plumbing must conform to local codes. Use a sealing compound
on male pipe threads. Install condensate drain line from the 3/4
inch NPT female connection on the unit to an open drain.
When fastening ductwork to side duct flanges on unit,
insert screws through duct flanges only. DO NOT insert
screws through casing. Outdoor ductwork must be
insulated and water-proofed.

1183755-YIM-A-1014
Johnson Controls Unitary Products 17
Figure 21: Condensate Drain
Compressors
The scroll compressor used in this product is specifically
designed to operate with R-410A Refrigerant and cannot be
interchanged.
The compressor also uses a polyolester (POE oil), Mobil 3MA
POE. This oil is extremely hygroscopic, meaning it absorbs water
readily. POE oil can absorb 15 times as much water as other oils
designed for HCFC and CFC refrigerants. Take all necessary
precautions to avoid exposure of the oil to the atmosphere.
POE (polyolester) compressor lubricants are known to cause
long term damage to some synthetic roofing materials.
Procedures which risk oil leakage include, but are not limited to,
compressor replacement, repairing refrigerant leaks, replacing
refrigerant components such as filter drier, pressure switch,
metering device or coil.
Units are shipped with compressor mountings which are
factory-adjusted and ready for operation.
Filters
Two-inch filters are supplied with each unit. One-inch filters may
be used with no modification to the filter racks. Filters must
always be installed ahead of evaporator coil and must be kept
clean or replaced with same size and type. Dirty filters reduce
the capacity of the unit and result in frosted coils or safety
shutdown. Refer to physical data tables, for the number and
size of filters needed for the unit. The unit should not be
operated without filters properly installed.
Power And Control Wiring
Field wiring to the unit, fuses, and disconnects must conform to
provisions of National Electrical Code (NEC), ANSI/NFPA No.
70 – Latest Edition (in U.S.A.), current Canadian Electrical
Code C221, and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC as
specified above and/or local codes.
Voltage tolerances which must be maintained at the
compressor terminals during starting and running conditions are
indicated on the unit Rating Plate and Table 1.
The internal wiring harnesses furnished with this unit are an
integral part of the design certified unit. Field alteration to
comply with electrical codes should not be required. If any of
the wire supplied with the unit must be replaced, replacement
wire must be of the type shown on the wiring diagram and the
same minimum gauge as the replaced wire.
A disconnect must be utilized for these units. Factory installed
disconnects are available. If installing a disconnect (field
supplied or York International®supplied accessory), refer to Figure 4 for the recommended mounting location.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.
Do not leave the system open to the atmosphere. Unit
damage could occur due to moisture being absorbed by
the POE oil in the system. This type of oil is highly
susceptible to moisture absorption
Exposure, even if immediately cleaned up, may cause
embrittlement (leading to cracking) to occur in one year
or more. When performing any service that may risk
exposure of compressor oil to the roof, take precautions
to protect roofing.
3" Minimum
Do not loosen compressor mounting bolts.
Make sure that panel latches are properly positioned on
the unit to maintain an airtight seal.
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and 415v power
supply respectively. Change tap on transformer for 208-
3-60 or 380-3-50 operation. See unit wiring diagram.

1183755-YIM-A-1014
18 Johnson Controls Unitary Products
NOTE: Since not all local codes allow the mounting of a
disconnect on the unit, please confirm compliance with
local code before mounting a disconnect on the unit.
Electrical line must be sized properly to carry the load. USE
COPPER CONDUCTORS ONLY. Each unit must be wired with
a separate branch circuit fed directly from the meter panel and
properly fused.
Refer to Figures 22, 23, 24 and 24 for typical field wiring and to
the appropriate unit wiring diagram mounted inside control
doors for control circuit and power wiring information.
Power Wiring Detail
Units are factory wired for the voltage shown on the unit
nameplate. Refer to Electrical Data Table 8 to size power
wiring, fuses, and disconnect switch.
Power wiring is brought into the unit through the side of the unit
or the basepan inside the curb.
Figure 22: Field Wiring Disconnect - Cooling Unit With/Without Electric Heat and All Units With VFD Option
Avoid damage to internal components if drilling holes for
disconnect mounting.
When connecting electrical power and control wiring to
the unit, water-proof connectors must be used so that
water or moisture cannot be drawn into the unit during
normal operation. The above water-proofing conditions
will also apply when installing a field supplied disconnect
switch.
THREE
PHASE
POWER
SUPPLY
FACTORY OR FIELD
SUPPLIED DISCONNECT
GROUND
LUG
TERMINAL BLOCK TB1

1183755-YIM-A-1014
Johnson Controls Unitary Products 19
Figure 23: Field Wiring Disconnect - Cooling Unit With Gas Heat Without VFD Option
L1
T1
L2
T2 T3
L3
THREE
PHASE
POWER
SUPPLY
FACTORY OR FIELD
SUPPLIED DISCONNECT
GROUND
LUG
CONTACTOR 1M

1183755-YIM-A-1014
20 Johnson Controls Unitary Products
Thermostat Wiring (Not applicable to units with VFD)
The thermostat should be located on an inside wall
approximately 56 inch above the floor where it will not be
subject to drafts, sun exposure or heat from electrical fixtures or
appliances. Follow the manufacturer's instructions enclosed
with thermostat for general installation procedure. Seven (7)
color-coded, insulated wires should be used to connect the
thermostat to the unit. Refer to Table 7 for control wire sizing
and maximum length.
Figure 24: Typical Electronic Thermostat Field Wiring
Table 7: Control Wire Sizes
Wire Size Maximum Length1
1. From the unit to the thermostat and back to the unit.
18 AWG 150 Feet
OCC
C
RC
G
Y2
Y1
W2
W1
X
R
THERMOSTAT
TERMINALS
CONTROL
TERMINAL
BLOCK
TERMINALS ON A
LIMITED NUMBER
OF THERMOSTATS
1
4
3
1
2
4
Second stageŚĞĂƟŶŐŶot required on single stage heĂƟŶg units.
Jumper is required if there is no Smoke Detector circuit.
Jumper is required for any coŵďŝŶĂƟŽŶ of R, RC, or RH.
5
5
OCC is an output from the thermostat to indicate the Occupied ĐŽŶĚŝƟon.
X is an input to the thermostat to display Error Status condiƟons.
3
W2
Y1
G
OCC
Y2
X
R
SD-24
C
W1
2
24V
C
24 VAC
Class 2
SD-24
Jumper Located on Harness
Smoke
Detector
SD-R
24V Output
R
(If No Smoke Detector) (If Smoke Detector Is Used)
208/230-3-60 and 380/415-3-50 units control
transformers are factory wired for 230v and 415v power
supply respectively. Change tap on transformer for 208-
3-60 or 380-3-50 operation. See unit wiring diagram.