York Predator ZR061 series User Manual

R-410A
ZR SERIES W/SMART EQUIPMENT™
3 - 5 Ton
60 Hertz
5167540-YIM-H-0518
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Optional Gas Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Economizer Sequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Airflow Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking Air Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 46
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reheat Mode Sequence Of Operation . . . . . . . . . . . . . . . . . . 48
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 49
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 49
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 50
Gas Heating Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 50
Start-Up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Start-Up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking Gas Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Charging The Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control Board Navigation Components . . . . . . . . . . . . . . . . . . . . 55
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
LIST OF TABLES
1 ZR037-061 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZR037-061 Unit Accessory Weights . . . . . . . . . . . . . . . . . . . . 8
4 ZR037-061 Unit Physical Dimensions . . . . . . . . . . . . . . . . . . 11
5 ZR037-061 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Side Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Left/End Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 27
12 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 28
13 Gas Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . . . 29
14 Smart Equipment™ Economizer Board Details . . . . . . . . . . 33
15 Supply Air Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
16 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38
17 ZR037-061 Side Duct Application . . . . . . . . . . . . . . . . . . . . . 40
18 ZR037-061 Bottom Duct Application. . . . . . . . . . . . . . . . . . . 41
19 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
20 Indoor Blower Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 42
21 Power Exhaust Specifications. . . . . . . . . . . . . . . . . . . . . . . . 42
22 Motor Sheave Datum Diameters. . . . . . . . . . . . . . . . . . . . . . 44
23 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 45
24 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
25 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 49
26 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 51
27 Gas Rate Cubic Feet Per Hour . . . . . . . . . . . . . . . . . . . . . . . 53
28 Gas Heat Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
29 Smart Equipment™ UCB Details . . . . . . . . . . . . . . . . . . . . . 56
30 Cable for FC Buses and SA Buses in Order of Preference . 61
31 Flash Codes for the Gas Heat Ignition Control Board . . . . . 62
32 ZR037 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
33 ZR049 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
34 ZR061 Charging Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
LIST OF FIGURES
1 Unit Shipping Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Condenser Covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Predator
®
Component Location (ZR037 Shown) . . . . . . . . . . 6
5 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 ZR037 Physical Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 9
9 ZR049-061 Physical Dimensions . . . . . . . . . . . . . . . . . . . . . 10
10 ZR037-061 Unit Bottom Duct Openings . . . . . . . . . . . . . . . . 12
11 ZR037-061 Unit Electrical Entry . . . . . . . . . . . . . . . . . . . . . . 13
12 ZR037-061 Unit Side Duct Openings . . . . . . . . . . . . . . . . . . 13
13 ZR037-061 Unit Left/End Duct Opening . . . . . . . . . . . . . . . . 14
14 ZR037-061 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
15 ZR037-061 Transition Roof Curb . . . . . . . . . . . . . . . . . . . . . 15
16 Side Duct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
17 Return Panel In Place For Side Duct Conversion . . . . . . . . 16
18 Supply Panel In Place For Side Duct Conversion . . . . . . . . 16
19 Save Side Panels For Economizer Hood Tops . . . . . . . . . . 16
20 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 Field Wiring Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
22 Typical Low Voltage Field Wiring . . . . . . . . . . . . . . . . . . . . . 19
23 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
24 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 33
26 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
27 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 38
28 Dry Coil Delta P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
29 Reheat Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48
30 Cooling Operation Piping Schematic . . . . . . . . . . . . . . . . . . 48
31 Typical Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
32 Typical Two Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . . 55
33 Typical Single Stage Gas Valve . . . . . . . . . . . . . . . . . . . . . . 55
34 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

York Predator ZR061 series Specifications

General

Brand	York
Model	Predator ZR061 series
Category	Air Conditioner
Language	English

Summary

General Information and Safety

Safety Warnings and Precautions

Crucial safety guidelines for installation, operation, and service.

Installation Guidelines and Compliance

Installation Codes and Standards

Adherence to electrical, fuel gas, and local codes is mandatory.

Installation Procedures

Fire and Explosion Hazard

Warning against using open flames for gas leak detection.

Site Preparation and Handling

Rigging and Lifting Procedures

Safe methods for moving and lifting the unit using chains or forklifts.

Component Handling and Safety

Compressor and Refrigerant Safety

Guidelines for R-410A refrigerant, oil handling, and compatibility.

Electrical Wiring and Filters

Filter Installation Requirements

Power and Control Wiring

Electrical code compliance, voltage, disconnects, and wiring practices.

Thermostat and Control Wiring

Thermostat Installation Guidelines

Proper location, type, and wiring of the thermostat.

Low Voltage Wiring Diagram

Gas Connection and Safety

Gas Piping Procedures

Recommendations for routing, materials, and leak testing of gas lines.

Gas Pressure Testing Caution

Procedures to follow during pressure testing to prevent damage.

Economizer and Free Cooling

Economizer Operation Modes

Free Cooling Operation

Control System Operation

Economizer Control Logic

Altitude and Temperature Corrections

Correcting Performance Data

How to adjust CFM, static pressure, and power for altitude and temperature.

Blower Drive Selection

Selecting Blower Motor and Drive

Steps for choosing the correct motor, drive, and sheave settings.

Air Balancing and Measurement

Air Balancing Procedures

Measuring Air Quantity (CFM)

Methods for measuring airflow using duct panel plugs or holes.

Supply Air Drive Adjustment

Adjusting Blower Speed

Procedures for adjusting blower speed via motor sheave for correct CFM.

Unit Operation Sequences

Cooling Operation Modes

Detailed sequences for cooling, economizer, and motorized dampers.

Cooling Operation Error Handling

How the unit monitors and responds to cooling system errors.

Safety Controls and Protection

Limit Switch Operations

Functionality of high-pressure, low-pressure, and evaporator low limit switches.

Compressor Protection Features

Heating Operation Sequences

Electric Heating Operation

Gas Heating Operation

Gas Pressure and Burner Adjustments

Manifold Gas Pressure Adjustment

Procedures for adjusting manifold pressure for single and two-stage gas heat.

Furnace Adjustments and Servicing

Temperature Rise Adjustment

Burner and Orifice Servicing

Unit Charging and Control Navigation

Refrigerant Charging Procedure

Startup Safety and Application Data

Startup Safety Warnings

Critical warnings regarding lethal voltages and moving parts during startup.

Operating Measurements - Air Flow

Air Flow Measurement Setup

Electrical Data Recording

Operating Measurements and Safety

Cooling Measurements and Refrigerant Safety

Gas Heating Measurements and Checks

Operational Verification and Final Inspection

Staging Controls and VFD Verification

Final Inspection and Data Backup