York ZD-03 User Manual

R-410A
ZD SERIES
3 - 5 Ton
60 Hertz
5188236-BIM-A-0316
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging And Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power And Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Field Power and Control Wiring . . . . . . . . . . . . . . . . . . . . 15
Typical Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical Cool/Heat Control Wiring (Simplicity Lite ZD-03 Thru -05)
15
Typical Cool/Heat Control Wiring (Simplicity S E ZD-03 Thru -05)
16
Optional Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Economizer And Power Exhaust Set Point Adjustments. . . . . 34
Jade Economizer Interface Overview . . . . . . . . . . . . . . . . . . . 34
Simplicity SE Economizer Sequences. . . . . . . . . . . . . . . . . . . 36
Dry Bulb Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dual Enthalpy Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Free Cooling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking Supply Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . 50
No Outdoor Air Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cooling Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Electric Heating Sequence Of Operations. . . . . . . . . . . . . . . . 52
Electric Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . 52
Gas Heating Sequence Of Operations . . . . . . . . . . . . . . . . . . 53
Gas Heat Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Flash Codes or Error Messages . . . . . . . . . . . . . . . . . . . . . . . 55
Resets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Start-up (Gas Heat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Checking Gas Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Fan On And Off Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Simplicity SE Control Board Navigation Components . . . . . . . . . 67
Simplicity™ SE (Smart Equipment) Firmware Version 3. Basic
Unit Control Board Navigation Examples: . . . . . . . . . . . . . . . . 68
Start-Up Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
LIST OF TABLES
1 ZD-03 Thru -05 Unit Limitations . . . . . . . . . . . . . . . . . . . . . . . 6
2 ZD-03 Thru -05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 ZD-03 Thru -05 Unit Accessory Weights . . . . . . . . . . . . . . . . . 8
4 ZD-03 Thru -05 Unit Clearances . . . . . . . . . . . . . . . . . . . . . . 10
5 ZD-03 Thru -05 Utilities Entry . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Control Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 ZD-03 Thru -05 Physical Data . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Electric Heat Minimum Supply Air . . . . . . . . . . . . . . . . . . . . . 31
10 Gas Heat Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11 Gas Pipe Sizing - Capacity of Pipe . . . . . . . . . . . . . . . . . . . . 32
12 Single Enthalpy and Dual Enthalpy High Limit Curves. . . . . . 36
13 Simplicity SE Economizer Board Details . . . . . . . . . . . . . . . . 38
14 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 42
15 ZD Blower Performance Side Duct . . . . . . . . . . . . . . . . . . . . 45
16 ZD Blower Performance Bottom Duct . . . . . . . . . . . . . . . . . . 47
17 Belt Drive RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
18 Indoor Blower Specifications (Belt Drive) . . . . . . . . . . . . . . . 48
19 Power Exhaust Specifications . . . . . . . . . . . . . . . . . . . . . . . . 48
20 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Electric Heat Limit Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
22 Electric Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . 53
23 Single Stage Gas Heat Limit Control Setting . . . . . . . . . . . . 55
24 2 Stage Gas Heat Limit Control Setting . . . . . . . . . . . . . . . . 55
25 Gas Heat Anticipator Setpoints . . . . . . . . . . . . . . . . . . . . . . . 55
26 Gas Rate-Cubit Feet per Hour . . . . . . . . . . . . . . . . . . . . . . . 58
27 ZD-03 (3.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
28 ZD-04 (4.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 61
29 ZD-05 (5.0 Ton) Operating Pressures . . . . . . . . . . . . . . . . . 62
30 Unit Control Board Flash Codes . . . . . . . . . . . . . . . . . . . . . . 67
31 Ignition Control Board Flash Codes . . . . . . . . . . . . . . . . . . . 67
32 Simplicity SE UCB Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
LIST OF FIGURES
1 ZD-03 thru -05 Component Location . . . . . . . . . . . . . . . . . . . 6
2 Unit 4 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Unit 6 Point Load Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Center of Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 ZD-03 Thru -05 Cooling Only/Electric Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 ZD-03 Thru -05 Cooling Only/Gas Heat Front View Physical
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 ZD-03 Thru -05 Fixed Outdoor Air Motorized Damper Rain
Hood Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 ZD-03 Thru -05 Disconnect Location . . . . . . . . . . . . . . . . . . 10
9 ZD-03 Thru -05 Unit Side Duct Openings . . . . . . . . . . . . . . . 11
10 ZD-03 Thru -05 Roof Curb . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Compressor Restraining Bracket . . . . . . . . . . . . . . . . . . . . . 13
13 Typical Field Power and Simplicity Lite Control Wiring . . . . 15
14 Typical Simplicity SE Control Wiring . . . . . . . . . . . . . . . . . . 16
15 Side Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
16 Bottom Entry Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
17 Vent And Combustion Air Hood . . . . . . . . . . . . . . . . . . . . . . 34
18 Economizer LCD and Keypad Layout. . . . . . . . . . . . . . . . . . 34
19 Single Enthalpy Curve And Boundaries . . . . . . . . . . . . . . . . 35
20 SE-ECO1001-0 Economizer Controller . . . . . . . . . . . . . . . . 38
21 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
22 Altitude/Temperature Correction Factors . . . . . . . . . . . . . . . 43
23 Pressure Drop Across Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 49
24 Gas Valve Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
25 Typical Single Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . 56
26 Typical 2 Stage Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Proper Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 57
28 Typical Flame Appearance . . . . . . . . . . . . . . . . . . . . . . . . . 57
29 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
30 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

York ZD-03 Specifications

General

Brand	York
Model	ZD-03
Category	Air Conditioner
Language	English

Summary

General

Safety Considerations

General safety warnings, cautions, and important notes for installation and operation.

Installation

Installation Safety Information

Essential safety guidelines and precautions for proper unit installation.

Wiring, Filters, and Control Systems

Power And Control Wiring

Electrical wiring requirements and safety standards for field connections.

Gas Piping and Connection

Gas Piping

Economizer and Accessories

Economizer And Power Exhaust Set Point Adjustments

Jade Economizer Interface Overview

Navigation and usage guide for the Jade Economizer control interface.

Economizer Operation

Free Cooling

Simplicity SE Economizer Sequences

Economizer Operation (Continued)

Drive Selection

Drive Selection

Air Flow Measurement

Checking Supply Air CFM

Method for measuring and verifying supply air volume.

Unit Operation

Cooling Sequence Of Operation

Step-by-step process for unit cooling operation modes.

Economizer With Single Enthalpy Sensor (Simplicity Lite) or Economizer With Dry Bulb Sensor (Simplicity S E)

Unit Operation (Continued)

Cooling Operation Errors

Identifies and explains cooling system fault conditions and responses.

Safety Controls

Overview of unit control board safety monitoring functions.

Compressor Protection

Features and mechanisms for protecting the compressor from damage.

Flash Codes or Error Messages

Electric Heating Sequence Of Operations

Step-by-step operation of single and two-stage electric heating.

Electric Heat Operation Errors (Continued)

Gas Heating Sequence Of Operations

Detailed sequence for gas furnace ignition and operation.

Gas Heating Sequence Of Operations (Continued)

Gas Heat Operation Errors

Fault conditions and error handling for gas heating systems.

Gas Heat Operation Errors (Continued)

Heat Anticipator Setpoints

Gas Heating Operation

Manifold Gas Pressure Adjustment

To Light Pilot And Main Burners

Step-by-step procedure for safely lighting the pilot and main burners.

Post-Start Check List (Gas)

Gas Heating Operation (Continued)

Checking Gas Input

Method for measuring gas input rate and verifying furnace rating.

Troubleshooting

Troubleshooting

General guidance and common fault diagnosis for system issues.

Gas Heat Troubleshooting Guide

Gas Heat Troubleshooting Guide

Comprehensive guide for diagnosing and resolving gas heating system problems.

Flash Code Troubleshooting

Gas Heat Troubleshooting Guide (Continued)

Ignition Control Board

Troubleshooting steps for the ignition control board and associated components.

Centrifugal Switch

Diagnosing faults related to the centrifugal switch in the draft motor.

Gas Heat Troubleshooting Guide (Continued)

Symptomatic Troubleshooting

Diagnosing heating system issues based on observed symptoms.

Simplicity SE Control Navigation

Simplicity SE Control Board Navigation Components

Identifies key components for navigating the Simplicity SE control.

Simplicity SE Control Navigation (Continued)

Start-Up Procedures

START-UP & SERVICE DATA INSTRUCTION

Comprehensive guide for equipment startup and service data recording.

EQUIPMENT STARTUP

Procedures for initiating equipment startup using local controls or portals.

Start-Up Procedures (Continued)

DESIGN APPLICATION INFORMATION

Key application data required from the specifying engineer for startup.

Operating Measurements

Air Flow Measurements

Operating Measurements (Continued)

COOLING Measurements

REFRIGERANT SAFETIES

GAS HEATING Measurements

Operational Measurements and Final Inspection

STAGING CONTROLS

FINAL - INSPECTION

Final checks to ensure proper installation, settings, and security.